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Transit: Description and Operation

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0% found this document useful (0 votes)

269 views2,938 pages

Transit: Description and Operation

Uploaded by

gerd

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Available Formats

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General Information - Information - Overview

Description and Operation

Transit

WARNING: Before beginning any service procedure in this manual, refer to health
and safety warnings in section 100-00 General Information. Failure to follow this
instruction may result in serious personal injury.

Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
General Information - About this Manual
Print

Description and Operation

Introduction

For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
This manual describes and directs repair procedures specified by Ford Motor Company for
the vehicle. Critical health and safety precautions are included. Anyone who deviates from
these instructions risks compromising personal safety or vehicle integrity.
SECTION CONTENT
This manual is divided into groups, each containing sections numbered based on the
component part number. Section contents may include:

• Specifications
- Fluid capacities, component specifications and torque values not covered in other
procedures
• Description and Operation
- Overview of the system, component locations, and system operation
• Diagnosis and Testing
- Symptom charts, DTC (diagnostic trouble code) charts and diagnostic tests
- See the Diagnosis and Testing Information in this document
• General Procedures
- Service adjustments, electronic programming and other special procedures
• Removal and Installation
- Component removal and installation instructions
• Removal
- Component removal instructions
• Installation
- Component installation instructions
• Disassembly and Assembly
- Component disassembly and assembly instructions
• Disassembly and Assembly of Subassemblies
- Assembly disassembly and assembly instructions

IMPORTANT INFORMATION
Section number 100-00 General Information contains the following important information
(including this document):

• Critical Health and Safety Precautions - service safety precautions applicable to the entire
manual.
For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
• A Symbols Glossary - definitions of the action directed by each symbol.
For additional information, refer to: Symbols Glossary (100-00 General Information,
Description and Operation).
• Diagnostic Methods - support information for diagnostics.
For additional information, refer to in this section.

Warnings, Notices and Notes

WARNINGS
Warnings provide information to avoid personal injury and to make sure service actions on
critical safety systems are performed correctly. Warnings that apply to an entire system or
workshop manual section are located in section 100-00 Description and Operation, Health
and Safety Precautions.
For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
NOTICES (in some publications, CAUTIONS)
Notices provide information to avoid damage to the vehicle or a component.
NOTES
Notes provide information critical for a complete and effective repair.
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the
beginning of the procedure. Warnings, Notices, or Notes that apply to a single step are
placed at the beginning of the step. Those that apply to a group of steps will be placed at
the first step requiring it.
Safety Relevant Systems
Repair of a vehicle safety relevant system is to be achieved only by replacement of the
failed component(s), unless specified otherwise in the procedure. Repair of a vehicle safety
relevant system component should not be attempted.
If directed during assembly of system components, lubricate any seal(s) only with the
specified material. Failure to follow this instruction may result in seal failure and leakage.
Specified Chemicals or Materials
Throughout this manual, chemicals or materials are specified that must be used to properly
complete a service procedure or diagnostic step. In the event a specific material is not
readily available, a substitute material meeting the same specification may be used. Ford
has not reviewed third party products for compliance with environmental, health or safety
regulations and is not responsible for their use. Use of third party products is at your own
risk. Additionally, such products may cause degraded performance, premature failures,
and/or vehicle component damage. All chemicals or materials used for vehicle servicing
should be checked for compliance with local environmental and health and safety
regulations.
LH (left-hand) and RH (right-hand) Designations
All LH and RH designations are oriented from the driver's seat position looking forward.
Vehicle LH and RH definition
Item Description
1 LH (left-hand)
2 RH (right-hand)
All LH and RH engine designations are oriented from the flywheel position looking toward
the crankshaft pulley.
Powertrain LH and RH definition

Item Description
1 Front
2 RH (right-hand)
3 Rear
4 LH (left-hand)
Standard Practices
The following rules apply, unless specified differently in the procedure:
FASTENERS

• Reuse standard fasteners.

• Replace fasteners with self-locking features.
- Examples of fastener self-locking coatings or mechanical locking (with the locking
features highlighted yellow) are shown in the illustration.
• Replace fasteners with torque angle specifications (those tightened a specified number of
degrees).

Examples of self-locking nuts and bolts

Item Description
1 Completely coated self-locking bolt
2 Partially coated self-locking bolt
3 Self-locking bolt with a locking washer
4 Self-locking nut with a plastic locking insert
5 Self-locking nut with thread deformation (3 indentations)
6 Self-locking nut with thread deformation (to oval shape)
7 Self-locking nut with integrated locking ring
THREAD FORMING FASTENERS
The following is a general description of best practices to be followed during handling of
thread forming fasteners and mating components.
Manual Torque Application
Hand tools are required for installation of a thread forming fastener. Do NOT use power
tools, as the possibility for over-torqueing or stripped threads exists. If a fastener is over-
torqued, the joint can fail.
Hand Start Fasteners in Reverse
To avoid the possibility of cross-threading pre-existing threads during fastener replacement,
begin by first hand-inserting the new fastener and rotating counter-clockwise. This reverse
rotation allows for the location of existing fastener threads to ensure the fastener does not
cross-thread upon thread re-engagement. Once the existing fastener threads are located,
hand-start individual fasteners manually until finger tight.
Risks of Over-Torque
Consult the Workshop Manual procedure when torqueing thread forming fasteners and
follow torque specification as listed. Make sure the fastener is fully seated against the
mating component with no gap during reassembly.
Corrosion
During fastener replacement, inspect both fastener and mating component for signs of rust
or other corrosion. If corrosion is found, replace corroded components with new
components.
Stripped Threads
If internal (mating component) threads or external (fastener) threads appear stripped or
galled, replace both fastener and mating component. When tightening, if minimum torque
is not reached, internal threads on mating component may have stripped. Remove the
fastener to inspect and replace mating component if stripped threads are found.
Face Seals
When replacing fasteners, inspect mating component surface for debris, damage,
disturbance, wear, or abrasion and replace any seals or gaskets if damage is found.
SEALS AND GASKETS
Replace seals and gaskets, unless specified differently in the procedure.
EXTERIOR TRIM PARTS
Replace exterior trim parts fastened with glue or adhesive tape, unless specified differently
in the procedure.
Mechanical Procedures
Illustrations in this manual may be used instead of written step instructions. Color-coding
(see color scheme illustration) is used to communicate the required step action or actions.
Service action icons may be used to add information regarding the required action.
For additional information, refer to: Symbols Glossary (100-00 General Information,
Description and Operation).
Illustration Color-coding

Item Description
1 Blue - Target or primary component to be removed/installed (or
disassembled/assembled).
2
Green - Components that need to be removed prior to or installed after
the target/primary.
3 Brown - Components that need to be removed prior to or installed
after the target/primary.
4 Yellow - Components to be set aside for access, but not removed. Also
highlighted areas to inspect or adjust.
5 Magenta - Electrical connectors and fasteners such as nuts, bolts,
clamps, or clips to be: detached, attached, loosened, moved, removed
or installed.
6 Pale Blue - Special tool(s), general equipment, or common tools used
in an uncommon way.
Other color coding

• Alternating Blue and White

- Chemical, adhesive or sealer apply areas
• Red
- Sectioned or cut-away areas
• Grey
- Background components shown for location information

ILLUSTRATION TASK SEQUENCE

Components that must be removed or installed in a specific sequence are identified with a
numbered callout. Any associated step text is numbered accordingly.
Simple procedure example showing color-coding and task sequence.

Black arrows are used to draw attention to components (usually fasteners). Arrows with
multiples specified (here, x2) identify an identical number of fasteners or items. Callouts
(numbers inside circles) show a required sequence or tightening torque.
In the illustration, the callouts indicate the removal sequence, which is reversed for
installation. The yellow coloring of the hose indicates it is to be positioned aside (not
removed). Two identical (magenta-colored) fasteners are indicated by the x2 arrow. The
fasteners in this illustration require different torques (same torque for the x2 fasteners) so
numbered callouts are used to identify them with torque values in the associated step text.
The (magenta-colored) hose clamp is another fastener to be removed.
Examples of fastener removal sequence and an identical service action for 12 fasteners.
Other possible symbols are shown on the right.
Part Number
-
Example of fastener
- sequence information with two persons required for the service action

HIDDEN DETAILS
Separate detail boxes or transparent components may be used to show hidden items in an
illustration.
Part
Example of Number
hidden fastener information
-
-
-
-
SERVICE ACTION ICONS
Service action icons may be used to add information regarding the required action.
For additional information, refer to: Symbols Glossary (100-00 General Information,
Description and Operation).
Location symbols show the location of a component or system on the vehicle.

Example of service action icons pointing to highlighted components.

Movement arrows and service action icons show three dimensional or rotational
movements.
Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent
to a component.

Part Number
-
-
-
-
-
-
-

Measurement symbols provide the information required to perform a specific measurement.

These symbols may include specific values.
SPECIAL TOOLS, EQUIPMENT, MATERIALS AND TORQUE VALUES
When Ford special tools are required for the procedure, the tool and tool number are shown
in an illustration. Special tool numbers, general equipment, materials or torque values for
the procedure step are shown in the text steps.
Example of special service tool and symbol used to hold the gear shift in the required gear
position. Other possible symbols are shown on the right.

Example of two illustrations used together with sequence steps, service action icons and
special service tools
Tool symbols direct the use of standard tools. The tool size or dimension may be specified.

HEALTH AND SAFETY SYMBOLS

Some procedures may contain health and safety symbols that are associated with a specific
service action.
For additional information, refer to: Symbols Glossary (100-00 General Information,
Description and Operation).
Always read and understand all health and safety precautions found in Section 100-00
before beginning any procedure.
For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
ISO warning symbols may be used to indicate potential hazards.
These symbols prohibit various hazardous actions

These symbols direct the use of personal protection equipment

Part Number
-

-
Diagnosis and Testing Information
ELEMENTS OF DIAGNOSIS AND TESTING
Diagnosis and Testing may include:

• Preliminary Inspection
- In older manuals, Inspection and Verification
• Symptom Chart
• DTC Chart
• Pinpoint Tests
• Component Tests

Some diagnostics may be contained in Symptom Based Diagnostics. Some engine

performance and emission diagnostics may be placed in a separately published PC/ED
(powertrain control/emissions diagnosis) manual.
MODULE NAMES MATCH THE DIAGNOSTIC SCAN TOOL
Module names and PID (parameter identification) names in this manual match the Ford
diagnostic scan tool: IDS (Integrated Diagnostic System).
The same diagnostic scan tool module name is found in some DTC definitions (for example,
U024B Lost Communication with Seat Control Module "G").
MODULE DESCRIPTIVE NAMES
A descriptive name is sometimes added to the diagnostic scan tool name to clarify module
function. The descriptive name will be followed by the diagnostic scan tool acronym in
brackets.

• Example: “Driver Active Motion Seat Module [SCMG]”.

• Driver Active Motion Seat Module is the descriptive name added to clarify the function of
the SCMG.
• The SCMG acronym is used by diagnostic scan tool, defined as “Seat Control Module G”.
-

-
General Information - Symbols Glossary
Print

Description and Operation

Symbols are used inside the graphics and in the text area to enhance the information
display.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These
component movements can be rotational or 1-3 dimensional movements.

Item Part Number Description

1 - Minor component movement clockwise/counterclockwise
2 - Major component movement clockwise/counterclockwise
3 - Component movement to the left/right/up/down
4 - Component movement towards/away
5 - 3 dimensional component movement
6 - 2 dimensional component movement
7 - 3 dimensional component rotation
8 - 3 dimensional component cycling

Turn Symbols
Turn symbols are used to provide further information on the direction or angle of
component turns.

Item Description
1 Turn the component clockwise through 45°
2 Turn the component counterclockwise through 45°
3 Turn the component clockwise through 90°
4 Turn the component counterclockwise through 90°
5 Turn the component clockwise through 180°
6 Turn the component counterclockwise through 180°
7 Turn the component clockwise through 2 complete turns
8 Turn the component counterclockwise through 2 complete turns

Steering Wheel Symbols

Steering wheel symbols are used to provide further information to a required steering wheel
position or steering column lock status.
Item Description
1 Steering wheel in straight ahead position
2 Steering column lock locked
3 Steering column lock unlocked
4 Turn the steering wheel to the 90° left position
5 Turn the steering wheel to the 90° right position
6 Turn the steering wheel to the left-hand end position
7 Turn the steering wheel to the right-hand end position

Body Types
Body type symbols are used to identify different body configurations.
Item Part Number Description
1 - 3, 4, 5-door body style
2 - Wagon body style
3 - Sports utility vehicle body style
4 - Coupe body style
5 - Convertible body style
6 - Van body style
7 - 3, 4, 5-door body style - Top View
8 - Wagon body style - Top View
9 Underview
10 Right-hand drive (RHD) vehicle
11 Left-hand drive (LHD) vehicle

Gearshift lever and selector lever position symbols

Gearshift lever and selector lever position symbols are used to show the lever position that
is required to be selected to carry out a procedure step.
Item Description
1 Replaced by symbol 9
2 Replaced by symbol 10
3 Replaced by symbol 11
4 Replaced by symbol 12
5 Replaced by symbol 12
6 Replaced by symbol 14
7 Replaced by symbol 15
8 Replaced by symbol 16
9 Set the selector lever to the park (P) position
10 Set the selector lever to the reverse (R) position
11 Set the selector lever to the neutral (N) position
12 Set the selector lever to the drive (D) position
13 Set the selector lever to the drive (S) position
14 Set the selector lever to the drive (M) position
15 Set the selector lever to the drive (-) position
16 Set the selector lever to the drive (+) position
17 Set the gearshift lever to the neutral (N) position
18 Further gearshift lever positions that may appear in illustrations

Screwdriver symbols
The screwdriver symbols are used to show which screwdriver bit is recommended to carry
out a procedure step.

Item Description
1 Screwdriver
2 Cross bladed screwdriver / Cross bladed Bit Socket
3 Flat bladed screwdriver / Flat bladed Bit Socket
4 Hexagonal screwdriver / Hexagonal Bit Socket
5 TORX screwdriver / TORX Bit Socket
6 Polydrive screwdriver / Polydrive Bit Socket
7 Ball drive hex bit

Pliers symbols
The pliers symbols are used to show which pliers is recommended to carry out a procedure
step.

Part Number
-
-
-
-
-
-
-

Item Description
1 Combination pliers
2 Side cutter pliers
3 Securing ring - inner
4 Securing ring - outer
5 Hose clamp pliers
6 Locking pliers
7 Long nose pliers

Drill symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry
out a procedure step.

Item Description
1 Drill bit with a specified diameter
2 Hole saw with a specified diameter
3 Stepped drill bit with a specified diameter
4 Tap with a specified diameter
5 Die with a specified diameter
6 Scraper for circular holes
7 Scraper for straight edges

Cutting tool symbols

The cutting tool symbols are used to show which type of cutting tool is recommended to
carry out a procedure step.
Item Description
1 Cutting knife
2 Air body saw
3 Scissors
4 Grinder
5 Jig saw
6 Plasma cutter
7 Sanding Paper
8 Wire brush
9 Belt Sander
10 Tin Snipes

Apply Chemical or load symbols

The apply chemical or load symbols are used to show where to apply which type of
chemical or load to carry out a procedure step.
Part Number
-
-
-
-
-
-
-
Item - Description
1 - Apply the substance from the specified tube
2 - Apply the substance from the specified cartridge
3 - Apply the specified chemical with a brush
4 Apply the specified load to the specified component
5 Apply a bead with a specific diameter from the specified tube
6 Apply a bead with a specific diameter from the specified cartridge
7 Apply the specified chemical with a roller
8 Apply hot glue to the specified component
9 Apply the specified amount of fluid from the fluid can
10 Apply fluid from the fluid can
11 Clean the specified component with the specified material
12 Apply a broken bead from the specified tube
13 Apply the specified chemical from a spray can
14 Apply the specified lubricant to the specified component
15 Apply spot welds to the specified component
16 Apply a continuous weld to the specified component
17 Handle the fluid using a syringe
18 Extract the specified amount of fluid using a syringe

Measurement symbols
The measurement symbols are used to show where to measure which type of measurement
to carry out a procedure step.

Item Description
1 Measure the current using a digital multimeter
2 Measure the voltage using a digital multimeter
3 Measure the resistance using a digital multimeter
4 Measure the length/distance
5 Check that the specified pressure is available using a suitable pressure
gauge
6 Measure the pressure at the specified port using a suitable pressure
gauge
7 Measure the time using a suitable stopwatch
8 Wait for the specified period of time
9 The specified task requires the specified minimum temperature
10 The specified task requires the specified maximum temperature not to
be exceeded
11 The specified task requires the specified temperature range
12 The specified task requires the specified temperature
13 Measure and check for the specified value using a dial indicator gauge
14 Measure and check for the specified MAX value using a dial indicator
gauge
15 Measure and check for the specified MIN value using a dial indicator
gauge

General equipment symbols

The general equipment symbols are used to show where to use which type of general
equipment to carry out a procedure step.
Part Number
-
Item - Description
1 - Hot air gun
2 - Soldering iron
3 - Scraper
4 - Scriber
5 - Securing strap
6 - File with a specified size
7 - Center punch
8 - Marker
9 - Mallet
10 - Hose clamp
11 - Interior trim remover
12 - Vacuum cleaner
13 Strap wrench
14 Wedge
15 Pin Punch
16 Air blow gun
17 Relocate and support the component
18 C-clamp

Item Description
1 Plastic scraper

Welding symbols
These symbols indicate the type of welding to be used.
Item Description
1 Metal inert gas (MIG) / Metal active gas (MAG) welding equipment
2 Metal inert gas (MIG) welding equipment
3 Metal inert gas (MIG) brazing equipment
4 Apply a continuous weld to the specified component
5 Apply spot welds to the specified component
6 C-clamp

Drilling and grinding symbols

These symbols indicate the type of drilling or grinding to be used.
-
-
-
-

Item Description
1 Drill through first body layer with a suitable diameter
2 Drill through first body layer with the specified diameter
3 Drill through the indicated number of body layers with a suitable
diameter
4 Drill through the indicated number of body layers with the specified
diameter
5 Part Number Drill through the indicated number of body layers with a suitable
diameter
-
6 Drill through the indicated number of body layers with the specified
- diameter
7 - Drill through all body layers with a suitable diameter
8 - Drill through all body layers with the specified diameter
9 - Grind one layer
10 Grind two layers
11 Grind to last layer
12 Grind all layers
13 Material thickness > Xmm

Material symbols
The material symbols are used to show where to use which type of material to carry out a
procedure step.

Item Description
1 Remove/Install the specified blind rivet
2 Apply tape to the specified component/area
3 Remove/Install the specified cable tie

Miscellaneous symbols
These symbols provide further information that is required to carry out a procedure step.
Item Description
1 Set the ignition switch to the 0 position
2 Set the ignition switch to the II position
3 The procedure step requires the aid of the specified number of
supporting technicians
4 Self contained breathing apparatus
5 General prohibition used in combination with another symbol
6 Do not use power tools
7 Visual check
8 Noise check
9 Dispose the specified component
10 Replaced by item 9 (Dispose the specified component)
11 Set the engine speed to the specified value
12 Fully apply the parking brake lever
13 - Fully release the parking brake lever
14 - Do not dispose of batteries into the waste bin
15 Visual check using a mirror
16 Area/component must be dry

Mandatory Protective equipment - Health and safety symbols

The protective equipment symbols advise to use a mandatory protective equipment to
avoid or at least reduce possible health and safety risks.

Item Description
1 Wear protective gloves
2 Wear face guard
3 Wear safety goggles
4 Part Number Wear ear protectors
5 - Wear safety goggles and ear protectors
6 - Wear a respirator
-
Prohibition - Health and safety symbols and component damage
-
The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce
-
possible component damage and health and safety risks.
-
-
Item Description
1 General prohibition symbol
2 No naked flames
3 No smoking
4 No water
5 Do not touch
6 Do not switch
7 No grinding

Warning symbols - Health and safety and component damage

The warning symbols are used to advise on hazardous conditions to avoid or at least reduce
possible component damage and health and safety risks.
Item Description
1 Hazardous voltage/Electrical shock/Electrocution
2 Fire Hazard/Highly flammable
3 Burn hazard/Hot surface
4 Automatic start-up
5 Toxic
6 Explosive material
7 Battery hazard
8 Corrosive material
9 Lifting hazard
10 Hand crush/Force from above
11 Cutting of fingers or hand
12 Pressure hazard
13 Invisible laser radiation. Do not view directly with optical instruments
(magnifiers). Class 1M laser product

Control Diagram symbols - Description and Operation procedures

These symbols provide further information on the type of connectivity, direction of flow or
type of data bus of a system.
Item Description
1 Mid-speed Controller Area Network (CAN)
2 High-speed Controller Area Network (CAN)
3 Local Interconnect Network (LIN)
Part Number
4 Wires crossing not connected
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General Information - Battery and Battery
Charging Health and Safety Precautions
Print

Description and Operation

WARNINGS:

Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated
area. Do not allow the battery to come in contact with flames, sparks or burning
substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the
battery to protect against possible splashing of acid solution. In case of acid contact with
skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt
medical attention. If acid is swallowed, call a physician immediately. Failure to follow
these instructions may result in serious personal injury.

Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the
vent caps, resulting in personal injury and/or damage to the vehicle or battery.

Battery posts, terminals and related accessories contain lead and lead components.
Wash hands after handling. Failure to follow these instructions may result in serious
personal injury.
General Information - Body Repair Health
and Safety and General Precautions
Print

Description and Operation

WARNINGS:

Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and
wear protective equipment as directed. Examples may include but are not limited to
respirators and chemically resistant gloves. Failure to follow these instructions may result
in serious personal injury.

Always wear protective equipment including eye protection with side shields, and a
dust mask when sanding or grinding. Failure to follow these instructions may result in
serious personal injury.

Do not carry out body side sectioning repairs in areas of door hinge or striker
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may
compromise structural integrity during a collision. Failure to follow these instructions may
result in serious injury to vehicle occupant(s).

Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes
and skin. Always use protection such as a welder's helmet with dark-colored filter lenses
of the correct density. Electric welding will produce intense radiation, therefore, filter
plate lenses of the deepest shade providing adequate visibility are recommended. It is
strongly recommended that persons working in the weld area wear flash safety goggles.
Also wear protective clothing. Failure to follow these instructions may result in serious
personal injury.

All safety belt components must be inspected and corrected as part of any collision
repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and
Repair After a Collision found in Section 501-20A General Procedures of this manual.
Failure to follow this instruction may result in incorrect operation of the safety belt system
and increase the risk of serious personal injury or death in a crash.

If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the
mounting areas to the original production configuration. A new RCM and sensors must be
installed whether or not the air bags have deployed. Failure to follow these instructions
may result in serious personal injury or death in a crash.

Seek immediate medical attention.

Antifreeze must not be used in any cooling or industrial water system that is
connected or linked to general water supplies.
General Information - Health and Safety
Precautions
Print

Description and Operation

General Service Warnings

Review carefully the information below before beginning any repair. Following these
warnings is a list of specific system warnings that must be reviewed before beginning work
on any listed system.
WARNINGS:

Vehicles with scheduled remote start technology may start at any time. Make sure
the scheduled remote start system is disabled when servicing or working in close
proximity to rotating engine parts. Remote start features should be disabled via the
instrument cluster settings. Refer to information display, settings in the owner's manual.
Failure to follow this instruction may result in serious personal injury.

Wear eye and ear protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.

Wear protective gloves when handling components or parts that have pointed or
sharp edges. Failure to follow this instruction may result in serious personal injury.

Chemicals or materials specified in this manual, if used improperly, may present a

personal health hazard. Always consult the material safety information sheet before using
any material specified by this manual. Failure to follow this instruction may result in
serious personal injury.

Do not work under the hood of a vehicle with a damaged cooling fan, as it can
separate during operation. With the ignition OFF, inspect all cooling fans for damage,
cracks or separation and replace with a new fan as necessary. Failure to follow this
instruction may result in serious personal injury.

Cooling fans may run with the ignition off. Disable the fans before working nearby.
On electric vehicles, disconnect the charging cable to prevent unexpected fan operation.
Failure to follow this instruction may result in personal injury.

Vehicles with engine auto start-stop technology may start automatically with the
ignition on. Make sure the ignition is off when servicing or working in close proximity to
rotating engine parts. Failure to follow this instruction may result in serious personal
injury.

Serious injury may occur if the engine is accidently started by another person during
service work. Remove the key from the vehicle to prevent unauthorized starts. Failure to
follow this instruction may result in serious personal injury.

Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the
vehicle weight, including any vehicle cargo or modifications. Identify the correct jacking
points in section 100-02 of this manual. Position the vehicle on a hard, level surface. After
jacking, always support vehicle with jack stands. Never get under a vehicle supported
only by a jack. Set the parking brake and block all wheels remaining on the ground.
Failure to follow these instructions may result in unintended vehicle movement and
serious personal injury or death.

Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for
the vehicle weight, including any vehicle cargo or modifications. Always position the hoist
lift arms as shown in section 100-02 of this manual. Do not use the engine to power the
drive wheels unless all drive wheels are elevated off the ground. Incorrect hoist arm
positioning or drive wheels in contact with the ground can cause unintended vehicle
movement. Failure to follow these instructions may result in serious personal injury or
death.

Removal of heavy components (such as engines, transmissions or axles) while the

vehicle is lifted on a hoist may create a dangerous weight imbalance. Restrain the vehicle
on the hoist with chains or straps to prevent vehicle movement. Failure to follow this
instruction may result in serious personal injury or death.

Always secure transmission, transfer case, and axle assemblies to their service jack.
Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or
contact with obstructions may cause the assembly to fall off the jack, which could result
in serious personal injury.

Always secure engines, transmissions, or other heavy components to the support

fixture with straps and wooden support blocks. Improperly secured assemblies could fall
off the fixture, resulting in serious personal injury.

Never support an engine by the intake or exhaust manifolds. The engine may drop
suddenly. Failure to follow this instruction may result in serious personal injury.

Turn off (disable) the power running boards (if equipped) before jacking, lifting or
placing any object under the vehicle. Never place your hand between the power running
board and the vehicle. Extended power running boards will retract when doors are closed.
Failure to follow these instructions may result in serious personal injury.

Keep solvents away from ignition sources. Solvents may be flammable and can
ignite or explode if not handled correctly. Failure to follow this instruction may result in
serious personal injury.

Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when
removing fasteners. Failure to follow this instruction may result in injured fingers.
Carefully review the safety warnings for each system using the links below before beginning
any service or repair.

For additional information, refer to in this section.

For additional information, refer to: Climate Control System Health and Safety Precautions
(100-00 General Information, Description and Operation).

For additional information, refer to: Battery and Battery Charging Health and Safety
Precautions (100-00 General Information, Description and Operation).

For additional information, refer to: Brake and Clutch Systems Health and Safety
Precautions (100-00 General Information, Description and Operation).

For additional information, refer to: Body Repair Health and Safety and General Precautions
(100-00 General Information, Description and Operation).

For additional information, refer to: Engine Cooling System Health and Safety Precautions
(100-00 General Information, Description and Operation).

For additional information, refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and
Safety Precautions (100-00 General Information, Description and Operation).
For additional information, refer to: Diesel Fuel System Health and Safety Precautions (100-
00 General Information, Description and Operation).

For additional information, refer to: Liquefied Petroleum Gas (LPG) and Compressed Natural
Gas (CNG) Fuel Systems Health and Safety Precautions (100-00 General Information,
Description and Operation).

For additional information, refer to: Pyrotechnic Device Health and Safety Precautions (100-
00 General Information, Description and Operation).

For additional information, refer to: Wheel and Tire Health and Safety Precautions (100-00
General Information, Description and Operation).
General Information - Pyrotechnic Device
Health and Safety Precautions
Print

Description and Operation

WARNINGS:

Service and handling of Pyrotechnic Components is restricted to qualified personnel.

The required qualifications vary by region. Always observe local laws and legislative
directives regarding Pyrotechnic Components service and handling. Failure to follow this
instruction may result in serious personal injury or death.

INHALED: Exposure to pyrotechnic residue may cause low blood pressure, severe
headache, irritation of mucous membranes, fainting, shortness of breath or rapid pulse.
Move a victim to fresh air. Seek immediate medical attention.

EYE CONTACT: Exposure to unburned pyrotechnic residue may cause irritation,

burning and etching of the eyes. Flush immediately with plenty of cold running water for
at least 15 minutes. Seek immediate medical attention.

EYE CONTACT: Exposure to burned pyrotechnic residue may cause irritation, burning
and etching of the eyes. Flush immediately with diluted boric acid solution. Seek
immediate medical attention.

SKIN CONTACT: Unburned pyrotechnic residue may be rapidly absorbed through the
skin in toxic quantities. Wash immediately with plenty of soap and water. Seek medical
attention.

SKIN CONTACT: Burned pyrotechnic residue may be rapidly absorbed through the
skin in toxic quantities. Wash with plenty of water. Do not use soap. Seek medical
attention.

SWALLOWED: Unburned pyrotechnic residue is extremely toxic. If conscious drink

plenty of water then induce vomiting. Seek immediate medical attention. If unconscious,
or in convulsions do not attempt to induce vomiting or give anything by mouth. Seek
immediate medical attention.

SWALLOWED: Burned pyrotechnic residue is extremely toxic. Drink plenty of water

and seek immediate medical attention.

The deployment key must only be accessible to authorized personnel.

Make sure that the deployment key remains removed from the deployment
equipment except during deployment.

If permenantly disabling or enabling the passenger air bag a new seat belt for
vehicles without or with a passenger air bag must be installed.

Undeployed pyrotechnic components must not be deployed in the vehicle.

Pyrotechnic components must be deployed following local regulations.

Check thoroughly that no loose objects can be spread during the deployment of
pyrotechnic components.

Pyrotechnic components must be transported following local regulations.

Never carry out any electrical measurement on disconnected, undeployed

pyrotechnic components.
Pyrotechnic components must not be disassembled.

Pyrotechnic components are not interchangeable between vehicles.

Always carry a live air bag module away from the body with the air bag or trim
cover pointing upwards.

Live air bag modules must be placed in a suitable cage when removed from the
vehicle. The air bag or trim cover must be facing upwards.

Do not install a rearward facing child safety seat to the passenger seat with an
activated passenger air bag.
NOTICE:

Pyrotechnic components must not be subjected to temperatures higher than 110°C.

Never install aftermarket accessories to the vehicle on or adjacent to the

supplemental restraint system module.
General Information - Road/Roller
Testing
Print

Description and Operation

Road or roller testing may be carried out for various reasons and a procedure detailing pre-
test checks, engine starting and stopping, pre-driving checks, on-test checks and final
checks to be completed on completion of the test is given below.
Unless complete vehicle performance is being checked, the full road test procedure need
not be carried out. Instead, those items particularly relevant to the system(s) being
checked can be extracted.
Pre-Test Checks

WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for
the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional tests of those systems and circuits which
affect the safe and legal operations of the vehicle, such as brakes, lights and steering,
should always be carried out before the road or roller test.
With the ignition switched off, check:

• the engine oil level.

• the engine coolant level.
• the tires, for correct pressure, compatible types and tread patterns, and wear within
limits.
• that there is sufficient fuel in the tank to complete the test.
• all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and
fuel leaks. Make a note of any apparent leaks and wipe off the surrounding areas to make
it easier to identify the extent of the leak on completion of the test.

Starting the Engine

NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress
the accelerator pedal beyond half travel until the vehicle has attained a minimum speed
of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator
pedal at full travel whilst the engine is cold.
With the ignition switched off, check:

• that the parking brake is applied.

• that the gear lever is in the neutral position.
• that all instrument gauges (except fuel gauge) read zero.

With the ignition switched on, check:

• that the ignition controlled warning lamps are illuminated.

• that the engine temperature gauge registers a reading compatible with the engine
temperature.
• that the fuel gauge registers a reading appropriate to the fuel level in the tank.
• the operation of the parking brake warning lamp and fluid level warning indicator.

Road or Roller Testing

NOTICE: If road testing, check the brake operation while still traveling at low speed
before continuing with the test. If the brakes pull to one side, or appear to be otherwise
faulty, do not continue with the road test until the fault has been found and rectified.
During the road or roller test, check:

• that the clutch pedal operation is not stiff or heavy.

• that the initial gear engagement is smooth and there is no evidence of clutch drag.
• that the parking brake control operates smoothly and releases quickly and completely.
• that the clutch takes up the drive smoothly, without slip or judder.
• that gear changing is smooth with no abnormal noises or vibrations from the
transmission.
• the engine power output is satisfactory, full power is achieved, acceleration is smooth
and pedal operation is not stiff or heavy, and engine speed returns to idle correctly.
• there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
• that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play or vibration.
• that the steering does not pull to one side and self centers smoothly after cornering.
• that the speedometer, coolant temperature gauge and tachometer (if equipped) register
the correct readings and operate correctly.
• that the switches and controls operate smoothly and positively, warning and indicator
lamps operate correctly and the direction indicator control self cancels when the steering
is returned to the straight ahead position.
• that the heating and ventilation systems operate correctly and effectively.
• the brake operation and efficiency.

Brake Testing

WARNING: When brake testing, avoid breathing the fumes from hot brakes, this may
contain asbestos dust which is hazardous to health. Failure to follow this instruction may
result in personal injury.
For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
NOTICE:

Avoid brake testing on busy roads where it may cause inconvenience or danger to
other road users.

Brake testing which includes heavy brake applications should not be carried out with
new brake pads/discs or linings/drums until the components have bedded-in. New brake
friction components will not reach full efficiency until the bedding-in process is complete.
Test the brakes at several speeds within the normal operating range using both light and
heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in
application or release.
Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the
brakes are binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check
the brake temperature. A brake disc or brake drum that feels hot or is appreciably hotter
than the others, indicates that the brake is binding.
After completion of the test, check for:

• oil, coolant, hydraulic, air and fuel leaks.

• abnormal temperature of any moving components or assemblies, for example wheel
hubs, transmission and axle, which might indicate over tightness or lack of lubrication.
General Information - Solvents, Sealants
and Adhesives
Print

Description and Operation

Introduction

WARNING: Always handle all solvents, sealers and adhesives with extreme care.
Some contain chemicals or give off fumes which can be dangerous to health. Always
follow the manufacturers instructions. If in doubt about any substance, particularly a
solvent, DO NOT use it.

NOTICE: If in doubt about the suitability of any proprietary solvent or sealer for a
particular application, contact the manufacturer of the product for information regarding
storage, handling and application.
The Health and Safety Precautions subsection refers to some commonly used chemicals and
materials, hazards associated with their use, and safety measures to be taken.
General Information - Steering System
Health and Safety Precautions
Print

Description and Operation

WARNINGS:

When handling the power steering fluid, always wear protective goggles and gloves
made of nitril.

EYE CONTACT: Power steering fluid contains long chain alkyl amine thiophosphate.
Avoid contact with the eyes. Wash hands thoroughly after handling. If power steering
fluid comes into contact with the eyes, flush the eyes with plenty of cold running water
for 15 minutes. Seek medical attention for any persistent eye irritation or abnormality.

SKIN CONTACT: If power steering fluid comes into contact with the skin, remove
contaminated clothing. Wash affected areas of skin with soap and water. Seek medical
attention for any persistent skin irritation or abnormality.

INHALED: If oil mist is inhaled, move a victim to fresh air. Keep a victim warm and
at rest. Seek immediate medical attention in cases of throat irritation or coughing.

SWALLOWED: Power steering fluid contains long chain alkyl amine thiophosphate. If
swallowed, drink plenty of water. Seek immediate medical attention.

Do not activate the APA system when the vehicle is on a roller rig.

Do not activate the APA system when working on any part of the steering system.
NOTICE:

When activated, the active park assist (APA) system may control the steering
system.

If the power steering fluid is spilled on the paintwork, the affected area must be
immediately washed down with cold water.
General Information - Wheel and Tire
Health and Safety Precautions
Print

Description and Operation

WARNINGS:

Never inflate a tire that has been run flat without first removing the tire from the
wheel to inspect for damage. A damaged tire can fail during inflation. Failure to follow this
instruction may result in serious personal injury.

Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type

wheels. Incorrect combinations could result in tire separation from wheel and may result
in serious injury to vehicle occupant(s).

Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal
of wheels from the vehicle. Failure to follow this instruction may result in serious personal
injury.

Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual
rear wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels
can loosen after initial tightening. Failure to follow this instruction may result in serious
injury to vehicle occupant(s).

Always match the tire size to the wheel size during assembly. Incorrect matching
can result in tire bead damage or tire separation from the wheel. Failure to follow this
instruction may result in serious personal injury to technician or vehicle occupant(s).

Do not weld or peen wheels. A wheel needing such repairs must have a new wheel
installed. Failure to follow these instructions may result in wheel failure and serious
personal injury.
General Information - Window Glass
Health and Safety Precautions
Print

Description and Operation

WARNINGS:

Cured polyurethane (PU) adhesive can degrade if subjected to high temperatures.

Isocyanide compounds can be released when grinding or welding in close proximity to
cured PU adhesive.

SKIN CONTACT: Prolonged exposure to polyurethane (PU) adhesive may cause skin
irritation. If PU adhesive comes into contact with the skin, remove any contaminated
clothing. Immediately wash the skin with soap and water. Seek medical attention for any
persistent skin irritation or abnormality.

EYE CONTACT: Polyurethane (PU) adhesive may cause severe irritation or damage.
If PU adhesive comes into contact with the eyes, immediately flush eyes with plenty of
running water for at least 15 minutes. Seek immediate medical attention.

SWALLOWED: If polyurethane (PU) adhesive is swallowed, flush the mouth

thoroughly. Do not induce vomiting. Provide rest, warmth and fresh air. Seek immediate
medical attention.

INHALED: Persons having a respiratory allergy may have an allergic reaction when
handling polyurethane (PU) adhesive.

INHALED: Polyurethane (PU) adhesive can cause asthma like symptoms. Isocyanate
vapor from primer or PU adhesive can cause allergies in the respiratory tract.

INHALED: If polyurethane (PU) adhesive fumes are inhaled, move victim to fresh air.
Provide oxygen if necessary. If breathing stops, provide artificial respiration. Keep a
victim warm and at rest. Seek immediate medical attention.
NOTICE:

Make sure that the direct glazing for bonded glass cutting blades are changed where
the cutting depth changes to avoid damage to the body and trim panels.

During the curing period of the PU adhesive, the door windows must be left open to
avoid a build up of pressure when the doors are opened and closed.
Identification Codes - Identification Codes
Print

Description and Operation

NOTE: The vehicle identification number (VIN) can be identified by an asterisk (*) at its
start and finish.
The visible VIN (label) is located on the instrument panel close to the windshield glass on
the driver side of the vehicle and is visible from the outside.
The VIN is also stamped on the VIN plate. The VIN plate is located on the passenger side
B-pillar.

Item Part Number Description

1 – Visible VIN, shown for a LHD vehicle
2 – VIN plate
Vehicle Identification Number
Item Description
3 Possible VIN positions
The VIN for registration purposes is stamped onto the front side member or the apron
panel, depending on the build date.
For detailed information regarding VIN and VIN plate numbering system, refer to FordEcat.
Part Number
-
Jacking and Lifting - Jacking and Lifting - Overview
Print

Description and Operation

Jacking

WARNING: Follow the safety instructions in the group 100-00 General Information.
Failure to follow this instruction may result in serious personal injury.

Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
Lifting
Noise, Vibration and Harshness - Noise, Vibration and
Harshness (NVH)
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the concern is not visually evident, verify the symptom and REFER to the Symptom
Chart.

How to Use this Diagnostic Procedure Section

• Noise, vibration and harshness (NVH) concerns have become more important as vehicles
have become more sensitive to these vibrations. This section is designed to aid in
identifying these concerns.
• The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place to start is under Shake and Vibration While
Driving.
• The road test procedure will tell how to sort the conditions into categories and how to tell
a vibration from a shake.
• A series of Road Test Quick Checks are provided to make sure that a cause is either
pinpointed or eliminated.
• Name the condition, proceed to the appropriate section and locate the correct diagnosis.
When the condition is identified, the job is partly done.
• Follow the diagnostic procedure as outlined.
• Quick Checks are described within the step, while more involved tests and adjustments
are outlined in General Procedures.
• Always follow each step exactly and make notes to recall important findings later.

Customer Interview

The road test and customer interview (if available) provide information that will help
identify the concern and will provide direction to the correct starting point for diagnosis.
Identify the Condition

NVH usually occur in four areas:

• tires
• engine accessories
• suspension
• driveline

It is important, therefore, that an NVH concern be isolated into its specific area(s) as soon
as possible. The easiest and quickest way to do this is to carry out the Road Test as
outlined. To assist in the diagnosis and testing procedure(s), use a suitable approved NVH
diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise

The five most common sources of non-axle noise are exhaust, tires, roof racks, trim panels
and transmission.
Therefore, make sure that none of the following conditions are the cause of the noise before
proceeding with a driveline teardown and diagnosis.
• In certain conditions, the pitch of the exhaust may sound very much like gear noise. At
other times, it can be mistaken for a wheel bearing rumble.
• Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic. Also, any non-standard tire with an
unusual tread construction may emit a roar or whine noise.
• Trim panels can also cause whistling or whining noise.
• Clunk may be a metallic noise heard when the automatic transaxle is engaged in
"R" (REVERSE) or "D" (DRIVE) or it may occur when the throttle is applied or released. It
is caused by backlash somewhere in the driveline.
• Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
damaged wheel bearing.

Noise Conditions

• Gear noise is typically a howling or whining due to gear damage or incorrect bearing
preload. It can occur at various speeds and driving conditions, or it can be continuous.
• Chuckle is a particular rattling noise that sounds like a stick against the spokes of a
spinning bicycle wheel. It occurs while decelerating from 64 km/h (40 mph) and can
usually be heard all the way to a stop. The frequency varies with vehicle speed.
• Knock is very similar to chuckle, though it may be louder and occurs on acceleration or
deceleration. The teardown will disclose what has to be corrected.

Clicking, popping or grinding noises may be caused by the following:

• worn, damaged or incorrectly installed wheel bearing, suspension or brake component.

Check and rule out tires, exhaust and trim items before disassembling the transmission to
diagnose and correct gear noise.
The noises described under Road Test usually have specific causes that can be diagnosed
by observation as the unit is disassembled. The initial clues are the type of noise heard on
the road test and driving conditions.
Vibration Conditions

Vibration at highway speeds may be caused by the following:

• out-of-balance front or rear wheels.

• out-of-round tires.

Shudder or vibration during acceleration may be caused by the following:

• damaged powertrain/drivetrain mounts.

• excessively high constant velocity (CV) joint operating angles caused by incorrect ride
height. Check ride height, verify correct spring rate and check items under inoperative
conditions.

Road Test
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and
may be audible at certain speeds or under various driving conditions, as on a newly paved
asphalt road. The slight noise is in no way detrimental and must be considered normal.
The road test and customer interview (if available) provide information needed to identify
the condition and give direction to the correct starting point for diagnosis.

1. Make notes throughout the diagnosis routine. Make sure to write down even the
smallest bit of information, because it may turn out to be the most important.

2. Do not touch anything until a road test and a thorough visual inspection of the vehicle
have been carried out. Leave the tire pressures and vehicle load just where they
were when the condition was first observed. Adjusting tire pressures, vehicle load or
making other adjustments may reduce the condition(s) intensity to a point where it
cannot be identified clearly. It may also inject something new into the system,
preventing correct diagnosis.
3. Make a visual inspection as part of the preliminary diagnosis routine, writing down
anything that does not look right. Note tire pressures, but do not adjust them yet.
Note leaking fluids, loose nuts and bolts, or bright spots where components may be
rubbing against each other. Check the load space for unusual loads.

4. Road test the vehicle and define the condition by reproducing it several times during
the road test.

5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This
will identify the correct diagnostic procedure. Carry out the Road Test Quick Checks
more than once to verify they are providing a valid result. Remember, the Road
Test Quick Checks may not tell where the concern is, but they will tell where it is
not.

Road Test Quick Checks

1. 24-80 km/h (15-50 mph): with light acceleration, a moaning noise is heard and
possibly a vibration felt in the front floor panel. It is usually worse at a particular
engine speed and at a particular throttle setting during acceleration at that speed. It
may also produce a moaning sound, depending on what component is causing it.
REFER to Tip-in Moan in the Driveline Noise and Vibration Symptom Chart.

2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is

sometimes noticed in the steering wheel/column, seats, front floor panel, front door
trim panel or front end sheet metal. It is a low frequency vibration (around 9-15
cycles per second). It may or may not be increased by applying the brakes lightly.
REFER to Idle Boom/Shake/Vibration in the Driveline Noise and Vibration Symptom
Chart.

3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake,
but with an accompanying sound or rumble, buzz, hum, drone or booming noise.
Coast with the clutch pedal depressed (manual transmission) or shift control
selector lever in "N" (NEUTRAL) (automatic transmission) and engine idling. If
vibration is still evident, it may be related to wheels, tires, front brake discs, wheel
hubs or front wheel bearings. REFER to Shake and Vibration While Driving in the
Driveline Noise and Vibration Symptom Chart.

4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular
rpm. It will disappear in neutral coasts. The vibration can be duplicated by operating
the engine at the problem rpm while the vehicle is stationary. It can be caused by
any component, from the accessory drive belt to the clutch or torque converter
which turns at engine speed when the vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise and Vibration Symptom Chart.

5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to
the following:

• worn, damaged or incorrectly installed front wheel bearing.

• damaged powertrain/drivetrain mounts.

Road Conditions
An experienced technician will always establish a route that will be used for all NVH
diagnosis road tests. The road selected should be reasonably smooth, level and free of
undulations (unless a particular condition needs to be identified). A smooth asphalt road
that allows driving over a range of speeds is best. Gravel or bumpy roads are unsuitable
because of the additional road noise produced. Once the route is established and
consistently used, the road noise variable is eliminated from the test results.
NOTE: Some concerns may be apparent only on smooth asphalt roads.
If a customer complains of a noise or vibration on a particular road and only on a particular
road, the source of the concern may be the road surface. If possible, try to test the vehicle
on the same type of road.
Vehicle Preparation
Carry out a thorough visual inspection of the vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust any condition until the road test is
carried out, unless the vehicle is inoperative or the condition could pose a hazard to the
technician. After verifying that the condition has been corrected, make sure all components
removed have been installed.
Power Steering Conditions
Check for the noise in the following conditions to verify the customer concern.

• Check for the noise in several temperature conditions.

• Is the noise from when the vehicle was new?
• Can the noise be repeated constantly or is it random?
• Check the condition of the vehicle age, mileage and service record.
• Interview the customer to find the operating condition in which the noise will occur. Test
the vehicle based on the detail(s) from the customer interview.
• Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.

Power Steering Operation Noise Check

Step 1: Check for NVH concerns from non-steering components, which may sound like
noises coming from the steering system.

Power assisted steering operating condition

Parking Driving
Steering central/slightly Steering at a steering Driving straight ahead Cornering condition
off center lock stop
REFER to NVH concerns REFER to NVH REFER to NVH REFER to NVH
from other components concerns from other concerns from other concerns from other
column A components column B components column C components column D

NVH CONCERNS FROM OTHER COMPONENTS

NVH concerns from other condition (column A to D)

Noise Driving Condition A B C D
Pedal box knocking Drive off, stop driving and slow X X O X
cornering over uneven roads
Stabilizer bar link Drive off, driving and cornering X O O X
knocking
Engine support Drive off, driving, acceleration and X X
insulator knocking deceleration
Air conditioning Engine on, activate switch for air X X O O
knocking conditioning
Suspension knocking Drive off, driving, cornering, X O X
(Subframe, Springs) acceleration and deceleration
Constant velocity Drive off, driving, cornering, X O X
(CV) joint knocking acceleration and deceleration
Washer bottle Deceleration, acceleration and single O X
impact
Loose suspension All driving conditions O O X
bolts
Instrument panel All driving conditions. Engine rpm X X X X
rattle/squeak dependant

• X = Noise will most likely occur in this operating condition.

• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.

Step 2: Check for steering system NVH concerns according to operation condition described
at the customer interview.
Power assisted steering operating condition
Parking Driving Vehicle stationary with engine off
Steering Steering at a Steering Steering at a Steering Steering at a
central/slightly steering lock central/slightly steering lock central/slightly off steering lock
off center stop off center stop centre stop
REFER to REFER to REFER to REFER to REFER to steering REFER to
steering steering steering steering system NVH steering system
system NVH system NVH system NVH system NVH concerns column NVH concerns
concerns concerns concerns concerns E column F
column A column B column C column D

STEERING SYSTEM NVH CONCERNS

Steering System operation condition (column A to F)

Noise Driving condition A B C D E F
Moan Parking between lock stops, at engine idle and X O
also increased engine speed
Whine Driving, high engine rpm. Must be present O O X X
from new
Hiss a) Parking between lock stops. Must be X X O O
present from new
b) Holding steering wheel against lock stops. X
Must be present from new
Lock stop impact a) Parking at lock stop. Must be present from X X
knock new
Mechanical knock b) Parking between lock stops, engine OFF. X
(power assisted Must be present from new
steering (PAS)
off)
Mechanical Knock c) Parking between lock stops, engine ON (ball X
(PAS on) joint knock)
Hammer knock d) Parking into lock stop and release (vehicle X
with hydraulic power assisted steering (HPAS)
only, not for vehicles with electro-hydraulic
power assisted steering (EHPAS))
Hydraulic knock e) Driving, cobble stones, rough road (clonk). O X
(clonk) Must be present from new
Column knock f) Parking, driving. cobble stones and rough X X O X X X
roads
Column rattle Mainly driving on rough roads O X X O
Toc-toc Steering left and right at high frequency. Must X
be present from new
Grinding When turning steering wheel X O X
Zip At engine start, low temperatures below -10°C X O
only

• X = Noise will most likely occur in this operating condition.

• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.

Step 3: According to each identified operating condition (Column A, B, C, D, E, F), check

each possible Steering System NVH concern with the detail symptom charts below.
Before conducting a vehicle test to identify a NVH concern carry out the following checks.

1. Check the tire pressures and adjust to specification, as necessary.

2. Make sure the steering system fluid is correct, the system is free of leaks and is
operating correctly.

3. Make sure the vehicle steering system temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively quiet location.

5. The heating - air conditioning (A/C) fan and radio must be turned off during
evaluations and the windows closed.

Symptom Chart
Power Steering Moan Noise

Test Condition
Listen for steering moan noise with the vehicle parked, transmission in neutral and all
windows closed in the following test conditions.

1. Engine speed at idle with no steering action.

2. Engine speed at idle with slow 90 degrees per second turning of the steering wheel.

3. Engine speed at 1250 +/- 50 rpm with no steering action.

4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the
steering wheel.

Symptom Possible Sources Action

Power steering lines. • CHECK the routing of the
power steering lines.
• CHECK the power
steering line clamps are
secure.
• CHECK the power
steering lines for
Power steering system moan
clearance from the
noise – A continuous low
vehicle body, front axle
pitched humming noise occurs
crossmember and
when the steering wheel is
steering gear.
turned and the steering system
Incorrect power steering fluid. FLUSH the power steering
is loaded. Noise frequency
system. REFER to: Power
changes with engine rpm
Steering System Flushing
changes. Particularly annoying
(211-00 Steering System -
at lower engine speed.
General Information, General
Procedures).
Power steering pump. Pressure pulses from the
power steering pump. Certain
amount of noise level
acceptable, not a safety critical
item.
Power Steering Whine Noise

Test Condition
Listen for steering whine noise with the vehicle parked, transmission in neutral and all
windows closed in the following test conditions.

1. Engine speed at 1800 +/- 50 rpm with no steering action.

2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering wheel.

3. Engine speed at 3000 +/- 50 rpm with no steering action.

4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering wheel.

Symptom Possible Sources Action

Power steering system whine Power steering fluid aeration. BLEED the power steering
noise – a high pitched buzzing system.
sound like an electric motor or REFER to: Power Steering
Symptom Possible Sources Action
System Bleeding (211-00
Steering System - General
Information, General
Procedures).
Incorrect power steering fluid. FLUSH the power steering
system. REFER to: Power
Steering System Flushing (211-
drill. Whine occurs at the 00 Steering System - General
higher engine rpm, 1500 - Information, General
5000 rpm, frequency does not Procedures).
change if system is loaded or Overheated power steering FLUSH the power steering
not loaded. fluid. system. REFER to: Power
Steering System Flushing (211-
00 Steering System - General
Information, General
Procedures).
Hydraulic operating condition Certain amount of noise level
of the power steering pump. acceptable, not a safety critical
item.
Power Steering Hiss Noise

Test Condition
Listen for steering hiss noise with the vehicle parked, transmission in neutral and all
windows closed in the following test conditions.

Symptom Possible Action

Sources
NOTE: Engine speed at idle turning the steering wheel Floor seal. CHECK the
slowly lock to lock. installation and
Power steering system hiss noise – a high frequency, potential damage of
continuous rush or swish noise like escaping air from a the floor seal.
balloon. Hiss occurs while turning between the steering Power steering Certain amount of
lock stops, all steering angles. Noise does not change with gear valve noise level
engine rpm and is worse at high operating temperatures. design. acceptable, not a
safety critical item.
Power steering Certain amount of
system noise level
hydraulic acceptable, not a
design. safety critical item.
NOTE: Engine speed at idle holding the steering wheel Power steering Certain amount of
against a steering lock for three seconds. Do not hold pump noise level
for more than five seconds. pressure relief acceptable, not a
Power steering system hiss noise – a continuous noise like valve. safety critical item.
escaping air occurs while holding the steering against a
steering lock stop.
Power Steering Lock Stop Impact Knock Noise

Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions
(noise also apparent with engine off).

1. Turn the steering wheel to the left-hand and right-hand steering locks and listen for
the impact noise.

Symptom Possible Sources Action

Power steering system knock noise – a Power steering gear Certain amount of noise
heavy loud sound like a knock on a door mechanical noise, metal to level acceptable, not a
that occurs in parking condition when metal at end of steering safety critical item.
hitting the lock stop. travel.
Power Steering Mechanical Knock Noise (PAS off)
Test Condition
Listen for steering knock noise with the engine off in the following test conditions (no power
assist).

1. Turn the steering wheel 90 degrees to the right, hold and then quickly release.

2. Turn the steering wheel 90 degrees to the left, hold and then quickly release.

Symptom Possible Sources Action

Power steering system knock noise – Certain amount of
a damped, metallic knock noise noise level
Power steering system knock noise which only occurs at steering acceptable, not a
– a heavy loud repeating sound like condition with engine off (very high safety critical item.
a knock on a door that occurs in efforts).
several driving and steering Tolerances in the steering gear Certain amount of
conditions. components. noise level
acceptable, not a
safety critical item.
Power Steering Mechanical Knock Noise (PAS on)

Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions
(power assist).

1. Turn the steering wheel to a steering lock and return to center quickly.

2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right
quickly.

Symptom Possible Sources Action

Power steering system knock Worn tie-rod ball REFER to Steering System.
noise – clear knock noise from joints (inner and REFER to: Steering System (211-00
steering gear linkage area. outer ball joints). Steering System - General
Information, Diagnosis and Testing).
Power Steering Hammer Knock (Hydraulic) Noise

Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions
(for vehicles with hydraulic power assisted steering only, not electro-hydraulic power
steering).

1. Turn the steering wheel to a steering lock position and return quickly.

Symptom Possible Sources Action

Power steering system knock noise – loud, metallic Hydraulic noise Certain amount of
sound if hitting the suspension crossmember with a created by noise level acceptable,
hammer (sounds like metallic noise but is created by pressure not a safety critical
pressure impulse in gear and return line). impulses. item.
Power Steering Hydraulic Knock/Clonk Noise

Test Condition
Listen for steering knock/clonk noise in the following test conditions with the windows
closed.

1. Drive over cobbled roads at low speed 10-30 km/h (6-20 mph) with and without
turning.

2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed
10-30 km/h (6-20 mph) both driving straight and with moderate turning.

Symptom Possible Sources Action

Symptom Possible Sources Action
Power steering Certain amount
return lines. of noise level
acceptable, not a
safety critical
item.
Power steering system knock/clonk noise – sounds
High power assist Certain amount
almost identical to column knock that occurs when driving
gain of power of noise level
and cornering over cobbled stones or rough roads. Noise
steering gear acceptable, not a
may appear to emanate from a location closer to the floor
valve (steering safety critical
than that for column knock (Sounds like metallic noise
gear design - no item.
but is created by pressure impulse in gear and return line
quality issue).
– similar to a sound like quickly turning off a water tap).
High power Certain amount
steering pump of noise level
flow rate (by acceptable, not a
design). safety critical
item.
Power Steering Column Knock Noise

Test Condition
Listen for steering knock noise in the following test conditions with windows closed.

1. Drive over cobbled stones at low speed 16-40 km/h (10-25 mph) with and without
steering input carefully listening for knock sounds.

2. Drive over straight tar strips, road rails or 25 mm tall harshness strips at low speed
16-40 km/h (10-25 mph) both driving straight and with moderate cornering.

Symptom Possible Action

Sources
CHECK the steering column
retaining bolts and attachments to
the steering column and secure if
necessary.
Power steering system column knock
Steering column Check steering column and
noise – a loose sounding rattle or
or steering intermediate shaft for free play or
vibration coming from the column.
column shaft. loose components.
Noticeable by hearing and touch.
REFER to: Steering System (211-00
Steering System - General
Information, Diagnosis and
Testing).
Power Steering Toc-Toc Noise

Test Condition
Listen for steering toc-toc noise with the engine speed at idle and the vehicle parked,
automatic transmission in "P" (PARK) or manual transmission in neutral and the windows
closed.

1. Turn the steering wheel from left to right abruptly changing direction.

2. Drive the vehicle for low speed parking manoeuvres constantly changing steering
direction.

Symptom Possible Sources Action

Power steering system toc-toc noise – a metallic Steering gear Certain amount of noise
noise created when changing direction of (design tolerance level acceptable, not a
steering wheel rotation during parking in steering rack). safety critical item.
manoeuvre or at standstill.
Power Steering Grinding Noise

Test Condition
Listen for steering grinding noise with the engine speed at idle and the vehicle parked,
automatic transmission in "P" (PARK) or manual transmission in neutral and the windows
closed.

1. Slowly turn the steering wheel from lock to lock.

2. Tilt and extend the steering column in various positions and slowly turn the steering
wheel from lock to lock.

Symptom Possible Sources Action

Steering wheel to Certain amount of noise
shroud interference. level acceptable, not a
safety critical item.
Steering column Certain amount of noise
bearing. level acceptable, not a
safety critical item.
Power steering system grinding noise – an CHECK if floor covering is
Foreign material in
abrasive noise (like sand paper rubbing obstructing the steering
contact with the
against wood) occurs between moving gear pinion.
steering column
components such as steering wheel and the CHECK the installation of
shaft.
steering column shroud. the floor seal.
Clockspring. CHECK the clockspring and
secure if necessary.
REFER to: Clockspring
(501-20B Supplemental
Restraint System, Removal
and Installation).
Power Steering Zip Noise

Symptom Possible Sources Action

High viscosity of Certain amount of noise
power steering level acceptable, not a
fluid at low safety critical item.
Power steering system zip noise – occurs when
temperature.
hydraulic fluid does not flow freely through the
Aeration of the BLEED the power steering
power steering pump supply hose from steering
power steering system.
fluid reservoir to power steering pump causing
fluid. REFER to: Power Steering
cavitation at the pump. Zip is primarily a cold
System Bleeding (211-00
weather start-up phenomenon (below -10°C).
Steering System -
General Information,
General Procedures).
Driveline Noise and Vibration

Symptom Possible Sources Action

Shake and vibration while • Wheel end vibration. GO to Pinpoint Test A.
driving • Engine/transmission.
Tip-in moan • Air cleaner. GO to Pinpoint Test B.
• Power assisted steering.
• Powertrain.
• Powertrain/drivetrain
mounts.
• Exhaust system.
Idle • Cable(s)/hose(s). GO to Pinpoint Test C.
boom/shake/vibration/shudder • Powertrain/drivetrain
mounts.
• Exhaust system.
• Belt/pulleys.
Suspension Noise and Vibration

Symptom Possible Sources Action

Wheel end vibration analysis • Suspension. GO to Pinpoint Test D.
• Wheel bearings.
Symptom Possible Sources Action
Non-axle noise • Trim panels. GO to Pinpoint Test E.
• Air conditioning (A/C)
system.
• Accessories.
Pinpoint Tests
NOTE: These Pinpoint Tests are designed to take the technician through a step-by-step
diagnosis procedure to determine the cause of a condition. It may not always be
necessary to follow the chart to its conclusion. Carry out only the pinpoint test steps
necessary to correct the condition. Then check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been corrected, make sure all components removed
have been installed.

PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
Does the vibration disappear during the neutral coast test?
Yes
GO to A2.
No
GO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as necessary.
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as
necessary.

PINPOINT TEST B : TIP-IN MOAN

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts, inlet tube, outlet tube,
resonators and all other components associated with the air induction
system for correct installation and tightness of all connections.
Are the components OK?
Yes
GO to B2.
No
REPAIR or INSTALL new components as necessary. ROAD TEST as
necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
REFER to in this section.
Is the exhaust system OK?
Yes
GO to B3.
No
REPAIR as necessary. ROAD TEST as necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for tip-in moan. REFER to:
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and
Installation).
Is the tip-in moan OK?
Yes
REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering System - General
Information, Diagnosis and Testing).
No
GO to B4.
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the powertrain/drivetrain mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as necessary.
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as
necessary.

PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any component that may have a touch
condition between the engine and body or chassis. For example: control
cable, air conditioning (A/C) hoses, acceleration cable.
Are the components OK?
Yes
GO to C2.
No
REPAIR or INSTALL new components as necessary. ROAD TEST as
necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings and bushings for security and
condition. Check the radiator installation for any component that may have
a touch condition.
Is the installation and bushings OK?
Yes
GO to C3.
No
REPAIR or INSTALL new components as necessary. ROAD TEST as
necessary.
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
REFER to in this section.
Is the exhaust system OK?
Yes
GO to C4.
No
REPAIR as necessary. ROAD TEST as necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the powertrain/drivetrain mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as necessary.
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as
necessary.

PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis and
Testing).
Are the wheels and tires OK?
Yes
GO to D2.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Removal and
Installation).
ROAD TEST as necessary.
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
Are the wheel bearings OK?
Yes
GO to D3.
No
INSTALL new wheel bearings as necessary. REFER to: Front Wheel Bearing
(204-01 Front Suspension, Removal and Installation). ROAD TEST as
necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
Is the wheel and tire runout OK?
Yes
Balance the wheels and tires. Refer to the wheel balance equipment
manufacturer's instructions. ROAD TEST as necessary.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Removal and
Installation).
ROAD TEST as necessary.

PINPOINT TEST E : NON-AXLE NOISE

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see if they are the source of
the noise.
Are the vehicle trim components causing the noise?
Yes
INSTALL new trim components or REPAIR as necessary. ROAD TEST as
necessary.
No
GO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Start the engine.
2 Ignition ON.
3 Check the A/C system components for noise by turning the A/C system on
and off.
Is the A/C system causing the noise?
Yes
INSPECT the A/C system. REFER to:
Climate Control System (412-00 Climate Control System - General
Information, Diagnosis and Testing),
ROAD TEST as necessary.
No
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for being the source of the
noise. For example: touch condition body-to-frame, antennas, deflectors
and fog lights.
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR, or INSTALL new accessories or fasteners as required.
ROAD TEST as necessary.
No
VERIFY the customer concern.
Suspension System - General Information - Specifications
Print

FRONT WHEEL ALIGNMENT (DECIMAL DEGREES AT CURB)

SIDE TO
TOTAL
BODY WHEELBASE GVM CAMBER CASTER SIDE CLEARVISION
TOE
CASTER

Van SWB ≤3100 -0.57 2.16 0.27 0 0

3100< -0.58 1.7 0.27 0 0

MWB ≤3100 -0.5 2.35 0.27 0 0

3100< -0.48 1.95 0.27 0 0

Kombi/DCIV SWB ≤3100 -0.67 2.07 0.27 0 0

3100< -0.69 1.76 0.27 0 0

MWB ≤3100 -0.63 2.2 0.27 0 0

3100< -0.67 1.97 0.27 0 0

Bus SWB - -0.73 2.25 0.27 0 0

MWB - -0.65 2.42 0.27 0 0

Sport Van SWB - -0.27 2.07 0.27 0 0

Tolerance ±0.5 ±0.6 ±0.25 ±0.7 ±3.0

• *GVM: Gross Vehicle Mass

• DCIV: Double Cab in Van

REAR WHEEL ALIGNMENT (DECIMAL DEGREES AT CURB)

CAMBER TOE PER SIDE THRUST

-1°±0.5° 0.2°±0.4° 0°±0.45°

Suspension System - General Information
- Suspension System
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Tire pressure(s)
• Wheels and tires
• Wheel knuckles
• Tie-rod ends
• Front suspension lower arm ball joints
• Front suspension lower arm bushings
• Front strut and spring assemblies
• Front and rear stabilizer bar and connecting links
• Front axle crossmember
• Rear springs
• Rear shock absorbers
• Rear suspension beam axle and bushings

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart
The table provides all possible symptoms related to the Suspension System. For a detailed
diagnosis, proceed to the Ford diagnostic equipment.

Drift left or right Vehicle attitude incorrect (front or rear is high or low)
Steering gear or linkage worn or damaged
Brake system
Incorrect wheel alignment
Incorrect front axle crossmember alignment
Worn front wheel bearings
Wheels and tires
Steering wheel off- Vehicle attitude incorrect (front or rear is high or low)
center Steering gear or linkage worn or damaged
Lower arm ball joint
Incorrect wheel alignment
Tracks incorrectly Incorrect front suspension toe, castor or camber angles
Front or rear suspension damage
Rough ride Front strut and spring assemblies
Front or stabilizer bar, connecting links or bushings
Front suspension lower arm bushings
Rear suspension bushings
Rear shock absorbers
Excessive noise Front strut and spring assembly or rear shock absorber and spring upper
mounting bolts or nuts loose or broken
Shock absorbers leaking
Shock absorber performance incorrect
Stabilizer bar components
Strut and spring assembly and springs
Springs moving on spring upper or lower seats
Suspension bushings
Lower / Upper arm ball joint
Worn front / rear wheel bearings
Wheels and tires
Incorrect tire wear Front or rear suspension damage
Incorrect wheel alignment
Vibration Damaged or worn front wheel bearings
Wheels and tires
Incorrect wheel alignment
Steering gear or linkage worn or damaged
Front strut and spring assemblies
Damaged front suspension lower / upper arm(s)
Component Tests
Raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Ball Joint Inspection

1. Firmly grasp the outer end of the suspension lower arm and try to move it up and
down, watching and feeling for any movement. Free movement will usually be
accompanied by an audible "click". There should be no free movement.

2. If there is any free movement, install a new lower arm ball joint. REFER to: Lower
Arm Ball Joint (204-01 Front Suspension, Removal and Installation).

3. If a new lower arm ball joint is installed it will be necessary to check and adjust the
front wheel alignment. REFER to: (204-00 Suspension System - General
Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).

Strut or Shock Absorber Inspection

NOTE: Inspect the struts or shock absorber for signs of oil weepage or leaks. Make sure
that the oil is not from another source.

Weepage:
• deposits a thin film of oil on the strut and spring assembly or shock absorber.
• is normally noticed due to a collection of dust on the strut and spring assembly or shock
absorber.
• occurs during the normal running-in period of 4800 - 8050 km. After this period no new
signs of oil should be visible.
• does not require new struts or shock absorbers to be installed.

Leakage:
• covers the entire strut and spring assembly or shock absorber with oil.
• will drip oil onto the surrounding suspension components.

• requires new struts or shock absorbers to be installed.

Strut or Shock Absorber Testing

NOTE: Struts or shock absorbers must be tested in the vertical position.

1. Remove both strut and spring assemblies or shock absorbers. The piston rods should
extend.
• Disassemble the strut and spring assemblies.
REFER to: Shock Absorber and Spring Assembly (204-01 Front Suspension,
Disassembly and Assembly).

2. Compress the piston rods. Both piston rods should offer the same resistance when
compressing.

3. Compress and release the piston rods. The piston rods should extent equally.

4. Compress and pull the piston rod in the vertical position. Feel if the resistance force
at the point of direction change-over is perceptible without a lag. If a lag is
perceptible it is an indication of damper valve damage and new struts or shock
absorbers must be installed. REFER to: (204-01 Front Suspension)
Driver Side Strut and Spring Assembly - Vehicles Built Up To: 20-11-2017 (Removal
and Installation),
Passenger Side Strut and Spring Assembly - Vehicles Built Up To: 20-11-2017
(Removal and Installation).
Suspension System - General Information - Caster Adjustment
Print

General Procedures

Check
1. 1. Set two marks 550 mm apart on the frame area shown in the picture.
2. Measure and note the distance 2 between vehicle frame and ground.
3. Measure and note the distance 3 between vehicle frame and ground.
4. Subtract 3 from 2 to calculate the difference in height between 2 and 3.
5. Compare the sum with the specification. See "Difference in height" table.

Refer to: Specifications (204-00 Suspension System - General Information,

Specifications).
Suspension System - General Information
- Front Toe Adjustment
Print

General Procedures

NOTE: Make sure that the vehicle is standing on a level surface.

1. Centralize the steering and lock it in position.

2. Loosen the tie-rod end locknuts.

3. Remove the steering gear boot outer clamps.

4.
Rotate the tie-rods an equal amount in either a clockwise or a counterclockwise
direction to adjust the toe setting.
For additional information, refer to: Specifications (204-00 Suspension System -
General Information, Specifications).
5.
Tighten the tie-rod end locknuts.
For additional information, refer to: Tie Rod End (211-03 Steering Linkage,
Removal and Installation).

6. Install the steering gear boot outer clamps.

Suspension System - General Information
- Wheel Bearing Inspection
Print

General Procedures
Special Tool(s) / General Equipment
Holding Fixture, Dial Indicator Gauge
205-044 (15-008)

Dial indicator gauge

Check
1. NOTE: Do not to confuse lower arm ball joint looseness with bearing looseness.
Raise and support the front of the vehicle. For additional information, refer to:
(100-02 Jacking and Lifting)
Jacking and Lifting (Description and Operation),
Jacking and Lifting (Description and Operation).

2. Check for loose front wheel bearings by rocking the wheels at the top and bottom.

3. Spin the wheel quickly by hand and make sure the wheel turns smoothly without
noise from the wheel bearings.

4.
Remove the front brake caliper anchor plate.
For additional information, refer to: Brake Caliper (206-03 Front Disc Brake,
Removal and Installation).

5. Position a suitable Dial indicator gauge fixture or equivalent, against the wheel hub,
then push and pull the wheel hub. Measure the end play of the wheel hub and
front wheel bearing assembly. There should be no end play. If end play exists,
install new wheel bearings.

6.
Install the front brake caliper anchor plate.
For additional information, refer to: Brake Caliper (206-03 Front Disc Brake,
Removal and Installation).
Front Suspension - Front Suspension - Component Location
Print

Description and Operation

Item Description
1 Stabilizer thrust rod
2 Subframe attachment points
3 Stabilizer bar
4 Helical spring
5 Shock absorber
6 Subframe
7 Lower arms
Front Suspension - Front Suspension -
Overview
Print

Description and Operation

General information
First of all, the spring rate of the front coil springs has been reduced compared with the
previous model, leading to an improved driving behavior of the vehicle.
In addition, the lower arms are made from high-strength steel and their mountings have
been strengthened by suitable measures. Compared with the previous model, use of this
high-strength material has both increased the stability and also reduced the weight.
The front stabilizer bar has also been strengthened, leading to a considerable increase in its
torsional rigidity and thus to substantially improved driving characteristics.
Front Suspension - Wheel Knuckle
Print

Removal and Installation

Special Tool(s) / General Equipment
204-015
Remover, Drop Arm

204-288A
Remover/Installer, Ball Joint

Lower Arm Down Force Lever

Two Leg Puller

Removal
FWD

1. Refer to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and
Installation).

RWD

All vehicles
2. NOTE: Make sure that the sensor housing is clean and free of foreign material.
Torque: 11 Nm

3. NOTICE: Make sure that the ball joint ball does not rotate.
Torque: 48 Nm
4. Install Special Service Tool: 204-015.

5. Loosen: 3 turn(s)
6.
1. Use the General Equipment: Two Leg Puller

2. Torque: 150 Nm

7. Torque:
Stage 1:100 Nm
Stage 2:180°

FWD

8. Use the General Equipment: Lower Arm Down Force Lever

RWD

9. Use the General Equipment: Lower Arm Down Force Lever

All vehicles
10.

11. 1. NOTE: Note the position of the component before removal.

Use Special Service Tool: 204-288A.

Installation
Vehicles With: Lower Arm Ball Joint Secured With Two
Bolts
1.
2. Torque: 215 Nm

Vehicles With: Lower Arm Ball Joint Secured With a

Circlip
3.
4. Torque: 150 Nm

All vehicles
5. 1. NOTE: Make sure that the component is installed to the position noted before
removal.
Use Special Service Tool: 204-288A.
6. To install, reverse the removal procedure.
Front Suspension - Front Wheel Bearing and Wheel Hub
Print

Removal and Installation

Special Tool(s) / General Equipment
204-161
Installer, Halfshaft

204-595
Remover/Installer, Wheel Hub/Wheel Bearing

204-609
Protection Cap, Ball Joint Gaiter

308-072-01
Adapter for 308-072

Lower Arm Down Force Lever

Puller
Two Leg Puller

Removal

2. Crown nut
3. All nuts

4. Refer to: Wheel and Tire (204-04A, Removal and Installation).

5. NOTICE: Make sure that no load is placed on the brake hose.

6. All nuts

7. Crown nut
8.

9. Use the General Equipment: Two Leg Puller

10.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

11. NOTE: This step is only necessary when installing a new component to the left-
hand side.

12. NOTE: This step is only necessary when installing a new component to the right-
hand side.
13. Use Special Service Tool: 308-072-01.
Use the General Equipment: Puller

14. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The outer constant velocity (CV) joint must not be bent more than 45°.
16. Install Special Service Tool: 204-595.

17.
18.

19.
20.

Installation

1. NOTICE: Make sure that the mating faces are clean and free of corrosion and
foreign material.
NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
2. Torque:
Stage 1:30 Nm
Stage 2:90°

3. Torque: 53 Nm

4. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.
The outer constant velocity (CV) joint must not be bent more than 45°.

5. Use Special Service Tool: 204-161.

Torque: 45 Nm

6. Crown nut

7. NOTE: Only tighten the nut finger tight at this stage.

All nuts
8.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

Vehicles With: Lower Arm Ball Joint Secured With Two

Bolts
9.
10. Torque: 215 Nm

Vehicles With: Lower Arm Ball Joint Secured With a

Circlip
11.
12. Torque: 150 Nm

All vehicles

13. Torque: 270 Nm

14. Refer to: Wheel and Tire (204-04A, Removal and Installation).
15. 1.
2. Crown nut

Torque: 250 Nm
3.
4. Crown nut

Torque: 500 Nm

16. NOTE: Make sure a new component is installed.

Crown nut

17. 1. turn
2. Self-locking nut

Torque: 100 Nm
3.
4. Self-locking nut

Torque: 250 Nm
5.
6. Self-locking nut

Torque: 515 Nm
18.

19. Fully depress and release the brake pedal 3 times.

Refer to: Specifications (206-00 Brake System - General Information, Specifications).

Front Suspension - Front Stabilizer Bar
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

2. On both sides.

Torque: 55 Nm

3. On both sides.

Torque: 63 Nm

Installation

1. To install, reverse the removal procedure.

2. Refer to: Front Toe Adjustment (204-00 Suspension System - General Information,
General Procedures).
Front Suspension - Front Stabilizer Bar
Bushing
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

2. On both sides.

Torque: 30 Nm

3. NOTE: Note the position of the components before removal.

NOTE: Make sure that the components are installed to the position noted before
removal.
On both sides.

Installation

1. To install, reverse the removal procedure.

Front Suspension - Front Stabilizer Bar Link
Print

Removal and Installation

4. Install Suggested Tool: 204-602. Tool shown or a commercially available equivalent can
be used.
5. Use the General Equipment: Lower Arm Down Force Lever

6. Torque: 150 Nm

7. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
8. Raise the vehicle until the front road wheels are clear of the floor.
9. Crown nut

10. NOTE: Only tighten the nut and bolt finger tight at this stage.
All nuts

11. 1.
2. Crown nut

Torque: 250 Nm
3.
4. Crown nut

Torque: 500 Nm

12. Crown nut

13. 1.
2. Self-locking nut
Torque: 100 Nm
3.
4. Self-locking nut

Torque: 250 Nm
5.
6. Self-locking nut

Torque: 515 Nm

14.

15. Refer to: Front Toe Adjustment (204-00 Suspension System - General Information,
General Procedures).
Front Suspension - Driver Side Strut and Spring Assembly—Vehicles Built
Up To: 20-11-2017
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

2. Torque: 25 Nm

3. NOTICE: Make sure that the ball joint ball does not rotate.
Torque: 55 Nm
4. Torque:
Stage 1:100 Nm
Stage 2:180°

5.
6.

7.
8.

9.
10.

11.
12.

13.
15. Torque: 30 Nm

Installation

1. To install, reverse the removal procedure.

Front Suspension - Passenger Side Strut and Spring Assembly—Vehicles
Built Up To: 20-11-2017
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

2. Torque: 25 Nm

3. NOTICE: Make sure that the ball joint ball does not rotate.
Torque: 55 Nm
4. Torque:
Stage 1:100 Nm
Stage 2:180°

5.
6.

7.
8.

9.
10.

11.
12. Torque: 10 Nm

13.
14. Torque: 30 Nm

Installation

1. To install, reverse the removal procedure.

Front Suspension - Shock Absorber and Spring Assembly
Print

Disassembly and Assembly

General Equipment
Spring Compressor

Disassembly

1. WARNING: Coil springs and strut assemblies are compressed under extreme
load. Always use a spring compressor for disassembly. Follow procedure
instructions carefully and make sure the spring compressor has the correct spring
plates or adapters. Failure to follow these instructions may result in serious
personal injury.
1. Use the General Equipment: Spring Compressor

2. 2. NOTICE: Make sure that the piston rod does not rotate.

2. NOTE: Note the position of the components before removal.

Assembly

WARNING: Take extra care when handling the compressed spring.

3. NOTE: Make sure that the components are installed to the position noted before
removal.

4. WARNING: Coil springs and strut assemblies are compressed under extreme
load. Always use a spring compressor for disassembly. Follow procedure
instructions carefully and make sure the spring compressor has the correct spring
plates or adapters. Failure to follow these instructions may result in serious
personal injury.

NOTICE: Make sure that the piston rod does not rotate.
1. Torque: 70 Nm

5. Remove the General Equipment: Spring Compressor

Rear Suspension - Rear Suspension - Component Location
Print

Description and Operation

Item Description
1 Shock absorber
2 Leaf spring
3 Bump stop
Rear Suspension - Rear Suspension - Overview
Print

Description and Operation

General information
In the area of the rear leaf springs, both their mountings and also the spring leaves
themselves have been adapted to meet the demands of the new generation of engines and
their increased torque. This has been done through considerably enlarged mountings and
thicker spring leaves than on the previous model.
An elastic element (shown in blue in the illustration) supports the leaf springs in their
function. The combined effect produces a progressive spring rate that optimizes the
handling under all load conditions.
NOTE: Even a low load condition results in contact between the supporting elastic
element and the axle. This is normal and is not an indicator of a defective component or a
violation of the maximum load limit.
Rear Suspension - Axle
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2. Refer to: Brake System Draining and Filling (206-00 Brake System - General
Information, General Procedures).
3. NOTE: This step is only necessary when installing a new component.
Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Disc Brakes (204-02 Rear
Suspension, Removal and Installation).
4. NOTE: This step is only necessary when installing a new component.
Torque: 133 Nm

5. NOTE: This step is only necessary when installing a new component.

Torque: 20 Nm
6. NOTICE: Make sure that no load is placed on the brake hose.
Torque: 115 Nm

7. On both sides.
8. NOTE: Make sure that the sensor housing is clean and free of foreign material.
On both sides.

Torque: 11 Nm

Vehicles Built Up To: 09-04-2013

9. Torque: 25 Nm
Vehicles Built From: 10-04-2013

10. Torque: 25 Nm

All vehicles
11. On both sides.
12. Torque: 18 Nm

13. On both sides.

14. Torque: 80 Nm

15.
16. NOTE: This step is only necessary when installing a new component.

Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
3. NOTICE: Make sure that the components are aligned.
NOTE: Only tighten the nuts finger tight at this stage.

4. NOTE: Only tighten the nuts and bolts when the suspension is in the normal drive
position.
Torque:
Stage 1:25 Nm
Stage 2:50 Nm
Stage 3:75 Nm
Stage 4:100 Nm
Stage 5:125 Nm
Stage 6:150 Nm
Stage 7:175 Nm
5. Equally tighten the U-bolts to ensure that the length x doesn’t differ more than 3mm.

6. Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information,
General Procedures).
Rear Suspension - Rear Shock Absorber
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2.
1. Torque: 175 Nm

2. Torque: 110 Nm

Installation

1. To install, reverse the removal procedure.

Rear Suspension - Wheel Bearing and Wheel Hub—Vehicles With: Rear
Disc Brakes
Print

Removal and Installation

Special Tool(s)
204-595
Remover/Installer, Wheel Hub/Wheel Bearing

204-595-09
Adapter for 204-595

205-295
Remover, Bearing (Main Tool)

205-295-05
Collet for 205-295

Removal

1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2. If equipped.
3. NOTICE: Make sure that no load is placed on the brake hose.

4. NOTE: Note the position of the components before removal.

5. Install Special Service Tools: 204-595, 204-595-09.

6. Install Special Service Tools: 205-295, 205-295-05.

Installation

1. Torque: 72 Nm
2. NOTE: Vehicles are equipped with a wheel hub retaining nut with a flange diameter
of either 45 mm or 51,2 mm.
Measure the wheel hub retaining nut flange diameter to aid installation.

3. NOTE: Only tighten the nut finger tight at this stage.

NOTE: Make sure that the components are installed to the position noted before
removal.
4.

5. Rotate the wheel hub in the opposite direction while tightening the wheel hub retaining
nut to the specified torque.

Torque: 200 Nm
6.

7. Rotate the wheel hub in the opposite direction while tightening the wheel hub retaining
nut to the specified torque.

Torque:
Wheel hub retaining nut with a flange diameter of 44mm 300 Nm
Wheel hub retaining nut with a flange diameter of 51mm 420 Nm
8.

9. Torque: 115 Nm
10. NOTE: Make sure that a new component is installed.

11. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
Rear Suspension - Spring
Print

Removal and Installation

General Equipment
Transmission Jack

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Use the General Equipment: Transmission Jack

3.
4.

5.
Installation

1.
1. Torque: 175 Nm

2. Torque: 275 Nm

2.
3. NOTICE: Make sure that the components are aligned.
NOTE: Only tighten the nuts finger tight at this stage.

4. To install, reverse the removal procedure.

5. NOTE: Only tighten the nuts and bolts when the suspension is in the normal drive
position.
Torque:
Stage 1:25 Nm
Stage 2:50 Nm
Stage 3:75 Nm
Stage 4:100 Nm
Stage 5:125 Nm
Stage 6:
150 Nm
Stage 7:175 Nm

6. Equally tighten the U-bolts to ensure that the length x doesn’t differ more than 3mm.
Rear Suspension - Wheel Spindle
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Disc Brakes (204-02 Rear
Suspension, Removal and Installation).

2. Torque: 133 Nm

Installation

1. To install, reverse the removal procedure.

Rear Suspension - Rear Stabilizer Bar
Print

Removal and Installation

Removal

NOTICE: Suspension fasteners are critical parts that affect the performance of vital
components and systems. Failure of these fasteners may result in major service expense.
Use the same or equivalent parts if replacement is necessary. Do not use a replacement
part of lesser quality or substitute design. Tighten fasteners as specified.
NOTE: Removal steps in this procedure may contain installation details.
1. NOTE: Do not use power tools to remove or install the stabilizer bar link nuts.
Damage to the stabilizer bar link ball joints and boots may occur.

2. Torque: 70 Nm

3. Remove and discard the rear stabilizer bar bracket bolts and remove the rear stabilizer
bar.

Torque: 70 Nm
4. NOTE: Do not use any lubrication on the stabilizer bar or the bushings or damage
to bushings may occur.
NOTE: Stabilizer bar bushings must be installed with slits facing the front of the
vehicle.
Inspect and, if necessary, install new stabilizer bar bushings.

Installation

1. To install, reverse the removal procedure.

2. NOTE: Apply water to the brackets to aid in installation.
Press the rear stabilizer bar brackets in place onto the rear stabilizer bar bushings.
Rear Suspension - Rear Stabilizer Bar Link
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. On both sides.Remove and discard the rear stabilizer bar link bolts and nuts and remove
he rear stabilizer bar link.

Torque:
1. 110 Nm
2. 70 Nm

Installation

1. To install, reverse the removal procedure.

Wheels and Tires - Specifications

BUS - TYRE PRESSURES (COLD TYRES)

VARIANT TIRE SIZE

300S 215/65 R 15 C

300S 215/65 R 16 C

300L 215/65 R 15 C

300L 215/65 R 16 C

VAN AND KOMBI - FRONT WHEEL DRIVE - TYRE PRESSURES (COLD TYRES)

NOTE: There are two options for tire pressures on your vehicle. The standard tire pressures are suitable for the majority of customers, giving the best balance

VARIANT TIRE SIZE

250S and 270S 215/65 R 15 C

250S and 270S 215/65 R 16 C

290S 215/65 R 15 C

290S 215/65 R 16 C

290S 235/50 R 18

290L 215/65 R 15 C

290L 215/65 R 16 C

300S 215/65 R 15 C

300S 215/65 R 16 C

300L 215/65 R 15 C

300L 215/65 R 16 C

310S 215/65 R 15 C

310S 215/65 R 16 C

310L 215/65 R 15 C

310L 215/65 R 16 C

330S 215/65 R 16 C

330L 215/65 R 16 C

330L SVO 215/65 R 16 C

VARIANT

All 185/75 R 16 C
Wheels and Tires - Wheels and Tires - Overview
Print

Description and Operation

General information

Item Description
1 Steel wheel rims (15" and 16")
2 Aluminum alloy rims (16")
3 Aluminum alloy rims (18")
Tire and wheel rim combinations

The following tire and wheel rim combinations are available:

• 6.5J x 15 steel wheel rim
- 215/65 R15C 104/102 T
• 6.5J x 16 steel or aluminum alloy wheel rim
- 215/65 R16C 109/107 R
• 7.5J x 18 aluminum alloy wheel rim
- 235/50 R18 101 W

Use of snow chains

If your vehicle has 215/65 R 16 C or 235/50 R 18 tires, fit 185/75 R 16 C tires to the front
wheels. Pump up the tires to the maximum permitted tire pressure.
Before fitting the snow chains, the tire pressure must be increased to the maximum
permitted value for this tire size. In addition, only fine-linked snow chains are allowed to be
used.
NOTE: The tire size 185/75 R 16 C is only permitted to be mounted on the front axle.
Spare wheel
Item Description
1 Winch
2 Safety cable
3 Bracket, wheel-side safety cable
4 Bracket, vehicle-side safety cable
5 Retaining plate, spare wheel
6 Winch cable
Wheels and Tires - Wheels and Tires
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
Wheel(s)
Tire(s)
Tire pressure(s) *
Valve stem(s)
Wheel nuts
Wheel studs
* Vehicles equipped with a tire pressure monitoring system must be inspected for correct
operation using the Ford diagnostic equipment.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

Tires should be checked for correct:

• tire pressure(s)
• tire sizes
• speed rating
• load range.
• tire construction type

The use of any other tire/wheel size, load range or type can seriously affect:

• ride
• handling
• speedometer/odometer calibration
• vehicle ground clearance
• tire clearance between the body and chassis
• wheel bearing life.
• braking performance

New wheels need to be installed when the vehicle wheels:

• are bent
• are cracked
• are dented
• are heavily corroded
• are leaking
• have elongated wheel hub bolt holes
• have excessive lateral or radial runout

It is mandatory to use only the tire sizes recommended on the tire label located on the door
pillar attached to the vehicle. Larger or smaller tires can damage the vehicle, affect
durability and require changing the speedometer calibration. Make sure wheel size and
offsets match those recommended for the tire in use.
Inspect the tires for signs of uneven wear. the following descriptions to identify the type of
wear.
Check the tires for:

• cuts
• stone bruises
• abrasions
• blisters
• embedded objects

Check the valve stems for:

• cracks
• cuts

Install a new valve stem when damage is found or when a new tire is installed.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are
many factors (driving style, road surfaces, type of vehicle, type of tire) that can affect tire
wear, there is no absolute mileage expectation for a normal wear condition. A tire is
considered worn-out when the tread has worn to the level of the tread-wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the
tread and that creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving
style (aggressive, passive), climate (hot, cold), road conditions, vehicle loading and
maintenance (correct tire pressure, rotation intervals and balance). It is important to
determine the root cause of wear on a vehicle before carrying out repair. Tires exhibiting
abnormal/incorrect tire wear may still be serviceable provided that the minimum tread
depth is greater than and the tire is not causing a vehicle performance (noise/vibration)
concern.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by
excessive toe out and/or excessive negative camber. If the tread depth of the outer
shoulder is at least 50% greater than the tread depth of the inner shoulder, the tire is
experiencing inner edge/shoulder wear. To determine whether tires have this type of wear,
visually inspect the tires. In some instances, it may be necessary to measure the tread
depth of each rib and compare it to that of the shoulder.
NOTE: Right-Front tire shown, others similar.

Outer Edge/Shoulder Wear

Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused
by excessive toe in and/or excessive positive camber. If the tread depth of the inner
shoulder is at least 50% greater than the tread depth of the outer shoulder, the tire is
experiencing outer edge/shoulder wear. To determine whether tires have this type of wear,
visually inspect the tires. In some instances, it may be necessary to measure the tread
depth of each rib and compare it to that of the shoulder.
NOTE: Right-Front tire shown, others similar.

Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder
of the tire. To determine whether tires have this type of wear, visually inspect the tires in
both the inside and outside shoulder ribs. In some instances, it may be necessary to
measure the difference in tread depth of leading versus trailing edge of each lug in the
inside and outside shoulder rib.

Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the
tire. To determine whether tires have this type of wear, visually inspect the tires to
determine if the wear pattern runs diagonally across the tread and around the
circumference of the tire. In some instances, the difference in tread depth along the
diagonal wear pattern may need to be measured.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure should begin with a road test. The road test and
customer interview (if available) will provide much of the information needed to find the
source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If
vibration is apparent, note and record the following:

• the speed at which the vibration occurs

• what type of vibration occurs in each speed range.
mechanical or audible
• how the vibration is affected by changes in the following:
engine torque
vehicle speed
engine speed
• type of vibration - sensitivity:
torque sensitive
vehicle speed sensitive
engine speed sensitive

The following explanations help isolate the source of the vibration.

Torque Sensitive

This means that the condition can be improved or made worse by accelerating,
decelerating, coasting, maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive

This means that the vibration always occurs at the same vehicle speed and is not affected
by engine torque, engine speed or the transmission gear selected.
Engine Speed Sensitive

This means that the vibration occurs at varying vehicle speeds when a different
transmission gear is selected. It can sometimes be isolated by increasing or decreasing
engine speed with the transmission in NEUTRAL or by stall testing with the transmission in
gear. If the condition is engine speed sensitive, the cause is probably not related to the
tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise
originates with the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat or has soft spots making a noise as
they slap the roadway. Tire whine can be distinguished from axle noise. Tire whine remains
the same over a range of speeds.

1. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart
The table provides all possible Wheels ans Tires symptoms. For a detailed diagnostics,
proceed to the Ford diagnostic equipment.

Symptom Possible Sources

Tire(s) show excess wear on edge of Tire(s) under-inflated
tread Vehicle overloaded
Incorrect wheel alignment
Tire(s) show excess wear in center of Tire(s) over-inflated
tread
Other excessive tire wear concerns Incorrect tire pressure(s)
Wheel and tire assemblies need rotating
Incorrect wheel alignment
Vehicle overloaded
Loose or leaking front strut and spring assembly
Wheel bearings worn
Suspension components, bushings and ball joints
Excessive lateral or radial runout of wheel or tire
Wobble or shimmy affecting wheel Damaged wheel
runout Front wheel bearing
Excessive vehicle vibration, rough Suspension components
steering Incorrect tire pressure(s)
Wheel or tire imbalance
Uneven tire wear
Brake disc imbalance
Water in tire(s) / Damaged wheel
Incorrectly seated tire bead
Excessive lateral or radial runout of wheel or tire
Foreign material between wheel mounting face and hub
mounting surface
Front wheel bearing
Rust streaks from the wheel stud holes Wheel nuts
in the wheel
Seized wheel nuts Corrosion
Vehicle overloaded
Wheels and Tires - Wheel and Tire
Print

Removal and Installation

Removal

1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2. NOTICE:

Do not use heat to loosen a seized wheel nut.

Do not use power tools on locking wheel nuts.

Loosen: 1 turn(s)

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4.

Installation

1. NOTICE: Make sure that the mating faces are clean and free of corrosion and
foreign material.
NOTE: Only tighten the nuts finger tight at this stage.
2. Lower the vehicle.

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

3. Torque: 200 Nm
Wheels and Tires - Wheel and Tire
Print

Disassembly and Assembly

Special Tool(s) / General Equipment
204-823
Torque Screw Driver, TPMS Sensor

Wooden Block

Disassembly
NOTICE:

Failure to follow the instructions below may result in damage to the TPMS (tire
pressure monitoring system).

The TPMS sensor is mounted to the valve stem. Removal of the valve stem requires
dismounting the tire from the wheel and removal of the TPMS sensor.
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to
be sure that accurate values are obtained.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

2. NOTICE: The valve stem is connected to the TPMS sensor. Do not pull the
valve stem from the wheel, or damage to the sensor will occur.
NOTE: If a new TPMS sensor is being installed, remove and discard the valve
stem-to-sensor screw and the sensor.
Remove the valve stem core and fully deflate all air from the tire.

3. NOTICE:

Do not allow the tire beads to move beyond the wheel mid-plane (middle of
the wheel) when separating the beads from the wheels, damage to the TPMS
sensor may occur.

Tire and valve stem position is critical to prevent damage to theTPMS sensor
when using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock
position instead of the paddle-type bead separator at the 3 o'clock position.
◦ For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6
o'clock position and the paddle at the 3 o'clock position.
◦ For a roller-type tire machine, align the valve stem with the roller at any position.
NOTE: Paddle type shown, roller type similar.
4. NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve
stem at the 11:30 position and the machine arm at the 12 o'clock position and dismount
the outer bead from the wheel.

5. Reset the wheel and tire assembly on the turntable of the tire machine with the valve
stem at the 11:30 position and the machine arm at the 12 o'clock position and dismount
the inner bead from the wheel.
6. NOTE: A new valve stem must be installed whenever a new tire or wheel is
installed.
Discard the specified component. Follow local disposal regulations.

NOTE: This step is only valid for vehicles with TPMS Snap-In Sensors.

7. NOTICE: Use care not to damage the wheel surface when removing the valve
stem.
Discard the specified component. Follow local disposal regulations.

Use the General Equipment: Wooden Block

NOTE: This step is only valid for vehicles with TPMS Bolt-On Sensors.
8. Discard the specified component. Follow local disposal regulations.

Assembly
NOTE: When installing a new wheel, always install a new valve stem and sensor screw.
Reuse theTPMS sensor from the previous wheel if possible. The TPMS will not have to be
trained if the sensor is reused.
NOTE: If the TPMS sensor is being reused, inspect the TPMS sensor for damage and
install a new sensor as necessary.
NOTE: This step is only valid for vehicles with TPMS Snap-In Sensors.

9. NOTICE: To prevent TPMS sensor and valve stem damage, the valve stem
must be installed onto theTPMS sensor and then installed into the wheel as an
assembly.
Use Special Service Tool: 204-823.
Torque: 1.5 Nm
NOTE: This step is only valid for vehicles with TPMS Snap-In Sensors.
10. NOTICE:

It is important to pull the valve stem and TPMS sensor assembly through the
wheel rim hole in a direction parallel to the valve stem hole axis. If the assembly is
pulled through at an angle, damage to the valve stem and sensor assembly may
occur.

Use care not to damage the wheel surface when installing the valve stem and
TPMS sensor assembly.
NOTE: Lubricate the valve stem with soapy water and install the valve stem and
TPMS sensor assembly into the wheel using a block of wood and a suitable valve
stem installer.
Use the General Equipment: Wooden Block

NOTE: This step is only valid for vehicles with TPMS Bolt-On Sensors.

11. NOTICE: To prevent TPMS sensor and valve stem damage, the valve stem
must be installed onto theTPMS sensor and then installed into the wheel as an
assembly.
Use Special Service Tool: 204-823.
Torque: 1.5 Nm
NOTE: This step is only valid for vehicles with TPMS Bolt-On Sensors.

12. NOTICE: Use care not to damage the wheel surface when installing the valve
stem and TPMS sensor assembly.
Torque: 8 Nm

NOTICE: Damage to the TPMS sensor may result if the tire mounting is not carried
out as instructed.
13. NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire
bead lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the
bottom bead of the tire on the wheel.
14. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock
position, and mount the bottom bead of the tire.

A number of reasons can cause the TPMS warning light to illuminate or flash. Before
proceeding with the actual diagnostic method using the FordETIS IDS Diagnostics, perform
these basic checks:

• Verify all tires are inflated to its recommended pressure, as mentioned in the Owner’s
Manual.
• Inspect all the tires and wheels for any visual damage.
• Check that all the wheels have a TPMS sensor appropriately installed.

If these above conditions are verified as fine, then proceed for further diagnosis.
The TPMS warning indicator alerts the customer of faulty conditions in 2 different ways.
TPMS indicator illuminates continuously
The TPMS warning indicator remains on continuously and the message center displays LOW
TIRE PRESSURE when any of the tire pressures fall below the low pressure limit. When this
condition exists, check that all tires are correctly inflated to the recommended cold tire
pressure indicated on the placat pressure label. Perform system reset.
TPMS indicator flashes
When the TPMS warning indicator flashes for 75 seconds and remains continuously on when
the ignition is set to ON, it means the TPMS is malfunctioning. The Parameter Identification
(PID) TP_STAT can be used to determine why the TPMS warning indicator is flashing.

• The message center displays TIRE PRESSURE SENSOR FAULT when a TPMS sensor is
malfunctioning.
• The TPMS warning indicator illuminates when the IPC has not received any signals from
the BCM for more than 5 seconds. The message center displays TIRE PRESSURE
MONITOR FAULT.
• The message center displays TIRE PRESSURE MONITOR FAULT when the TPMS is
malfunctioning.

TPMS replacement is called for when the TPMS fails due to mechanical or electrical failure,
broken accelerometer, low TPMS battery power or blocked pressure port. One of the most
common causes of failure is inappropriate handling during wheel or tire removal or
servicing. The TPMS is an electronic component fitted as part of a heavyweight mechanical
process.
Resetting TPMS
TPMS must be reset after every manual change to the tires or the tire pressure (wheel
change or pressure adjustment).
Automatic learning process TPMS
After every reset, TPMS must go through an automatic learning process. During this time,
the system knows all parameters that are required to work precisely and the warm tire
pressure (depending on isolation, surface temperature, ambient air temperature, tire
pressure, driving situation and friction) is learned. The process lasts 10 minutes but the
system already works with default parameters before it is completed.
For all TPMS malfunctioning issues, proceed to the FordETIS IDS Diagnostics for a detailed
diagnosis. FordETIS provides only supporting information to the FordETIS IDS Diagnostics.
DTC Chart: BCM (body control module)
A certain skill level and knowledge of Ford-specific diagnostic practices is assumed to
perform this diagnostics.
DTC Description
B1182:00 Tire Pressure Monitoring System: No Sub Type Information
B1182:55 Tire Pressure Monitoring System: Not Configured
B124D:02 Tire Pressure Sensor: General Signal Failure
B1251:00 Tire Pressure Sensor Low Battery: No Sub Type Information
B1254:51 Right Rear (Outside on Dual Wheel) Tire Pressure Sensor and Transmitter Assembly:
Not Programmed
B1255:51 Left Rear (Outside On Dual Wheel) Tire Pressure Sensor and Transmitter Assembly:
Not Programmed
C1A56:51 Left Front Tire Pressure Sensor and Transmitter Assembly: Not Programmed
C1A58:51 Right Front Tire Pressure Sensor and Transmitter Assembly: Not Programmed

For all DTC code diagnosis, proceed to the FordEtis IDS Diagnostics.
Tire Pressure Monitoring System (TPMS) -
Tire Pressure Monitoring System (TPMS)
Sensor Activation
Print

General Procedures
Special Tool(s)
204-D081A
Tire Pressure Monitor (TPMS)

Activation
1. NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is
stationary to conserve battery power. The sensors do not transmit information
while in sleep mode. It will be necessary to wake them up so they will transmit the
latest tire pressure information.
NOTE: The tire pressure data in the BCM (body control module) can be cleared
when the module performs a reset. When this occurs the air pressure DIDs will be
reset to the factory default of 1033 kPa (149.96 psi) and the cluster will display
dashes.
Turn the ignition switch to the ON position.

2. Position the special tool against the Left Front (LF) tire sidewall at the tire valve stem.

Use Special Service Tool: 204-D081A.

3. NOTE: The special tool should provide feedback in the form of a flashing green
light and a beep sound for each successful response from a tire pressure sensor.
This feedback may not always be present, do not rely on it as a confirmation that
the module heard a particular sensor.
NOTE: If a sensor does not respond to the special tool move the vehicle to rotate
the wheels at least one-fourth of a turn and attempt to activate the same sensor
again. If the sensor still does not respond, attempt to activate the same sensor
again using the customer activation tool (if available). If the sensor still fails to
train, attempt to train the sensor with the vehicle doors open.
Press the test button on the special tool to activate the sensor. Activate the sensor at
least 2 times.

Use Special Service Tool: 204-D081A.

4. Repeat Steps 2 and 3 for the remaining tires.

5. If the TPMS (tire pressure monitoring system) indicator remains illuminated after
adjusting and activating each sensor,

Refer to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire
Pressure Monitoring System (TPMS), General Procedures).
Tire Pressure Monitoring System (TPMS) -
Tire Pressure Monitoring System (TPMS)
Sensor Location Calibration
Print

General Procedures
Special Tool(s)
204-D081A
Tire Pressure Monitor (TPMS)

Activation
1. NOTE: Before performing the TPMS sensor location calibration, have the vehicle
parked at least 2 meter away from any other vehicle equipped with TPMS to avoid
activating other TPMS sensors.
With the ignition OFF, press and release the brake pedal.
2. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the
RUN position.
3. Press and release the brake pedal.
4. Position the ignition to OFF position.
5. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the
RUN position.

6. The horn will sound once and the TPMS (tire pressure monitoring system) indicator will
flash if the training mode has been entered successfully. If equipped, the message
center will display TRAIN Left Front (LF) TIRE.
7. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this
time, the special tool must remain in place at the valve stem.
Place the special tool on the Left Front (LF) tire sidewall at the valve stem. Press and
release the test button on the special tool. The horn will sound briefly to indicate that
the tire pressure sensor has been recognized by the BCM (body control module).

Use Special Service Tool: 204-D081A.

8. Within 2 minutes of the horn sounding, place the special tool on the Right Front (RF) tire
sidewall at the valve stem and press and release the test button to train the Right Front
(RF) tire pressure sensor.

Use Special Service Tool: 204-D081A.

9. NOTE: Do not wait more than 2 minutes between training each sensor or the BCM
will time out and the entire procedure must be repeated and the already
trainedTPMSsensors have to be activated again.
Repeat Step 7 for the Right Rear (RR) and Left Rear (LR) tires. The procedure is
completed after the last tire has been trained. When the training procedure is complete,
the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will
be verified by positioning the ignition to OFF without the horn sounding. If the horn
sounds twice when the ignition is positioned to OFF, the training procedure was not
successful.
10. Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and
document them on the applicable warranty claim.
11. This step is required to clear DTC (diagnostic trouble code) B1182:55, cause the BCM to
exit the manufacturing mode and to make sure there are no other concerns with a newly
programmed BCM.

12. If the sensors are being trained due to the installation of a new BCM, clear anyDTC and
carry out the BCM On-Demand Self Test.
13. NOTE: TPMS sensor identifiers are stored as long no new TPMS sensor identifiers
have been trained by either performing this procedure or performing TPMS
customer reset.
Tire Pressure Monitoring System (TPMS) -
Tire Pressure Monitoring System (TPMS)
Sensor
Print

Removal and Installation

Removal

1. WARNING: The Tire Pressure Monitoring System (TPMS) sensor battery may
release hazardous chemicals if exposed to extreme mechanical damage. If these
chemicals contact the skin or eyes, flush immediately with water for a minimum of
15 minutes and get prompt medical attention. If any part of the battery is
swallowed, contact a physician immediately. When disposing of Tire Pressure
Monitoring System (TPMS) sensors, follow the correct procedures for hazardous
material disposal. Failure to follow these instructions may result in serious personal
injury.
NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed
without disassembly of the wheel and tire.
NOTE: The maximum shelf life of a TPMS snap in valve stem before being mounted
to a wheel is 1 year. The production date / week / year is marked on the TPMS
sensor / valve stem itself. Snap in valve stems which are older than 1 year are to
be scrapped. TPMS snap in sensors with valve stems older than one year should
not be mounted but the valve stem should be replaced.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).

Installation

1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be installed
without disassembly of the wheel and tire.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
Vehicle Dynamic Suspension - Air Leaks
Print

General Procedures

Activation

1. WARNING: Vent all air pressure from the air suspension system prior to
disconnecting or removing any air suspension components. It is dangerous to
remove air suspension components while under pressure. Failure to follow this
instruction may result in serious personal injury.
2. Apply a soapy water solution to the air lines, air line fittings, air springs and the air
compressor.
3. NOTE: If a leak is detected within the air compressor, install a new compressor. If
a leak is detected in a line, carry out the air line repair procedure using VOSS
repair procedure.
Verify the location of air leak(s) and install new components as necessary.

Air Line Service/Fitting Removal

4. NOTE: If the VOSS fitting is taken off of the airline then a new VOSS fitting will
need to be replaced on the component per VOSS standards SV203_Product
Description.
Service the airline.

5. NOTICE: The tube must be cut at a right angle. The tube must not be cut
using a saw, as this causes burring. Burring reduces the sealing ability of the
connection.
The surface of the push-in section of the tube must be undamaged and clean.
Cutting the polyamide tube to length

6. Check the connecting bore

7. NOTE: When screwing in make sure that the grip ring is not sitting on the thread.
8. NOTE: The first two thread pitches must be screwed centrally into the bore without
applying pressure.

9. NOTE: When inserting a new VOSS fitting on to the valve block, screw it in and
this force must not exceed 2 Nm of torque as to not strip the threads.
Torque: 2 Nm

10. Pull out the assembly plug.

11. NOTE: Pulling back the tube ensures that the retaining edges of the grip ring
engage into the polyamide tube.
4. Insert the airline past the first white paint mark into the VOSS fitting.

12. NOTE: Check system for leaks.

Inflate the air suspension system

Refer to: Ride Height Adjustment (204-05, General Procedures).

Replacing a system component or a connection

13. NOTE: Before disconnecting, the line must be free of pressure.
NOTE: If the fitting is unscrewed from the valve block component and remain
attached to the airlines while serviced, then these can be re-screwed on to the
valve block.
Disconnect the tube with assy.
Vehicle Dynamic Suspension - Air Line Fluid Purge
Print

General Procedures

Activation

1. WARNING: Vent all air pressure from the air suspension system prior to
disconnecting or removing any air suspension components. It is dangerous to
remove air suspension components while under pressure. Failure to follow this
instruction may result in serious personal injury.
2. NOTE: Carry out this procedure if fluid (water and/or oil) is found in the air tube.
Purge fluid from rear air tubes and install new components if affected.
Disconnect the air tube at the air compressor drier.
3. Connect shop air to the disconnected air tube and blow any fluid out.
4. NOTE: When installing the air tubes, make sure the white paint line on the tube is
fully inserted into the fitting for correct installation.
NOTE: Make sure that new components are installed.

5. Install a new air compressor drier

Refer to: Air Suspension Compressor (204-05 Vehicle Dynamic Suspension, Removal
and Installation).
6. Reconnect the air tube to the air compressor drier.
7. Fitting the polyamide tube into the assy.

8. Make sure that all air tube fittings are sealed.

Vehicle Dynamic Suspension - Air
Suspension System Depressurize and
Pressurize
Print

General Procedures
General Equipment
Ford Diagnostic Equipment

Adjustment
1. NOTE: No Diagnostic Trouble Codes (DTC's) present.
All doors must be closed.
2. Turn the ignition switch to the RUN position.

3. Connect the scan tool to the IDS (Integrated Diagnostic System) tool.

Use the General Equipment: Ford Diagnostic Equipment

4. NOTICE: Place jack under the body as well as the front and rear axle in order
to support the vehicle and prevent the axle from lowering or dropping into the
extremes of its range and possible damaging the air springs.
Pumping Air Springs:

• Using a scan tool, enter test System Pressurize/Depressurize Function.

• Select Pressurize. System will pump air into the air springs until height reaches
TRIM height.

5. NOTICE: Place jack under the body as well as the front and rear axle in order
to support the vehicle and prevent the axle from lowering or dropping into the
extremes of its range and possible damaging the air springs.
Venting Air Springs:

• Using a scan tool, enter test System Pressurize/Depressurize Function.

• Select Depressurize. System will vent all the air from the rear air springs.
Vehicle Dynamic Suspension - Rear Suspension Height Sensor
Print

Removal and Installation

Removal

NOTICE: Suspension fasteners are critical parts that affect the performance of vital
components and systems. Failure of these fasteners may result in major service expense.
Use the released parts if replacement is necessary. Do not use a replacement part of
lesser quality or substitute design. Tighten fasteners as specified.
NOTE: Removal steps in this procedure may contain installation details.
NOTE: The RR and LR height sensor assemblies cannot be used on opposite sides of the
vehicle.
1. Disable the RAS system for service.

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. LR height sensor.

Torque:
3. 9 Nm
4. 25 Nm

3. RR height sensor.

Torque:
3. 9 Nm
4. 25 Nm
Installation

1. To install, reverse the removal procedure.

2. Calibrate the LR and RR height sensors.

Refer to: Suspension Height Sensor Calibration (204-05 Vehicle Dynamic Suspension,
General Procedures).
Vehicle Dynamic Suspension - Air Suspension Compressor
Print

Removal and Installation

Removal

NOTICE: Vent all air pressure from the air suspension system prior to disconnecting
or removing any air suspension components. It is dangerous to remove air suspension
components while under pressure. Failure to follow this instruction may result in serious
personal injury.
NOTE: Removal steps in this procedure may contain installation details.

1. WARNING: The air suspension isolator switch must be in the OFF position
before working on the air suspension components. Failure to follow this instruction
may result in personal injury.
Turn the air suspension to the OFF position in the instrument panel.

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

3. Remove the air intake bracket bolt and air intake hose and bracket from inside B-pillar.

Torque: 15 Nm

4. Disconnect the both (8 pin and 4 pin) electrical connectors.

5. NOTE: Make sure not to overtighten the VOSS fittings.It will strip the valve block
causing a leak in the system.
Remove Voss fittings from valve block.

Torque: 2 Nm

6. NOTE: Make sure there are no objects trapped under or on the bracket. Make sure
that the air compressor is not in contact with any surrounding components that
could cause vibration noises.
Remove air compressor bracket bolts and remove the air compressor and bracket
assembly.

Torque: 15 Nm
7. NOTE: Make sure that the compressor moves freely in the rubber isolators to load
against each other.
Make sure that the bracket has no deformations that could cause the rubber
isolators to load against each other.
Remove the splash shield.

8. Remove the air compressor bracket bolts and remove the air compressor and bracket
assembly.

Torque: 15 Nm
9. NOTE: This step is only necessary when installing a new component.
Remove the air suspension compressor.

Torque: 3 Nm

Installation

1. To install, reverse the removal procedure.

2. NOTE: When installing the air lines, make sure the white inner paint line is fully
inserted into the fitting for correct installation.
Refer to: Air Leaks (204-05 Vehicle Dynamic Suspension, General Procedures).
Refer to: Air Suspension System Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
3. NOTE: If the air springs do not fully inflate to ride height within eight minutes, the
air suspension compressor will switch off. To start the compressor, turn the
ignition switch to the OFF position and then to the RUN position to reset the air
suspension control module. If the springs do not fully inflate after the VDM (vehicle
dynamics control module) has been reset, check the system for air leaks.
Turn the ignition switch to the RUN position to activate the air suspension compressor to
charge the air system.
Vehicle Dynamic Suspension - Rear Air Spring
Print

Removal and Installation

General Equipment
Transmission Jack

Removal

Make sure the air pressure in the air springs is fully evacuated by squeezing
the air springs. Failure to follow this instruction may result in personal injury.

Residual air pressure may be present in the air springs. Wear gloves and eye
protection when disconnecting air lines from the air springs. Failure to follow this
instruction may result in personal injury.

2. WARNING: The air suspension isolator switch must be in the OFF position
before working on the air suspension components. Failure to follow this instruction
may result in personal injury.

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

4. Depressurize the air springs

Refer to: Air Suspension System Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).

5. Use the General Equipment: Transmission Jack

6. NOTE: LR spring unscrew counterclockwise.
LR spring

7. NOTE: RR spring unscrew clockwise.

RR spring

Installation

1. WARNING: Make sure the air spring is upright and seated correctly before
inflation. Failure to follow this instruction may result in personal injury.
NOTE: Make sure the shock is fully attached to both the suspension and the body
in order to prevent over extension of the air spring during installation.
NOTE: Check the air lines for damage and trim the ends if necessary before
installing them into the collets.
NOTE: Ensure the three upper tabs are all engaged in the proper spring seat slots.
To install, reverse the removal procedure.
2. NOTE: When installing the air lines, make sure the white inner paint line is fully
inserted into the fitting for correct installation.
Turn the air suspension isolator switch to the ON position.

Refer to: Air Suspension System Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
3. NOTE: If the air springs do not fully inflate to ride height within eight minutes, the
air suspension compressor will switch off. To start the compressor, turn the
ignition switch to the OFF position and then to the RUN position to reset the air
suspension control module. If the air springs do not fully inflate after the VDM
(vehicle dynamics control module) has been reset, check the system for air leaks.
Turn the ignition switch to the RUN position to activate the air suspension compressor to
charge the air system.
Vehicle Dynamic Suspension - Air Suspension Compressor Drier
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Suspension Compressor (204-05 Vehicle Dynamic Suspension, Removal
and Installation).
2. Remove jumper tube by rotating clip 90 degrees and pulling off the nozzle.
3. NOTE: Make sure that the air filter O-ring does not remain inside of the
compressor assembly.
NOTE: Inspect the compressor drier O-ring for damage and install a new O-ring as
necessary.
Remove the compressor drier screw.

Torque: 3 Nm

4. Rotate the compressor drier 90 degrees counterclockwise to unlock, then remove the air
compressor drier.

Installation

1. To install, reverse the removal procedure.

2. NOTE: When installing the air lines, make sure the white paint line is fully inserted
into the fitting for correct installation.
To install, turn clip back 90 degrees and push firmly onto drier nozzle until it clicks and
locks in place.
Vehicle Dynamic Suspension - Trailing Arm
Print

Removal and Installation

General Equipment
Transmission Jack

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Use the General Equipment: Transmission Jack

3.
4.

5. Torque: 9 Nm

6. Refer to: Rear Air Spring (204-05 Vehicle Dynamic Suspension, Removal and
Installation).

7. Torque: 275 Nm
8.

Installation

1. To install, reverse the removal procedure.

2. NOTICE: Make sure that the components are aligned.

NOTE: Only tighten the nuts finger tight at this stage.
3. NOTE: Only tighten the nuts and bolts when the suspension is in the normal drive
position.
Torque:
Stage 1:25 Nm
Stage 2:50 Nm
Stage 3:75 Nm
Stage 4:100 Nm
Stage 5:125 Nm
Stage 6:150 Nm
Stage 7:175 Nm
Front Drive Halfshafts - Specifications
Print

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

SPECIFICATIONS

Inner Constant Velocity Joint Grease 6G9N-39209-CAAGA

Outer Constant Velocity Joint Grease 6G9N-39209-JAAJA

CAPACITY

DRIVESHAFT JOINT GREASE FILL CAPACITY

DESCRIPTION
INNER BOOT JOINT GREASE OUTER BOOT JOINT GREASE
(GRAMS) (GRAMS)

1T Vehicles up to 310 Series 200 200

2T Vehicles 330 Series and 220 260

above
Front Drive Halfshafts - Front Drive Halfshafts - Overview
Print

Description and Operation

• The halfshafts have constant velocity joints at both ends to ensure that driving is smooth.
• The inner constant velocity joints are slip joints.
• On the wheel side, constant velocity joints without longitudinal adjustment are installed.
• The left-hand constant velocity joint is secured in the differential by a circlip.
• The intermediate shaft (right-hand) is located in position in the differential by the
intermediate shaft center bearing.
• The wheel-side constant velocity joints are attached to the wheel hubs.

Item Description
1 Left-hand halfshaft
2 Intermediate shaft
3 Intermediate shaft bearing
4 Right-hand halfshaft

How the halfshafts work

• The halfshafts transfer the engine torque to the wheels.

• In order to permit vertical movement of the wheels and also engine movement, the
halfshafts operate with different lengths and angles.
• The tripod joints permit a change in the halfshaft lengths when there are axial
movements.

Handling halfshafts

NOTICE: Make sure that the inner constant velocity (CV) joint does not separate.
When removing and installing halfshafts, and also dismantling and assembling them, the
following points must be followed:

• The inner CV joint must not be bent more than 21 degrees, the outer CV joint must not
be bent more than 45 degrees!
• Halfshafts must be suspended in a professional way so that the maximum bending angle
is not exceeded.
• Check the finished surfaces and splines for damage.
• The boots and retaining straps must not come into contact with sharp edges, a hot
engine or a hot exhaust system.
• Do not allow the halfshafts to drop, as this can damage the inside of the boots without
there being any signs of damage on the outside.
• Never use halfshafts as a lever to install other components.
• The tripod joint can be damaged by impacts outside the joint enclosure.

Wheel balancing, front

Whenever possible, wheels should be removed for balancing, and balanced using a
stationary wheel balancing unit.
When the wheels are balanced dynamically using a portable wheel balancing unit, care
must be taken that the lower arms are in the driving position.
Where necessary, the lower arms must be brought into the appropriate position using a
jack.
This prevents the joints being bent too far when the wheels are balanced.
Raising the vehicle
NEVER use joints or driveshafts as leverage points.
Underbody protection and corrosion prevention
The boots must be protected when underbody protection or corrosion prevention is applied!
Foreign bodies can be the cause of premature material wear. Foreign matter on the
halfshafts can cause the imbalance.
Front Drive Halfshafts - Front Drive
Halfshafts
Print

Diagnosis and Testing

Inspection and Verification

NOTE: New front drive halfshafts should not be installed unless disassembly and
inspection reveals unusual wear.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Constant velocity (CV) joint boot
• CV joint
• Front halfshaft
• Intermediate shaft bearing
• Intermediate shaft

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart
The table provides all possible Front Drive halfshafts symptoms. For a detailed diagnostics,
proceed to the Ford diagnostic equipment.

Symptom Possible Sources

Clicking, Popping or Grinding Inadequate or contaminated lubricant in the inner or outer
Noises While Turning front drive halfshaft constant velocity (CV) joint
Another component contacting front drive halfshaft assembly
Wheel bearings, brakes, suspension or steering components
Vibration at Highway Speeds Out of balance front wheels or tires
Out-of-round tires
Incorrectly seated outer constant velocity (CV) joint in front
wheel hub
Wearing in the constant velocity (CV) joint, due to grease
degradation
Shudder Vibration During Excessively high CV joint operating angles caused by incorrect
Acceleration ride height
Excessively worn or damaged inner or outer front drive
halfshaft constant velocity (CV) joint
Halfshaft Joint Pullout Outer front drive halfshaft retainer circlip missing or not
correctly seated differential side
Front suspension components worn or damaged
Engine/transaxle assembly misalignment
Frame rail or strut tower out of position or damaged
Front Drive Halfshafts - Halfshaft Bearing
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

205-080
Installer, Differential Bearing

205-310
Remover, Bearing/Gear

303-255
Installer, Timing Cover Seal

Flat Headed Screw Driver

Hydraulic Press

Removal

1. Refer to: Front Halfshaft RH - 6-Speed Manual Transmission - VMT6 (205-04 Front Drive
Halfshafts, Removal and Installation).
2.
4. Use Special Service Tool: 205-310.
Use the General Equipment: Hydraulic Press

Installation

1. Use Special Service Tools: 205-080, 303-255.

Use the General Equipment: Hydraulic Press
2.
1. Refer to: Specifications (205-04 Front Drive Halfshafts, Specifications).

2.
3. 1. NOTE: Make sure that the rubber is not damaged.
Release any trapped air.

Use the General Equipment: Flat Headed Screw Driver

2.
3.
4. NOTE: Make sure that the rubber is not damaged.
Use the General Equipment: Flat Headed Screw Driver
4. NOTE: Make sure that a new component is installed.
Use Special Service Tool: 204-169.

5. Refer to: Front Halfshaft RH - 6-Speed Manual Transmission - VMT6 (205-04 Front Drive
Halfshafts, Removal and Installation).
Front Drive Halfshafts - Front Halfshaft LH—6-Speed Automatic
Transmission - 6F55
Print

Removal and Installation

Special Tool(s) / General Equipment
204-161
Installer, Halfshaft

204-609
Protection Cap, Ball Joint Gaiter

205-1048
Protector, Driveshaft Seal

308-072-01
Adapter for 308-072

Lower Arm Down Force Lever

Puller
Tire Lever
Two Leg Puller

Removal

1. Crown nut

2. All nuts

Loosen: 360°
3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
4.

5. Crown nut

6.
7. Use the General Equipment: Two Leg Puller

8.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

9.
10. Use Special Service Tool: 308-072-01.
Use the General Equipment: Puller

11. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The outer constant velocity (CV) joint must not be bent more than 45°.
12. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the mating faces.

Take extra care not to damage the seal.

1. Use the General Equipment: Tire Lever

13. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the seal.

1. Use Special Service Tool: 205-1048.
14.

Installation

1. Refer to: Halfshaft Seal LH (307-01 Automatic Transmission, Removal and Installation).
2. NOTE: Install a new component if it is damaged or has excessive wear.
3. NOTE: Make sure that a new component is installed.

4. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the seal.

1. Remove the special tool before completely installing the halfshaft.

Use Special Service Tool: 205-1048.

5. NOTICE: Take extra care not to damage the seal.
NOTE: Make sure that the component is correctly installed.
Remove the special tool before completely installing the halfshaft.

6.
7. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The outer constant velocity (CV) joint must not be bent more than 45°.

8. Use Special Service Tool: 204-161.

Torque: 45 Nm
9. Crown nut

10. NOTE: Only tighten the nut finger tight at this stage.
All nuts

11.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

Vehicles With: Lower Arm Ball Joint Secured With Two

Bolts

12. Torque: 215 Nm

Vehicles With: Lower Arm Ball Joint Secured With a
Circlip

13. Torque: 150 Nm

All vehicles

14. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
15. 1.
2. Crown nut

Torque: 250 Nm
3.
4. Crown nut

Torque: 500 Nm

16. NOTE: Make sure that a new component is installed.

Crown nut

17. 1.
2. Self-locking nut

Torque: 100 Nm
3.
4. Self-locking nut

Torque: 250 Nm
5.
6. Self-locking nut

Torque: 515 Nm
18.

19. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Front Drive Halfshafts - Front Halfshaft RH—6-Speed Automatic
Transmission - 6F55
Print

Removal and Installation

Special Tool(s) / General Equipment
204-161
Installer, Halfshaft

204-609
Protection Cap, Ball Joint Gaiter

205-1048
Protector, Driveshaft Seal

308-072-01
Adapter for 308-072

Lower Arm Down Force Lever

Puller
Two Leg Puller

Removal

1. Crown nut

2. All nuts

Loosen: 360°
3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
4.

5. Crown nut

6.
7. Use the General Equipment: Two Leg Puller

8.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

9.
10. Use Special Service Tool: 308-072-01.
Use the General Equipment: Puller

11. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The outer constant velocity (CV) joint must not be bent more than 45°.
12. NOTICE: Take extra care not to damage the seal.
NOTE: Be prepared to collect escaping fluid.

13. NOTICE:

Take extra care not to damage the seal.

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
NOTE: Be prepared to collect escaping fluid.
1. Use Special Service Tool: 205-1048.
Installation

1. Refer to: Halfshaft Seal RH (307-01 Automatic Transmission, Removal and Installation).
2. NOTE: Install a new component if it is damaged or has excessive wear.
1.
2. If equipped.

3. NOTE: Install a new component if it is damaged or has excessive wear.

4. NOTICE: The inner constant velocity (CV) joint must not be bent more than
18°.
1.

2. 2. NOTICE: Take extra care not to damage the seal.

Remove the special tool before completely installing the halfshaft.

Use Special Service Tool: 205-1048.

5. NOTE: Make sure that the component is correctly installed.

6. NOTE: Make sure that the components are correctly installed.
1. NOTE: Make sure that a new component is installed.
2. NOTE: Make sure a new nut is installed.
Torque: 6 Nm

3. NOTE: Make sure a new nut is installed.

Torque: 6 Nm

4. Torque: 25 Nm

5. Torque: 25 Nm

7.
8. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The outer constant velocity (CV) joint must not be bent more than 45°.

9. Use Special Service Tool: 204-161.

Torque: 45 Nm
10. Crown nut

11. NOTE: Only tighten the nut finger tight at this stage.
All nuts

12.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

Vehicles With: Lower Arm Ball Joint Secured With Two

Bolts

13. Torque: 215 Nm

Vehicles With: Lower Arm Ball Joint Secured With a
Circlip

14. Torque: 150 Nm

All vehicles

15. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
16. 1.
2. Crown nut

Torque: 250 Nm
3.
4. Crow nut

Torque: 500 Nm

17. NOTE: Make sure that a new component is installed.

Crown nut

18. 1.
2. Self-locking nut

Torque: 100 Nm
3.
4. Self-locking nut

Torque: 250 Nm
5.
6. Self-locking nut

Torque: 515 Nm
19.

20. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

308-046
Installer, Transmission Extension Housing Bushing/Seal

Copper Hammer
Flat Headed Screw Driver
Hydraulic Press
Puller
Wooden Block

Removal
6-Speed Automatic Transmission - 6F55

1. Refer to: Front Halfshaft LH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).

All vehicles
2.

3. Use the General Equipments: Wooden Block, Copper Hammer

5. Use the General Equipments: Hydraulic Press, Puller

Installation

1. Use Special Service Tool: 308-046.

Use the General Equipment: Copper Hammer

2. 1. NOTE: Make sure that a new component is installed.

3. NOTE: Make sure that the component is clean, free of foreign material and
lubricant.

4. NOTE: Make sure that a new component is installed.

Use Special Service Tool: 204-169.
Torque: 21 Nm

5. Refer to: Specifications (205-04 Front Drive Halfshafts, Specifications).

6. 1. NOTE: Make sure that the rubber is not damaged.
Release any trapped air.

Use the General Equipment: Flat Headed Screw Driver

2.
3.
4. Use the General Equipment: Flat Headed Screw Driver
7. NOTE: Make sure that a new component is installed.
Use Special Service Tool: 204-169.
Torque: 21 Nm
6-Speed Automatic Transmission - 6F55

8. Refer to: Front Halfshaft LH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).
Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

Flat Headed Screw Driver

Removal

1. Refer to: Inner Constant Velocity (CV) Joint Boot (205-04 Front Drive Halfshafts,
Removal and Installation).
2.

Installation

1. NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
2. Refer to: Specifications (205-04 Front Drive Halfshafts, Specifications).
3. NOTE: Make sure that the rubber is not damaged.
Release any trapped air.

Use the General Equipment: Flat Headed Screw Driver

5. NOTE: Make sure that new components are installed.

Use Special Service Tool: 204-169.
Torque: 21 Nm
6. Refer to: Inner Constant Velocity (CV) Joint Boot (205-04 Front Drive Halfshafts,
Removal and Installation).
Front Drive Halfshafts - Intermediate Shaft Bearing
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

205-080
Installer, Differential Bearing

303-255
Installer, Timing Cover Seal

Bearing Separator
Flat Headed Screw Driver
Hydraulic Press

Removal
6-Speed Automatic Transmission - 6F55

All vehicles
2.
3.

4. Use the General Equipments: Bearing Separator, Hydraulic Press

Installation

1. Use Special Service Tools: 205-080, 303-255.

Use the General Equipment: Hydraulic Press
2.
1. Refer to: Specifications (205-04 Front Drive Halfshafts, Specifications).

2.
3. 1. NOTE: Make sure that the rubber is not damaged.
Release any trapped air.

Use the General Equipment: Flat Headed Screw Driver

2.
3.
4. NOTE: Make sure that the rubber is not damaged.
Use the General Equipment: Flat Headed Screw Driver
4. NOTE: Make sure that a new component is installed.
Use Special Service Tool: 204-169.

6-Speed Automatic Transmission - 6F55

5. Refer to: Front Halfshaft LH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04 Front
Drive Halfshafts, Removal and Installation).
Brake System - General Information -
Specifications
Print

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

ITEM SPECIFICATION

DOT 4 LV brake fluid WSS-M6C65-A2

High temperature grease WSS-M12A4-A

FRONT DISC BRAKE SPECIFICATION

Brake disc diameter 288 mm / 308

New brake disc nominal thickness 33 mm

Worn brake disc discard thickness * 30 mm

Maximum brake disc thickness variation 0.020 mm

Worn brake pad discard thickness * 1.5 mm

Maximum brake disc runout (installed) 0.1 mm

*When the discard thickness has been reached, install a new brake disc/brake
pads.

REAR DISC BRAKE SPECIFICATION

Brake disc diameter 288 mm / 308

New brake disc nominal thickness 16 mm

Worn brake disc discard thickness * 13 mm

Maximum brake disc thickness variation 0.020 mm

Worn brake pad discard thickness * 1.5 mm

Maximum brake disc runout (installed) 0.1 mm

*When the discard thickness has been reached, install a new brake disc/brake
pads.
Brake System - General Information - Brake System - Component
Location
Print

Description and Operation

Item Description
1 Brake fluid reservoir
2 Brake master cylinder
3 Brake booster
4 Parking brake control
5 Rear brake caliper
6 Rear brake disc
7 Parking brake cable
8 Front brake disc
9 Front brake caliper
10 ABS (anti-lock brake system) module
Brake System - General Information -
Brake System
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Principles of Operation
The brake system operates by transferring effort applied to the brake pedal by the driver to
the brakes at each wheel.
The braking effort is distributed to each wheel, using an hydraulic system. The system is
assisted using a vacuum brake booster that reduces pedal effort and increases hydraulic
pressure. The parking brake operates on the rear wheels and is applied using a hand
operated control.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Tire pressure
• Wheels and tires
• Fluid leak from brake line(s)
• Fluid level
• Fluid contamination

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.

Road Test
Carry out a road test to compare actual vehicle braking performance with the performance
standards expected by the driver. The ability of the test driver to make valid comparison
and detect performance deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted
general performance guidelines to make good comparisons and detect performance
concerns.
An experienced brake technician will always establish a route that will be used for all brake
diagnosis road tests. The roads selected will be reasonably smooth and level. Gravel or
bumpy roads are not suitable because the surface does not allow the tires to grip the road
equally. Crowned roads should be avoided because of the large amount of weight shifted to
the low set of wheels on this type of road. Once the route is established and consistently
used, the road surface variable can be eliminated from the test results.
Before a road test, obtain a complete description of the customer concerns or suspected
condition. From the description, the technician's experience will allow the technician to
match possible causes with symptoms. Certain components will be tagged as possible
suspects while other will be eliminated by the evidence. More importantly, the customer
description can reveal unsafe conditions which should be checked or corrected before the
road test. The description will also help form the basic approach to the road test by
narrowing the concern to specific components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Keeping the description of the
concern in mind, test the brakes at different vehicle speeds using both light and heavy
pedal pressure. To determine if the concern is in the front or rear braking system, use the
brake pedal and then use the parking brake control. If the condition (pull, vibration,
isolation) occurs only with the parking brake, the concern is in the rear brake system.
Avoid locking the brakes and sliding the tires. Locked brakes and sliding tires do not
indicate brake efficiency. A heavily braked and turning wheel will stop the vehicle in a
shorter distance than locked brakes.
If the concern becomes evident during this check, verify it fits the description given before
the road test. If the concern is not evident, attempt to duplicate the condition using the
information from the description.
If a concern exists, use the Symptom Chart in order to isolate it to a specific sub-system
and condition description. From this description, a list of possible sources can be used to
further narrow the cause to a specific component or condition.
Symptom Chart
The following table provides all the possible symptoms and sources related to the Brake
System. For the actual diagnosis, proceed to use the Ford diagnostic equipment.

Symptoms Possible Sources

Brakes pull or drift Wheel alignment angles
Brake pads
Brake disc
Brake caliper
The red brake warning indicator is always on Brake fluid level sensor
Parking brake control
Excessively worn brake pads
Brake master cylinder primary piston cup
Vibration when the brakes are applied Brake pads
Brake caliper
Brake disc
Pedal goes down fast Air in system
Brake master cylinder
Brake disc
Brake pads
Pedal eases down slowly Brake caliper
Brake master cylinder
Pedal is low or feels spongy Brake pads
Air in the system
Brake booster
Brake lockup during light brake pedal force Brake pads
Brake disc
Brake booster
Excessive or erratic pedal travel Insufficient grease on sliding parts
Brake pads
Brake disc
Wheel bearing
Brake pedal
Brake drag Brake booster
Brake caliper
Brake pedal
Stability assist system (if equipped)
Slow or incomplete brake pedal return Brake master cylinder
Stability assist system (if equipped)
Brake pedal
Component Tests
Brake Booster

1. Inspect all hoses and connections. All unused vacuum connectors should be capped.
Hoses and their connections should be correctly secured and in good condition with
no holes and no collapsed areas. Inspect the brake booster check valve for damage.

2. Check the hydraulic brake system for leaks or low fluid.

3. With the transmission in PARK (automatic transmission), stop the engine and operate
the parking brake. Operate the brake pedal several times to exhaust all vacuum in
the system.

4. With the engine turned OFF and all vacuum in the system exhausted operate the
brake pedal and hold it down. Start the engine. If the vacuum system is operating,
the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the vacuum booster system is not functioning.

5. Remove the vacuum hose from the brake booster. Manifold vacuum should be
available at the brake booster end of the hose with the engine at idle speed and the
transmission in PARK or NEUTRAL. Make sure that all unused vacuum outlets are
correctly capped, hose connectors are correctly secured and vacuum hoses are in
good condition. When it is established that manifold vacuum is available to the
brake booster, connect the vacuum hose to the brake booster and repeat Step 3. If
no downward movement of the brake pedal is felt, the vacuum booster system is
not functioning.

6. Run the engine for a minimum of 10 seconds at fast idle. Stop the engine and let the
vehicle stand for 10 minutes. Then, operate the brake pedal with approximately 98N
(20 lb) of force. The pedal feel (brake applications) should be the same as noted
with the engine running. If the brake pedal feels hard (no power assist), install a
new check valve and then repeat the testing. If the brake pedal still feels hard,
install a new brake booster. If the brake pedal movement feels spongy, bleed the
brake system. Refer to General Procedures.

Brake Master Cylinder

Usually, the first and strongest indicator of anything wrong in the brake system is a feeling
through the brake pedal. In diagnosing the condition of the brake master cylinder, check
brake pedal feel as evidence of a brake concern.
Check for brake warning indicator illumination and the brake fluid level in the brake fluid
reservoir.
Normal Conditions

The following conditions are considered normal and are not indications that the brake
master cylinder is in need of repair.

1. New brake systems are not designed to produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be compared to pedal efforts of another
vehicle, same model and year.

2. During normal operation of the brake master cylinder, the brake fluid level in the
reservoir will rise during brake application and fall during release. The net brake
fluid level (after brake application and release) will remain unchanged.

3. A trace of brake fluid exists on the brake booster shell below the master cylinder
mounting flange. This results from the normal lubricating action of the master
cylinder bore end seal.

4. Brake fluid level will fall with brake pad wear.

Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the
brake system. The diagnostic procedure and techniques are brake pedal feel, brake warning
indicator illumination and low brake fluid level as indicators in diagnosing brake system
concerns. The following condition are considered abnormal and indicate that the brake
master cylinder is in need of repair.

1. Brake pedal goes down fast. This could be caused by an external or internal leak.

2. Brake pedal eases down slowly. This could be caused by an external or internal leak.

3. Brake pedal is low or feels spongy. This condition may be caused by no fluid in the
brake master cylinder reservoir, brake fluid reservoir cap vent holes blocked or air
in the hydraulic system.

4. Brake pedal effort is excessive. This may be caused by a bind or obstruction in pedal
or linkage, blocked fluid control valve or insufficient brake booster vacuum.

5. Rear brakes lock up during light pedal force. This may be caused by grease or fluid on
brake pads, damaged brake pads and linings, incorrectly adjusted parking brakes,
damaged or contaminated brake pressure control valve.

6. Brake pedal effort is erratic. This condition could be caused by the brake booster
being in operative, extreme brake caliper piston knock back or incorrectly installed
brake pads.

7. Brake warning indicators is always ON. This may be caused by low fluid level, ignition
wire routing too close to the fluid level indicator, or float assembly damage.

Bypass Condition Test

1. Check the brake fluid level in the brake fluid reservoir. Fill the brake fluid reservoir to
the MAX mark if low or empty.

2. Observe the brake fluid level in the brake fluid reservoir. If after several brake
applications, the brake fluid level remains the same, measure the wheel turning
torque required to rotate the wheels with rearward with brakes applied as follows:

Place the transmission in NEUTRAL and raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
With the aid of another technician, operate the brakes with a minimum of 445N (100 lb)
and hold for approximately 15 seconds. With the brakes still applied, exert torque on the
front wheels to 10.1 Nm (75 lbf.ft). If either wheel rotates, install a new brake master
cylinder.
Non-Pressure Leaks

Any empty brake fluid reservoir condition may be the result of two types of non-pressure
external leaks.
Type 1: An external leak may occur at the brake fluid reservoir cap because of incorrect
positioning of the gasket and cap.
Reposition the gasket and cap.
Type 2: An external leak may occur at the brake fluid reservoir mounting seals. Repair such
a leak by installing new seals.
Brake System - General Information - Brake Disc Runout Check
Print

General Procedures
Special Tool(s)
205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

206-003
Holding Fixture, Dial Indicator Gauge (Disc Brake)

Check
1. Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
2.
1. Position the dial indicator gauge so that it contacts the brake disc face
approximately 10 mm from the outer edge (inner face measurement shown).

Use Special Service Tools: 205-069, 205-070, 206-003.

2. Slowly rotate the brake disc and note the readings.
3. Repeat sub-steps 1 and 2 on the brake disc outer face.
4. If any of the measurements exceed the brake disc runout specification, a new
brake disc must be installed and the brake disc runout re-checked.

Refer to: Specifications (206-00 Brake System - General Information,

Specifications).
3. 1. Measure the brake disc thickness at eight positions, 45 degrees apart and
approximately 15 mm from the outer edge of the brake disc.
2. If any of the measurements exceed the brake disc thickness variation
specification, a new brake disc must be installed and the brake disc runout re-
checked.

Refer to: Specifications (206-00 Brake System - General Information,

Specifications).

4. If all the brake disc runout measurements and the thickness variation are within the
specifications, check the wheel balance.
Brake System - General Information - Brake System Bleeding
Print

General Procedures
General Equipment
Fluid Container

Bleeding
NOTE: Make sure that the vehicle is standing on a level surface.
1. Refer to: Brake System Health and Safety Precautions (100-00, Description and
Operation).

Vehicles with stability assist

2. Bleed the brake system using the BleedMASTER function in the diagnostic tool.

Vehicles without stability assist

4. NOTICE: The brake fluid reservoir must remain full with new, clean brake fluid
at all times during bleeding.
Refer to: Specifications (206-00 Brake System - General Information, Specifications).
5.

6. NOTICE: Make sure that the pressure within the brake system does not
exceed 1 bar.
Use the General Equipment: Fluid Container
7. Loosen: 180°

8. Operate the brake pedal fully (pumping brake fluid and air into the bleed jar) and allow
the brake pedal to return to the rest position.
9. Continue operating the brake pedal until air-free fluid is being pumped into the bleed
jar.

10. Refer to: Specifications (206-00 Brake System - General Information, Specifications).
11. With the brake pedal fully depressed tighten the bleed nipple.

Torque: 9 Nm

12.
13. Repeat the procedure for the remaining brake lines.
14.
Brake System - General Information - Brake System Draining and Filling
Print

General Procedures
General Equipment
Fluid Container

Draining
1. Refer to: Brake System Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4. On both sides.
5. On both sides.

Use the General Equipment: Fluid Container

6. On both sides.

Loosen: 180°
7.

8. On both sides.

Torque: 9 Nm
Filling
1. Refer to: Brake System Bleeding (206-00 Brake System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information,
General Procedures).
Refer to: Component Bleeding (206-00 Brake System - General Information, General
Procedures).
Brake System - General Information - Brake System Pressure Bleeding
Print

General Procedures
General Equipment
Ford approved diagnostic tool
Brake/Clutch System Pressure Bleeder/Filler
Fluid Container

Bleeding
NOTE: Make sure that the vehicle is standing on a level surface.
Vehicles with stability assist

1. Bleed the brake system using the BleedMASTER function in the diagnostic tool.

Use the General Equipment: Ford approved diagnostic tool

Use the General Equipment: Fluid Container

Vehicles without stability assist

2. NOTICE: If the fluid is spilled on the paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Make sure the area around the master cylinder cap is clean and free of
foriegn material.
3. Refer to: Specifications (206-00 Brake System - General Information, Specifications).

4. 1. 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.

Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler

2. NOTE: Make sure the bleeder tank contains enough clean specified brake
fluid to complete the bleeding operation.
Open the valve on the bleeder tank and apply 207-345 kPa (30-50 psi) to the
brake system.
5. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
6. Repeat the following bleeding steps in order indicated in the graphic.

8. Refer to: Specifications (206-00 Brake System - General Information, Specifications).

Use the General Equipment: Fluid Container

9.
10.
1. Loosen: 180°

2. Leave open until clear, bubblefree brake fluid flows, then tighten the bleeder
screw
3. NOTE: Due to the complexity of the fluid path within the rear integral
parking brake calipers, it is necessary to apply and release the parking brake
during the bleed procedure.
This step is only necessary for vehicles with rear integral parking brake
calipers: Apply and release the parking brake 5 times. Loosen the rear bleeder
screw and leave open until clear, bubble-free fluid flows and then tighten the
bleeder screw. Repeat as necessary.
4. Refer to: Specifications (206-00 Brake System - General Information,
Specifications).

5. Remove the General Equipment: Fluid Container

11.

12. Goto step 7 and repeat the procedure for the remaining brake lines.
13. Lower the vehicle.

14. Remove the General Equipment: Brake/Clutch System Pressure Bleeder/Filler

All vehicles

15. Refer to: Specifications (206-00 Brake System - General Information, Specifications).
16.
Brake System - General Information - Component Bleeding
Print

General Procedures
General Equipment
Brake/Clutch System Pressure Bleeder/Filler
Fluid Container

Bleeding
NOTE: Make sure that the vehicle is standing on a level surface.
Vehicles with stability assist
1. Bleed the brake system using the BleedMASTER function in the diagnostic tool.

Vehicles without stability assist

3. NOTICE: The brake fluid reservoir must remain full with new, clean brake fluid
at all times during bleeding.
Refer to: Specifications (206-00 Brake System - General Information, Specifications).
4. 1. 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.

Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler

5. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
6.

7. Refer to: Specifications (206-00 Brake System - General Information, Specifications).

Use the General Equipment: Fluid Container
8.

9.
1. Loosen: 180°

5. Remove the General Equipment: Fluid Container

10.

11. Lower the vehicle.

12. Remove the General Equipment: Brake/Clutch System Pressure Bleeder/Filler

All vehicles

13. Refer to: Specifications (206-00 Brake System - General Information, Specifications).
14.
Front Disc Brake - Front Disc Brake - Overview
Print

Description and Operation

General information

Item Description
1 Brake calliper
2 Brake pad wear sensor
3 Brake pad
4 Brake caliper support
5 Brake disk
6 wheel hub assembly,
On the new Transit Custom, there is a brake pad wear indicator on one brake pad of each
brake. This is a new feature compared with the previous model, on which respectively only
one brake was monitored.
A further change compared with the previous model is the dimension of the brake disc,
which is as follows:

• 288x33 mm for all models up to and including the 310 series

• 308x33 mm for models of the 330 series

All the front brake discs are ventilated.

Front Disc Brake - Brake Caliper
Print

Removal and Installation

General Equipment
Hose Clamp(s)

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2. If equipped.

3. NOTICE: Make sure that all openings are sealed.

NOTE: Note the position of the component before removal.
Use the General Equipment: Hose Clamp(s)
Torque: 17 Nm

4. Torque: 60 Nm
Installation

1. NOTE: Make sure that the component is installed to the position noted before
removal.
To install, reverse the removal procedure.

2. Refer to: Component Bleeding (206-00 Brake System - General Information, General
Procedures).
Front Disc Brake - Brake Disc
Print

Removal and Installation

Removal

1. Refer to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and
Installation).

1. To install, reverse the removal procedure.

2. Refer to: Component Bleeding (206-00 Brake System - General Information, General
Procedures).
Rear Disc Brake - Rear Disc Brake - Overview
Print

Description and Operation

General information

Item Description
1 wheel hub assembly,
2 Brake disk
3 Brake caliper support
4 Brake pad
5 Brake pad wear sensor
6 Brake calliper
As for the front brakes, there is a brake pad wear indicator on one brake pad of each of the
rear wheel brakes.
The dimensions of the rear brake discs are as follows:

• 288x16 mm for all models up to and including the 310 series

• 308x16mm for the 330 series

The rear brake discs are not ventilated on any of the variants.
Rear Disc Brake - Brake Caliper
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2. If equipped.

3. Loosen: 90°

5. NOTICE: Make sure that no load is placed on the brake hose.

Torque: 31 Nm

6. NOTICE: Make sure that all openings are sealed.

Torque: 18 Nm

Installation

1. To install, reverse the removal procedure.

2. Refer to: Component Bleeding (206-00 Brake System - General Information, General
Procedures).
Rear Disc Brake - Brake Disc
Print

Removal and Installation

Removal

1. Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Disc Brakes (204-02 Rear
Suspension, Removal and Installation).

Installation

1. To install, reverse the removal procedure.

Rear Disc Brake - Brake Pads
Print

Removal and Installation

Special Tool(s)
206-085
Retractor, Rear Brake Caliper Piston

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2. If equipped.

3. NOTICE: Make sure that no load is placed on the brake hose.

Torque: 31 Nm

4. NOTE: Note the position of the components before removal.

NOTE: Make sure that the mating faces are clean and free of foreign material.
Installation

1. NOTE: Make sure that the components are installed to the position noted before
removal.
To install, reverse the removal procedure.
2.

4. Depress the brake pedal, check the brake fluid level in the brake fluid reservoir and top
up as necessary with brake fluid
Refer to: Specifications (206-00 Brake System - General Information, Specifications).

Vehicles with single rear wheels

5. Install Special Service Tool: 206-085.

Vehicles with twin rear wheels

6. Install Special Service Tool: 206-085.

Rear Disc Brake - Rear Brake Flexible Hose
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

NOTICE: Make sure that all openings are sealed.

2. Torque: 15 Nm

Vehicles with twin rear wheels

3. Torque: 18 Nm

Vehicles with single rear wheels

4. Torque: 18 Nm
Installation

1. To install, reverse the removal procedure.

2. Refer to: Component Bleeding (206-00 Brake System - General Information, General
Procedures).
Parking Brake and Actuation - Parking
Brake
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern by operating the parking brake system.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Parking brake control. • Parking brake warning circuit.
• Cable and conduit.
• Brake pads
• Brake caliper

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. For all detailed diagnostics, proceed to use the Ford diagnostic equipment.

Symptom Chart

Symptom Possible Sources

The parking brake will not apply Parking brake control
Cable and conduit
The parking brake will not release Parking brake control
Cable and conduit
Parking Brake and Actuation - Parking Brake Cable Adjustment
Print

General Procedures
General Equipment
Feeler Gauge

4. NOTE: Note the position of the components before removal.

NOTE: Make sure that the components are installed to the position noted before
removal.

5.
6. Torque: 22 Nm

Vehicles with front wheel drive (FWD)

7. NOTE: Note the position of the components before removal.
NOTE: Make sure that the components are installed to the position noted before
removal.
Torque: 22 Nm

Vehicles with rear wheel drive (RWD)

8. NOTE: Note the position of the components before removal.
NOTE: Make sure that the components are installed to the position noted before
removal.
Torque: 22 Nm

Installation

1. To install, reverse the removal procedure.

2. Refer to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General
Procedures).
Parking Brake and Actuation - Parking
Brake Intermediate Cable
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

Installation

1. To install, reverse the removal procedure.

2. Refer to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General
Procedures).
Hydraulic Brake Actuation - Brake Pedal and Bracket
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Refer to: Steering Column (211-04 Steering Column, Removal and Installation).

4. NOTICE:
Make sure that the clutch pedal remains in the rest position.

Make sure that the brake pedal remains in the rest position.

5. Refer to: Clutch Master Cylinder (308-02 Clutch Controls, Removal and Installation).
6.

7. Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).

8. NOTICE: Make sure that the brake booster vacuum is released.

9. Support the brake booster.

Torque: 20 Nm

Installation

1. NOTICE:

Make sure that the clutch pedal remains in the rest position.

Make sure that the brake pedal remains in the rest position.
To install, reverse the removal procedure.
Hydraulic Brake Actuation - Brake Pedal and Bracket
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Refer to: Accelerator Pedal (310-02 Acceleration Control, Removal and Installation).

4. Refer to: Clutch Master Cylinder (308-02 Clutch Controls, Removal and Installation).
5. Refer to: Steering Column (211-04 Steering Column, Removal and Installation).
6.

8. NOTICE:

Make sure that the clutch pedal remains in the rest position.

Make sure that the brake pedal remains in the rest position.
9.

10. Torque: 10 Nm
11. Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).

12. NOTICE: Make sure that the brake booster vacuum is released.

13. Torque: 20 Nm
14. Support the brake booster.

Torque: 20 Nm

Installation

1. NOTICE:

Make sure that the clutch pedal remains in the rest position.

Make sure that the brake pedal remains in the rest position.
To install, reverse the removal procedure.
Hydraulic Brake Actuation - Brake Master Cylinder
Print

Removal and Installation

General Equipment
Brake/Clutch System Pressure Bleeder/Filler

Removal

NOTICE: If the fluid is spilled on the paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Removal steps in this procedure may contain installation details.
1. Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler

All vehicles
2.

3. NOTICE: Make sure that all openings are sealed.

1.
2. Torque: 18 Nm

3. Torque: 25 Nm
Installation

1. To install, reverse the removal procedure.

2. NOTICE: An incorrectly set Stop Lamp Switch causes either over-heating

brakes in the case of the pedal being pushed down or ABS faults in the case of it
being lifted during Stop Lamp Switch installation. To avoid damages to the brake
system, remove the Stop Lamp Switch and install with the brake pedal in neutral
position.
Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).

3. Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information,
General Procedures).
Power Brake Actuation - Brake Booster
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Refer to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and
Installation).
3.

4.
5. Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).

6. Torque: 24 Nm

Installation

NOTICE: An incorrectly set Stop Lamp Switch causes either over-heating brakes in
the case of the pedal being pushed down or ABS faults in the case of it being lifted during
Stop Lamp Switch installation. To avoid damages to the brake system, remove the Stop
Lamp Switch and install with the brake pedal in neutral position.
1. To install, reverse the removal procedure.
Power Brake Actuation - Brake Vacuum Hose
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Installation

1. To install, reverse the removal procedure.

Power Brake Actuation - Brake Vacuum Pump—2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN)
Print

Removal and Installation

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

3. Torque: 10 Nm
4.

5. Torque: 10 Nm

6.
7.

8.
Installation

1. NOTE: Make sure a new component is installed.

NOTE: Make sure that the mating faces are clean and free of foreign material.

2. NOTICE: Align the camshaft and vacuum pump couplings correctly or damage
to the camshaft or vacuum pump may occur.
3.

4. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. NOTE: Before fitting bolts, check that the vacuum pump couple drive and
camshaft keyway are aligned. If a gap is present between vacuum pump and
cylinder head, do not fit and run bolts.
NOTE: Under no circumstances should the retaining bolts be tightened if a
gap between pump and head faces is present.
2. NOTE: Only tighten the bolts finger tight at this stage.
5. Torque:
Stage 1:5 Nm
Stage 2:10 Nm

6. To install, reverse the removal procedure.

Anti-Lock Brake System (ABS) and Stability Control - Anti-Lock Brake
System (ABS) and Stability Control - Component Location
Print

Description and Operation

Item Description
1 Right-hand rear wheel speed sensor
2 Steering wheel rotation sensor
3 RCM (restraints control module) module
4 Left-hand front wheel speed sensor
5 ABS (anti-lock brake system)/ESP module
Anti-Lock Brake System (ABS) and
Stability Control - Anti-Lock Brake System
(ABS) - Overview
Print

Description and Operation

General information
The ABS (anti-lock brake system) system in the new Transit Custom includes the following
functions:

• ABS
• EBD (electronic brake force distribution)
• Emergency Brake Assist
• Traction control
• Dynamic cornering control
• Rollover protection
• Trailer stabilization system
• Hill launch assist

Dynamic cornering control

While cornering, ongoing measurements of the steering angle sensor and the yaw rate
sensor are taken. If the vehicle begins to understeer or oversteer, in that the actual yaw
rate differs from the yaw rate required by the driver, the dynamic cornering control system
initiates the necessary measures to bring the vehicle back into the required lane. Among
others, these are individual braking of single wheels, as well as a reduction in the engine
torque.
The dynamic cornering control system, which is controlled by the stability assist module,
processes signals from the steering angle sensor which it receives via the CAN (controller
area network) data bus. In addition, it receives information from the RCM (restraints
control module) module about the yaw rate and the longitudinal and lateral acceleration
rates. This information is transmitted via a private CAN data bus between the stability
assist module and the RCM module.
Furthermore, the stability assist module can require a reduction in engine torque by the
CAN via the PCM (powertrain control module) data bus as well as cause direct braking of
individual wheels via the corresponding ABS valves.
Anti-Lock Brake System (ABS) and
Stability Control - Anti-Lock Brake System
(ABS) and Stability Control
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 042-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Wheel speed sensor(s) • Fuse(s)
• Wheel speed sensor ring(s) • Wiring harness
• Hydraulic control unit • Electrical connector(s)
• Wheel speed sensor(s)
• Brake vacuum switch
• Battery Junction Box (BJB)
• Steering column control module (SCCM)
• ABS module
• Restraints control module (RCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, refer to the Ford diagnostic equipment to
diagnose the system.
Anti-Lock Brake System (ABS) and
Stability Control - Anti-Lock Brake System
(ABS) Module
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake System (ABS) and
Stability Control, Removal and Installation).

2. NOTICE: Extreme cleanliness must be exercised when handling these

components.

1. 1. NOTICE: Use lint free cloth.

Remove any contamination or debris - DO NOT USE A CLEANING AGENT.
2. If the contact surface or contact pins show any signs of damage or corrosion, a
new HCU must be installed.

Installation

1.
1. 1. NOTICE:

Extreme cleanliness must be exercised when handling these

components.

Make sure that the mating faces are clean and free of foreign material.

Use lint free cloth.

Take extra care not to damage the seal.

If accidentally dropped or knocked install a new hydraulic control unit

(HCU) and module assembly.

The blanking caps/plugs must not be removed until the brake tubes are
ready to be connected.
Using the outer edges of the stability assist module, lower the module onto the
HCU. DO NOT APPLY PRESSURE ONTO THE MODULE COVER.
2. If the module cover is damaged or deformed, install a new module.
2. NOTICE: Make sure that the module is correctly located on the hydraulic
control unit (HCU).
Torque:
Stage 1:2 Nm
Stage 2:3 Nm

NOTE: Note the position of the brake tubes to aid installation.
Torque: 18 Nm

4. Torque: 20 Nm
Installation

1. NOTICE:

If accidentally dropped or knocked install a new hydraulic control unit (HCU) and
module assembly.

The blanking caps/plugs must not be removed until the brake tubes are ready to
be connected.
To install, reverse the removal procedure.

2. Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information,
General Procedures).
Steering System - General Information -
Specifications
Print

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

ITEM SPECIFICATION

Power steering fluid - vehicles build before March 12, 2013 WSS-M2C204-A2

Power steering fluid - vehicles build March 12, 2013 onwards WSS M2C938 A

STEERING WHEEL CLEAR VISION

NOMINAL AND
DESCRIPTION
TOLERANCE RANGE

Clear Vision 0° ± 3°
Steering System - General Information -
Steering System
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Tire pressure(s) • Power steering pressure (PSP) switch
• Accessory drive belt
• Loose tie-rod end(s)
• Tie-rod(s)
• Steering gear housing
• Loose strut and spring assemblies or ball
joints
• Loose pinch bolts on steering column
shaft flexible coupling
• Wheels and tires
• Power steering lines fluid leaks
• Steering gear bellows

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart
The following table provides all the possible symptoms and sources related to the Steering
System. For the actual diagnosis, proceed to use the Ford diagnostic equipment.

Symptom Chart Possible Sources

Drift left or right Wheels and tires
Vehicle attitude incorrect (front or rear is high or
low)
Incorrect wheel alignment
Damaged or worn front wheel bearing(s)
Brake system
Steering linkage
Steering gear
Steering wheel off center Vehicle attitude incorrect (front or rear is high or
low)
Incorrect wheel alignment
Suspension lower arm ball joint
Steering linkage / Steering gear
Vibration Wheels and tires
Damaged or worn front wheel bearing(s)
Front strut and spring assemblies
Damaged front suspension lower arm(s)
Steering linkage
Incorrect wheel alignment
Steering effort is high/low Power steering hose restriction
Power steering fluid contamination
Aeration of the power steering fluid
Steering gear floor seal touch condition
Steering column
Steering linkage
Steering gear
Worn power steering pump
Excessive noise Power steering operation noise
Aeration of the power steering fluid
Power steering lines
Loose steering gear retaining bolts
Power steering pump
Tie-rod
Steering does not vary with increased wheel Worn tie-rod ends
rotation Worn front suspension bushings
Suspension lower arm ball joint
Steering gear insulator bushings worn or perished
Loose steering gear retaining bolts
Loose steering column retaining bolts
Loose steering column to steering gear pinion
retaining bolt
Excessive steering gear backlash
Components Tests
Steering Linkage

1. Grasp the steering wheel firmly and move it up and down and to the left and right
without turning the steering wheel to check the steering column bearing for wear,
steering column shaft for wear, steering wheel for looseness and steering column
for looseness. If the steering column bearing or the steering column shaft is worn
install a new steering column shaft.
REFER to: Steering Column (211-04 Steering Column, Removal and Installation).
If the steering wheel or the steering column is loose, tighten the steering wheel or
the steering column retaining bolts.

2. With the road wheels in the straight ahead position, gently turn the steering wheel to
the left and the right to check for free play in the steering linkage.

3. There should be no excessive free play at the steering wheel rim. If there is excessive
free play, CHECK the tie-rod inner and outer ball joints, REFER to Tie-Rod
Component Test in this procedure. CHECK the steering column universal joint,
REFER to Steering Column Universal Joint Component Test in this procedure. If
there is no free play in the tie-rod and the steering column, install a new steering
gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).

Tie-Rod

1. Noises such as knocks, which may appear to originate from the steering linkage, may
also be generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and
Harshness, Diagnosis and Testing).

2. Raise and support the vehicle.

REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).

REFER to in this section.

3. Firmly grasp the road wheel and apply a rocking motion checking for any free play in
the wheel bearing or suspension components.

4. Turn the steering wheel to position the steering linkage against the right-hand
steering lock stop.

5. With the aid of another technician holding the steering linkage against the right-hand
steering lock stop, firmly grasp the right-hand road wheel and apply a rocking
motion checking for any free play in the steering linkage.

6. Detach the steering gear boot from the steering gear body and check for free play at
the tie-rod inner ball joint.

7.
If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).

8. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).

9. Attach the steering gear boot to the steering gear body. Install new steering gear
boot clamps.

10. Turn the steering wheel to position the steering linkage against the left-hand steering
lock stop.
11. With the aid of another technician holding the steering against the left-hand steering
lock stop, firmly grasp the left-hand road wheel and apply a rocking motion
checking for any free play in the steering linkage.

12. Detach the steering gear boot from the steering gear body and check for free play at
the tie-rod inner ball joint.

13.
If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).

14. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).

15. Attach the steering gear boot to the steering gear body. Install new steering gear
boot clamps.

Turning Effort Test

1. Before carrying out the turning effort test, make sure that the following are
serviceable:

• Suspension components.
• Steering column.
• Toe adjustment.
REFER to: Front Toe Adjustment (204-00 Suspension System - General Information,
General Procedures).
• Tire pressures.

2. Park the vehicle on a dry, even surface and apply the parking brake.

3. Remove the driver air bag module.

REFER to: Driver Airbag (501-20B Supplemental Restraint System, Removal and
Installation).

4. Connect the air bag simulators to the sub-harnesses in place of the driver air bag
module at the top of the steering column.

5. Start the engine and turn the steering wheel from lock to lock several times until the
power steering fluid has reached normal operating temperature.

6. Using a suitable torque wrench and socket, check the steering wheel turning effort.
7. If the steering wheel turning effort is greater than the specification, install a new
steering gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).

Steering Column Universal Joint

1. WARNING: Make sure that a new steering column flexible coupling bolt is
installed.
Detach the steering column from the steering gear pinion.
• Discard the steering column to steering gear pinion retaining bolt.

2.
Check for smooth movement of the steering column universal joint.
1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight movement.
• If the movement is not smooth or resistance is felt, install a new steering column
or shaft as necessary.
REFER to: Steering Column (211-04 Steering Column, Removal and Installation).

3.
Hold both of the steering column universal joint yokes and twist them clockwise and
counterclockwise.
• If movement is felt, install a new steering column or shaft as necessary.
REFER to: Steering Column (211-04 Steering Column, Removal and Installation).

Lower Arm Ball Joint Inspection

1. Raise and support the vehicle.

REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).

2. Firmly grasp the outer end of the suspension lower arm and try to move it up and
down, watching and feeling for any movement. Free movement will usually be
accompanied by an audible "click". There should be no free movement.

3. If there is any free movement, install a new lower arm.

REFER to: Lower Arm (204-01 Front Suspension, Removal and Installation).
Steering System - General Information -
Steering Gear Checks After a Collision
Print

Diagnosis and Testing

General Equipment
Feeler gauge
Straight edge
Items to be observed when checking the steering system
The following list of steering gear conditions and the methods of testing should be taken
into account when carrying out checks to the steering system:

• If the steering gear has no faults after completing the following checks, do not install a
new steering gear.
• Surface corrosion and marks on the tie-rod are acceptable.
• When checking for turning effort torque peaks in the steering gear, turn the steering
wheel from steering lock stop to steering lock stop in approximately 15 seconds.
• A steady increase of turning effort torque from steering center to steering lock stop is
acceptable.
• When checking for power steering fluid leaks, turn the steering wheel to the steering lock
stop in approximately 10 seconds.
• Noises from the power steering, for example the power steering pump relief valve, are
acceptable.

STEERING GEAR HOUSING

• Raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
• Visually inspect the steering gear housing for cracks and damage. If the steering gear
housing is cracked or damaged, install a new steering gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).

TIE-RODS
• Using a straight edge and feeler gauge, check the tie-rods to see if they are straight. If
the distance between the tie-rod and straight edge is greater than 0.5 mm, install a new
steering gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).
• Check the tightening torque of the tie-rod end to wheel knuckle nut.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
• Check the tightening torque of the tie-rod end locking nut.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).

CHECK FOR TURNING EFFORT TORQUE PEAKS IN THE STEERING GEAR

• Lower and support the vehicle making sure that the road wheels are just clear of the
floor.
• With the ignition switch in position I, slowly turn the steering wheel from steering lock
stop to steering lock stop. If a turning effort torque peak or judder is felt while turning
the steering wheel, detach the tie-rods from the wheel knuckles.
• Slowly turn the steering wheel from steering lock stop to steering lock stop. If a turning
effort torque peak or judder is felt while turning the steering wheel, install a new steering
gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).

CHECK FOR POWER STEERING FLUID LEAKS

• Lower the vehicle.
• Run the engine at a fast idle and slowly turn the steering wheel to the left-hand steering
lock stop. Hold the steering wheel in this position for 5 seconds with a turning effort
torque of 15 Nm at the steering wheel rim.
• Turn the steering wheel away from the left-hand steering lock stop for 30 seconds.
• Run the engine at a fast idle and slowly turn the steering wheel to the right-hand
steering lock stop. Hold the steering wheel in this position for 5 seconds with a turning
effort torque of 15 Nm at the steering wheel rim.
• Turn the steering wheel away from the right-hand steering lock stop.
• Check for power steering fluid leaks at the steering gear housing and the power steering
line connections to the steering gear. If there is a power steering fluid leak at the
steering gear, install a new steering gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).
Steering System - General Information - Power Steering System
Bleeding
Print

General Procedures
Special Tool(s)
211-265
Evacuation Cap, Power Steering

416-D001
Hand Vacuum Pump/Pressure Pump

Bleeding
1.

2. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

3. NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air
could enter the system.
4. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

5. When bleeding the power steering system the vacuum will decrease. Using the special
tools, maintain a sufficient vacuum of 38cm-Hg. If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be checked for leaks.

Install Special Service Tools: 416-D001, 211-265.

6. Remove Special Service Tools: 211-265, 416-D001.

7. NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air
could enter the system.

8. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

9.
1. Install Special Service Tools: 211-265, 416-D001.

2. Using the special tools, create a vacuum of 38cm-Hg. Maintain the vacuum until
the air is evacuated from the system (minimum of five minutes).
3. Release the vacuum.

10. Remove Special Service Tools: 416-D001, 211-265.

11. NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air
could enter the system.

12. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

13.
Steering System - General Information - Power Steering System Filling
Print

General Procedures
Special Tool(s)
211-265
Evacuation Cap, Power Steering

416-D001
Hand Vacuum Pump/Pressure Pump

Filling
1.

2. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

3. Raise the vehicle until the road wheels are clear of the floor. Support the vehicle.

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4. NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air
could enter the system.
Slowly turn the steering wheel from lock to lock and add power steering fluid until the
power steering fluid in the power steering fluid reservoir stops dropping.
5. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

6. Switch the engine OFF and using the special tools, create a vacuum of 62cm-Hg - 75cm-
Hg for 30 seconds.

Install Special Service Tools: 211-265, 416-D001.

7. 1. Observe the vacuum gauge reading.

2. If the vacuum decreases by more than 5cm-Hg in 5 minutes, the system should
be checked for leaks.

8. Remove Special Service Tools: 416-D001, 211-265.

9. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

10.

11. Lower the vehicle.

Steering System - General Information - Power Steering System
Flushing
Print

General Procedures
General Equipment
Long Nose Pliers

Flushing
1. NOTE: Vehicles build December 15, 2015 onwards don’t require flushing after a
PAS system repair based on a new permanent filter that is part of the reservoir.
1. Standard reservoir used for vehicles build up to December 14, 2015 inclusive.
2. Reservoir with permanent filter used for vehicles build December 15, 2015
onwards.

3.
4. NOTE: Make sure that a new component is installed.
Use the General Equipment: Long Nose Pliers

5. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

6. Slowly turn the steering wheel from lock to lock for 30 seconds and add power steering
fluid until the fluid level remains constant at the MAX mark.
7.

Filling
1. Refer to: Specifications (211-00 Steering System - General Information, Specifications).

2.
Power Steering - Power Steering - Component Location
Print

Description and Operation

Item Description
1 Reservoir
2 Power steering lines
3 Steering column
4 Multifunction switch - steering column
5 Steering wheel
6 Steering gear
7 Power steering pump
Power Steering - Power Steering -
Overview
Print

Description and Operation

General information
The steering area of the Transit Custom also conveys a car-like feel, just like the complete
interior of the vehicle. In particular, the steering response and feedback give the driver a
feeling of comfort which is new in the commercial vehicle sector.
In addition, for the first time, the steering wheel position is now adjustable in both height
and reach.
For variants with a short wheelbase as well as those with a long wheelbase, the turning
circle of the new Transit Custom has been improved compared with the previous model as
follows:

• 11.14 meters with short wheelbase and 15" wheel rims

• 12.4 meters with long wheelbase and 15" wheel rims
• 11.6 meters with short wheelbase and 16" wheel rims
• 12.9 meters with long wheelbase and 16" wheel rims
Power Steering - Power Steering Fluid Reservoir
Print

Removal and Installation

General Equipment
Flat Headed Screw Driver
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Use the General Equipment: Flat Headed Screw Driver

3. Use the General Equipment: Hose Clamp Remover/Installer

Installation

1. To install, reverse the removal procedure.

2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Fluid
Reservoir to Power Steering Pump Hose
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Use the General Equipment: Hose Clamp Remover/Installer

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

4. Use the General Equipment: Hose Clamp Remover/Installer

Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
Refer to: Power Steering System Flushing (211-00 Steering System - General
Information, General Procedures).
3. NOTE: This step is not necessary when installing a new component.
Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Pump—2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN)
Print

Removal and Installation

General Equipment
6 mm Drill Bit

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

4. Torque: 10 Nm
5. Torque:
1 10 Nm
2 10 Nm
3 9 Nm

6. Use the General Equipment: 6 mm Drill Bit

7. Torque: 25 Nm

8. Torque: 24 Nm
Installation

1. To install, reverse the removal procedure.

3. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Steering Gear
Print

Removal and Installation

Special Tool(s) / General Equipment
204-015
Remover, Drop Arm

Transmission Jack
Two Leg Puller

Removal
NOTE: Removal steps in this procedure may contain installation details.

1. NOTICE: Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.

2. NOTICE: The steering column is designed to absorb energy in a crash and

must be handled carefully. The energy-absorbing steering column shaft cannot be
subjected to force or impact shocks. Follow the removal procedure instructions
carefully to avoid damage.
NOTE: Make sure a new bolt is installed.
Torque: 28 Nm

3.
4. On both sides.

Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

5. NOTICE: Make sure that the ball joint ball does not rotate.
On both sides.

Torque: 48 Nm

6. On both sides.

Use Special Service Tool: 204-015.

7. On both sides.

Loosen: 3 turn(s)

8.
1. On both sides.

Use the General Equipment: Two Leg Puller

2. On both sides.

9.
10.

11. Torque: 10 Nm
All vehicles
12.
1. 1. NOTICE: Make sure a new bolt is installed.
Torque: 133 Nm

2. 2. NOTICE: Make sure a new bolt is installed.

If equipped. W706661-S442 / M14x1,5

Torque: 150 Nm

3. 3. NOTICE: Make sure a new bolt is installed.

If equipped. W718556-S439 / M14x2,0

Torque: 175 Nm

13. Torque: 30 Nm
14. Use the General Equipment: Transmission Jack

15.
1. Torque: 175 Nm

2. Torque: 275 Nm
16. Torque: 7 Nm

17. Torque: 115 Nm

Installation

1. To install, reverse the removal procedure.

2. On both sides.

Torque: 150 Nm

3. NOTE: This step is only necessary when installing a new component..

Refer to: Power Steering System Flushing (211-00 Steering System - General
Information, General Procedures).

4. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).

5. Refer to: Front Toe Adjustment (204-00 Suspension System - General Information,
General Procedures).
Power Steering - Power Steering Pump to Steering Gear Pressure
Line—2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN)
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque:
1 25 Nm
2 24 Nm
3 9 Nm

3. Torque: 10 Nm
Installation

1. To install, reverse the removal procedure.

2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Steering Gear to Power Steering Fluid Reservoir Return
Line
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Use the General Equipment: Hose Clamp Remover/Installer

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4.
5. Torque: 1 Nm

Installation

1. To install, reverse the removal procedure.

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
3.

4.
5. Torque: 11 Nm

Installation

1. To install, reverse the removal procedure.

2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Fluid Cooler to Power Steering Fluid
Reservoir Return Hose
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
3.

4.
5. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
6.

7.
Installation

1. To install, reverse the removal procedure.

2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Steering Gear to Fluid Cooler Return Hose
Print

Removal and Installation

Removal

NOTICE: While repairing the power steering system, care should be taken to prevent
the entry of foreign material or failure of the power steering components may result.
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
3.

4.
5.

6. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

7. Torque: 1 Nm
Left-hand drive vehicles

8. Torque: 1 Nm

9. NOTICE: Install new O-ring seals any time the lines are disconnected from the
steering gear or a fluid leak may occur.
Torque: 23 Nm
Right-hand drive vehicles

10. Torque: 1 Nm

11. NOTICE: Install new O-ring seals any time the lines are disconnected from the
steering gear or a fluid leak may occur.
1. Torque: 1 Nm

2. Torque: 23 Nm
Installation

1. To install, reverse the removal procedure.

2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Steering Linkage - Steering Gear Boot
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

Hose Clamp Remover/Installer

Materials
Name Specification
Grease - Silicone ESE-M1C171-A

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).

3. Use the General Equipment: Hose Clamp Remover/Installer

Installation

1. To install, reverse the removal procedure.

2. Material: ESE-M1C171-A (Grease - Silicone)

3. Install Special Service Tool: 204-169.

4.
Steering Linkage - Tie Rod
Print

Removal and Installation

Special Tool(s) / General Equipment
204-169
Clamping Tool, Boot Retaining Clamp

Vise
Vise Jaw Protectors

Materials
Name Specification
Grease - Silicone ESE-M1C171-A

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Steering Gear (211-02 Power Steering, Removal and Installation).
3. NOTE: Make sure that the tie rod end is installed with the same number of turns as
when removed.
Torque: 90 Nm

4. NOTICE: Note the position of the components before removal.

5.
6.
1. Use the General Equipment: Vise

2. Use the General Equipment: Vise Jaw Protectors

7.
1. Use the General Equipment: Vise

2. Use the General Equipment: Vise Jaw Protectors

Installation

1. To install, reverse the removal procedure.

2. Torque: 90 Nm

3. Material: ESE-M1C171-A (Grease - Silicone)

4. Install Special Service Tool: 204-169.

5.
Steering Linkage - Tie Rod End
Print

Removal and Installation

Special Tool(s)
204-015
Remover, Drop Arm

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information,
Description and Operation).

2. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

3. NOTICE: Make sure that the ball joint ball does not rotate.
1. Torque: 90 Nm

2. Torque: 48 Nm

4. Use Special Service Tool: 204-015.

5. NOTE: Make sure that the tie rod end is installed with the same number of turns as
when removed.

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3.
4.

Installation

1. To install, reverse the removal procedure.

Steering Wheel and Column Electrical Components - Steering Column
Lock and Ignition Switch Housing
Print

Removal and Installation

General Equipment
Punch

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation).
2.

3.
4.

5. Torque: 3 Nm
6. Torque: 3 Nm

7.
8. On both sides.

Use the General Equipment: Punch

9. On both sides.

10.
Installation

1. To install, reverse the removal procedure.

Steering Wheel and Column Electrical Components - Steering Column
Multifunction Switch LH
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Torque: 1 Nm
Installation

1. To install, reverse the removal procedure.

Steering Wheel and Column Electrical Components - Steering Column
Multifunction Switch RH
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Torque: 1 Nm
Installation

1. To install, reverse the removal procedure.

Engine System - General Information - Specifications
Print

OIL DRAIN PLUG

NOTE: The oil drain plug O-ring seal is to be reused or replaced in accordance with the table below.
NOTE: If the seal is damaged it must always be replaced.
VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

Ka 2009 (07/08 - ) 1.2 Duratec-8V reuse

1.3 Duratorq-TDCi reuse

Ka+ 2016.50 (01/16 - ) 1.2 Duratec 16V Ti-VCT reuse

Fiesta 2008.75 (06/08 - )/ Fiesta 2013 1.0 Duratec replace

(05/12 - )

1.0 Duratec replace

1.0 EcoBoost replace

1.25 Duratec-16V reuse

1.4 Duratec-16V reuse

1.6 Duratec-16V Ti-VCT reuse

1.6 EcoBoost reuse

1.4 Duratorq-TDCi reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

Fiesta 2017.75 (01/2017 - ) 1.0 EcoBoost replace

1.1 Duratec replace

1.5 EcoBoost - I3 reuse

1.5 Duratorq-TDCi reuse

B-MAX 2012.75 (01/12 - ) 1.0 EcoBoost replace

1.4 Duratec-16V reuse

1.6 Duratec-16V Ti-VCT reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

Fusion 2002.75 (06/02 - ) 1.25 Duratec-16V reuse

1.3 Duratec 8V reuse

1.4 Duratec-16V reuse

VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

1.6 Duratec-16V Ti-VCT reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

Mondeo 2007.5 (02/07 - ) 1.6 Duratec-16V Ti-VCT reuse

1.6 EcoBoost reuse

2.0 Duratec-HE reuse

2.0 EcoBoost reuse

2.3 Duratec-HE reuse

2.5 Duratec-ST reuse

1.6 Duratorq-TDCI reuse

1.8 Duratorq-TDCi replace

2.0 Duratorq-TDCi reuse

2.2 Duratorq-TDCi reuse

Mondeo 2014.75 (10/14 - ) 1.0 EcoBoost replace

2.0 EcoBoost reuse

2.0 Duratec-HE HEV reuse

2.5 Duratec-ST reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

Focus 2004.75 (07/04 - ) 1.4 Duratec-16V reuse

1.6 Duratec-16V reuse

1.6 Duratec-16V Ti-VCT reuse

1.8 Duratec-HE reuse

2.0 Duratec-HE reuse

2.5 Duratec-ST reuse

1.6 Duratorq-TDCi reuse

1.8 Duratorq-TDCi replace

2.0 Duratorq-TDCi reuse

VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

Focus 2011.25 (07/10 - ) 1.0 EcoBoost replace

1.5 EcoBoost reuse

2.0 Duratec-HE reuse

2.0 EcoBoost reuse

1.6 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

Focus 2015 (05/14 - ) 1.0 EcoBoost replace

1.5 EcoBoost reuse

1.6 Duratec-16V Ti-VCT reuse

2.0 Duratec-HE reuse

2.0 EcoBoost reuse

2.3 EcoBoost reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

Focus 2019 (01/18 - ) 1.0 EcoBoost replace

1.5 Duratec I3 reuse

1.5 EcoBoost I3 reuse

1.5 EcoBlue reuse

2.0 EcoBlue replace

C-MAX 2003.75 (06/03 - ) 1.6 Duratec-16V reuse

1.6 Duratec-16V Ti-VCT reuse

1.8 Duratec-HE reuse

2.0 Duratec-HE reuse

1.6 Duratorq-TDCi reuse

1.8 Duratorq-TDCi replace

2.0 Duratorq-TDCi reuse

C-MAX 2011.0 (04/10 -) 1.0 EcoBoost replace

1.6 Duratec-16V Ti-VCT reuse

VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

1.6 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

C-MAX Hybrid (10/14 - ) 2.0 Duratec-HE HEV reuse

C-MAX 2015.5 (03/15 - ) 1.0 EcoBoost replace

1.5 EcoBoost reuse

1.6 Duratec-16V Ti-VCT reuse

1.6 EcoBoost reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

Kuga 2008.5 (02/08 - ) 2.0 Duratorq-TDCi reuse

2.0 Duratec-ST reuse

Kuga 2013.25 (05/12 - ) 1.5 EcoBoost reuse

1.6 EcoBoost reuse

2.0 Duratec reuse

1.5 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

EcoSport 2013 (05/12 - ) 1.0 EcoBoost replace

1.5 Duratec-16V Ti-VCT reuse

1.6 Duratec-16V Ti-VCT reuse

2.0 Duratec-HE reuse

1.5 Duratorq-TDCi reuse

EcoSport 2018.25 1.0 EcoBoost replace

1.5 Duratec I3 reuse

2.0 Duratec-HE reuse

1.5 EcoBlue reuse

Ranger 2006.5 (05/06 - ) 2.5 Duratorq-TDCi replace

3.2 Duratorq-TDCi replace

Ranger 2012 (04/11 - ) 2.2 Duratorq-TDCi replace

VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

3.2 Duratorq-TDCi replace

Edge 2016 (08/15 - ) 2.0 Duratorq-TDCi reuse

2.0 EcoBlue replace

Mustang 2015 (02/14 - ) 2.3 EcoBoost reuse

5.0 Ti-VCT reuse

S-MAX/Galaxy 2006.5 (02/06 - ) 1.6 EcoBoost reuse

2.0 Duratec-HE reuse

2.0 EcoBoost reuse

2.3 Duratec-HE reuse

2.5 Duratec-ST reuse

1.6 Duratorq-TDCi reuse

1.8 Duratorq-TDCi reuse

2.0 Duratorq-TDCi reuse

2.2 Duratorq-TDCi reuse

S-MAX/Galaxy 2015.5 (01/15 - ) 1.5 EcoBoost reuse

2.0 EcoBoost reuse

2.0 Duratorq-TDCi reuse

2.0 EcoBlue replace

Transit 2006.5 (04/06 - ) RWD 2.3 Duratec-HE reuse

2.2 Duratorq-TDCi replace

2.4 Duratorq-TDCi replace

3.2 Duratorq-TDCi replace

Transit 2006.5 (04/06 - ) FWD 2.2 Duratorq-TDCi replace

2.4 Duratorq-TDCi replace

Transit 2014.5 (08/13 - ) FWD 2.0 EcoBlue reuse

2.2 Duratorq-TDCi replace

Transit 2014.5 (08/13 - ) AWD 2.0 EcoBlue reuse

2.2 Duratorq-TDCi replace

Transit Custom 2012.75 (04/12 - ) 2.0 EcoBlue reuse

VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG

2.2 Duratorq-TDCi replace

Transit/Tourneo Connect 2002.5 (06/02 - ) 1.8 Duratec replace

1.8 Duratorq-TDCi replace

Transit/Tourneo Connect 2014 (02/13 - ) 1.0 EcoBoost replace

1.6 EcoBoost reuse

1.5 EcoBlue reuse

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

Transit Courier/Tourneo Courier 2014.50 1.0 EcoBoost replace

(10/2013-)

1.5 Duratorq-TDCi reuse

1.6 Duratorq-TDCi reuse

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Specifications
Print

MATERIALS

NOTICE: These Parts urgently needed by engine removal and installation !

NECESSARY PARTS QUANTITY PART NUMBER

Lifting eye engine 1 GK2Q-17A084-AA

Bolt 2 W500624-S

ENGINE DATA - 105 PS

DESCRIPTION

Code YLFS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Stroke 90.03 mm

Displacement 1996 cc

Compression ratio 16.5:1

Power output at 3500 rpm 77 kW (105 PS)

Torque between 1375 to 2000 rpm 360 Nm

Idle speed 850 rpm

ENGINE DATA — 130 PS

DESCRIPTION

Code YMFS

Emission level Stage 6

Firing order 1-3-4-2

DESCRIPTION

Bore diameter 84.01 mm

Stroke 90.03 mm

Displacement 1996 cc

Compression ratio 16.5:1

Power output at 3500 rpm 95 kW (130 PS)

Torque between 1500 to 2000 rpm 385 Nm

Idle speed 850 rpm

ENGINE DATA — 170 PS

DESCRIPTION

Code YNFS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Stroke 90.03 mm

Displacement 1996 cc

Compression ratio 16.5:1

Power output at 3500 rpm 125 kW (170 PS)

Torque between 1750 to 2500 rpm 405 Nm

Idle speed 850 rpm

ENGINE DATA — 105 PS

DESCRIPTION

Code YLF6

Emission level Stage 6

DESCRIPTION

Oil service fill with filter change 8.3

ENGINE OIL CAPACITY WITH YELLOW DIPSTICK END

LITERS

Initial fill including oil filter 10

Oil Service fill without filter change 9.2

Oil service fill with filter change 9.8

CYLINDER BLOCK DIMENSIONS

DESCRIPTION MM

Cylinder bore diameter 84.000 - 84.020

Main bearing housing diameter 65.000 - 65.020

DESCRIPTION MM

Main bearing running clearance 0.035 - 0.065

PISTON DIMENSIONS

DESCRIPTION MM

Piston diameter 83.915 - 83.931

Squish hight 0.6045

Piston clearance in cylinder 0.069 - 0.105

Piston ring end gaps

— upper compression ring 0.250 - 0.400

— lower compression ring 0.850 - 1.100

— oil control ring 0.200 - 0.400

Piston ring gap position: The piston ring gaps must be distributed evenly around
the circumference of the piston. This also applies to the oil control ring elements.
Align the piston ring gaps at 120 degrees to each other.

CRANKSHAFT DIMENSIONS

Connecting rod width 24.280 - 24.300

Connecting rod bearing shell inner diameter — bearings installed 46.971 - 47.015

Connecting rod bearing radial clearance 0.017 - 0.029

Connecting rod bearing axial clearance 0.100 - 0.320

Connecting rod big end bore diameter 53.000 - 53.013

Connecting rod small end bore diameter 30.012 - 30.020

PISTON PIN DIMENSIONS

DESCRIPTION MM

Piston pin length 63.350 - 63.650

Piston pin diameter 29.994 - 30.000

Piston pin slide clearance 0.011 - 1.860

Piston pin bore diameter 30.017 - 29.989

CAMSHAFT DIMENSIONS

DESCRIPTION MM

Camshaft end float - Axial play 0.025 - 0.060

VALVE DIMENSIONS

DESCRIPTION MM

Valve stem to valve guide clearance — intake valve 0.0255 - 0.0605

Valve stem to valve guide clearance — exhaust valve 0.0355 - 0.705

CYLINDER HEAD DIMENSIONS

DESCRIPTION MM

Maximum distortion — measured longitudinally and diagonally 0.100

Peak to valley height of mating surface 0.150

Thickness of cylinder head gasket with piston protrusion of 0.671 - 1.30 (one tooth)
0.720 mm Grade 1

Thickness of cylinder head gasket with piston protrusion of 0.721 - 1.35 (two teeth)
0.770 mm Grade 2

Thickness of cylinder head gasket with piston protrusion of 0.771 - 1.40 (three teeth)
0.820 mm Grade 3

Thickness of cylinder head gasket with piston protrusion of 0.821 - 1.45 (four teeth)
0.870 mm Grade 4

Thickness of cylinder head gasket with piston protrusion of 0.871 - 1.50 (five teeth)
0.920 mm Grade 5

OIL PRESSURE SPECIFICATIONS

DESCRIPTION PRESSURE BAR (KPA)

Minimum oil pressure at idle speed 1.0 (100)

Minimum oil pressure at 2000 rpm 1.5 (150)

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

ITEM SPECIFICATION

SAE 0W-30 Material: WSS-

M2C950-A (Engine
Oil - SAE 0W-30)
ITEM SPECIFICATION

Sealer — oil pan, crankshaft rearseal , ladderframe and engine front Material: WSE-
cover M4G323-A4
(Silicone Sealant)
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine - Component Location
Print

Description and Operation

Item Description
1 Oil cooler
2 Oil filter
3 Coolant pump
4 Intake manifold
5 Fuel rail
6 High pressure fuel pump
Item Description
1 Oil pan
2 Exhaust manifold
3 Thermostat
4 Vacuum pump
5 Valve cover
6 Turbocharger
Engine - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN)
- Engine - System Operation and
Component Description
Print

Description and Operation

System Operation
Intelligent Oil-Life Monitor (IOLM) and ‘variable’ oil change intervals
Ford vehicles are equipped with an Intelligent Oil-Life Monitor (IOLM) that determines when
the engine oil must be changed, based on how the vehicle is used. By considering several
important factors in its calculations, the IOLM helps to ensure that the engine performs at
its best while also helping to avoid unnecessary oil changes. The IOLM together with
advanced, high specification oils, allow greater distances to be achieved in between oil
changes, but this varies depending on how and where vehicles are driven.
Driving conditions and driving styles have an impact on the vehicle’s oil life. For example,
vehicles that are driven predominantly on highways will not experience the same level of oil
dilution as vehicles driven predominantly around town or in city centers, where frequent
engine starting and stationary periods are normal. Vehicles used as taxis, for multi-drop
deliveries, for short journeys, when stationary with the engine running for long periods of
time, will all experience greater levels of oil dilution than vehicles not operating under such
conditions.
Therefore, depending on driving style and conditions, some customers may not reach the
scheduled service interval before the engine oil life is depleted and requires changing. When
the oil life is fully depleted the following information message is displayed in the vehicle’s
instrument cluster: Oil Change Required. The driver is reminded with this message every
time the vehicle’s ignition is switched on. It is important that this message is not ignored
and the engine oil is changed as soon as possible to protect the engine from premature
wear and failure, no later than 1.500 km (1,000 mi) or one month, occurs first.
The following factors can reduce the interval between oil changes:
• Frequent low-speed city-center driving (below 50 kph/30 mph)
• Frequent short journeys (below 3 km/2 mi), where the engine does not reach its normal
operating temperature
• Frequent engine starting
• High engine load conditions, for example: driving the vehicle fully loaded, trailer towing,
frequent hill climbs.
To maximize the intervals between oil changes, the following conditions are recommended:
• The vehicle is not stationary with the engine running for long periods of time
• The vehicle is driven with engine speeds mainly above 1,700 rpm for at least 15 minutes
once the engine has reached normal operating temperature, at least once a week.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Engine
Print

Diagnosis and Testing

Special Tool(s) / General Equipment
Compression Test Adapter
303-1651

Ford diagnostic equipment

Compression tester
Oil pressure gauge
UV leak detection lamp

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Coolant leaks • Fuse(s)
• Oil leaks • Loose or corroded connector(s)
• Fuel system leaks • Damaged or worn switch(es)
• Visibly damaged or worn parts • Powertrain control module (PCM)
• Loose or missing nuts or bolts

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Loss of oil * Oil leaks from the engine or * CHECK for evidence of oil leaks
auxiliary components. on components. Use an ultraviolet
(UV) leak tester if oil leak is not
evident. INSTALL new gaskets or
components as required.
* Internal or external leak at the * CHECK the coolant expansion
oil cooler. tank for oil film on the coolant
surface. INSTALL a new oil cooler
or oil cooler gasket.
* Leak at the crankshaft front or * INSTALL a new crankshaft oil
rear oil seal. seal. REFER to: (303-01B Engine)
Crankshaft Front Seal
(Removal and Installation),
Crankshaft Rear Seal
(Removal and Installation).
Oil consumption * Use of the wrong type of engine * DETERMINE the last type of
oil. engine oil used (refer to the latest
invoice or oil receipt) and
compare with the specification.
INSTALL a new engine oil filter
and the correct engine oil.
REFER to: Specifications (303-
01A Engine, Specifications).
* Faulty positive crankcase * CHECK that the crankcase
ventilation system. ventilation system is operating
- Hoses or ventilation/breather correctly and repair as necessary.
valves are blocked. This causes
excessive pressure in the
crankcase which causes oil to
enter the combustion chamber.
- Crankcase ventilation oil
separator is faulty and engine
oil can enter the combustion
chamber through the intake
manifold.
* Turbocharger seals. * INSTALL a new turbocharger.
REFER to: Turbocharger (303-04C
Fuel Charging and Controls -
Turbocharger, Removal and
Installation).
* Damaged gaskets or mating * CHECK the gaskets and mating
surfaces. surfaces for damage.
- Cylinder head gasket is - REMOVE the cylinder head. Check
damaged or mating faces are the mating faces, cylinder head
warped. gaskets and the flatness of the
- Valve stem seals are worn cylinder head and engine block
causing engine oil to enter the mating faces.
combustion chamber between - INSTALL new valve stem seals.
the valve stem and the valve REFER to: Valve Stem Seals
stem guide. (303-01A Engine, Removal and
Installation).
* Piston ring or cylinder liner * INSTALL new components as
wear. necessary.
Coolant consumption * Cooling system components. *
REFER to: Engine Cooling (303-
03A Engine Cooling, Diagnosis
and Testing).
* Exhaust gas recirculation (EGR) * INSTALL a new EGR cooler.
cooler (if equipped). REFER to: Exhaust Gas
Recirculation (EGR) Cooler (303-
08A Engine Emission Control,
Removal and Installation).
* Oil cooler. * INSTALL a new oil cooler.
* Damaged gaskets or warped * REMOVE the cylinder head.
mating faces. REFER to: Cylinder Head -
Vehicles Built From: 01-11-2016
(303-01A Engine, Removal and
Installation).
CHECK the cylinder head gasket
for damage. CHECK the cylinder
head and cylinder block for
distortion.
* Cracks or fractures in engine * DETERMINE the damaged engine
components surrounded by component and INSTALL a new
coolant, such as cylinder liners component.
and cylinder head combustion
chamber.
Engine will not crank * Battery or cables. * CHECK the battery and cables.
REFER to: Charging System (414-
00 Charging System - General
Information, Diagnosis and
Testing).
* Starter motor or cables. * CHECK the starting system.
REFER to: Starting System (303-
06A Starting System, Diagnosis
and Testing).
Engine cranks but will * Fuel tank is empty. * CHECK the fluid level.
not start * Water in fuel. * DRAIN the water from the fuel
system.
REFER to: Diesel Filter Water
Drain-Off (310-00A Fuel System -
General Information, General
Procedures).
* Fuel filter blocked. * INSTALL a new fuel filter element.
REFER to: Fuel Filter Element
(310-01A Fuel Tank and Lines,
Removal and Installation).
* Air in fuel lines. * BLEED the fuel system. Check the
fuel system for leaks.
REFER to: Fuel System Bleeding
(310-00A Fuel System - General
Information, General Procedures).
* Engine intake air system. * CHECK the intake air system.
REFER to: Intake Air Distribution
and Filtering (303-12A Intake Air
Distribution and Filtering,
Diagnosis and Testing).
* Glow plug faulty. * CHECK the glow plugs.
REFER to: Glow Plug System
(303-07A Glow Plug System,
Diagnosis and Testing).
INSTALL new glow plugs as
necessary.
REFER to: Glow Plugs (303-07A
Glow Plug System, Removal and
Installation).
* Engine management system. * CHECK the engine management
system.
REFER to: Electronic Engine
Controls (303-14A Electronic
Engine Controls, Diagnosis and
Testing).
* Fuel pump faulty. * CHECK the fuel pump.
REFER to: Fuel Charging and
Controls (303-04A Fuel Charging
and Controls, Diagnosis and
Testing).
* Incorrect valve timing. * CHECK and adjust the valve
timing.
* Broken or damaged timing * CHECK the timing chain and
chain or sprocket. sprockets. INSTALL new
components as necessary.
Very poor power * Fuel system. * CHECK the fuel system
output/fuel components.
consumption too * Engine intake air system. * CHECK the intake air system.
high/engine running REFER to: Intake Air Distribution
rough and Filtering (303-12A Intake Air
Distribution and Filtering,
Diagnosis and Testing).
* Exhaust system blocked. * CHECK the exhaust system.
* Engine management system. *
CHECK the engine management
system.
REFER to: Electronic Engine
Controls (303-14A Electronic
Engine Controls, Diagnosis and
Testing).
* Turbocharger. * CHECK the turbocharger.
REFER to: Turbocharger (303-04C
Fuel Charging and Controls -
Turbocharger, Diagnosis and
Testing).
* Fuel pump faulty. * CHECK the fuel pump.
REFER to: Fuel Charging and
Controls (303-04A Fuel Charging
and Controls, Diagnosis and
Testing).
* Incorrect valve timing, timing * CHECK and adjust the valve
chain or timing sprocket timing. INSTALL new components
damaged. as necessary.
Noisy running * Engine auxiliary components * CHECK engine auxiliary
loose or damaged. components for
damage/looseness.
Noisy running, * Incorrect fuel * DETERMINE which type of fuel
misfiring/backfiring was the last put in the tank (note
the country specific fuel
specifications).
* Water in fuel or fuel * CHECK the fuel system for water
contaminated. or other contamination.
REFER to: Diesel Filter Water
Drain-Off (310-00A Fuel System -
General Information, General
Procedures).
* Fuel pump faulty. * CHECK the fuel pump.
REFER to: Fuel Charging and
Controls (303-04A Fuel Charging
and Controls, Diagnosis and
Testing).
* Valve timing incorrect, timing * CHECK and adjust valve timing.
chain or timing sprocket INSTALL new components as
damaged. necessary.
Noisy running/valve * Excessive valve clearance due * INSTALL new hydraulic valve
train noise to faulty hydraulic valve tappets.
tappets.
* Timing chain damaged. * INSTALL a new timing chain.
* Timing chain incorrectly * CHECK the timing chain tension.
tensioned. INSTALL a new tensioner, as
necessary.
* Timing chain guides worn or * CHECK the timing chain guides.
damaged. INSTALL new guides as
necessary.
Noisy running/engine * Engine components * CHECK the engine components
block - Pistons for wear or damage. Make sure
- Piston rings all components are within
- Connecting rod large end, main specification. INSTALL new
bearing or thrust bearing components as necessary.
journals
- Connecting rods bent or
damaged.

Engine Oil Leaks

NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly
established.
If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:
Ultraviolet (UV) Testing

1. Clean the engine and transmission with a suitable cleaning fluid such as brake
cleaner.

2. Pour test fluid GV-2911-3090A in accordance with the quantity specified by the
manufacturer through the oil filler neck into the engine and install the oil filler cap.

WARNING: On manual transmissions put the transmission into NEUTRAL. Failure to

follow these instructions may result in personal injury.

3. Start the engine and let it run for about five minutes.

4. Switch off the engine.

NOTE: If no leak can be found, road test the vehicle under various loads and again check
the engine for leaks.

5. Check the engine for oil leaks using a UV leak detection lamp GV-2929 or UV leak
detection lamp GV-2911 B11.

6. Rectify any leaks found and recheck the engine for oil leaks.

Measure the Compression Pressure

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 can ignite. Failure to follow these instructions may result in personal injury.
NOTE: The powertrain control module (PCM) receives an error message when the relay is
removed or electrical components are disconnected. This error message must be deleted
from the fault memory by connecting the Ford diagnostic equipment after completing the
measurement.
NOTE: Valve clearance must be set correctly before performing a compression test. Make
sure engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor
speeds normally only allows to check if the compression is even in all cylinders.
NOTE: The readings from the compression pressure check should be used as an indication
of cylinder balance. If one or more of the readings is significantly lower than the others,
investigate that particular cylinder for concerns.

1. Remove the glow plugs.

REFER to: Glow Plugs (303-07A Glow Plug System, Removal and Installation).

2. Install a suitable compression tester with Special Tool 303-1051 into the glow plug
bore.
NOTE: Crank the engine with the starter motor until the reading on the compression
tester stops rising.

3. Carry out the measurement on all cylinders, following the measuring equipment
manufacturer's instructions and compare each cylinder compression reading.

4. Detach the compression tester and adapter.

5.
Install the glow plugs.
REFER to: Glow Plugs (303-07A Glow Plug System, Removal and Installation).

6. Reset the PCM fault memory.

Measure the Oil Pressure

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
NOTE: Measure the oil pressure at the specified engine speed. Measure the oil pressure at
an oil temperature of 80°C.
NOTE: The graphics used are for illustration purposes only.

1. Raise and support the vehicle.

REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).

2. Disconnect the oil pressure switch electrical connector.

3. Remove the oil pressure switch.

4. Attach the oil pressure gauge (GV 2134) with the oil pressure gauge connector.

5. Lower the vehicle.

6. Start the engine

7.
Raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).

NOTE: Oil pressure at 2000 rpm must be between 2.0 bar minimum and 5.0 bar
maximum.
NOTE: Oil pressure at idle must be 1.25 bar minimum.

8. Measure the oil pressure.

9. Lower the vehicle.

10. Stop the engine.

11.
Raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).

12. Remove the oil pressure gauge and the oil pressure gauge connector.
13. Install the oil pressure switch.

14. Connect the oil pressure switch electrical connector.

15. Lower the vehicle.

Valve Train Analysis - Static (Engine Off)

1. Remove the valve cover.

Check all components of the valve train for damage and wear. Make sure that only original
components are installed and that all nuts and bolts are tightened to the specified torque.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Camshaft and Carrier
Assembly
Print

Removal and Installation

Materials
Name Specification
Brake Cleaner -
Grease WSD-M1C227-A

Removal

1. Refer to: Timing Belt (303-01A Engine, Removal and Installation).

3.
4.

5. NOTE: Use suitable paper to absorb any escaping fluid.

Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
6.

7.
8. NOTICE:

Extreme cleanliness must be exercised when handling the components.

Make sure that all openings are sealed with clean blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.

9.
10.

11.
12. NOTICE:

Extreme cleanliness must be exercised when handling the components.

Make sure that all openings are sealed with clean blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).

13.
14.

15.
16.

17. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
18. NOTICE:

Extreme cleanliness must be exercised when handling the components.

Make sure that the area around the component is clean and free of foreign
material.
NOTE: Discard the bolts.
NOTE: Note the position of the components before removal.
Discard the clamps.

19.
20. NOTE: Make sure that the component is at ambient air temperature.
Loosen each bolt 2 turns at a time until all bolts are removed.

21.
22. NOTE: This step is only necessary when installing a new component.
Torque: 10 Nm

Installation

1. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Brake Cleaner)
2. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that a new component is installed.

3. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that the component is at ambient air temperature.
NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 2 turns at a time.

Torque:
1-19: 5 Nm
4. Torque:
1-18: 10 Nm
19: 23 Nm

5. NOTICE: To avoid corrosion, lubricate the injector bodies prior to installation.

Material: WSD-M1C227-A (Grease)
6. NOTICE:

Extreme cleanliness must be exercised when handling the components.

Take extra care when handling the components.

NOTE: Use new seals.
Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls,
General Procedures).

7. NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Make sure that new bolts are installed.
Make sure that new clamps are installed.
Torque:
Bolts:
Stage 1:9 Nm
Stage 2:Loosen: 45°
Stage 3:6 Nm
Stage 4:180°

8. Torque: 10 Nm

9. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
10. NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1 33 Nm
2 10 Nm

11. Torque: 10 Nm
12. Torque: 10 Nm

13. NOTICE: Extreme cleanliness must be exercised when handling the

components.
NOTE: Only tighten the nuts and bolts finger tight at this stage.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
Torque:
1:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
2 13 Nm
3 10 Nm

14. Torque: 10 Nm

15. Torque:
1 15 Nm
2 48 Nm
3 48 Nm
16. NOTICE: Extreme cleanliness must be exercised when handling the
components.
NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1: 10 Nm
2:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°

17.
18.

19. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
20.

21. Torque: 10 Nm
22. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).

23. Refer to: Timing Belt (303-01A Engine, Removal and Installation).
Engine - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN)
- Crankshaft Front Seal
Print

Removal and Installation

Removal

1. Refer to: Timing Cover (303-01A Engine, Removal and Installation).

Installation

1. Refer to: Timing Cover (303-01A Engine, Removal and Installation).

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Crankshaft Rear Seal
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1643
Locking Tool, Flywheel

Fluid Container
Plastic Scraper

Materials
Name Specification
Primer -
Silicone Sealant WSE-M4G323-A4

Removal

1. Refer to: Transmission - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)

(YM)/2.0L EcoBlue (125kW/170PS) (YN) (308-03 Manual Transmission, Removal).
Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
2. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container

3. Install Special Service Tool: 303-1643.

4. Loosen: 2 turn(s)

5. Remove Special Service Tool: 303-1643.

7. NOTE: Use suitable paper to absorb any escaping fluid.

Installation

1.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
Material: - (Primer)
2.
NOTE: Make sure that a new component is installed.
NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Primer)

3. NOTE: Make sure that the mating faces are clean and free of foreign material.

4. NOTE: The component must be installed within 5 minutes of applying the sealant.

Complete this step within: 5min

Material: WSE-M4G323-A4 (Silicone Sealant)
5. NOTICE: Take extra care not to damage the mating faces.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve
which must be removed after installation.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

6. NOTICE: Make sure that the flywheel is in full contact with the crankshaft
flange before installing the flywheel bolts.
NOTE: The component can only be installed in 1 position.
NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
Install Special Service Tool: 303-1643.

7. Torque:
Stage 1:15 Nm
Stage 2:30 Nm
Stage 3:75 Nm
Stage 4:45°

8. Remove Special Service Tool: 303-1643.

9. Refer to: Transmission - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (308-03 Manual Transmission, Removal).
Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
10. NOTE: Use a new seal.
Torque: 39 Nm

11.
12. Refer to: Specifications (303-01A Engine, Specifications).

13.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cylinder Head—Vehicles Built
From: 01-11-2016
Print

Removal and Installation

Special Tool(s) / General Equipment
205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

303-1611
Torque Multiplier

303-1611-03
Adapter for 303-1611, Torque Multiplier

303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)

1/2 Inch Square Drive Breaker Bar

Fluid Container
Hose Clamp Remover/Installer
Plastic Scraper
Wooden Block

Materials
Name Specification
Brake Cleaner -

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. NOTE: Change engine oil and oil filter.
NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container
3. NOTE: Make sure a new bolt is installed.
Torque: 39 Nm

4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Refer to: Camshaft and Carrier Assembly (303-01A Engine, Removal and Installation).

6. Refer to: Intake Manifold (303-01A Engine, Removal and Installation).

7. NOTE: Only tighten the bolts finger tight at this stage.
8. NOTE: Only tighten the nuts and bolts finger tight at this stage.

9. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Hose Clamp Remover/Installer
10.

11.
12. NOTE: Be prepared to collect escaping fluid.

13. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Hose Clamp Remover/Installer
14. NOTE: Be prepared to collect escaping fluid.

15.
16. NOTE: Make sure that no components catch.
1. NOTE: Note the position of the component before removal.
2.

17. NOTICE: Take extra care when handling the component.

NOTE: Use suitable paper to absorb any escaping fluid.
18. NOTE: Note the position of the components before removal.

19. NOTICE: Make sure that the cylinder head is at ambient air temperature
before removing the cylinder head bolts.
Use Power Tool only.
20.

21. NOTICE: Take extra care when handling the component.

NOTE: Make sure that no components catch.
22. Use the General Equipment: Wooden Block

23.
Installation

1.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
Material: - (Brake Cleaner)

2. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC)
Measure the distance between the piston crown and the cylinder block at the points
indicated.
3. The largest measurement determines the choice of the cylinder head gasket.

Use Special Service Tools: 205-070, 205-069, 303-432.

4. NOTICE: Make sure that no fluids are present in the cylinder head bolt
threaded bores.
1. NOTE: Make sure that a new component is installed.
Refer to: Specifications (303-01A Engine, Specifications).

2. 2. NOTICE: Make sure that the gasket is correctly located.

5. NOTICE: Take extra care when handling the component.
NOTE: Make sure that no components catch.
NOTE: The component can only be installed in 1 position.

6. NOTE: Only tighten the bolts finger tight at this stage.

NOTE: Make sure that new bolts are installed.
7. Torque:
Stage 1:15 Nm
Stage 2:25 Nm
Stage 3:40 Nm
Stage 4:90°
Stage 5:90°

8. Mark the position of the bolts.

9. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

10. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
11. Remove Special Service Tools: 303-1611, 303-1611-03.

12. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

13. Remove Special Service Tools: 303-1611, 303-1611-03.

14. Remove Special Service Tool: 303-1611-03.

15. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

16. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
17. Remove Special Service Tools: 303-1611, 303-1611-03.

18. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

19. Remove Special Service Tools: 303-1611, 303-1611-03.

20. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
21. Remove Special Service Tools: 303-1611, 303-1611-03.

22. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

23. Remove Special Service Tools: 303-1611, 303-1611-03.

24. Remove Special Service Tool: 303-1611.

25. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

26. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
27. Remove Special Service Tools: 303-1611, 303-1611-03.

28. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

29. Remove Special Service Tools: 303-1611, 303-1611-03.

30. Remove Special Service Tool: 303-1611-03.

31. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

32. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
33. Remove Special Service Tools: 303-1611, 303-1611-03.

34. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

35. Remove Special Service Tools: 303-1611, 303-1611-03.

36. Remove Special Service Tool: 303-1611-03.

37. Stage 7: Repeat the steps 9 to 36.
38. 1. NOTE: Component must be lubricated with clean engine oil.
Refer to: Specifications (303-01A Engine, Specifications).

2. NOTE: Make sure that the components are installed to the position noted
before removal.

39. NOTICE: Take extra care when handling the components.

NOTE: Only tighten the nut and bolts finger tight at this stage.
NOTE: Make sure that a new O-ring seal is installed.
NOTE: Make sure that a new component is installed.
1. Torque: 10 Nm
2. Torque: 10 Nm

3. Torque: 20 Nm

4. Torque: 10 Nm

5. Torque: 10 Nm

40. NOTE: Only tighten the nuts and bolt finger tight at this stage.
1. NOTE: Make sure that the component is installed to the position noted before
removal.
Torque: 8 Nm

2. Torque: 25 Nm
41. Torque: 25 Nm

42. NOTE: Make sure that the mating faces are clean and free of foreign material.
43. NOTICE: The bolts must not be reused more than 1 time.
NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Use a new seal.

44. NOTICE: The bolts must not be reused more than 1 time.
NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Make sure that the seal is correctly located.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:4 Nm
Stage 2:10 Nm
45. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Hose Clamp Remover/Installer

46. NOTE: Make sure that a new O-ring seal is installed.

NOTE: Only tighten the bolts finger tight at this stage.
Torque: 10 Nm
47.

48. Torque:
1: 25 Nm
2: 25 Nm
3: 10 Nm
49. Use the General Equipment: Hose Clamp Remover/Installer

50. Remove the component.

51. Remove the component.

52. Refer to: Intake Manifold (303-01A Engine, Removal and Installation).

53. Refer to: Camshaft and Carrier Assembly (303-01A Engine, Removal and Installation).
54.
55. Refer to: Specifications (303-01A Engine, Specifications).

56.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Exhaust Manifold
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Removal
and Installation).

2. Torque: 10 Nm

3. NOTE: Make sure that the component is correctly installed.

NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm
4. Torque: 10 Nm

5. NOTE: This step is only necessary when installing a new component.

Torque: 10 Nm
Installation

1. To install, reverse the removal procedure.

2. NOTE: Make sure that a new component is installed.
NOTE: Make sure that the component is correctly installed.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Intake Manifold
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Exhaust Gas Recirculation (EGR) Outlet Tube (303-08A Engine Emission
Control, Removal and Installation).

2. Torque: 10 Nm

3.
4. NOTE: Make sure that the seal is correctly located.
Torque:
Stage 1:10 Nm
Stage 2:23 Nm

5. Torque: 8 Nm

6. NOTE: This step is only necessary when installing a new component.

NOTE: Make sure that the seal is correctly located.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
Installation

1. To install, reverse the removal procedure.

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Cooler
Print

Removal and Installation

General Equipment
Fluid Container
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. NOTE: Be prepared to collect escaping fluid.
Use the General Equipments: Fluid Container, Hose Clamp Remover/Installer

3. NOTE: Component(s) must be lubricated with clean engine oil.

NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container
Torque: 15 Nm
4. NOTE: Be prepared to collect escaping fluids.
NOTE: Install all the bolts finger tight before final tightening.
Use the General Equipment: Fluid Container
Torque:
1 55 Nm
2 10 Nm

Installation

1. To install, reverse the removal procedure.

2. NOTE: Make sure that the seal is correctly located.
3.

4. Refer to: Specifications (303-01A Engine, Specifications).

5.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Pan
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1668
Sealer Gun, Front Cover

303-428
Separator, Oil Pan

Fluid Container
Plastic Scraper

Materials
Name Specification
Primer -
RTV Silicone Sealant WSE-M4G323-A6

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

3. NOTE: Change engine oil and oil filter.

NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container

4. NOTE: Use suitable paper to absorb any escaping fluid.

5.
NOTE: Use suitable paper to absorb any escaping fluid.
Use Special Service Tool: 303-428.
Use the General Equipment: Fluid Container
Installation

1.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
Material: - (Primer)

2. NOTE: Make sure that a new component is installed.

NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

3. Torque:
Stage 1:5 Nm
Stage 2:10 Nm

4. Torque: 39 Nm
5.

6. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
7.
8. Refer to: Specifications (303-01A Engine, Specifications).

9.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Pump
Print

Removal and Installation

Removal

1. Remove the following items:

• Refer to: Oil Pan (303-01A Engine, Removal and Installation).
2.

4.
5.

Installation

1. NOTE: Make sure that the components are correctly located.

2. NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

3. Torque: 10 Nm
4.

5. Install the following items:

• Refer to: Oil Pan (303-01A Engine, Removal and Installation).
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Timing Belt
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1637
Holding Tool, Crankshaft

303-1643
Locking Tool, Flywheel

303-1650
Mounting Device, Timing Belt

6 mm Drill Bit
Adhesive Tape

Removal

NOTICE: The crankshaft or camshafts must not be rotated while the timing belt is
removed.
1. Refer to: Timing Cover (303-01A Engine, Removal and Installation).

2. Remove Special Service Tool: 303-1643.

3. NOTE: Only tighten the bolt finger tight at this stage.

4. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
5.

6. NOTICE: The special tool must only be used to align the crankshaft timing.
NOTE: Only tighten the bolt finger tight at this stage.
Install Special Service Tool: 303-1637.
7. Install the following items:
1. Use the General Equipments: 6 mm Drill Bit, Adhesive Tape

8. Install the General Equipments: 6 mm Drill Bit, Adhesive Tape

Installation

1. NOTE: Make sure that new components are installed.

Torque: 25 Nm
2. Install Special Service Tool: 303-1650.

3. NOTICE: Take extra care when handling the component.

NOTE: Make sure that a new component is installed.
4. Remove the General Equipment: 6 mm Drill Bit

5. Remove the following items:

1. Use Special Service Tool: 303-1650.

2. Use the General Equipment: 6 mm Drill Bit

6. Remove Special Service Tool: 303-1637.

7. NOTE: Only tighten the bolt finger tight at this stage.

8. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft 4 revolutions.

9.
10. NOTICE: The special tool must only be used to align the crankshaft timing.
NOTE: Only tighten the bolt finger tight at this stage.
Install Special Service Tool: 303-1637.

11. NOTICE: Visually check if the timing holes of the camshaft sprockets are in a
clockwise overlap position to the timing holes in the camshaft module.
12. Remove Special Service Tool: 303-1637.

13. Install Special Service Tool: 303-1643.

14. Refer to: Timing Cover (303-01A Engine, Removal and Installation).
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Valve Springs
Print

Removal and Installation

Special Tool(s)
303-060
Compressor, Valve Spring

303-060-07
Adapter for 303-060

303-060-09A
Adapter for 303-060

303-362
Installer, Valve Stem Collets

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Camshaft and Carrier Assembly (303-01A Engine, Removal and Installation).
2. NOTE: Note the position of the components before removal.

3. Position the appropriate piston at top dead center (TDC).

4.
NOTE: Note the position of the components before removal.
Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.

Installation

1. To install, reverse the removal procedure.

2. NOTE: Component must be lubricated with clean engine oil.
NOTE: Make sure that the components are installed to the position noted before
removal.
Refer to: Specifications (303-01A Engine, Specifications).
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Valve Stem Seals
Print

Removal and Installation

Special Tool(s)
303-508
Pliers, Valve Stem Seal

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Valve Springs (303-01A Engine, Removal and Installation).

2. Use Special Service Tool: 303-508.

Installation

1. To install, reverse the removal procedure.

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Primary Drive Idler Gear
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1635
Remover/Installer, Fuel Injection Pump

303-1643
Locking Tool, Flywheel

303-1650
Mounting Device, Timing Belt

4 mm Drill Bit
6 mm Drill Bit
Adhesive Tape

Materials
Name Specification
Clutch and Brake Cleaner -

Removal

1. Refer to: Timing Cover (303-01A Engine, Removal and Installation).

2. Remove Special Service Tool: 303-1643.

3. NOTE: Only tighten the bolt finger tight at this stage.

4. NOTICE: Only rotate the crankshaft clockwise.

5. Install Special Service Tool: 303-1643.

6. Use the General Equipments: 6 mm Drill Bit, Adhesive Tape

8. 1.
2. Install the General Equipments: 6 mm Drill Bit, Adhesive Tape

3.
9. Max Length 32mm.

Install the General Equipment: 4 mm Drill Bit

10. Install Special Service Tool: 303-1635.

11. NOTE: Discard the bolt.

Installation

1. NOTICE:

Make sure that the surface is clean and free of foreign material.

Use lint free cloth.

Material: - (Clutch and Brake Cleaner)
2.

3. NOTE: Make sure that a new component is installed.

NOTE: Make sure that the installation marks are aligned.
NOTE: Make sure a new bolt is installed.
NOTE: Install the bolt finger tight before final tightening.
Torque:
Standard bolts torque
Stage 1:60 Nm
Stage 2:Loosen: 90°
Stage 3:20 Nm
Stage 4:45 Nm
Stage 5:45°
Self-locking bolts torque
Stage 1:60 Nm
Stage 2:Loosen: 90°
Stage 3:20 Nm
Stage 4:30 Nm
Stage 5:60°

4. Install Special Service Tool: 303-1650.

5. NOTICE: Take extra care when handling the component.

NOTE: Make sure that a new component is installed.
6. Remove the General Equipment: 6 mm Drill Bit

7. Remove Special Service Tool: 303-1650.

Remove the General Equipment: 6 mm Drill Bit
8. Remove the General Equipment: 4 mm Drill Bit

9. Remove Special Service Tool: 303-1643.

10. NOTICE: Only rotate the crankshaft clockwise.
Torque: 2.25 turn(s)

11. Refer to: Timing Cover (303-01A Engine, Removal and Installation).
12.
13. Refer to: Specifications (303-01A Engine, Specifications).

14.
15. Run the High Pressure Fuel System Reset in FDRS.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Print

Removal
Special Tool(s) / General Equipment
303-1196
Holding Wrench, Pulley

307-569
Disconnect Tool TOC Line (1/2)

3.5 mm Drill Bit

Center Punch
Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Mounting Table Set
Retaining Strap
Wooden Block

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

2. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
3.
4. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).
5.

7.
8.

9. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Hose Clamp Remover/Installer
10. NOTE: Be prepared to collect escaping fluid.

11. NOTICE: Make sure that all openings are sealed with clean blanking caps.
NOTE: Be prepared to collect escaping fluid.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
12. On both sides.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
13. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Hose Clamp Remover/Installer

14. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
15.
16.

17.
18.

19. NOTICE: Make sure that the components are not forcibly bent.
If equipped.
20. NOTICE: Make sure that the components are not forcibly bent.

21.
22.

23.
24.

25.
26.

27.
28. If equipped.

Use the General Equipments: Center Punch, 3.5 mm Drill Bit

29.
30.

31.
32. NOTICE: Make sure that all openings are sealed with clean blanking caps.
NOTE: Be prepared to collect escaping fluid.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).

Vehicles With: Rear Climate Control

33. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).
34.
6-Speed Automatic Transmission - 6F55
35.

36.
37.

38.

39.
40.

41. 1.
2. NOTE: Be prepared to collect escaping fluid.
Use Suggested Tool: 307-569. Tool shown or a commercially available equivalent
can be used.

3. Remove Special Service Tool: 307-569.

42. 1.
2. NOTE: Be prepared to collect escaping fluid.
Use Suggested Tool: 307-569. Tool shown or a commercially available equivalent
can be used.

3. Remove Special Service Tool: 307-569.

43.

44. Refer to: Front Halfshaft LH - Detach from the transmission - 6-Speed Automatic
Transmission - 6F55 (205-04 Front Drive Halfshafts, Removal and Installation).
45. Remove the following items:
• Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04
Front Drive Halfshafts, Removal and Installation).
46. NOTE: Note the different lengths of the bolts.

All vehicles

47. WARNING: Always secure engines, transmissions, or other heavy components

to the support fixture with straps and wooden support blocks. Improperly secured
assemblies could fall off the fixture, resulting in serious personal injury.
Install the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap

48.
49.

50. NOTE: Make sure that no components catch.

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
51. NOTICE: It is mandatory to use the specified materials!
Refer to: Specifications (303-01A Engine, Specifications).
Torque: 33 Nm

52. Install the General Equipments: Lifting Bracket, Floor Crane

53. Remove the General Equipments: Retaining Strap, Wooden Block, Mounting Table Set

54.
6-Speed Automatic Transmission - 6F55
55.

56. NOTICE: Only rotate the crankshaft clockwise.

NOTE: Note the position of the component before removal.
57.

58. NOTICE: Make sure that the torque converter remains in the transmission.
59. NOTICE: Make sure that the locating dowels remain installed.

60. NOTICE: Make sure that the torque converter remains in the transmission.
Tool shown or a commercially available equivalent can be used.

Install Suggested Tool: 303-1196. Tool shown or a commercially available equivalent

can be used.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine Accessories
Print

Removal
Special Tool(s) / General Equipment
303-1635
Remover/Installer, Fuel Injection Pump

303-1643
Locking Tool, Flywheel

303-435
Mounting Stand

303-435-04
Mounting Bracket for 303-435

303-435-12C
Mounting Plate

Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
1.
2.

3.
4. Install Special Service Tools: 303-435, 303-435-04, 303-435-12C.

5. Remove the General Equipments: Floor Crane, Lifting Bracket

6. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Hose Clamp Remover/Installer

7. NOTE: Be prepared to collect escaping fluids.

Use the General Equipment: Hose Clamp Remover/Installer
8.

9.
10.

11.
12. NOTE: Be prepared to collect escaping fluid.

13.
14.

15.
16. Use the General Equipment: Hose Clamp Remover/Installer

17.
18. Use the General Equipment: Hose Clamp Remover/Installer

19.
20.

21.
22. Torque: 10 Nm

23.
24.

25.
26.

27.
28.

29. NOTICE:

Make sure that the area around the component is clean and free of foreign
material.

Make sure that all openings are sealed with new blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.
30.

31.
32.

33.
34. Install Special Service Tool: 303-1643.

35.
36. Install Special Service Tool: 303-1635.

37. Remove Special Service Tool: 303-1643.

38. Install Special Service Tool: 303-1635.
Torque: 3 turn(s)

39.
40. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Only use moderate force.

41. Remove Special Service Tool: 303-1635.

42. Remove Special Service Tool: 303-1635.

43.
44. NOTE: Discard the bolts.
NOTE: Note the position of the components before removal.
Discard the clamps.

45.
46.

47. NOTE: Note the position of the components before removal.

48. NOTE: Note the position of the components before removal.

49.
50.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Print

Disassembly
Special Tool(s) / General Equipment
204-158-01
Adapter for 204-158 (Thrust Pad)

303-1635
Remover/Installer, Fuel Injection Pump

303-1637
Holding Tool, Crankshaft

303-1643
Locking Tool, Flywheel

303-428
Separator, Oil Pan

4 mm Drill Bit
6 mm Drill Bit
Adhesive Tape
Fluid Container
Two Leg Puller

1. Install Special Service Tool: 303-1643.

3. Use Special Service Tool: 204-158-01.

Use the General Equipment: Two Leg Puller
4.

5. Loosen: 180°
6. Loosen: 6 turn(s)

7. Remove Special Service Tool: 303-1643.

9. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Fluid Container
10. NOTE: Use suitable paper to absorb any escaping fluid.

11.
NOTE: Use suitable paper to absorb any escaping fluid.
Use Special Service Tool: 303-428.
12.

13.
NOTE: Be prepared to collect escaping fluid.
Use Special Service Tool: 303-428.
14. NOTE: Only tighten the bolt finger tight at this stage.

15. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
16. Remove the component.

17. NOTICE: The special tool must only be used to align the crankshaft timing.
NOTE: Only tighten the bolt finger tight at this stage.
Install Special Service Tool: 303-1637.
18. Install the following items:
1. Use the General Equipments: 6 mm Drill Bit, Adhesive Tape

19. Use the General Equipment: 6 mm Drill Bit

20.

21.
22. NOTE: Make sure that the component is at ambient air temperature.
NOTE: Make sure that no components catch.
Loosen each bolt 2 turns at a time until all bolts are removed.

23.
24. NOTE: Note the position of the components before removal.

25. NOTICE: Make sure that the cylinder head is at ambient air temperature
before removing the cylinder head bolts.
Use Power Tool only.
26.

27. NOTE: Make sure that no components catch.

28.

29. Refer to: Specifications (303-01A Engine, Specifications).

30. Remove Special Service Tool: 303-1637.

31.
1. 1. NOTICE: Make sure that the crankshaft is not rotated
Mark the position of the component.

2. 2. NOTICE: Only rotate the crankshaft clockwise.

3. NOTE: Make sure that the installation marks are aligned.
32. Install the General Equipments: 4 mm Drill Bit, Adhesive Tape

33. NOTICE: Make sure that the crankshaft is not rotated

1. NOTE: Make sure that the installation marks are aligned.
2.
3.
34.

35. NOTE: Only tighten the nuts and bolts finger tight at this stage.
Install Special Service Tool: 303-1635.
36.

37.
38.

39. NOTE: Use suitable paper to absorb any escaping fluid.

40.

41.
42.

43.
44.

45.
46.

47.
48.

49. NOTE: Note the position of the components before removal.

NOTE: Discard the bolts.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cylinder Head
Print

Disassembly and Assembly of Subassemblies

Special Tool(s) / General Equipment
303-060
Compressor, Valve Spring

303-060-07
Adapter for 303-060

303-060-09A
Adapter for 303-060

303-362
Installer, Valve Stem Collets

303-508
Pliers, Valve Stem Seal

Wooden Block

Disassembly

NOTICE: Take extra care when handling the components.

NOTE: Removal steps in this procedure may contain installation details.
1. Use the General Equipment: Wooden Block
2. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 33 Nm
2: 10 Nm
3: 11 Nm
4: 13 Nm

3. Torque: 10 Nm
4. NOTE: Make sure that the component is correctly installed.
NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm

5. NOTE: Make sure that new components are installed.

Torque: 10 Nm
6.
NOTE: Note the position of the components before removal.
Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.

7.
8.

9.
10. Use Special Service Tool: 303-508.

11. NOTE: Note the position of the components before removal.

Refer to: Specifications (303-01A Engine, Specifications).
Assembly

12. To assemble, reverse the disassembly procedure.

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Engine
Print

Assembly
Special Tool(s) / General Equipment
205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

303-1611
Torque Multiplier

303-1611-03
Adapter for 303-1611, Torque Multiplier

303-1637
Holding Tool, Crankshaft

303-1643
Locking Tool, Flywheel

303-1650
Mounting Device, Timing Belt

303-1668
Sealer Gun, Front Cover
303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)

1/2 Inch Square Drive Breaker Bar

4 mm Drill Bit
6 mm Drill Bit
Plastic Scraper

Materials
Name Specification
Primer -
Brake Cleaner -
RTV Silicone Sealant WSE-M4G323-A6

NOTICE: Extreme cleanliness must be exercised when handling the components.

1. NOTE: Make sure that new bolts are installed.
NOTE: Make sure that the components are correctly located.
Torque: 10 Nm

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)
3. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

4.
5. NOTE: Only tighten the bolts finger tight at this stage.
Make sure that a new bolt is installed on position 8.

6. Make sure that a new bolt is installed on position 8.

Torque:
1-13 5 Nm
7. Make sure that a new bolt is installed on position 8.

Torque:
1-7: 23 Nm
8: 13 Nm
9-10: 23 Nm
11: 13 Nm
12-13: 23 Nm

8. NOTICE: Make sure that no excess sealant residue is evident.

9. Rotate the crankshaft until piston No. 1 is at top dead center (TDC).

10.
11. NOTICE: The special tool must only be used to align the crankshaft timing.
Install Special Service Tool: 303-1637.

12. NOTICE:

Make sure that the surface is clean and free of foreign material.

Use lint free cloth.

Material: - (Brake Cleaner)
13.
1. 1. NOTICE: Make sure that the component aligns with the installation mark.

2. 2. NOTICE: Make sure that a new bolt is installed.

Torque:
Standard bolts torque
Stage 1:60 Nm
Stage 2:Loosen: 90°
Stage 3:20 Nm
Stage 4:45 Nm
Stage 5:45°
Self-locking bolts torque
Stage 1:60 Nm
Stage 2:Loosen: 90°
Stage 3:20 Nm
Stage 4:30 Nm
Stage 5:60°

3. Remove the General Equipment: 4 mm Drill Bit

14. Remove Special Service Tool: 303-1637.

15.
1. 1. NOTICE: Make sure that the crankshaft is not rotated
Mark the position of the component.
2. NOTE: Only tighten the bolt finger tight at this stage.

3. 3. NOTICE: Only rotate the crankshaft clockwise.

16. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Use lint free cloth.

NOTE: Make sure that the threaded holes are clean and free of foreign matter.
NOTE: Make sure that a new O-ring seal is installed.
NOTE: Make sure that the seal is correctly located.
NOTE: The component must be installed by hand before final tightening.

17. NOTE: Make sure that new bolts are installed.

Torque: 23 Nm
18. Install the General Equipment: 4 mm Drill Bit

19. NOTE: Make sure that the installation marks are aligned.
20. NOTE: Make sure a new bolt is installed.
NOTE: Make sure that the installation marks are aligned.
NOTE: Only tighten the bolt finger tight at this stage.

21. Remove the General Equipment: 4 mm Drill Bit

22.

23.
24. NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

25. Torque: 10 Nm
26. Torque:
1: 10 Nm
2: 10 Nm

27. Torque: 10 Nm
28.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Primer)

29.
NOTE: Make sure that a new component is installed.
NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Primer)
30. NOTE: Make sure that the mating faces are clean and free of foreign material.

31. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)
32. NOTICE: Take extra care not to damage the mating faces.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which
must be removed after installation.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

33. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
34.

35.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Brake Cleaner)
36. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC)
Measure the distance between the piston crown and the cylinder block at the points
indicated.

37. The largest measurement determines the choice of the cylinder head gasket.

Use Special Service Tools: 205-070, 205-069, 303-432.

38. NOTICE: Make sure that no fluids are present in the cylinder head bolt threaded
bores.
1. NOTE: Make sure that a new component is installed.
Refer to: Specifications (303-01A Engine, Specifications).

2. 2. NOTICE: Make sure that the gasket is correctly located.

39. NOTICE: The special tool must only be used to align the crankshaft timing.
Install Special Service Tool: 303-1637.
40. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that no components catch.

41. NOTE: Only tighten the bolts finger tight at this stage.
NOTE: Make sure that new bolts are installed.
42. Torque:
Stage 1:15 Nm
Stage 2:25 Nm
Stage 3:40 Nm
Stage 4:90°
Stage 5:90°

43. Mark the position of the bolts.

44. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

45. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
46. Remove Special Service Tools: 303-1611, 303-1611-03.

47. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

48. Remove Special Service Tools: 303-1611, 303-1611-03.

49. Remove Special Service Tool: 303-1611-03.

50. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

51. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
52. Remove Special Service Tools: 303-1611, 303-1611-03.

53. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

54. Remove Special Service Tools: 303-1611, 303-1611-03.

55. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
56. Remove Special Service Tools: 303-1611, 303-1611-03.

57. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

58. Remove Special Service Tools: 303-1611, 303-1611-03.

59. Remove Special Service Tool: 303-1611.

60. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

61. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
62. Remove Special Service Tools: 303-1611, 303-1611-03.

63. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

64. Remove Special Service Tools: 303-1611, 303-1611-03.

65. Remove Special Service Tool: 303-1611-03.

66. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm

67. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
68. Remove Special Service Tools: 303-1611, 303-1611-03.

69. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°

70. Remove Special Service Tools: 303-1611, 303-1611-03.

71. Remove Special Service Tool: 303-1611-03.

72. Stage 7: Repeat the steps 45 to 72.
73. • NOTE: Component must be lubricated with clean engine oil.
Refer to: Specifications (303-01 Engine - 2.0L EcoBlue (88kW/120PS) (YN), 2.0L
EcoBlue (110kW/150PS) (YM), 2.0L EcoBlue (140kW/190PS) (BC), Specifications).

• NOTE: Make sure that the components are installed to the position noted before
removal.

74. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Brake Cleaner)
75. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that a new component is installed.

76. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that the component is at ambient air temperature.
1. Tighten each bolt 2 turns at a time.

Torque:
1-19 5 Nm
2. Torque:
1-18 10 Nm
3. Torque:
19 23 Nm

77. NOTE: Install all the bolts finger tight before final tightening.
Torque:
1: 10 Nm
2: 10 Nm
3: 20 Nm
4: 13 Nm
5: 11 Nm
6: 10 Nm

78. NOTE: Make sure that a new component is installed.

Torque: 25 Nm
79. Install Special Service Tool: 303-1650.

80. NOTE: Make sure that a new component is installed.

81.

82. Remove the following items:

1. Use Special Service Tool: 303-1650.

2. Use the General Equipment: 6 mm Drill Bit

83. Remove Special Service Tool: 303-1637.

84. NOTE: Only tighten the bolt finger tight at this stage.
85. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft 14 revolutions.

86.
87. NOTICE: The special tool must only be used to align the crankshaft timing.
NOTE: Only tighten the bolt finger tight at this stage.
Install Special Service Tool: 303-1637.

88. NOTICE: Visually check if the timing holes of the camshaft sprockets are in a
clockwise overlap position to the timing holes in the camshaft module.
89. Remove Special Service Tool: 303-1637.

90. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange
before installing the flywheel bolts.
NOTE: The component can only be installed in 1 position.
NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
Install Special Service Tool: 303-1643.
91. Torque:
Stage 1:15 Nm
Stage 2:30 Nm
Stage 3:50 Nm
Stage 4:90°

92. NOTE: Only tighten the bolt finger tight at this stage.
Torque:
Stage 1:25 Nm
Stage 2:75 Nm
93.
NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Make sure that a new component is installed.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

94. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)
95. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that a new component is installed.

96. NOTE: Only tighten the bolts finger tight at this stage.
97. NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Only tighten the bolts finger tight at this stage.

98. Torque:
Stage 1:12 Nm
Stage 2:80 Nm
Stage 3:90°
99. NOTE: Only tighten the bolts finger tight at this stage.

100. Torque:
1-2 18 Nm
3-17 10 Nm
101. NOTE: Install the bolt finger tight before final tightening.
NOTE: Make sure a new bolt is installed.
Torque: 55 Nm

102.
103. NOTE: Make sure a new bolt is installed.
NOTE: Only tighten the bolt finger tight at this stage.
Torque:
Stage 1:10 Nm
Stage 2:Loosen: 60°
Stage 3:20 Nm
Stage 4:70 Nm
Stage 5:150 Nm
Stage 6:Loosen: 90°
Stage 7:100 Nm
Stage 8:300 Nm
Stage 9:90°

104. Remove Special Service Tool: 303-1643.

105.
1. Use the General Equipment: Plastic Scraper

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Primer)

106. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)
107. Torque:
Stage 1:5 Nm
Stage 2:10 Nm

108. NOTE: Make sure a new bolt is installed.

Torque: 39 Nm
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Print

Installation
Special Tool(s) / General Equipment
303-1196
Holding Wrench, Pulley

Floor Crane
Ford Diagnostic Equipment
Hose Clamp Remover/Installer
Lifting Bracket
Mounting Table Set
Retaining Strap
Wooden Block

Materials
Name Specification
Grease - High Temperature WSS-M1C273-A

6-Speed Automatic Transmission - 6F55

1. NOTICE: Make sure that the torque converter remains in the transmission.
Apply a thin coating.

Remove Suggested Tool: 303-1196.

Material: WSS-M1C273-A (Grease - High Temperature)

2. NOTICE: Make sure that the locating dowels remain installed.

3. NOTICE:

Make sure that no part of the wiring harness is trapped.

Make sure that the component is correctly located on the locating dowels.

Only rotate the crankshaft clockwise.

NOTE: Make sure that the component is installed to the position noted before
removal.
NOTE: Only tighten the nuts finger tight at this stage.

4. Torque: 48 Nm
5. Torque: 48 Nm

6. NOTICE: Only rotate the crankshaft clockwise.

Torque: 48 Nm
7.

All vehicles

8. Torque:
2: 12 Nm
3: 8 Nm
4: 35 Nm
9. Install the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap

10. Remove the General Equipments: Floor Crane, Lifting Bracket

11.

12. NOTE: Make sure that no components catch.

Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
13. Torque:
1: 115 Nm
2: 70 Nm

14. Torque:
1: 70 Nm
2: 133 Nm
3: 70 Nm
15. WARNING: Always secure engines, transmissions, or other heavy components
to the support fixture with straps and wooden support blocks. Improperly secured
assemblies could fall off the fixture, resulting in serious personal injury.
Remove the General Equipments: Retaining Strap, Wooden Block, Mounting Table Set

6-Speed Automatic Transmission - 6F55

16. Torque: 175 Nm

17. Install the following items:
• Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04
Front Drive Halfshafts, Removal and Installation).

18. Refer to: Front Halfshaft LH - Attach to the transmission - 6-Speed Automatic
Transmission - 6F55 (205-04 Front Drive Halfshafts, Removal and Installation).

19. Torque: 11 Nm

20. NOTE: Make sure that new components are installed.

21.
22. Torque: 8 Nm

23. NOTE: Make sure that the component terminals are not bent or damaged.
24.

25. If equipped.

26.
Vehicles With: Rear Climate Control
27.
1. Torque: 20 Nm

2. Torque: 15 Nm

3. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-
00 Climate Control System - General Information, General Procedures).

All vehicles

28. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
29.

30. Torque:
1: 10 Nm
2: 5 Nm
31.

32. Tighten the shear bolt until the head is sheared off.
33.

34.
35.

36.
37. Torque: 10 Nm

38.
39.

40. NOTICE: Make sure that the components are not forcibly bent.
Torque: 23 Nm
41. NOTICE: Make sure that the components are not forcibly bent.
If equipped.

Torque: 25 Nm

42. NOTE: Only tighten the bolts finger tight at this stage.
43. NOTE: Use a new seal.
NOTE: Make sure that a new O-ring seal is installed.

44. NOTE: Make sure that new bolts are installed.

NOTE: Only tighten the bolts finger tight at this stage.
45.
1. Torque:
1: 10 Nm
2: 10 Nm
3: 10 Nm

2. Torque:
1: 23 Nm
2: 23 Nm
3: 23 Nm

3. Torque:
4: 10 Nm
5: 10 Nm
4: 10 Nm
6: 10 Nm
7: 10 Nm
6: 10 Nm
46.

47. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).

48. Use the General Equipment: Hose Clamp Remover/Installer

49. On both sides.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
50.

51. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
52. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Hose Clamp Remover/Installer

53.
54. Torque:
1: 10 Nm
2: 10 Nm

55. Torque: 10 Nm
56. Torque: 10 Nm

57. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).
58.
59. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

60. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
61.

62. NOTICE: Make sure that the engine oil is to specification.

NOTE: Make sure that fluid level is to the MAX mark.
Refer to: Specifications (303-01A Engine, Specifications).
63.

64. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).

6-Speed Automatic Transmission - 6F55

65. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).

66. Reset the High-Pressure Fuel System Learned Values.

Use the General Equipment: Ford Diagnostic Equipment

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine Accessories
Print

Installation
Special Tool(s) / General Equipment
303-1635
Remover/Installer, Fuel Injection Pump

303-1643
Locking Tool, Flywheel

303-435
Mounting Stand

303-435-04
Mounting Bracket for 303-435

303-435-12C
Mounting Plate

308-204
Aligner, Clutch Disc

Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Long Nose Pliers

Materials
Name Specification
Grease WSD-M1C227-A

1. Torque: 40 Nm
2.

3. NOTICE: The cone on the special tool must only be tightened finger tight to
prevent damage to the clutch disc.
Use Special Service Tool: 308-204.
4. NOTE: Make sure that the components are installed to the position noted before
removal.
Use Special Service Tool: 308-204.

5. NOTE: Make sure that new bolts are installed.

NOTE: Only tighten the bolts finger tight at this stage.
Use Special Service Tool: 308-204.
Torque: 30 Nm
6. Remove Special Service Tool: 308-204.

7. NOTICE: To avoid corrosion, lubricate the injector bodies prior to installation.

Material: WSD-M1C227-A (Grease)
8. NOTE: Use a new seal.
NOTE: This step is only necessary if the original component is to be reused.
Use the General Equipment: Long Nose Pliers

9. NOTE: The O-ring seal is to be reused unless damaged.

Material: WSD-M1C227-A (Grease)
10. NOTE: Make sure that new bolts are installed.
NOTE: Make sure that the components are installed to the position noted before
removal.
Make sure that new clamps are installed.

Torque:
Stage 1:9 Nm
Stage 2:Loosen: 45°
Stage 3:6 Nm
Stage 4:180°

11. Torque: 10 Nm
12. NOTE: Use a new seal.
NOTE: Make sure that the components are installed to the position noted before
removal.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

13. Torque: 10 Nm
14.

15.
16.

17. Install Special Service Tool: 303-1635.

18.

19.
20. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Use lint free cloth.

NOTE: Make sure that the seal is correctly located.
NOTE: The component must be installed by hand before final tightening.

21. NOTE: Only use moderate force.

Install Special Service Tool: 303-1635.
22. NOTE: Make sure that new bolts are installed.
Torque: 23 Nm

23. Remove Special Service Tool: 303-1635.

24. NOTE: Make sure a new bolt is installed.
NOTE: Only tighten the bolt finger tight at this stage.
Remove Special Service Tool: 303-1635.

25. Torque:
1:
Stage 1:5 Nm
Stage 2:18 Nm
2:
Stage 1:5 Nm
Stage 2:10 Nm
26. Install Special Service Tool: 303-1643.

27. Torque:
Stage 1:25 Nm
Stage 2:75 Nm
28. Remove Special Service Tool: 303-1643.

29.
30. NOTE: Make sure that new components are installed.

31. NOTICE: Make sure that the area around the component is clean and free of
foreign material.
NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
2: 13 Nm
3: 10 Nm
4:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°

32. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 10 Nm
2: 33 Nm

33. NOTICE: Make sure that the gasket is correctly located.

NOTE: Use a new seal.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 10 Nm
2: 33 Nm

34. NOTE: Make sure that the component is correctly installed.

NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm

35. NOTE: Only tighten the bolts finger tight at this stage.
NOTE: Make sure that a new O-ring seal is installed.
1. Torque: 10 Nm
2. Torque: 10 Nm

36. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 23 Nm
2: 10 Nm

37.
38. Torque: 10 Nm

39. NOTICE: Make sure that the gasket is correctly located.

NOTE: Use new seals.
40. NOTICE: Make sure that the gasket is correctly located.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 55 Nm
2: 10 Nm

41. NOTE: Use a new seal.

NOTE: Make sure that the seal is correctly located.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:4 Nm
Stage 2:10 Nm
42. NOTE: Component must be lubricated with clean engine oil.
Refer to: Specifications (303-01A Engine, Specifications).
Torque: 15 Nm

43. NOTE: Only tighten the bolts finger tight at this stage.
Use the General Equipment: Hose Clamp Remover/Installer
Torque: 10 Nm
44.

45. Use the General Equipment: Hose Clamp Remover/Installer

Torque:
1: 10 Nm
2: 10 Nm
46.

47.
48. NOTE: Make sure that the components are correctly located.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1: 23 Nm
2: 23 Nm

49.
1. 1. NOTICE: Use lint free cloth.
NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
2. NOTE: Make sure that a new component is installed.
50. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
Stage 3:23 Nm

51. Torque: 63 Nm
52.

53. NOTE: Be prepared to collect escaping fluids.

54.

55. NOTE: Only tighten the bolts finger tight at this stage.
Use the General Equipment: Hose Clamp Remover/Installer
Torque: 10 Nm
56. Use the General Equipment: Hose Clamp Remover/Installer

57. Install the General Equipments: Lifting Bracket, Floor Crane

58. Remove Special Service Tools: 303-435-12C, 303-435-04, 303-435.

59. Torque: 23 Nm
60. NOTE: Only tighten the nut and bolts finger tight at this stage.
Torque:
1: 20 Nm
2: 10 Nm
3: 10 Nm
4: 10 Nm

61. Torque: 63 Nm
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Timing Cover
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1554
Engine Support Bar

303-1554-07
Adapter for 303-1554, Engine Support Bar

303-1554-08
Adapter for 303-1554, Engine Support Bar

303-1554-09
Adapter for 303-1554, Engine Support Bar

303-1643
Locking Tool, Flywheel

303-290A-15
Adapter for 303-290A

303-428
Separator, Oil Pan

Oil Suction Equipment

Plastic Scraper
Two Leg Puller

Materials
Name Specification
Primer -
Silicone Sealant WSE-M4G323-A4

Removal

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

2. Use the General Equipment: Oil Suction Equipment

3. Right Side Only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

4. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

5. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).

6. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).

7. Install Special Service Tool: 303-1643.

RHD FWD
8.

All vehicles
9. NOTE: The component must be installed by hand before final tightening.
Use Special Service Tool: 303-1554-09.
Torque: 36 Nm
10. Use Special Service Tool: 303-1554.

11. NOTE: The component must be installed by hand before final tightening.
Use Special Service Tool: 303-1554.
12. Use Special Service Tools: 303-1554-08, 303-1554-07.

13. Install Special Service Tool: 303-290A-15.

14. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
15.

16.
17.

18.
19.

20.
21. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
22. NOTE: Make sure that no components catch.

23.
24. Loosen: 5 turn(s)

25. Use the General Equipment: Two Leg Puller

26. Remove the General Equipment: Two Leg Puller
27. NOTE: Discard the bolt.

28. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
29. NOTE: Be prepared to collect escaping fluid.
30.
NOTE: Be prepared to collect escaping fluid.
Use Special Service Tool: 303-428.

Installation

1. NOTICE: Protect the engine and the oil pan from contamination by sealer
debris.
2. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

3.
4. NOTE: Make sure that a new component is installed.
NOTE: The component must be installed within 5 minutes of applying the sealant.

Complete this step within: 5min

Material: WSE-M4G323-A4 (Silicone Sealant)

5. NOTE: The component must be installed within 5 minutes of applying the sealant.

Complete this step within: 5min

Material: WSE-M4G323-A4 (Silicone Sealant)
6. NOTICE: Make sure that the component is correctly located on the locating
dowels.

7. NOTE: Only tighten the bolts finger tight at this stage.

8. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:12 Nm
Stage 2:80 Nm
Stage 3:90°

9. NOTE: Only tighten the bolts finger tight at this stage.

10. Torque:
1-2 18 Nm
3-17 10 Nm

11. NOTE: Only tighten the bolt finger tight at this stage.
NOTE: Make sure that new bolts are installed.
Torque: 40 Nm
12.

13. Torque: 48 Nm
14. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
15. NOTE: Make sure a new bolt is installed.
NOTE: Only tighten the bolt finger tight at this stage.
Torque:
Stage 1:10 Nm
Stage 2:Loosen: 60°
Stage 3:20 Nm
Stage 4:70 Nm
Stage 5:150 Nm
Stage 6:Loosen: 90°
Stage 7:100 Nm
Stage 8:300 Nm
Stage 9:90°
16. Torque: 23 Nm

17. NOTE: Make sure that no components catch.

18. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
19.
20. Torque: 10 Nm

21.
22. NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1 115 Nm
2 70 Nm

23. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

24. Remove Special Service Tool: 303-290A-15.

25. Remove Special Service Tools: 303-1554-08, 303-1554-07.

26. Remove Special Service Tool: 303-1554.

27. Remove Special Service Tool: 303-1554.

28. Remove Special Service Tool: 303-1554-09.

RHD FWD

29. Torque: 7 Nm

All vehicles

30. Remove Special Service Tool: 303-1643.

31. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).

32. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).

33. Right side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

34. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

35. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
36.
37. Refer to: Specifications (303-01A Engine, Specifications).

38.
Engine Cooling - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Specifications
Print

ANTIFREEZE SPECIFICATIONS

DESCRIPTION SPECIFICATION

Motorcraft Super Plus 2000 Material: WSS-M97B44-D (Antifreeze)

Specific gravity (providing no other additive 1.110 - 1.145 at 68°F (+20°C)

is in the coolant)

PERCENT ANTIFREEZE/COOLANT TO DISTILLED WATER FREEZE PROTECTION

42/58 -26°C

58/42 (Extreme Cold Climates) -50°C

COOLING SYSTEM CAPACITIES

DESCRIPTION CAPACITY

Vehicles with fuel fired heater and auxiliary 13.7 L

heater

Vehicles with auxiliary heater 13.3 L

Vehicles with fuel fired heater 12 L

Vehicles with front heater only 11.2 L

COOLING SYSTEM PRESSURE SPECIFICATION

DESCRIPTION PRESSURE

Radiator pressure test 138 kPa

Coolant expansion tank cap release pressure 145 kPa

Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Cooling - Component Location
Print

Description and Operation

Item Description
1 Coolant hoses to heater core
2 Degas bottle
3 Radiator
4 EGR cooler bypass vacuum actuator
5 Thermostat housing (incorporating three-plate thermostat with electric heating element
and ECT (engine coolant temperature) sensor
6 Electric heating element connector
7 Engine oil cooler
8 EOP (engine oil pressure) sensor
9 EGR cooler
10 Coolant pump
11 Electrical coolant pump (supplies coolant to Diesel Exhaust Fluid (DEF) injector)
Item Description
1 Electrical coolant pump (supplies coolant to Diesel Exhaust Fluid (DEF) injector)
2 Radiator
3 Coolant pump
4 Coolant pump rear housing
5 Coolant hoses to DEF injector
Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Cooling - Overview
Print

Description and Operation

2.0L EcoBlue Engine Cooling

The engine cooling system contains the following components:

• Coolant pump
• Degas bottle
• Heater core
• AdBlue® electric coolant pump
• AdBlue® injector (cooled by coolant)
• CHT (cylinder head temperature) sensor
• EGR cooler and EGR cooler bypass vacuum actuator
• Three-plate thermostat
• Engine oil cooler
• ECT (engine coolant temperature) sensor
• Radiator
• Electric cooling fans and shroud

Item Description
1 Feed to the EGR (exhaust gas recirculation) cooler
2 Feed to the thermostat
3 Feed to the engine oil cooler
4 Coolant pump
Coolant is circulated in the cooling system using an externally mounted coolant pump which
is driven by the engine accessory drive belt.
The cooling system uses a 3 way thermostat that controls the coolant flow through the
engine, cylinder head, EGR cooler, AdBlue® injector and heater core. The thermostat allows
the engine to reach operating temperature as quickly as possible to meet strict emission
regulations.
The engine cooling circuit in the cylinder head is split into an upper and lower cooling circuit
to improve efficiency. The flow through each of the cylinder head cooling circuits is
controlled by the 3 way thermostat.
Cooling system drain plug

The degas bottle holds surplus coolant and removes air from the cooling system. It also
allows for coolant expansion, system pressurization, replenishes coolant to the cooling
system and serves as the location for service fill.

Dual electric cooling fans provide additional airflow to cool the radiator and A/C evaporator
when the vehicle is stationary, at low speeds or at high engine and condenser
temperatures.
The cooling system is also equipped with an electric coolant pump which is used by the
{Acronym.SCR} ({Acronym.SCR}) or AdBlue® system to cool the AdBlue® injector.
Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Cooling - System Operation and Component Description
Print

Description and Operation

System Operation
Engine Cooling System Operation

Item Description
1 Bypass hose connection to coolant pump
2 Return from the oil cooler
3 Main connection to cylinder head
4 Hose connection to radiator (top hose)
The engine enters the warm-up phase after a cold start. During this period the thermostat
is closed and the coolant circulates through the inner upper cylinder circuit.
The thermostat bypass valve opens during normal operation and the coolant is routed
through the inner upper and lower engine circuits in the cylinder head.
The bypass is closed during the hot phase and the entire volumetric coolant flow is passed
through the radiator.
Cooling System During the Warm-up Phase

Coolant Temperature Below 70 °C

Item Description
A No flow
B Hot flow
C Cold flow
1 Coolant pump
2 AdBlue® injector
3 CHT (cylinder head temperature) sensor
4 Heater
5 Rear heater (if equipped)
6 EGR (exhaust gas recirculation)
7 EGR cooler
8 Degas bottle
9 Thermostat
10 Bypass to coolant pump
11 Radiator
12 Oil cooler
13 ECT (engine coolant temperature) sensor
14 AdBlue® injector electric pump
15 Cylinder head lower deck
16 Cylinder head top deck
The coolant temperature is below 70 °C when the engine is in the warm-up phase. The
thermostat is closed and the coolant circulates through the inner upper engine circuit.
Cooling System During Normal Operation

Coolant temperature between 70 °C and 88 °C

Item Description
A No flow
B Hot flow
C Cold flow
1 Coolant pump
2 AdBlue® injector
3 CHT sensor
4 Heater
5 Rear heater (if equipped)
6 EGR
7 EGR cooler
8 Degas bottle
9 Thermostat
10 Bypass to coolant pump
11 Radiator
12 Oil cooler
13 ECT sensor
14 AdBlue® injector electric pump
15 Cylinder head lower deck
16 Cylinder head top deck
The coolant temperature reaches the thermostat opening temperature of 70 °C. The
thermostat bypass valve opens during normal operation (between 70 °C and 88 °C) and the
coolant is routed through the inner-upper and lower engine circuits in the cylinder head.
Cooling System During Hot Operation

Coolant temperature above 88 °C

Item Description
A No flow
B Hot flow
C Cold flow
1 Coolant pump
2 AdBlue® injector
3 CHT sensor
4 Heater
5 Rear heater (if equipped)
6 EGR
7 EGR cooler
8 Degas bottle
9 Thermostat
10 Bypass to coolant pump
11 Radiator
12 Oil cooler
13 ECT sensor
14 AdBlue® injector electric pump
15 Cylinder head lower deck
16 Cylinder head top deck
NOTE: The 'Overheating' warning lamp comes on at an ECT of 112 °C and the engine
switches off above an ECT of 118 °C.
When the coolant temperature reaches above 88 °C the thermostat bypass is closed. The
thermostat opens fully, enabling coolant to flow to the top radiator hose. The entire
volumetric flow is passed through the radiator.

Component Description
Three-Plate Thermostat
Item Description
1 ECT (engine coolant temperature) sensor
2 Vent assembly
3 Bypass plate
4 Closing plate
5 Housing with wax element
6 Main valve plate
7 Heating element
8 Pin
This is an electrically assisted thermostat which functions in the same way as a
conventional thermostat, but at a higher engine temperature. Coolant flows around the
thermostat and as the temperature rises, the wax material in the thermostat melts,
increasing in volume, moving a piston which opens the thermostat allowing coolant to flow
to the radiator.
Under some heavy load conditions as determined by the PCM, the thermostat heating
element (integrated in the thermostat) is actuated by the PCM. This additional heat source
allows the wax material to expand quickly, opening the thermostat regardless of the coolant
temperature. The PCM is able to increase coolant flow when it needs to, enabling the engine
to operate within its optimum temperature range without the danger of overheating.
The heating element is controlled via a PWM (pulse width modulation) signal from the PCM
(powertrain control module).
The ECT sensor is mounted to the thermostat housing. The voltage value supplied by the
ECT sensor is assigned to a corresponding temperature value by the PCM.
The engine coolant temperature is required for the following calculations:

• Idle speed
• Injection timing
• Injected fuel quantity
• EGR quantity
• Glow plug control
• Actuation of the temperature gauge and glow plug warning indicator
• Fan control
Coolant Pump

Item Description
1 Drive pulley
2 Bearing with pump shaft
3 Pump housing
4 Mechanical seal package
5 Impeller
The mechanical coolant pump is flange-mounted directly to the engine case and is driven
by the crankshaft pulley using a dedicated toothed drive belt.
The coolant pump bearing shaft is an integral part of the bearing. This means that the balls
roll directly on the pump shaft.
NOTE: The coolant pump must not be operated when the mechanical seal is dry.
The mechanical seal package contains two slide rings used to seal around the rotating
pump shaft. The coolant in the cooling system lubricates and cools the slide rings. The
pressure in the cooling system and the rotation of the pump shaft pushes coolant between
the slide rings for low-wear fluid friction.
Engine Cooling - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Engine Cooling
Print

Diagnosis and Testing

Special Tool(s) / General Equipment
Pressure Tester, Cooling System
303-396 (24-001A)

Adapter for 303-396

303-396-08

Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Coolant hose(s) • Fuse(s)
• Gaskets/seals • Wiring harness
• Coolant expansion tank cap and seal • Electrical connector(s)
• Coolant expansion tank • Cylinder head temperature (CHT) sensor
• Radiator • Engine cooling fan motor(s)
• Coolant pump • Powertrain control module (PCM)
• Thermostat
• Thermostat housing
• Cooling fan
• Accessory drive belt
• Exhaust gas recirculation (EGR) cooler
• Engine oil cooler

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Loss of coolant * Radiator. * CARRY OUT the Pressure Test Component
Test in this section. INSTALL a new radiator
as necessary.
REFER to: Radiator (303-03A Engine
Cooling, Removal and Installation).
* Coolant pump. * CARRY OUT the Pressure Test Component
Test in this section. INSTALL a new coolant
pump as necessary.
REFER to: Coolant Pump (303-03A Engine
Cooling, Removal and Installation).
* Thermostat housing. * CARRY OUT the Pressure Test Component
Test in this section. INSTALL a new
thermostat housing as necessary.
REFER to: Thermostat (303-03A Engine
Cooling, Removal and Installation).
* Coolant expansion * CARRY OUT the Coolant Expansion Tank Cap
tank cap. Pressure Test Component Test in this
section.
* Coolant expansion * CHECK the coolant expansion tank for
tank. damage. INSTALL a new coolant expansion
tank as necessary.
* EGR cooler. * CARRY OUT the Pressure Test Component
Test in this section. INSTALL a new EGR
cooler as necessary.
REFER to: Exhaust Gas Recirculation (EGR)
Cooler (303-08A Engine Emission Control,
Removal and Installation).
* Engine oil cooler. * CARRY OUT the Pressure Test Component
Test in this section. INSTALL a new engine
oil cooler as necessary.
* Heater core. * CHECK the heater core for leaks. REFER to:
(412-01 Climate Control)
Heater Core - LHD FWD (Removal and
Installation),
Heater Core - RHD FWD (Removal and
Installation).
* Engine. * CHECK the engine, cylinder head, coolant
manifold, cylinder block and cylinder head
gasket.
The engine overheats. * Cooling system does * CARRY OUT the Coolant Expansion Tank Cap
not hold pressure. Pressure Test Component Test in this
section.
- CHECK the coolant expansion tank for
damage. INSTALL a new coolant expansion
tank as necessary.
- CHECK the coolant pump for damage.
INSTALL a new coolant pump as necessary.
REFER to: Coolant Pump (303-03A Engine
Cooling, Removal and Installation).
- CHECK the engine, cylinder head, coolant
manifold, cylinder block and cylinder head
gasket.
* Air in system. * BLEED the cooling system.
REFER to: Cooling System Draining, Vacuum
Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
* Coolant expansion * CARRY OUT the Coolant Expansion Tank Cap
tank cap. Pressure Test Component Test in this
section.
* Coolant expansion * CHECK the coolant expansion tank for
tank. damage. INSTALL a new coolant expansion
tank as necessary.
* Coolant * CHECK the coolant level/condition. REFILL
level/condition. the cooling system.
REFER to: Cooling System Draining, Vacuum
Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
* Coolant *
concentration. REFER to: Specifications (303-03A Engine
Cooling, Specifications).
* Radiator grille. *
CHECK the radiator grille for air
restrictions/damage. REPAIR as necessary.
* Coolant pump. * CHECK the coolant pump for leaks. INSTALL
a new coolant pump as necessary.
REFER to: Coolant Pump (303-03A Engine
Cooling, Removal and Installation).
* Thermostat. * CARRY OUT the Thermostat Test Component
Test in this section. INSTALL a new
thermostat as necessary.
REFER to: Thermostat (303-03A Engine
Cooling, Removal and Installation).
* Accessory drive belt. * CHECK the accessory drive belt for correct
operation.
REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* Cooling fan. * CHECK operation of the cooling fan motor.
INSTALL a new cooling fan motor as
necessary.
REFER to: Cooling Fan Motor and Shroud
(303-03A Engine Cooling, Removal and
Installation).
* Engine. * CHECK the engine, cylinder head, coolant
manifold, cylinder block and cylinder head
gasket.
The engine does not * CHT sensor. * CHECK the CHT sensor for correct operation.
reach normal operating REFER to the Ford diagnostic equipment to
temperature. diagnose the system.
* Thermostat. * CARRY OUT the Thermostat Test Component
Test in this section. INSTALL a new
thermostat as necessary.
REFER to: Thermostat (303-03A Engine
Cooling, Removal and Installation).
* Circuit(s). * CHECK the circuit(s). REFER to the Ford
diagnostic equipment to diagnose the
system.
* Oil cooler * CHECK the oil cooler thermostatic valve for
thermostatic valve. correct operation. INSTALL a new oil cooler
thermostatic valve as necessary.

Component Tests
Pressure Test

WARNING: When releasing the system pressure, cover the coolant expansion tank
cap with a thick cloth to prevent the possibility of coolant scalding. Failure to follow this
instruction may result in personal injury.

1. Remove the coolant expansion tank cap.

2. Install the special tools to the coolant expansion tank.

3. Pressurize the system to the coolant expansion tank cap release pressure.
REFER to: Specifications (303-03A Engine Cooling, Specifications).

4. Observe the cooling system pressure tester gauge reading for approximately two
minutes. The pressure should not drop during this time. If the system holds
pressure, proceed to step 7. If the system does not hold pressure, check it
thoroughly for coolant leaks.

5. If a coolant leak cannot be found, check the EGR cooler (this may leak internally),
engine oil cooler (this may produce oil in the coolant expansion tank) and the
engine for cylinder leakage. Drain the cooling system, repair any coolant leaks
found and fill and bleed the cooling system as necessary.
REFER to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

6. Recheck the system by repeating steps 3 and 4 at least twice.

Radiator Leak Test, Removed From Vehicle

NOTICE: Radiator internal pressure must not exceed 130 kpa (20 psi) or damage
may result.
Clean the radiator thoroughly before leak testing it, to prevent contamination of the water
in the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure.
Check it thoroughly for air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03A Engine Cooling, Removal and Installation).
Coolant Expansion Tank Cap Pressure Test

1. Remove the coolant expansion tank cap.

2. Use water to clean the area of the rubber seal and pressure relief valve. Install the
pressure tester and adapter and immerse the coolant expansion tank cap in water .

NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure
reading will result.

3. Slowly depress the plunger of the pressure test pump until the pressure test gauge
reading stops increasing, and note the highest pressure reading obtained.

4. Release pressure by turning the pressure relief screw counterclockwise. Tighten the
pressure relief screw and repeat step 3 at least twice to make sure that the
pressure test gauge reading is repeatable and within acceptable gauge reading
limits of the coolant expansion tank cap.

5. If the pressure test gauge readings are not within the acceptable gauge reading
limits, INSTALL a new coolant expansion tank cap.

Thermostat Test

1. Connect the Ford diagnostic equipment to the data link connector (DLC).

2. Using the Ford diagnostic equipment datalogger function, SELECT the following
sensors (as applicable to the application):

• IAT - intake air temperature (IAT) sensor

• ECT - engine coolant temperature (ECT) sensor
• CHT - cylinder head temperature (CHT) sensor
• LOAD - engine load
• VSS - vehicle speed sensor (VSS)
• RPM - engine speed
• DSRPM - desired engine speed

The IAT sensor output is useful if the engine being tested is cold or after an over-night cold
soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the same
value or be within 1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as it indicates the engine warm-up and
opening temperature for the thermostat. It will initially indicate a slightly higher reading
just before the thermostat opens and then drops back before settling to a near flat line
output (see graphic below).
Item Description
A Thermostat opens
B Thermostat settles into a cyclic open and closure pattern

NOTICE: If the ECT sensor output reaches the 120ºC default line under normal
cooling system pressure, internal damage may be caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM. The test should be stopped and the cause
located and corrected. If the cooling system does not pressurize, the coolant will boil at
100ºC which may also damage the engine. CARRY OUT the Coolant Expansion Tank Cap
Pressure Test Component Test in this section.
If the Ford diagnostic equipment only allows the ECT sensor to be displayed in volts, refer
to the following table for corresponding Celsius values:

Volts ºCelsius
1.33 60
1.02 70
0.78 80
0.60 90
0.46 100
0.35 110
0.27 120
The CHT sensor output is useful to examine the cylinder head temperature rise during the
warm-up cycle and later during the normal light throttle cruise test. This sensor output may
vary between vehicles with manual transmission and vehicles with automatic transmission
and should be used for reference only.
The LOAD display is used for reference as it is necessary to maintain a stable load line
during the test. It is necessary to carry out the test under normal light throttle cruise
driving conditions and average loads, typically 40% to 70% of the load value.
The VSS output is used for reference but can help to identify misfires and sensors which fail
during the warm-up cycle.
The RPM display indicates the engine speed and can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed which the PCM commands the engine to
reach. If the thermostat opens too early (before the correct opening temperature has been
reached), the engine will not reach this value.
When using the Ford diagnostic equipment in data logger mode, the signals recorded
should remain within the DEFAULT values set by the Ford diagnostic equipment.

3. WARNING: Make sure that the Ford diagnostic equipment is placed in the
vehicle so that it does not interfere with the safe operation of the vehicle. Do not
place the Ford diagnostic equipment in the deployment path of any air bag. Failure
to follow these instructions may result in personal injury.
NOTE: The road test is best carried out with the aid of another technician in the
vehicle to enable the vehicle to be driven safely while the sensor outputs are
monitored within datalogger. If there is only one technician available, the Ford
diagnostic equipment can be set up (using the record/capture mode camera icon)
before leaving the workshop to record a 16 km (10 mile) test.
NOTE: The results from the test are more conclusive if the engine is cold when the
test is started.
Carry out a road test.

4. Drive the vehicle at a constant throttle opening and set speed until the ECT value
settles into a shallow rise and fall signal, close to a straight line. This indicates that
the thermostat is functioning correctly.

NOTE: Some thermostats indicate the temperature(s) in Celsius and Fahrenheit.

The graphic below shows the location and an example of the opening temperature (88ºC)
and fully open temperature (102ºC) of a thermostat.

The graphic below shows an alternative method used to show the opening temperature
(88ºC) and fully open temperature (112ºC) of a thermostat.

Item Description
A Opening temperature
B Fully open temperature
NOTE: Generally, most thermostats maintain a coolant temperature between 88ºC
(190ºF) and 92ºC (198ºF) although dual stage electric thermostats may increase the
coolant temperature up to 100ºC (212ºF) under light engine load conditions.
The engine should start cleanly and the ECT value will rise quite quickly with smooth
progression. If the ECT signal appears unstable or erratic, the ECT sensor, electrical
connector and wiring harness to the PCM need to be visually inspected for damage, chafing
or water ingress.
The temperature should rise to approximately 90ºC for a thermostat that has an 88ºC
value. The signal value will then fall as cooler coolant enters the engine.
If the ECT value fails to maintain a constant value and falls back to lower figures, typically
between 60ºC (140ºF) and 70ºC (150ºF), the thermostat and its sealing function within the
thermostat housing must be checked.

5.
INSTALL a new thermostat.
REFER to: Thermostat (303-03A Engine Cooling, Removal and Installation).

6. Carry out another road test from step 1 using the same criteria to confirm that the
concern has been rectified.
7. Using the Ford diagnostic equipment, clear the PCM electrically erasable
programmable read only memory (EEPROM) so that new drive values can be learnt.
Part Number
-
-
Part Number
-
-
Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cooling
System Draining, Vacuum Filling and Bleeding
Print

General Procedures
General Equipment
Cooling System Vacuum Tester and Refiller
Fluid Container

Materials
Name Specification
Antifreeze WSS-M97B44-D

Draining

WARNING: When releasing the cooling system pressure, cover the coolant expansion
tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this
instruction may result in personal injury.
NOTE: Always follow the manufacturer's instructions when handling the equipment.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2.
Release the cooling system pressure by slowly turning the coolant expansion tank cap
between 2 and 3 turns.

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4. NOTE: Be prepared to collect escaping fluid.
Use a suitable coolant hose to drain the coolant.

Use the General Equipment: Fluid Container

Loosen: 4 turn(s)
Filling
1.
• If the cooling system was completely drained, fill the fluid container with the full
cooling system fill capacity plus 0.5L of additional coolant.

Material: WSS-M97B44-D (Antifreeze)

• If the cooling system was partially drained, fill the fluid container with the
removed and spilled amount of coolant plus 1.0L of additional coolant. When in
doubt always use the full cooling system fill capacity plus 0.5L of additional
coolant.

Material: WSS-M97B44-D (Antifreeze)

2. Use the General Equipment: Cooling System Vacuum Tester and Refiller
3. 1. Close the valve, install the coolant hose and place it into the fluid container.
2. Close the valve and connect the compressed air hose.

4. Open the valve until the specificied vacuum is achieved.

5. • Open the valve until the coolant reservoir fluid level is at the MAX mark.
• If no coolant is visible in the coolant expansion tank, add 2.0L of coolant to the
fluid container and repeat the evacuating and filling procedure.

6.
Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Coolant Pump
Print

Removal and Installation

Special Tool(s)
303-1554
Engine Support Bar

303-1554-07
Adapter for 303-1554, Engine Support Bar

303-1554-08
Adapter for 303-1554, Engine Support Bar

303-1554-09
Adapter for 303-1554, Engine Support Bar

303-290A-15
Adapter for 303-290A

Materials
Name Specification
Grease WSD-M1C227-A

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

2. Refer to: Coolant Pump Belt (303-05A Accessory Drive, Removal and Installation).

3. Torque: Nm
4. Torque: Nm

5. NOTE: The component must be installed by hand before final tightening.

Use Special Service Tool: 303-1554-09.
Torque: 36 Nm
6. Use Special Service Tool: 303-1554.

7. NOTE: The component must be installed by hand before final tightening.

Use Special Service Tool: 303-1554.
8. Use Special Service Tools: 303-1554-08, 303-1554-07.

9. Install Special Service Tool: 303-290A-15.

10. NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1 115 Nm
2 70 Nm

11. NOTE: Make sure that no components catch.

12. Torque: 10 Nm

13. Torque: 25 Nm
14. NOTE: Make sure a new component is installed.
Apply a thin coating.

Material: WSD-M1C227-A (Grease)

Installation

1. To install, reverse the removal procedure.

Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cooling Fan Motor
and Shroud
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Installation
1. To install, reverse the removal procedure.
Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Electric
Coolant Pump
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

2. Torque: 10 Nm

3. NOTE: Be prepared to collect escaping fluid.

4. Torque: 10 Nm

5. Torque: 8 Nm
Installation

1. To install, reverse the removal procedure.

Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Radiator
Print

Removal and Installation

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

2. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

3. Torque:
1: 10 Nm
2: 10 Nm

4. Torque: 10 Nm

5.
6. NOTE: Be prepared to collect escaping fluid.

7.
8.

9.
10.

Installation

1. To install, reverse the removal procedure.

Engine Cooling - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Thermostat
Print

Removal and Installation

Materials
Name Specification
Grease WSD-M1C227-A

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

3. Torque: 10 Nm

4.
5. NOTE: Be prepared to collect escaping fluid.

6. Torque: 10 Nm
7.

8. Apply a thin coating.

Material: WSD-M1C227-A (Grease)

Installation

1. To install, reverse the removal procedure.

Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Fuel Charging and Controls
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 023-1 for schematic and connector information.
Inspection and Verification
WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times.
Failure to follow this instruction may result in personal injury.

NOTICE: Diesel fuel injection equipment is manufactured to very precise tolerances

and fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always fit blanking plugs to any open orifices or lines.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is repaired.
Failure to clear all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately four liters, rough
running will occur. This is to signal to the driver that the vehicle requires refuelling in
order to prevent the fuel system from running dry.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Fuel leak(s) • Fuse(s)
• Fuel filter element • Relay(s)
• Air cleaner element • Wiring harness
• Vacuum line(s)/vacuum connectors • Electrical connector(s)
• Hose(s)/hose connectors • Fuel injectors
• Tube(s)/tube connectors • Fuel temperature sensor
• Contaminated fuel • Fuel rail pressure sensor
• Fuel supply line(s) • Fuel metering valve
• Fuel return line(s) • Fuel line low pressure sensor
• High-pressure fuel supply line(s) • Fuel pump and sender unit
• Fuel injectors • Passive anti-theft system (PATS) LED
• Fuel rail operation
• Fuel pump • Glow plug indicator
• PCM

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. NOTE: A PCM calibration update should only be carried out if it is applicable to the
symptoms exhibited by the vehicle.
If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment. Check for the availability of an applicable PCM calibration
update. Continue using the Ford diagnostic equipment and retrieve the DTCs and
refer to the DTC Index Chart.
DTC INDEX CHART

DTC Description/Condition Possible Source Action

P1250Fuel metering valve controllability failure Circuit(s), air ingress into the GO to
(displayed in addition to DTC P0089) fuel lines, fuel metering valve Pinpoint Test
A.

5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to
continue diagnostics.

Symptom Chart

Symptom Possible Sources Action

Engine does not crank * DTC detected. * REFER to the Ford diagnostic equipment.
and glow plug indicator
is flashing
Engine does not crank * Passive anti-theft * CHECK the PATS LED extinguishes within 3
system (PATS). seconds when the ignition is turned on.
REFER to: Passive Anti-Theft System
(PATS) (419-01B Passive Anti-Theft
System (PATS), Diagnosis and Testing).
* Starting system. *
REFER to: Starting System (303-06C,
Diagnosis and Testing).
* Ignition switch. * REFER to the Wiring Diagrams.
* PCM. * REFER to the Ford diagnostic equipment.
* Engine seized. *
REFER to: Engine (303-01A Engine,
Diagnosis and Testing).
* Accessories locked. *
REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
Engine cranks but does * DTC detected. * REFER to the Ford diagnostic equipment.
not start and glow plug
indicator is flashing
Engine cranks but does * Low fuel tank fuel * CHECK the fuel tank fuel level is greater
not start level. than four liters. If the fuel tank fuel level is
less then four liters, FILL with fuel.
* Fuel filter element * INSTALL a new fuel filter element. REFER
blocked. to: Fuel Filter Element (310-01A Fuel Tank
and Lines, Removal and Installation).
* Fuel line(s) damaged * INSPECT the fuel line(s) for damage or
or blocked. blockage. INSTALL new fuel line(s) as
necessary.
* Air ingress into the * REFER to: Fuel System (310-00A Fuel
fuel lines. System - General Information, Diagnosis
and Testing).
* Fuel pump and sender * REFER to the Ford diagnostic equipment.
unit.
* Glow plug relay. * REFER to the Ford diagnostic equipment.
* Glow plug module. * REFER to the Ford diagnostic equipment.
* Glow plugs. * REFER to the Ford diagnostic equipment.
* Crankshaft position * REFER to the Ford diagnostic equipment.
(CKP) sensor.
* Camshaft position * REFER to the Ford diagnostic equipment.
(CMP) sensor.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Fuel pump. * REFER to the Ford diagnostic equipment.
* Fuel injectors. * REFER to the Ford diagnostic equipment.
* Incorrect valve * CHECK the valve timing.
timing.
* Low cylinder * TEST the cylinder compression. REFER to:
compression. Engine (303-01A Engine, Diagnosis and
Testing).
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to: (303-04A Fuel Charging and Controls)
Fuel Injection Pump (Removal and
Installation),
Fuel Injectors (Removal and
Installation),
Fuel Rail (Removal and Installation).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Accessories load. * REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* Air intake blocked. * REFER to: Intake Air Distribution and
Filtering (303-12A Intake Air Distribution
and Filtering, Diagnosis and Testing).
* PCM. * REFER to the Ford diagnostic equipment.
Poor starting and glow * DTC detected. * REFER to the Ford diagnostic equipment.
plug indicator is flashing
Poor starting * Low fuel tank fuel * CHECK the fuel tank fuel level is greater
level. than four liters. If the fuel tank fuel level is
less then four liters, FILL with fuel.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to: (303-04A Fuel Charging and Controls)
Fuel Injection Pump (Removal and
Installation),
Fuel Rail (Removal and Installation).
* Fuel filter element * INSTALL a new fuel filter element. REFER
blocked. to: Fuel Filter Element (310-01A Fuel Tank
and Lines, Removal and Installation).
* Air cleaner element * INSTALL a new air cleaner element.
blocked.
* Glow plug relay. * REFER to the Ford diagnostic equipment.
* Glow plug module. * REFER to the Ford diagnostic equipment.
* Glow plugs. * REFER to the Ford diagnostic equipment.
* Fuel system leak. * CHECK the system for fuel leak(s). REPAIR
the system as necessary.
* *
Air ingress into the REFER to: Intake Air Distribution and
fuel lines. Filtering (303-12A Intake Air Distribution
and Filtering, Diagnosis and Testing).
* Fuel line(s) damaged * INSPECT the fuel line(s) for damage or
or blocked. blockage. INSTALL new fuel line(s) as
necessary.
* Fuel pump. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Accessories load. * REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* Incorrect engine oil. * INSTALL a new engine oil filter and engine
oil. CARRY OUT the oil reset procedure.
REFER to the Service interval indicator
lamp section within the Owner's Guide.
* Incorrect power * DRAIN and REFILL the power steering
steering fluid. system with the correct fluid. REFER to:
(211-00 Steering System - General
Information)
Power Steering System Flushing
(General Procedures),
Power Steering System Filling
(General Procedures),
Power Steering System Bleeding
(General Procedures).
* CKP sensor. * REFER to the Ford diagnostic equipment.
* Manifold absolute * REFER to the Ford diagnostic equipment.
pressure (MAP)
sensor.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter as necessary. REFER to:
Catalytic Converter (309-00A Exhaust
System, Removal and Installation).
* Low cylinder * TEST the cylinder compression. REFER to:
compression. Engine (303-01A Engine, Diagnosis and
Testing).
Engine starts but * DTC detected. * REFER to the Ford diagnostic equipment.
immediately stops and
glow plug indicator is
flashing
Engine starts but * Incorrect or * INSTALL a new air cleaner element.
immediately stops contaminated fuel.
* Air ingress into the * CHECK for signs of contamination such as
fuel lines. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to: (303-04A Fuel Charging and Controls)
Fuel Injection Pump (Removal and
Installation),
Fuel Injectors (Removal and
Installation),
Fuel Rail (Removal and Installation).
* *
Air cleaner element REFER to: Fuel System (310-00A Fuel
blocked. System - General Information, Diagnosis
and Testing).
* PCM relay. * CHECK the PCM relay. INSTALL a new PCM
relay as necessary.
* Accessories load. * REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* CKP sensor. * REFER to the Ford diagnostic equipment.
* CMP sensor. * REFER to the Ford diagnostic equipment.
* PCM. * REFER to the Ford diagnostic equipment.
Poor idling and glow * DTC detected. * REFER to the Ford diagnostic equipment.
plug indicator is flashing
Poor idling * Low fuel tank fuel * CHECK the fuel tank fuel level is greater
level. than four liters. If the fuel tank fuel level is
less then four liters, FILL with fuel.
* Air cleaner element * INSTALL a new air cleaner element.
blocked.
* Accessories load. * REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* Fuel filter element * INSTALL a new fuel filter element. REFER
blocked. to: Fuel Filter Element (310-01A Fuel Tank
and Lines, Removal and Installation).
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to: (303-04A Fuel Charging and Controls)
Fuel Injection Pump (Removal and
Installation),
Fuel Injectors (Removal and
Installation),
Fuel Rail (Removal and Installation).
* Air ingress into the * REFER to: Fuel System (310-00A Fuel
fuel lines. System - General Information, Diagnosis
and Testing).
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* MAP sensor. * REFER to the Ford diagnostic equipment.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Fuel pump. * REFER to the Ford diagnostic equipment.
Engine stumbling and * DTC detected. * REFER to the Ford diagnostic equipment.
glow plug indicator is
flashing
Engine stumbling * Low fuel level. * CHECK the fuel tank level is greater than
four liters. If the fuel tank level is less than
four liters, FILL with fuel.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
*
If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Accelerator pedal * REFER to the Ford diagnostic equipment.
position (APP) sensor.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Fuel pump. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* CMP sensor. * REFER to the Ford diagnostic equipment.
Engine lacks power and * DTC detected. * REFER to the Ford diagnostic equipment.
glow plug indicator is
flashing
Engine lacks power * Low fuel level. * CHECK the fuel tank level is greater than
four liters. If the fuel tank level is less than
four liters, FILL with fuel.
* Fuel system leak(s). * Carry out a Fuel System Leak Test using
the Ford diagnostic equipment menu
options: ToolBox/Powertrain/Service
Functions. REFER to the Ford diagnostic
equipment.
* Brakes binding. * CHECK the braking system.
REFER to: Brake System (206-00 Brake
System - General Information, Diagnosis
and Testing).
* Vehicle overloaded, or * ADVISE the customer about the effects of
excessive wind overloading the vehicle and wind
resistance (roof racks, resistance on the performance.
towing etc).
* Accessories load. * REFER to: Accessory Drive (303-05A
Accessory Drive, Diagnosis and Testing).
* Air cleaner element * INSTALL a new air cleaner element as
blocked. necessary.
* Fuel filter element * INSTALL a new fuel filter element. REFER
blocked. to: Fuel Filter Element (310-01A Fuel Tank
and Lines, Removal and Installation).
* Fuel line(s) damaged * INSPECT the fuel line(s) for damage or
or blocked. blockage. INSTALL new fuel line(s) as
necessary.
* Fuel pump. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Air ingress into the * REFER to: Fuel System (310-00A Fuel
fuel lines. System - General Information, Diagnosis
and Testing).
* Turbocharger. * REFER to the Ford diagnostic equipment.
* Turbocharger variable
vane actuator.
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Charge air cooler * INSPECT for visible signs of damage or
blocked or cracked. blockage. CLEAN, REPAIR or INSTALL new
* Charge air cooler parts as necessary.
pipes split or cracked.
* Charge air cooler
retaining clips missing
or loose.
* Incorrect or *CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
*CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Vehicle speed sensor * REFER to the Ford diagnostic equipment.
(VSS).
* MAP sensor. * REFER to the Ford diagnostic equipment.
* MAFT sensor. * REFER to the Ford diagnostic equipment.
* APP sensor. * REFER to the Ford diagnostic equipment.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Incorrect valve * CHECK the valve timing.
timing.
* Low cylinder * CHECK the cylinder compression. REFER
compression. to: Engine (303-01A Engine, Diagnosis and
Testing).
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
Catalytic Converter (309-00A Exhaust
System, Removal and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Black smoke at idle and * DTC detected. * REFER to the Ford diagnostic equipment.
glow plug indicator is
flashing
Black smoke at idle * Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Air cleaner element * INSTALL a new air cleaner element as
blocked. necessary.
* Glow plug relay. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Turbocharger. * REFER to the Ford diagnostic equipment.
* Turbocharger variable
vane actuator.
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* MAP sensor. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Incorrect valve * CHECK the valve timing.
timing.
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
Catalytic Converter (309-00A Exhaust
System, Removal and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Excessive black smoke * DTC detected. * REFER to the Ford diagnostic equipment.
during acceleration and
glow plug indicator is
flashing
Excessive black smoke * Air cleaner element * INSTALL a new air cleaner element as
during acceleration blocked. necessary.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* APP sensor. * REFER to the Ford diagnostic equipment.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
Catalytic Converter (309-00A Exhaust
System, Removal and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Black smoke at cruising * DTC detected. * REFER to the Ford diagnostic equipment.
speeds and glow plug
indicator is flashing
Black smoke at cruising * Incorrect or * CHECK for signs of contamination such as
speeds contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Air cleaner element * INSTALL a new air cleaner element.
blocked.
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Turbocharger. * REFER to the Ford diagnostic equipment.
* Turbocharger variable
vane actuator.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* MAP sensor. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
Catalytic Converter (309-00A Exhaust
System, Removal and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Blue smoke and glow * DTC detected. * REFER to the Ford diagnostic equipment.
plug indicator is flashing
Blue smoke * Engine burning oil. * CARRY OUT a controlled oil consumption
test over 1000 km (600 miles). CONFIRM
that the oil consumption is less than 0.1
litre per 1000 km (600 miles).
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Positive crankcase * INSPECT for visible signs of damage or
ventilation (PCV) blockage. CLEAN, REPAIR or INSTALL new
system. parts as necessary.
* Turbocharger oil * REFER to: Turbocharger (303-04C Fuel
return tube blocked or Charging and Controls - Turbocharger,
damaged. Diagnosis and Testing).
* Worn or damaged * REMOVE the cylinder head. INSPECT the
valve guide(s), piston cylinder head, pistons and cylinder bores
ring(s), cylinder bore for signs of wear or damage. REFER to:
(s), cylinder head or Cylinder Head - Vehicles Built From: 01-
gasket. 11-2016 (303-01A Engine, Removal and
Installation).
White smoke and glow * DTC detected. * REFER to the Ford diagnostic equipment.
plug indicator is flashing
White smoke * Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Incorrect valve * CHECK the valve timing.
timing.
* Coolant in the * CARRY OUT a cooling system pressure
combustion chamber. test. REFER to: Engine Cooling (303-03A
Engine Cooling, Diagnosis and Testing).
REMOVE the cylinder head. INSPECT the
cylinder head, cylinder head gasket and
cylinder bores for wear or damage. REFER
to: Cylinder Head - Vehicles Built From:
01-11-2016 (303-01A Engine, Removal
and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Engine misfire and glow * DTC detected. * REFER to the Ford diagnostic equipment.
plug indicator is flashing
Engine misfire * Low fuel tank level. * CHECK the fuel tank level is greater than
four liters. If the fuel tank level is less than
four liters, FILL with fuel.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* Air ingress into the *
fuel lines.
REFER to: Fuel System (310-00A Fuel
System - General Information, Diagnosis
and Testing).
* Fuel pump. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Engine operating * REFER to: Engine Cooling (303-03A Engine
temperature too high. Cooling, Diagnosis and Testing).
* CKP sensor. * REFER to the Ford diagnostic equipment.
* CMP sensor. * REFER to the Ford diagnostic equipment.
* MAP sensor. * REFER to the Ford diagnostic equipment.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Low cylinder * CHECK the cylinder compression. REFER
compression. to: Engine (303-01A Engine, Diagnosis and
Testing).
* Worn or damaged * REMOVE the cylinder head. INSPECT the
valve(s), tappet(s), cylinder head, valves, tappets and
camshaft(s) or camshafts for signs of wear or damage.
cylinder head gasket. REFER to: Cylinder Head - Vehicles Built
From: 01-11-2016 (303-01A Engine,
Removal and Installation).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Engine knock at idle and * DTC detected. * REFER to the Ford diagnostic equipment.
glow plug indicator is
flashing
Engine knock at idle * Low engine oil level. * CHECK the engine oil level. REFILL as
necessary.
* Incorrect or * CHECK for signs of contamination such as
contaminated fuel. strange odours from the fuel tank.
* CHECK for signs of water or petrol in the
diesel.
* If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* CKP sensor. * REFER to the Ford diagnostic equipment.
* Incorrect valve * CHECK the valve timing.
timing.
* Excessive carbon * REMOVE the cylinder head. INSPECT the
build up. cylinder head and pistons for signs carbon
build up. REFER to: Cylinder Head -
Vehicles Built From: 01-11-2016 (303-01A
Engine, Removal and Installation).
* Worn or damaged oil * INSPECT the engine components.
pump.
* Worn or damaged
timing chain or
sprocket.
* Major mechanical
engine failure.
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Engine knock during * DTC detected. * REFER to the Ford diagnostic equipment.
acceleration and glow
plug indicator is flashing
Engine knock during * Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
acceleration * Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Fuel pump. * REFER to the Ford diagnostic equipment.
* Major mechanical * REFER to: Engine (303-01A Engine,
engine failure. Diagnosis and Testing).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Excessive fuel * DTC detected. * REFER to the Ford diagnostic equipment.
consumption and glow
plug indicator is flashing
NOTE: Before * Brakes binding. * CHECK the braking system.
proceeding with any REFER to: Brake System (206-00 Brake
of the actions in System - General Information, Diagnosis
relation to the and Testing).
possible sources for * Vehicle overloaded, or * ADVISE the customer about the effects of
excessive fuel excessive wind overloading the vehicle and wind
consumption, a fuel resistance (roof racks, resistance on the fuel consumption.
consumption test towing etc).
must be carried out * Incorrect or *CHECK for signs of contamination such as
using the Ford contaminated fuel. strange odours from the fuel tank.
diagnostic *CHECK for signs of water or petrol in the
equipment. diesel.
Excessive fuel *If contaminated fuel is found, DRAIN the
consumption complete fuel system. FLUSH the fuel
system through with clean diesel. INSTALL
a new fuel filter element. REFER to: Fuel
Filter Element (310-01A Fuel Tank and
Lines, Removal and Installation). INSTALL
a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines. REFER
to:
Fuel Injection Pump (303-04A Fuel
Charging and Controls, Removal and
Installation),
Fuel Injectors (303-04A Fuel Charging
and Controls, Removal and
Installation),
Fuel Rail (303-04B Fuel Charging and
Controls, Removal and Installation).
* Air cleaner element * INSTALL a new air cleaner element.
blocked.
* Fuel filter element * INSTALL a new fuel filter element. REFER
blocked. to: Fuel Filter Element (310-01A Fuel Tank
and Lines, Removal and Installation).
* Incorrect pilot learn.* REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* Incorrect engine * REFER to the Ford diagnostic equipment.
timing.
* Fuel system leak(s). * CHECK the system for fuel leak(s). REPAIR
or INSTALL new parts as necessary.
* Incorrect engine oil. * INSTALL a new oil filter and engine oil.
* Generator. *
REFER to: Charging System (414-00
Charging System - General Information,
Diagnosis and Testing).
* EGR valve sticking * REFER to: Engine Emission Control (303-
open. 08C, Diagnosis and Testing).
* Turbocharger variable * REFER to the Ford diagnostic equipment.
vane actuator.
* Air ingress into the * REFER to: Fuel System (310-00A Fuel
fuel lines. System - General Information, Diagnosis
and Testing).
* MAP sensor. * REFER to the Ford diagnostic equipment.
* Fuel injector(s). * REFER to the Ford diagnostic equipment.
* Turbocharger. * REFER to: Turbocharger (303-04C Fuel
Charging and Controls - Turbocharger,
Diagnosis and Testing).
* Incorrect valve * CHECK the valve timing.
timing.
* Slipping clutch. * REFER to Clutch
* Low cylinder * CHECK the cylinder compression. REFER
compression. to: Engine (303-01A Engine, Diagnosis and
Testing).
* Wiring * REFER to the Ford diagnostic equipment.
harness/connector.
* PCM. * REFER to the Ford diagnostic equipment.
Engine cuts out during * CMP sensor. * REFER to the Ford diagnostic equipment.
hard acceleration * CKP sensor. * REFER to the Ford diagnostic equipment.
* Incorrect pilot learn. * REFER to the Ford diagnostic equipment.
* Incorrect pump learn.
* FRP sensor. * REFER to the Ford diagnostic equipment.
* Fuel pressure relief * REFER to the Ford diagnostic equipment.
valve.
* Fuel pump. * REFER to the Ford diagnostic equipment.

Pinpoint Tests

PINPOINT TEST A : DTC P1250 - FUEL METERING VALVE

CONTROLLABILITY FAILURE
TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: CHECK FOR AIR INGRESS INTO THE FUEL LINES
1 Check for air ingress into the fuel system. REFER to: Fuel System (310-00A
Fuel System - General Information, Diagnosis and Testing).
Are there signs of air ingress into the fuel system?
Yes
REPAIR the system as recommended in the fuel system diagnostic. CLEAR
the DTCs. TEST the system for normal operation.
No
GO to A2.
A2: CHECK THE FUEL RAIL PRESSURE SENSOR CIRCUIT
1 Using the wiring diagrams, CHECK the fuel rail pressure sensor circuit
wiring harnesses and electrical connectors for electrical shorts or damage.
Is the fuel rail pressure sensor circuit shorted or damaged?
Yes
REPAIR the circuit as necessary. TEST the system for normal operation.
No
GO to A3.
A3: CHECK THE FUEL METERING VALVE CIRCUIT
1 Using the wiring diagrams, CHECK the fuel metering valve circuit wiring
harnesses and electrical connectors for electrical shorts or damage.
Is the fuel metering valve circuit shorted or damaged?
Yes
REPAIR the circuit as necessary. TEST the system for normal operation.
No
GO to A4.
A4: CHECK THE OPERATION OF THE FUEL METERING VALVE
NOTE: This test requires the aid of another technician.
1 Connect the Ford diagnostic equipment.
2 Start the engine.
3 Using the Ford diagnostic equipment, DATALOGGER, set the parameters
FRP, FRP_DSD, VSS, RPM, MFDES,SCV_DC, SCV_AMP.
4 Carry out a road test.
5 Select second gear.
6 Release the accelerator pedal and allow the engine speed to decrease to
idle while the vehicle is moving with second gear engaged.
7 Rapidly apply full throttle until the engine speed reaches 4,000 RPM and
then immediately release the accelerator pedal, allowing the engine speed
to return to idle while the vehicle is moving with second gear engaged.
8 Repeat step 7 approximately four times consecutively.
9 Observe the recorded data from the tests.
Is the value for the FRP parameter data either staying constant or not changing
with the FRP_DSD parameter data?
Yes
This indicates that the fuel metering valve is either stuck or not responding.
INSTALL a new fuel metering valve. TEST the system for normal operation.
No
CLEAR the DTC and REPEAT the test. If the concern persists, INSTALL a
new fuel metering valve. TEST the system for normal operation.
Fuel Charging and Controls - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Fuel Injection
Component Cleaning
Print

General Procedures

General Equipment
Pneumatic Vacuum Gun

Materials
Name Specification
Brake Cleaner -

Cleaning
1. WARNINGS:

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 ignite. Failure to follow these instructions may result in
personal injury.

Do not carry out any repairs to the fuel injection system with the engine
running. The fuel pressure within the system can be as high as 1600 bar. Failure to
follow this instruction may result in personal injury.

Eye protection must be worn at all times when working on or near any fuel
related components. Failure to follow this instruction may result in personal injury.
NOTICE:

Make sure that the workshop area in which the vehicle is being worked on is
as clean and dust-free as possible. Areas in which work on clutches, brakes or
where welding or machining are carried out are not suitable in view of the risk of
contamination to the fuel system.

Make sure that clean non-plated tools are used. Clean tools using a new
brush that will not lose its bristles and fresh suitable evaporative cleaning agent,
prior to starting work on the vehicle.

Use a steel topped workbench and cover it with clean, lint-free non-flocking
material.

Make sure that all parts removed from the vehicle are placed on the lint-free
non-flocking material.

Make sure that any protective clothing worn is clean and made from lint-free
non-flocking material.

Make sure that any protective gloves worn are new and are of the non-
powdered latex type.

Before using the suitable evaporative cleaning agent, protect all electrical
components and connectors with lint-free non-flocking material.
2.
3. NOTICE: Use lint free cloth.
Material: - (Brake Cleaner)

4. Using a new brush that will not lose its bristles, brush a suitable evaporative cleaning
agent onto the components being removed and onto the surrounding area.

5. Remove all traces of evaporative cleaning agent and foreign material.

Use the General Equipment: Pneumatic Vacuum Gun

6. Dispose of any unused evaporative cleaning agent and the brush after completing the
repair.
Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel
Injector Bore Cleaning
Print

General Procedures
Special Tool(s)
303-1315
Cleaning Kit, Injector Hole Bottom

303-1315-01
Adapter for 303-1315

Cleaning
1. Install Special Service Tool: 303-1315.

2. Remove Special Service Tool: 303-1315.

3. Use Special Service Tool: 303-1315-01.

4. Use Special Service Tool: 303-1315.

5. NOTICE: Make sure that the surface is clean and free of foreign material.
Use Special Service Tool: 303-1315.

6. Use Special Service Tool: 303-1315.

7. Use Special Service Tool: 303-1315.

8. NOTICE: Make sure that the surface is clean and free of foreign material.
Use Special Service Tool: 303-1315.
9. Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls,
General Procedures).
Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel
Injection Pump
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1635
Remover/Installer, Fuel Injection Pump

303-1643
Locking Tool, Flywheel

Ford Diagnostic Equipment

Removal

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).
3.

4.
5. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
6.

7.
8.

9.
10.

11.
12. NOTICE:

Make sure that all openings are sealed with new blanking caps.

Extreme cleanliness must be exercised when handling the components.

NOTE: Use suitable paper to absorb any escaping fluid.

13. NOTICE: Only rotate the crankshaft clockwise.

14. Install Special Service Tool: 303-1643.

15.
16.
1. Install Special Service Tool: 303-1635.

2. NOTE: Discard the bolt.

17. Remove Special Service Tool: 303-1643.

18. Install Special Service Tool: 303-1635.
Torque:
7: 3 turn(s)

19.
20. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Only use moderate force.

Installation

1. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Use lint free cloth.

NOTE: Make sure that the threaded holes are clean and free of foreign matter.
NOTE: Make sure that the seal is correctly located.
NOTE: The component must be installed by hand before final tightening.

2. NOTICE: Only use moderate force.

Install Special Service Tool: 303-1635.

3. NOTE: Make sure that new bolts are installed.

Torque: 23 Nm
4. Remove Special Service Tool: 303-1635.

5. 1. NOTE: Make sure a new bolt is installed.

NOTE: Only tighten the bolt finger tight at this stage.
2. Remove Special Service Tool: 303-1635.
6. NOTE: Only tighten the bolts finger tight at this stage.
Torque:
1:
Stage 1:5 Nm
Stage 2:18 Nm
2:
Stage 1:5 Nm
Stage 2:10 Nm

7. Install Special Service Tool: 303-1643.

8. Torque:
Stage 1:25 Nm
Stage 2:75 Nm

9. Remove Special Service Tool: 303-1643.

10. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Only tighten the nuts finger tight.
Torque:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°

11. NOTE: Make sure that a new component is installed.

12. Torque: 23 Nm

13. Torque: 48 Nm
14. Torque: 10 Nm

15.
16.

17. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).

18. Torque:
1: 10 Nm
2: 10 Nm
19. Torque: 10 Nm

20. Torque: 10 Nm
21. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).

22. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).

23. Reset the High-Pressure Fuel System Learned Values.

Use the General Equipment: Ford Diagnostic Equipment

Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel
Injector Fuel Return Line
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
3.

4. Torque: 10 Nm
5.

6.
7. Torque: 10 Nm

RHD FWD
8.
All vehicles
9.

10. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
11.
12.

13. Torque: 10 Nm
14. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

15. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Make sure that new components are installed.
Torque:
1: 12 Nm
2: 12 Nm
1: 16 Nm
2: 16 Nm
1: 55°
2: 55°
16. Torque: 10 Nm

17. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.
Installation

1. To install, reverse the removal procedure.

Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel
Injectors
Print

Removal and Installation

General Equipment
Long Nose Pliers

Materials
Name Specification
Grease WSD-M1C227-A

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any
type when working on or near any fuel-related component. Highly flammable
mixtures may be present and may be ignited. Failure to follow these instructions
may result in serious personal injury.
Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
3.

4.
5.

6.
7.

RHD FWD
8.
All vehicles
9.

10. NOTICE:

Make sure that the area around the component is clean and free of foreign
material.

Make sure that the fuel line remains in contact at both ends until both unions
nuts have been unscrewed and the area around the joints thoroughly cleaned.

Make sure that all openings are sealed with new blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.
11.

12.
13. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

14. NOTE: Note the position of the components before removal.

NOTE: Discard the bolts.
Discard the clamps.

15. NOTE: Note the position of the components before removal.

16. Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls,
General Procedures).

Installation

1. NOTICE: To avoid corrosion, lubricate the injector bodies prior to installation.

Material: WSD-M1C227-A (Grease)

2. NOTE: Use a new seal.

NOTE: This step is only necessary if the original component is to be reused.
Use the General Equipment: Long Nose Pliers
3. NOTE: The O-ring seal is to be reused unless damaged.
Material: WSD-M1C227-A (Grease)

4. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Note the identification code of each new fuel injector to load into the
diagnostic tool.
Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls,
General Procedures).
5. NOTE: Make sure that new bolts are installed.
NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Only tighten the bolts finger tight at this stage.
Make sure that new clamps are installed.

6. NOTICE: Make sure that all openings are sealed with new blanking caps.
7. NOTE: The O-ring seal is to be reused unless damaged.
Apply a thin coating.

Material: WSD-M1C227-A (Grease)

8. Torque: 10 Nm
9. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Make sure that new components are installed.
NOTE: Only tighten the nuts finger tight at this stage.

10. NOTE: Make sure that new bolts are installed.

Make sure that new clamps are installed.

Torque:
Bolts
Stage 1:9 Nm
Stage 2:Loosen: 45°
Stage 3:6 Nm
Stage 4:180°
11. NOTICE: Make sure that all openings are sealed with new blanking caps.
Torque:
1: 12 Nm
2: 12 Nm
1: 16 Nm
2: 16 Nm
1: 55°
2: 55°

12.
RHD FWD
13.

All vehicles

14. Torque: 10 Nm
15.

16.
17. Torque: 10 Nm

18.
19. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
20. 1. 1. Fuel injector correction factors updated as required.
2. 2. Reset the fuel injector learned values for the engine cylinders containing new
fuel injectors.
3. 3. Clear the PCM DTCs.

21. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).
Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel
Rail
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
3.

4. Torque: 10 Nm
5.

6.
7. Torque: 10 Nm

RHD FWD
8.
All vehicles
9.

10. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
11.
12.

13. Torque: 10 Nm
14. NOTICE:

Make sure that the area around the component is clean and free of foreign
material.

Make sure that the fuel line remains in contact at both ends until both unions
nuts have been unscrewed and the area around the joints thoroughly cleaned.

Make sure that all openings are sealed with new blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.
NOTE: Make sure that a new component is installed.
Torque:
1: 12 Nm
2: 12 Nm
1: 16 Nm
2: 16 Nm
1: 55°
2: 55°
15. NOTICE: Make sure that all openings are sealed with new blanking caps.
NOTE: Make sure that new components are installed.
NOTE: Only tighten the nuts finger tight at this stage.

16. NOTICE: Make sure that all openings are sealed with new blanking caps.
Torque:
1: 12 Nm
2: 12 Nm
1: 16 Nm
2: 16 Nm
1: 55°
2: 55°
17.

18. Torque: 13 Nm
Installation

1. To install, reverse the removal procedure.

2. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).
Fuel Charging and Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Throttle Body
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

3.
4. Torque: 10 Nm

5. NOTE: The O-ring seal is to be reused unless damaged.

Installation

1. To install, reverse the removal procedure.

Fuel Charging and Controls - Turbocharger - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Turbocharger
Print

Diagnosis and Testing

Special Tool(s) / General Equipment
Hand Vacuum/Pressure Pump
416-D001 (23-036A)

Ford diagnostic equipment

Inspection and Verification

NOTE: The turbocharger uses engine oil as a lubricant and coolant. Due to the high operating
temperatures of the turbocharger and with the expansion and contraction of the internal components a
proportion of engine oil may enter the air intake system. This is not an indication that the turbocharger oil
seal has failed. The turbocharger oil seal will not fail unless the bearings fail first, which will cause the
turbocharger to become noisy. Do not install a new turbocharger due to oil inside the turbocharger or the
air intake components. If a leak is detected in the supply or return tubes or connections, locate and rectify
the source. Do not install a new turbocharger due to an oil leak.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Oil leak(s) • Wiring harness(es)
• Air cleaner element • Electrical connector(s)
• Air cleaner outlet pipe • Variable vane electric actuator
• Air cleaner intake pipe • PCM
• Turbocharger oil supply tube
• Turbocharger oil return tube
• Turbocharger housing
• Charge air cooler
• Charger air cooler intake pipe
• Charger air cooler outlet pipe

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

NOTICE: The variable vane electric actuator must not be transferred between the old and new
turbochargers. Failure to follow this instruction may result in incorrect calibration, exhaust emissions and
engine operation.

Symptom Possible Sources Action

Blue smoke with excessive * Turbocharger compressor * GO to Pinpoint Test A.
turbocharger noise rubbing on housing walls.
* Turbocharger turbine
rubbing on housing walls.
* Turbocharger bearings and
oil seal(s).
* Turbocharger oil supply tube
blocked or damaged.
Blue smoke without * Turbocharger oil return tube * GO to Pinpoint Test B.
excessive turbocharger blocked or damaged.
noise
Poor engine performance * Charge air cooler system. * CHECK the charge air cooler and charge air cooler
pipe(s) for leaks and obstructions. REPAIR as
necessary.
* Air cleaner intake pipe. * CHECK the air cleaner intake pipe for obstructions.
REPAIR as necessary.
* Variable vane electric * REFER to the Ford diagnostic equipment.
actuator.
Pinpoint Tests

PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
1 Disconnect the air cleaner
outlet pipe from the
turbocharger.

2 Inspect the turbocharger

rotor vanes for damage.

Is there visible damage to the

rotor vanes?
Yes
GO to A2.
No
GO to A3.
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
1 Check the intake air
system components for
signs of foreign material.
Are there any signs of foreign
material?
Yes
CLEAN the intake air
system components.
INSTALL a new
turbocharger.
REFER to: Turbocharger
(303-04C Fuel Charging
and Controls -
Turbocharger, Removal
and Installation).
TEST the system for
normal operation.
No
GO to A4.
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal.
NOTE: The initial rotor rotation of a cold turbocharger may feel rough and uneven but should rotate freely
after a few turns.
1
Make sure the
turbocharger rotor spins
freely within the housing.

• 1. With the
turbocharger stationary,
gently lift the shaft (the
shaft will naturally lay in
the bottom of the
bearings).

• 2. Make sure the rotor

spins freely within the
housing.
Does the rotor spin freely
within the housing?
Yes
GO to A4.
No
INSTALL a new
turbocharger.
REFER to: Turbocharger
(303-04C Fuel Charging
and Controls -
Turbocharger, Removal
and Installation).
TEST the system for
normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
1 Remove the turbocharger
oil supply tube.

2 Using workshop
compressed air and a
compressed air nozzle,
check the oil supply tube
for blockage.
Is the oil supply tube free
from blockage?
Yes
GO to A5.
No
INSTALL a new
turbocharger and
turbocharger oil supply
tube.
REFER to: Turbocharger
(303-04C Fuel Charging
and Controls -
Turbocharger, Removal
and Installation).
TEST the system for
normal operation.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
1 Visually inspect the oil
supply tube oil gallery in
the cylinder block for
blockage.
Is the oil supply tube oil
gallery free from blockage?
Yes
INSTALL a new
turbocharger and
turbocharger oil supply
tube.
REFER to: Turbocharger
(303-04C Fuel Charging
and Controls -
Turbocharger, Removal
and Installation).
TEST the system for
normal operation.
No
REMOVE the blockage.
INSTALL a new
turbocharger.
REFER to: Turbocharger
(303-04C Fuel Charging
and Controls -
Turbocharger, Removal
and Installation).
TEST the system for
normal operation.

PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE TURBOCHARGER OIL RETURN TUBE
1 Disconnect the turbocharger oil return tube from the turbocharger.

2 Remove the turbocharger oil return tube.

3 Check the turbocharger oil return tube for a blockage or signs of

damage.
Is the turbocharger oil return tube blocked?
Yes
GO to Fuel Charging and Controls for further blue smoke diagnostics.
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and
Controls, Diagnosis and Testing).
No
INSTALL a new turbocharger oil return tube. TEST the system for
normal operation.
Fuel Charging and Controls - Turbocharger - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN) - Turbocharger
Print

Removal and Installation

General Equipment
Snap Ring Pliers

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

3.
4.

5. Use the General Equipment: Snap Ring Pliers

7. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
8.
9.

10.
11. 1. Remove the component.
2. Loosen: 5 turn(s)

12. NOTE: Make sure that no components catch.

13.

14. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
15. NOTE: Make sure that no components catch.
16. NOTE: This step is only necessary when installing a new component.

17.
Installation

1. NOTE: Make sure a new component is installed.

Torque:
1: 20 Nm
2: 10 Nm

2. NOTE: This step is only necessary when installing a new component.

NOTE: Use a new seal.
Torque: 10 Nm
3. NOTE: Use a new seal.

4. NOTE: Use a new seal.

5. NOTE: Make sure that new nuts are installed.
1. NOTE: Only tighten the nuts finger tight at this stage.
2. Torque: 23 Nm

3. Torque: 23 Nm

6. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

7. Torque:
1: 10 Nm
2: 10 Nm
3: 10 Nm
8.

9. Torque:
1: 25 Nm
2: 25 Nm
10. Torque: 15 Nm

11.
12. Torque:
1: 15 Nm
2: 15 Nm
3: 10 Nm

13. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

14. Torque:
1: 10 Nm
2: 10 Nm
15. NOTE: Use a new seal.

16. Use the General Equipment: Snap Ring Pliers

17. Torque: 25 Nm

18.
19.

20. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
Accessory Drive - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Accessory Drive
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Damaged or contaminated accessory drive belt
• Damaged or contaminated pulley(s)
• Incorrect accessory drive belt
• Incorrect installation of the accessory drive belt
• Accessory drive belt tensioner
• Accessory drive belt idler pulley
• Generator
• Power steering pump
• Power steering pump leakage
• Air conditioning (A/C) compressor
• Pulley(s)
• Loose hardware

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

Accessory Drive Belt Concerns

NOTICE: Do not lubricate the accessory drive belt, accessory drive belt tensioner or
idler pulley(s) as potential damage to the accessory drive belt material construction,
accessory drive belt tensioner damping mechanism, accessory drive belt tensioner pulley
bearing and idler pulley(s) bearing may occur.
Cracking
Accessory drive belts are made from rubber which hardens with time and can develop
cracks. As the accessory drive belt runs on the back of some of the pulleys, the cracks are
opened up. Small cracks are not considered to be a failure of the accessory drive belt. Only
if the crack is deep enough to reach the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory drive belt, is the accessory drive belt
condition considered to be unacceptable.

1. Check the accessory drive belt for cracks. If the damage exceeds the acceptable limit,
install a new accessory drive belt. REFER to: Accessory Drive Belt (303-05A
Accessory Drive, Removal and Installation).

Chunking
Chunking describes the condition where long lengths of rubber become detached from the
ribs of the accessory drive belt. This is considered to be a failure of the accessory drive belt.
2.
Check the accessory drive belt for damage. If any chunks are found to be missing,
install a new accessory drive belt. REFER to: Accessory Drive Belt (303-05A
Accessory Drive, Removal and Installation).

Pilling
Pilling is dust that forms in between the ribs of the accessory drive belt from rubber that is
worn off the accessory drive belt when it is new. There may also be loose particles left on
the accessory drive belt during the manufacturing process. These are worn off and form
into small balls of rubber that then get trapped in the grooves of the accessory drive belt.
This condition will usually clear itself within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.

3.
Check the accessory drive belt for pilling. The condition of the accessory drive belt
should be compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent. REFER to: Accessory Drive Belt (303-05A
Accessory Drive, Removal and Installation).
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent. REFER to: Accessory Drive Belt (303-05A
Accessory Drive, Removal and Installation).
5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt. REFER to: Accessory Drive Belt (303-05A Accessory Drive,
Removal and Installation).
6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt. REFER to: Accessory Drive Belt (303-05A Accessory Drive,
Removal and Installation).

Incorrect installation
Accessory drive belt noise can be generated by the accessory drive belt being incorrectly
fitted on the pulley as shown in the following illustration. Make sure that all the V grooves
on the accessory drive belt contact correctly with the pulley.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Accessory drive belt * Accessory drive * CHECK the system with the engine running and
noise system. the accessory drive belt removed (only run the
engine for a very short period). If a noise is
apparent, the cause is not the accessory drive
system. If a noise is not apparent, the cause is
the accessory drive system. CHECK where the
noise is coming from. Use a stethoscope or
other listening device to determine the source
of the noise. INSTALL new components as
necessary. TEST the system for normal
operation.
* Accessory drive * CHECK the accessory drive belt is correctly
belt incorrectly installed in the pulley grooves. INSTALL a new
installed. accessory drive belt as necessary. REFER to:
Accessory Drive Belt (303-05A Accessory Drive,
Removal and Installation). TEST the system for
normal operation.
* Pulley(s). * CHECK the pulley(s) for damage, freedom of
rotation, stone entrapment and alignment.
INSTALL new components as necessary. TEST
the system for normal operation.
* Lubricant or other * CHECK the accessory drive belt for
contamination. contamination or damage. RECTIFY the source
of the leak and INSTALL a new accessory drive
belt. REFER to: Accessory Drive Belt (303-05A
Accessory Drive, Removal and Installation).
TEST the system for normal operation.
NOTE: Squeal is * Accessory drive * CHECK the accessory drive belt tensioner for
defined as a belt tensioner correct operation, damage or contamination.
continuous shriek, worn, damaged or REFER to the Accessory Drive Belt Tensioner
most noticeable contaminated with Component Test in this procedure. INSTALL a
when the engine is oil. new accessory drive belt tensioner as
being accelerated necessary. TEST the system for normal
or with electrical operation.
load.
Accessory drive belt
squeal
NOTE: Whine is * Poor surface finish * REMOVE the accessory drive belt. REFER to:
defined as a on accessory drive Accessory Drive Belt (303-05A Accessory Drive,
continuous noise at belt idler pulley Removal and Installation). INSPECT the idler
the same flat surface(s). pulley(s) for surface finish. INSTALL a new idler
frequency, pulley(s) as necessary. TEST the system for
generally associated normal operation.
with plastic pulleys. * Accessory drive * REMOVE the accessory drive belt. REFER to:
Accessory drive belt belt idler pulley Accessory Drive Belt (303-05A Accessory Drive,
whine bearing failure. Removal and Installation). INSPECT the idler
pulley(s) for smooth rotation. INSTALL a new
idler pulley(s) as necessary. TEST the system
for normal operation.
NOTE: Chirp is * Pulley * CHECK that the accessory drive belt is running
defined as a misalignment centrally on the flat pulleys. TEST the system
twittering noise, (usually evident at for normal operation.
often intermittent idle). * CHECK the pulleys for excessive end float and
Accessory drive belt bent flanges.
chirp * With the engine running at idle, use a
stethoscope to identify the source of the noise.
INSTALL new components as necessary. TEST
the system for normal operation.
NOTE: Rattle is * Accessory drive * CHECK the accessory drive belt tensioner for
defined as a belt tensioner correct operation or damage. REFER to the
metallic knocking hitting the end Accessory Drive Belt Tensioner Component Test
noise stops. in this procedure. INSTALL a new accessory
Accessory drive belt drive belt tensioner as necessary. TEST the
rattle system for normal operation.
* Loose components * CHECK the components or hardware for correct
or hardware. installation and tighten as necessary. TEST the
system for normal operation.
Accessory drive belt * Accessory drive * CHECK the extent of the fraying by referring to
fraying belt. the illustrations shown in the Visual Inspection
* Pulley(s). section. Only INSTALL a new accessory drive
belt if the fraying is within the criteria quoted in
the Visual Inspection section. TEST the system
for normal operation.
* CHECK the pulley(s) for damage, freedom of
rotation and alignment. INSTALL new
components as necessary. TEST the system for
normal operation.

Component Tests
Accessory Drive Belt Tensioner - Static Check

The accessory drive belt tensioner may be checked statically as follows:

1. Inspect the area surrounding the accessory drive belt tensioner for lubricant or other
contamination. Rectify any leaks before installing a new accessory drive belt
tensioner. If the accessory drive belt tensioner is contaminated, do not attempt to
clean it as the damping mechanism inside may be damaged. INSTALL a new
accessory drive belt tensioner as necessary. TEST the system for normal operation.

2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.

3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a
friction device, therefore some friction within the system is normal.
Using the correct tool, move the accessory drive belt tensioner from its relaxed
position through its full stroke and back to the relaxed position to make sure there
is no excessive stick, grab or bind, and to make sure there is tension on the
accessory drive belt tensioner spring.

4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of
rotation and alignment. INSTALL a new accessory drive belt tensioner as necessary.
TEST the system for normal operation.

5. If the accessory drive belt tensioner meets the above criteria, proceed to test the
accessory drive belt tensioner dynamically. If the accessory drive belt tensioner
does not meet the above criteria, INSTALL a new accessory drive belt tensioner.
TEST the system for normal operation.

Accessory Drive Belt Tensioner - Dynamic Check

The accessory drive belt tensioner may be checked dynamically as follows:

1. With the engine running, observe the accessory drive belt tensioner movement. The
accessory drive belt tensioner should move (respond) when the engine is
accelerated rapidly or when the A/C clutch cycles ON and OFF (the degree of
movement can be up to 4 mm). If the accessory drive belt tensioner movement is
not constant without engine acceleration or A/C clutch cycling, a pulley or shaft is
possibly bent, out of round, or the damping mechanism inside the accessory drive
belt tensioner may be damaged. INSTALL a new accessory drive belt tensioner as
necessary. TEST the system for normal operation.

2.
Excessive accessory drive belt rideout (uneven depth of grooves in the accessory
drive belt) may cause excessive accessory drive belt tensioner movement. Check
the condition by installing a new accessory drive belt. REFER to: Accessory Drive
Belt (303-05A Accessory Drive, Removal and Installation). TEST the system for
normal operation.
Accessory Drive - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Accessory
Drive Belt
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1596
Installer, Stretchy Belt

6 mm Drill Bit

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque: 10 Nm

3. Torque:
1: 10 Nm
2: 10 Nm
3: 9 Nm
4.

5. Use the General Equipment: 6 mm Drill Bit

Installation

1. To install, reverse the removal procedure.

2. Use Suggested Tool: 303-1596. Tool shown or a commercially available equivalent can
be used.

3.
Accessory Drive - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Coolant Pump
Belt
Print

Removal and Installation

Special Tool(s)
303-1596
Installer, Stretchy Belt

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque: 10 Nm

3. Torque:
1: 10 Nm
2: 10 Nm
3: 9 Nm
4.

Installation

1. To install, reverse the removal procedure.

2. Use Suggested Tool: 303-1596. Tool shown or a commercially available equivalent can
be used.
3.
Starting System - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Starting System
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
For Starting System, refer to Wiring Diagram Section 020-1 for schematic and connector
information.
For Auto-Start-Stop System, refer to Wiring Diagram Section 040-1 for schematic and
connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION CHART

Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay(s)
• Switch(es)
• Battery
• Starter motor
• Start control unit
• Battery junction box (BJB)
• Auxiliary junction box (AJB)
• Body Control Module (BCM)
• Powertrain Control Module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment.
Starting System - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Starter Motor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
3.

4. Torque:
1: 12 Nm
2: 8 Nm
5. Torque: 35 Nm

Installation

1. To install, reverse the removal procedure.

Glow Plug System - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Glow Plug System
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION CHART

Electrical
• Fuse(s)
• Relay
• Wiring harness
• Electrical connector(s)
• Glow plug(s)
• Glow plug wire
• Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Glow Plug System - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Glow Plugs
Print

Removal and Installation

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

2. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)

(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
3.

4.
5. Torque: 13 Nm

Installation

1. To install, reverse the removal procedure.

Engine Emission Control - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Specifications
Print

CAPACITIES

LITERS

Diesel exhaust fluid (AdBlue) fill capacity. 21

SPECIFICATION

Diesel exhaust fluid (AdBlue) Material: WSS-M99C130-A (Diesel Exhaust Fluid)

Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Engine Emission Control—Vehicles Without: Selective Catalytic
Reduction System - Component Location
Print

Description and Operation

Crankcase Ventilation System

Item Description
1 Crankcase ventilation hose
2 Oil separator box
3 Pressure control valve
4 Drain tube
Exhaust Gas Recirculation (EGR) System
Item Description
1 EGR (exhaust gas recirculation) valve
2 Coolant outlet
3 Cooled exhaust gas to intake manifold
4 EGR cooler
5 Hot exhaust gas to the EGR assembly
6 EGR cooler bypass vacuum actuator
7 Coolant inlet
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Engine Emission Control—Vehicles Without: Selective Catalytic
Reduction System - Overview
Print

Description and Operation

Crankcase Ventilation System

Item Description
1 Oil separator
NOTE: Do not permanently remove or render inoperative any part of the vehicle emission
control system including related hardware.
The crankcase ventilation system cycles crankcase gases back through the intake air
system and into the combustion chamber where they are burned. The system regulates the
amount of ventilated air and blow-by gases to the intake manifold. An oil separator is used
to separate the oil from the blow-by gases, preventing them from entering the intake air
system.
The oil separator on the Panther engine is directly mounted on top of the camshaft module
using four bolts and consists of an impactor plate with fleece.
One side of the crankcase ventilation hose is fixed to the spigot on the oil separator and
other is connected to the clean air duct.
The oil captured by the oil separator flows down an isolated drain channel though the
cylinder head, block and ladder frame to the engine sump.
Exhaust Gas Recirculation (EGR) System
Item Description
1 Inlet housing
2 Electric EGR (exhaust gas recirculation) valve
3 Cylinder head integrated EGR exhaust tube
4 Exhaust manifold
5 Cylinder head coolant tube (to EGR cooler)
6 Cylinder head
7 Cylinder head integrated EGR exhaust tube
8 Pneumatic EGR cooler bypass actuator
9 EGR assembly
10 EGR cooler
11 EGR cooler coolant pipe
The EGR system is used to control Nitrogen Oxides (NOx) emissions from the exhaust
system. Small amounts of exhaust gas are recirculated back into the combustion chamber
to mix with the air and fuel charge. This causes the combustion chamber temperature to
reduced, lowering NOx emissions.
The panther engine uses a duct integrated into the cylinder head to deliver the exhaust
from the exhaust manifold to the EGR assembly.
An electric EGR valve is used to control the amount of exhaust entering the intake system.
This system also incorporates an EGR cooler, which is used to cool the exhaust gases by
transferring heat from the exhaust to the engine coolant. Cooling the exhaust gases further
aids in the NOx reduction process.
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Engine Emission Control—Vehicles Without: Selective Catalytic
Reduction System - System Operation and Component Description
Print

Description and Operation

System Operation
Exhaust Gas Recirculation (EGR) System Operation

Item Description
1 Air cleaner line to the clean side of the air cleaner
2 Brake booster
3 Vacuum pump
4 PCM (powertrain control module)
5 EGR cooler bypass valve
6 EGR valve
7 EGR cooler bypass actuator
8 EGR cooler
9 Intake manifold flap
The exhaust gas is extracted directly at the exhaust manifold and routed through the
cylinder head runner to the EGR assembly.
The EGR assembly consists of a double-plate EGR valve, an EGR cooler for cooling the
exhaust gases and an EGR cooler bypass vacuum actuator.
A DC motor with a non-contacting position transmitter serves as the drive for the EGR
valve. The voltage signal range of the EGR valve is between 0.5 volts (valve closed) and
4.5 volts (valve fully open). The valve position and the drive are controlled using a PWM
(pulse width modulation) signal. A 10% PWM signal is required to close the EGR valve.
The EGR flow rate is adapted to specific engine operating states by the PCM (powertrain
control module) varying the EGR valve PWM signal duty cycle. A position sensor in the EGR
valve provides feedback on the exact valve positioning. This means that the PCM is able to
learn and adapt to cater for valve position changes caused by soot deposits.
The EGR cooler bypass valve (electro-pneumatic solenoid valve) enables or disables
vacuum to the EGR cooler bypass actuator (pneumatic actuator) which opens or closes to
enable or disable exhaust flow through the EGR cooler depending on the EGR requirement.
The EGR cooler bypass valve is actuated by the PCM using a PWM (pulse width modulation)
signal.
In unactuated condition, the EGR cooler bypass valve supplies ambient (no vacuum) air to
the EGR cooler bypass actuator. In this state the EGR cooler bypass actuator arm is
extended and the exhaust flow is directed through the center (bypass) passage of the EGR
cooler (no cooling).
During cold starting the recirculated exhaust gas is routed past the EGR cooler via the
bypass. As a result, the engine and catalytic converter reach their operating temperature
faster.
As soon as the engine cooling temperature reaches 50 °C or the engine speed exceeds
1750 rpm, the EGR cooler bypass valve is actuated and the system switches to cooling
mode.
In cooling mode the EGR cooler bypass valve supplies vacuum (approximately 500 mbar) to
the EGR cooler bypass actuator which opens the bypass valve against the spring load.
There is an electronic intake manifold flap upstream of the intake manifold on the fresh-air
side. It generates the necessary pressure difference between the exhaust gas and intake
sides in order to achieve the high exhaust gas recirculation rates.
The intake manifold flap (throttle body) is actuated by a DC (direct current) motor and
controlled via PWM by the PCM.
Depending on the driving situation, the volume air flow drawn in is varied in accordance
with the position of the intake manifold valve and thereby influences the composition of the
recirculated exhaust gas. Its other function is to ensure the engine does not run on when it
has been switched off.
Engine Emission Control - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Engine Emission
Control
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Exhaust gas recirculation (EGR) valve • Fuse(s)
• EGR valve outlet tube • Wiring harness
• EGR cooler • Electrical connector(s)
• Gaskets/seals • Relay(s)
• Hose(s)/hose joints • Sensor(s)
• Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Exhaust Gas Recirculation (EGR) Cooler
Print

Removal and Installation

Materials
Name Specification
Grease - High Temperature WSS-M1C273-A

Removal

1.
Release the cooling system pressure by slowly turning the coolant expansion tank cap
between 2 and 3 turns.

Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

3. Torque: 10 Nm
4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
5. If equipped.

6. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

7. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling, Removal and
Installation).
8.

9.
10. NOTE: Be prepared to collect escaping fluid.

11. NOTE: Be prepared to collect escaping fluid.

Torque: 10 Nm
12. NOTE: Be prepared to collect escaping fluid.

13. NOTE: Discard the bolts.

14.

15.
16. NOTE: Discard the bolts.
NOTE: Use new seals.

Installation

1. NOTE: Make sure that the mating faces are clean and free of foreign material.
2. NOTICE: The bolts must not be reused more than 1 time.
NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Use a new seal.

3. NOTICE:

Make sure that no components catch.

The bolts must not be reused more than 1 time.

NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Only tighten the bolts finger tight at this stage.
4. Torque:
1-7: 4 Nm
1-6: 10 Nm
1-6: 10 Nm
7 10 Nm

5.
6. Refer to: Exhaust Gas Recirculation (EGR) Outlet Tube (303-08A Engine Emission
Control, Removal and Installation).
7.

8. NOTE: Use a new seal.

Apply a thin coating.

Material: WSS-M1C273-A (Grease - High Temperature)

9. Torque: 10 Nm

10.
11.

12. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling, Removal and
Installation).

13. If equipped.

Torque: 10 Nm
14. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

15. Torque: 10 Nm

16. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

17. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Exhaust Gas Recirculation (EGR) Valve
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08A Engine Emission Control,
Removal and Installation).
2.

Installation

1. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1:4 Nm
Stage 2:9 Nm
Stage 3:10 Nm
2. Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08A Engine Emission Control,
Removal and Installation).
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Exhaust Gas Recirculation (EGR) Outlet Tube
Print

Removal and Installation

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

Installation

1. Loosen: 3 turn(s)
2. NOTE: Make sure that a new O-ring seal is installed.
NOTE: Use a new seal.

3. NOTE: Make sure that new bolts are installed.

NOTE: Only tighten the bolts finger tight at this stage.
4. Torque:
1: 10 Nm
2: 10 Nm
3: 10 Nm
1: 23 Nm
2: 23 Nm
3: 23 Nm
4: 10 Nm
5: 10 Nm
4: 10 Nm
6: 10 Nm
7: 10 Nm
6: 10 Nm
5. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Reductant Injector
Print

Removal and Installation

General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

3. Torque:
1: 30 Nm
2: 48 Nm
4. Torque: 48 Nm

5. Torque:
1: 10 Nm
2: 15 Nm
6.

7. NOTE: Be prepared to collect escaping fluid.

Use the General Equipments: Hose Clamp Remover/Installer, Hose Clamp(s)
Torque: 15 Nm
8. Torque: 9 Nm

Installation

1. To install, reverse the removal procedure.

Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Reductant Pressure Line
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque:
1: 15 Nm
2: 15 Nm
3: 10 Nm

3.
4. NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

5.
6. NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

Installation

1. To install, reverse the removal procedure.

Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Reductant Pump
Print

Removal and Installation

General Equipment
Fuel Tank Draining Equipment

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Use the General Equipment: Fuel Tank Draining Equipment

3.
4. NOTICE:

Make sure to follow the instruction in the video.

Take extra care not to damage the component.

5. NOTE: Be prepared to collect escaping fluid.

Installation

1. To install, reverse the removal procedure.

Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Reductant Tank
Print

Removal and Installation

General Equipment
Fuel Tank Draining Equipment
Transmission Jack

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Use the General Equipment: Fuel Tank Draining Equipment

3.
4.

5.
6. NOTE: Be prepared to collect escaping fluid.
Torque: 35 Nm

7. NOTICE: Make sure that no strain is placed on the fuel lines and wiring
harnesses.
Use the General Equipment: Transmission Jack
8.

9.
Installation

1. To install, reverse the removal procedure.

Engine Emission Control - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Reductant Tank Filler Hose
Print

Removal and Installation

General Equipment
Hose Clamp(s)

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2.

3. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
Use the General Equipment: Hose Clamp(s)
4.

Installation

1. To install, reverse the removal procedure.

Intake Air Distribution and Filtering - 2.0L
EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Intake Air
Distribution and Filtering
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Air cleaner element • Fuse(s)
• Air cleaner intake hose • Relay(s)
• Air cleaner outlet hose • Wiring harness
• Charge air cooler (CAC) • Electrical connector(s)
• Charge air cooler (CAC) intake hose • Mass air flow and temperature (MAFT)
• Charge air cooler (CAC) outlet hose sensor
• Intake air temperature (IAT) sensor

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Excessive * Detached air cleaner * CHECK the hose(s) for security and leaks to
intake air hose(s). atmosphere. INSTALL new intake air components as
noise * Detached turbocharger necessary. TEST the system for normal operation.
hose(s).
* Detached charge air
cooler hose(s).
Oil in the air * Blocked or damaged *
intake positive crankcase REFER to: Engine Emission Control (303-08A
system ventilation (PCV) valve. Engine Emission Control, Diagnosis and Testing).
* Blocked or damaged
PCV pipe(s)/hose(s).
* Blocked or damaged
crankcase vent oil
separator.
* Turbocharger. *
REFER to: Turbocharger (303-04C Fuel Charging
and Controls - Turbocharger, Diagnosis and
Testing).
Water in the * Air intake pipe splash * CHECK the air intake pipe splash shield for correct
air cleaner shield. installation and alignment. REPAIR/INSTALL the air
intake pipe splash shield as necessary. TEST the
system for normal operation.
* Blocked air cleaner * CHECK the air cleaner drain for blockage. TEST the
drain. system for normal operation.
* *
Engine lacks Air cleaner element INSPECT the air cleaner for signs of blockage.
power blocked. INSTALL a new air cleaner element as necessary.
* CAC pipe(s). * INSPECT the CAC pipes for damage. INSTALL a new
CAC pipe(s) as necessary.
* CAC blocked. * INSPECT the CAC for blockage. INSTALL a new
charge air cooler as necessary.
REFER to: Charge Air Cooler (CAC) (303-12A Intake
Air Distribution and Filtering, Removal and
Installation).
* Fuel charging and *
controls REFER to: Fuel Charging and Controls (303-04A
Fuel Charging and Controls, Diagnosis and Testing).
* Turbocharger. *
REFER to: Turbocharger (303-04C Fuel Charging
and Controls - Turbocharger, Diagnosis and
Testing).
Intake Air Distribution and Filtering - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN) - Air Cleaner
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque: 8 Nm

3.
4.

5.
Installation

1. To install, reverse the removal procedure.

Intake Air Distribution and Filtering - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN) - Charge Air Cooler (CAC)
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque:
10 Nm
10 Nm

2. Torque: 10 Nm

3. Torque: 8 Nm
Installation

1. To install, reverse the removal procedure.

Electronic Engine Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Electronic Engine Controls - Component Location
Print

Description and Operation

Item Description
1 CMP (camshaft position) sensor
2 Fuel pressure and fuel temperature sensor (low pressure system)
3 CHT (cylinder head temperature) sensor
4 CKP (crankshaft position) sensor
5 Oil level sensor
6 EOP (engine oil pressure) sensor
7 ECT (engine coolant temperature) sensor
8 MAPT (manifold absolute pressure and temperature) sensor
9 MAF (mass air flow) sensor
Electronic Engine Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Electronic Engine Controls - System Operation and Component
Description
Print

Description and Operation

System Operation
Electronic Engine Controls

Item Description
1 MAPT (manifold absolute pressure and temperature) sensor
2 Exhaust Gas Temperature (EGT) sensors x3
3 MAF (mass air flow) sensor
4 Low-pressure and fuel temperature sensor
5 Position sensor, turbocharger guide vanes (variable turbocharger)
6 CHT (cylinder head temperature) sensor
7 CMP (camshaft position) sensor
8 CKP (crankshaft position) sensor
9 EGR cooler bypass valve
10 CPP (clutch pedal position) sensor
11 BPP (brake pedal position) sensor
12 Stoplamp switch
13 EOP (engine oil pressure) sensor
14 Oil level sensor
15 FRP (fuel rail pressure) sensor
16 Battery
17 Ignition lock
18 Start inhibit relay
19 APP (accelerator pedal position) sensor
20 Generator
21 Water-in-fuel sensor/fuel filter pressure switch
22 Relative pressure sensor
23 Oxygen sensor (for passenger cars only)
24 Thermostat heating element
25 Electric EGR (exhaust gas recirculation) valve with integrated position sensor
26 Electric intake manifold valve
27 PCM
28 NOx sensor
29 Fuel injectors
30 Pressure control valve (fuel rail)
31 Glow plug control module
32 Digital Inlet Valve (DIV)
33 Cooling fan control and A/C compressor
34 PCM relay
Electronic Engine Controls - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Electronic Engine
Controls
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Principles of Operation
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the powertrain control module (PCM). This
system continuously monitors vehicle emission components. The system includes a
malfunction indicator lamp (MIL) which indicates when there is a concern that can affect
emissions or the system malfunctions. Data stored within the module DTC memory can be
accessed using a generic scan tool or WDS.
EOBD is mandated within European Union regulations from the year 2000 for passenger
vehicles with petrol engines and from 2003 onwards for passenger vehicles with diesel
engines.

EOBD Functions:
• Establishes when and how emissions control faults must be indicated.
• Actuates emission control malfunction indicator lamp (MIL) and fault memory.
• Indicates operating conditions in which the concern occurred (freeze frame data).
• Standardized output of operating data such as engine speed, engine coolant temperature
etc.
• Standardized names and abbreviations for components and systems.
• Standardized DTCs for all manufacturers.
• Standardized communication with the diagnostic equipment.
• Standardized 16-pin data link connector (DLC) in area of the instrument panel.
• Concern display must be possible using a generic scan tool.

EOBD consists of the following elements:

Warm-up Cycle
The warm-up cycle is an operation that consists of key on, engine start and a coolant
temperature increase of 22°C, exceeding 71°C on completion.
Drive Cycle
A drive cycle commences when the engine is started (cold or warm) and ends when the
engine is switched off.
Trip
A trip begins when the engine is started and is complete when all the EOBD monitors have
completed a self-test. This may take place over a number of drive cycles. On diesel
variants, the information gathered from one drive cycle is not carried over to a subsequent
cycle or cycles.
When a concern has been rectified, particularly after electronic engine control components
have been changed, the DTC memory, which is part of the EEPROM must be cleared of all
trouble codes. When the DTC memory has been cleared, the code P1000 (known as the
readiness code) is set in the PCM memory, which indicates that since the EEPROM has been
cleared, not all of the monitoring systems have completed their tests. P1000 can only be
cleared by carrying out a trip, which includes driving the vehicle under variable conditions
of speed, load and time so that all of the monitors are completed. As P1000 will not
illuminate the MIL it is not necessary to carry out the trip before returning the vehicle to the
customer.
Freeze Frame Data
When a concern is detected, various data is stored depending on application including:

• Diagnostic trouble code.

• Vehicle speed.
• Engine coolant temperature.
• Engine speed.
• Engine load.
• Mixture formation trim value (trim value for engine wear) (All except vehicles with diesel
engine).
• State of oxygen sensor control (open and closed loop) (All except vehicles with diesel
engine).
• Distance covered since the concern was first registered.

Monitors
The purpose of the monitors is to continuously check the operation of the emission related
sensors and actuators. It then establishes if they are operating within specified tolerances.
All monitors carry out their functions in such a way as to be unnoticeable by the driver of
the vehicle. Each one is carried out under specific conditions of load, speed and engine
temperature. The Comprehensive Component Monitor, Combustion Misfire Monitor and
Air/Fuel Ratio Monitor operate continuously. The remaining monitors are only invoked under
certain operating conditions. On diesel variants, all of the monitors operate under normal
driving conditions: There are no monitors which intervene and cause special operating
modes to enable the monitors to work. Some diesel monitors are non-continuous. This
means that in a drive cycle, monitoring is done as and when suitable driving conditions
exist and potential faults are accumulated and compared with acceptance criteria. Examples
of this type are the turbocharger boost pressure and exhaust gas recirculation (EGR)
monitors on vehicles with common rail fuel injection.
Comprehensive Component Monitor (CCM)
When the CCM detects a component operating out of tolerance, it sets a Diagnostic Trouble
Code (DTC), which is stored in the EEPROM. If the same concern is confirmed during the
next trip the MIL will be switched on. The CCM monitors many components, sub-systems
and signals. The following is a list of those that can effect emissions depending on
application:

• Electronic Ignition (EI) System.

• Crankshaft Position (CKP) Sensor.
• Ignition Coil.
• Electronic Throttle Control Unit.
• Camshaft Position (CMP) Sensor.
• Air Conditioning (A/C) Clutch.
• Idle Air Control (IAC) Valve.
• Mass Air Flow (MAF) Sensor.
• Manifold Absolute Pressure (MAP) Sensor.
• Intake Air Temperature (IAT) Sensor.
• Engine Coolant Temperature (ECT) Sensor.
• Cylinder Head Temperature (CHT) Sensor.
• Heated Oxygen Sensor (HO2S).
• Catalyst Monitor Sensor.
• Charge Air Temperature Sensor.
• Knock Sensor (KS).
• Throttle Position (TP) Sensor.
• Vehicle Speed Sensor (VSS).
• Boost Pressure Sensor.
• Cam-Crank Phasing Sensor.
• EEPROM.
• High Pressure Fuel Injection Pump.
• Exhaust Gas Recirculation (EGR) Valve Monitor.
• Fuel Injectors.
• Turbocharger.
• Combustion Noise Monitor.
• Barometric Pressure (BARO) Sensor.

Combustion Misfire Monitor (All except vehicles with diesel engine)

The combustion misfire monitor operates independently of the others, and can detect
misfires caused by the ignition system, fuel system or mechanical engine components. As
each cylinder fires, a characteristic crankshaft acceleration is produced. The monitor detects
irregularities in the acceleration pattern using the crankshaft position (CKP) sensor, thus
detecting the misfire. It can also detect which cylinder has misfired. Combustion misfires
can be categorized as follows:
Type A: These can cause catalytic converter damage due to excessive internal
temperatures. If a certain number of misfires occur over a pre-determined number of
engine revolutions, the MIL will be switched on to alert the driver of the concern.
Type B: These can lead to an increase in emissions to a point above the EOBD threshold. If
the misfire is detected during a second trip, over a pre-determined number of engine
revolutions, the MIL will be switched on. If the misfire does not occur over the next three
trips, the MIL will be extinguished
Air/Fuel Ratio (AFR) Monitor (All except vehicles with diesel engine)
The HO2S fitted before the catalytic converter (upstream) measures the oxygen content of
the exhaust gas and the variations in it. This then enables the PCM to adjust the opening
times of the fuel injectors to maintain the correct AFR. This is known as Short Term Fuel
Trim (STFT). If the same variation is registered a pre-determined number of times, a
permanent correction factor is applied. This is known as Long Term Fuel Trim (LTFT), which
is stored in the EEPROM. When the correction factors exceed pre-determined limits a DTC
will be set in the EEPROM. If a concern is detected in either the STFT or LTFT, and it is still
present on a second trip, the MIL will be switched on.
Heated Oxygen Sensor (HO2S) Monitor (All except vehicles with diesel engine)
This monitors the operation of the pre (upstream) and post (downstream) catalytic
converter HO2S sensors. It will detect deviations in air/fuel ratios (AFR) and sensor faults.
The HO2S will cause emission increase when its response time increases too much. To
diagnose a sensor a period is measured and the number of lean/rich transitions are
counted. The sum of valid periods is then calculated. To avoid non-representative
measurements, the period is valid only if the HO2S has been below a low threshold and
above a high threshold between 2 consecutive lean/rich transitions. A failure is declared
when the sum of the measured periods exceeds the sum of the corresponding limit (held
within the PCM) and the MIL is illuminated.
Catalytic Converter Efficiency Monitor (All except vehicles with diesel engine)
The efficiency of a catalytic converter is measured by its ability to store and later release
oxygen to convert harmful gases. The efficiency is reduced if the converter becomes
contaminated as it ages, and at high gas flow rates, because the exhaust gas does not
remain in the converter long enough to complete the conversion process.
This monitor checks for the oxygen storage capacity (OSC) of the catalytic converter.
During a controlled period, the catalyst monitor sensor signal is analyzed to evaluate the
OSC of the catalyst. It represents the quantity of oxygen that is really used for the
oxidation-reduction reaction by the catalytic converter If a fault has occurred with the
catalyst monitor sensor during the catalyst diagnosis, a sensor diagnosis is carried out.
During the controlled diagnosis phase, the catalyst monitor sensor activity is measured and
is compared to the OSC of the catalyst. If this activity is high (low OSC) the MIL will be
illuminated. If throughout the controlled phase, repeated several times, the downstream
sensor output has not moved, the closed loop mode is delayed in order to test the sensor.
If the catalyst monitor sensor is set to rich, the injection time is forced to lean and
conversely if the downstream sensor is set to lean, the injection time is forced to rich until
the sensor switches over or until the end of a delay. If this delay expires or the sensor does
not switch, the sensor is treated as failed.
Combustion Noise Monitor (Vehicles with common rail fuel injection)
In diesel variants, the Combustion Noise Monitor is used to trim the fuel injection pulse
lengths. Each fuel injector has an associated set of correction data that is determined
during a production end of line test. The Combustion Noise Monitor is used to determine
how the fuel injector characteristic changes from this initial calibration over the life of the
fuel injector.
EGR Monitor (Vehicles with diesel engine)
The functionality of the EGR system is checked by comparing either the MAP sensor output
or EGR valve lift potentiometer output (depending upon application) with expected values.
Diagnostic Requirements
Vehicles equipped with EOBD, can be diagnosed using the WDS. In order for the EOBD
system to be invoked, a number of criteria must be met. After any repair, which could
affect emissions, a trip must be carried out on the vehicle, to make sure that engine
management system operates correctly.
Malfunction Indicator Lamp (MIL)
The MIL is located in the instrument cluster and is fitted to alert the driver to the fact that
an abnormal condition has developed in the engine management system, that is having an
adverse effect on emissions. In cases of misfires which are likely to cause catalytic
converter damage, it is switched on immediately. With all other faults it will illuminate
continuously from the second trip after the condition occurred. Under normal operation it
should illuminate at key-on and go out almost as soon as the engine is started.
Diagnostic Trouble Codes (DTCs)
The DTCs given by the PCM are standardized, which means that generic scan tools can read
results from all vehicles.

• The DTC is always a 5 digit alphanumerical code, for example ”P0100".

• The first digit of a code (letter) identifies the system which has set the code. Provision
has been made for a total of four systems to be identified although only the 'P' code is
required for EOBD.
- 'B' for the body
- 'C' for the chassis
- 'P' for the powertrain
- 'U' for the network communications systems
• All of the ”x0xxx" codes are standardized codes. However, any manufacturer can use
additional codes over and above the standardized codes. These will be labelled ”x1xxx"
• The third digit of a code (numeric) identifies the sub-system which has set the code.
- 'Px1xx' for metering of fuel and air supply
- 'Px2xx' for metering of fuel and air supply
- 'Px3xx' for ignition system – combustion misfires
- 'Px4xx' for auxiliary emission control equipment
- 'Px5xx' for vehicle speed, idle setting and other related inputs
- 'Px6xx' for trip computer and other related outputs
- 'Px7xx' for transmission.
- 'Px8xx' for transmission.
- 'Px9xx' category to be determined
- 'Px0xx' category to be determined
• When a concern occurs, the actions taken include storage of the relevant information and
actuation of the MIL occurs in line with the relevant legislation.

Inspection and Verification

1. Verify the customer concern by operating the system.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Sensors • Fuse(s)
• Actuators • Wiring harness
• Electrical connector(s)
• Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Electronic Engine Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Camshaft Position (CMP) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

3. Torque: 10 Nm
4.

5.
6.

7. Torque: 8 Nm
Installation

1. To install, reverse the removal procedure.

Electronic Engine Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) -
Crankshaft Position (CKP) Sensor
Print

Removal and Installation

General Equipment
Fluid Container

2. Left-hand side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
3.

4. If equipped.

Use the General Equipments: Center Punch, 3.5 mm Drill Bit

6.
7.

8.
Installation

2. Torque: 10 Nm
3.

4. Torque: 10 Nm
5. Tighten the shear bolt until the head is sheared off.

6.
7. Left-hand side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

8. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
Electronic Engine Controls - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Post
Diesel Particulate Filter (DPF) Exhaust Gas Temperature Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque: 35 Nm

1. To install, reverse the removal procedure.

Automatic Transmission - 6-Speed Automatic
Transmission - 6F55 - Specifications
Print

TRANSMISSION FLUID CAPACITIES

AUTOMATIC TRANSMISSION OIL C-ML5 SPECIFICATION PART NUMBER FILL CAPACITY

Total system filling capacity* WSS-M2C938-A 7U7J-M2C938-AA 10.8 L ***

Top-up quantity WSS-M2C938-A 7U7J-M2C938-AA 5.3 L*

*Includes cooler, cooler tubes and hoses.

**New or remanufactured transmissions are prefilled. Top-up quantity need to be
added before starting the engine.
***A transmission fluid level check is always mandated.

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

SPECIFICATIONS

Grease FL-LL WSD-M1C227-A

GENERAL SPECIFICATION

Transmission Weight

6F55 100 kg

GEAR RATIO CHART

Gear Ratio

1st 4.484:1

2nd 2.872:1

3rd 1.842:1

4th 1.414:1

5th 1:1

6th 0.742:1

Reverse 2.882:1
Final Drive 3.65:1
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Description - Overview
Print

Description and Operation

Overview

This electronically controlled automatic transmission is a 6-speed transmission with

electronic shift control. It is designed for operation in a transverse powertrain for FWD
(front wheel drive) and AWD (all-wheel drive) vehicles. Gear selection is achieved by the
control of transmission fluid flow to operate various internal clutches. The TCM
(transmission control module) operates the electrical components and provides control of
gear selection shift pressure, which increases refinement and torque converter slip.
This transmission has the following features:

• Six forward speeds

• Torque converter with an integral converter clutch
• Electronic shift and pressure controls
• Three planetary gearsets
• Three fixed multi-disc clutches
• Two multi-plate drive clutches
• TCM

All hydraulic functions are directed by electronic solenoids to control the following:

• Engagement feel
• Shift feel
• Shift scheduling
• Modulated TCC (torque converter clutch) applications

This transmission has a main control which contains:

• Solenoid body with TFT (transmission fluid temperature) sensor

• Upper Valve body
• Lower Valve body

The TCM receives inputs directly from:

• TR (transmission range) sensor.

• TFT sensor.
• TSS (turbine shaft speed) sensor.
• ISS (input shaft speed) sensor.
• OSS (output shaft speed) sensor.

The TCM also receives information from other modules via CAN (controller area network)
such as:
• Engine speed.
• Engine torque.
• ECT (engine coolant temperature).
• TP (throttle position).
• APP (accelerator pedal position).
• ABS (anti-lock brake system) wheel speed.
• Traction control status.

In the event of a system fault, the TCM also provides for Failure Mode Effect Management
to maintain maximum functional operation of the transmission with a minimum power
reduction. In the event of a total loss of control or electrical power, the basic transmission
functions P, R, N and D are retained. Also 5th gear is retained by the hydraulic system.
Identification Tags
Identification Tag Location

Item Description
1 Transmission identification tag
2 Solenoid body identification tag
Transmission Identification Tag

Item Description
1 Transmission part number
2 Transmission build date
3 Transmission serial number
Original Solenoid Body Tag
Item Description
1 13 - digit solenoid body strategy
2 7 - digit solenoid body identification
Replacement Solenoid Body Tag

Item Description
1 13 - digit solenoid body strategy
2 7 - digit solenoid body identification
Solenoid Body Identification Tag

Item Description
1 13 - digit solenoid body strategy
2 7 - digit solenoid body identification
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Description - System Operation and Component
Description
Print

Description and Operation

System Diagram

Item Description
1 HS-CAN (high speed-controller area network)
2 Hardwire Connection
3 PCM (powertrain control module)
4 TCM (transmission control module)
5 TFT (transmission fluid temperature)
6 TR (transmission range)
7 TSS (turbine shaft speed)
8 OSS (output shaft speed)
9 {Acronym.LPC} ({Acronym.LPC})
10 {Acronym.SSA} ({Acronym.SSA})
11 {Acronym.SSB} ({Acronym.SSB})
12 {Acronym.SSC} ({Acronym.SSC})
13 {Acronym.SSD} ({Acronym.SSD})
14 {Acronym.SSE} ({Acronym.SSE})
15 TCC (torque converter clutch)

Network Message Chart

Broadcast Originating
Message Purpose
Message Module
Engine Speed TCM
Directly affects shift scheduling, TCC control, line pressure
and transmission diagnostics. Indirectly affects shift
pressure control.
Directly affects shift pressure control, TCC control and
Engine torque
TCM transmission diagnostics. Indirectly affects shift scheduling
estimate
and TCC scheduling.
Directly affects shift scheduling, TCC scheduling and
APP (accelerator
TCM transmission diagnostics. Indirectly affects TCC control and
pedal position)
shift control.
Commanded engine Directly affects shift scheduling, TCC scheduling and
TCM
torque transmission diagnostics. Indirectly affects shift control.
BPP (brake pedal
TCM Directly affects shift scheduling and TCC scheduling.
position)

System Operation
The TCM and its input/output network controls the following operations:
Shift timing
Line pressure (shift feel)
Transmission operation is controlled by an external TCM located in the LHS front wheel
arch.
The transmission control strategy is separate from the engine control strategy by an
external TCM, located in the LHS front wheel arch. Although some of the input signals are
shared. When determining the best operating strategy for transmission operation, the TCM
uses input information from engine and driver related sensors and switches.
In addition, the TCM receives input signals from transmission related sensors and switches.
The TCM uses these signals when determining transmission operating strategy.
Using all of these input signals, the TCM can determine when the time and conditions are
right for a shift or when to apply or release the TCC. It also determines the best line
pressure to optimize shift engagement feel. To accomplish this, the TCM uses output
solenoids to control transmission operation.

Component Description
Sensors and Switches
The TCM controls the electronic functions of this transmission. The TCM receives input
signals from engine and transmission sensors and uses these inputs to control line
pressure, shift time, TCC and shift solenoids.

Item Description
TFT This sensor is located in the transmission solenoid body. It is a temperature-sensitive
Sensor device called a thermistor. The resistance value of the TFT sensor will vary with
temperature change. The TCM monitors the voltage across the TFT sensor to determine
the temperature of the transmission fluid. The TCM uses this initial signal to determine
whether a cold start shift schedule is necessary. The cold start shift schedule allows
delayed shifts when the transmission fluid is cold to help warm the transmission fluid.
The TCM also inhibits TCC operation at low transmission fluid temperatures and adjusts
line pressure for temperature.
TR The TR sensor has a 6-pin electrical connector. The TR sensor is located on the inside
Sensor of the transmission at the manual control lever. The TR sensor sends a signal to the
TCM/PCM to start the vehicle in PARK and NEUTRAL. The TR sensor opens/ closes a set
of 4 switches that are monitored by the TCM to determine the position of the manual
control lever.
TSS This TSS sensor is a Hall-effect pickup that sends a signal to the TCM that indicates
Sensor transmission turbine shaft input speed. The TSS information is compared to engine rpm
to determine TSS performance. TSS is also compared to OSS to determine shift quality
and clutch performance.
OSS The OSS sensor is a Hall-effect pickup, located on the transfer shaft drive gear, that
Sensor sends a signal to the TCM to indicate transmission output speed. The OSS is used for
shift scheduling. OSS is also compared to TSS to determine shift quality and clutch
performance.
Transmission Fluid Auxiliary Pump Components

Item Description
1 Transmission assembly
2 Gasket - Transmission fluid auxiliary pump-to-transmission case
3 Transmission fluid auxiliary pump
4 Transmission fluid auxiliary pump-to-transmission case bolts
Mechanical Operation

The transmission fluid auxiliary pump is an electric external pump bolted to the
transmission case that draws fluid from the sump area of the transmission. The
transmission fluid auxiliary pump maintains line pressure during engine shut down on
vehicles equipped with the Auto-Start-Stop System. The transmission auxiliary fluid pump
is controlled by the TCM.
Item Description
1 Decrease Pressure (Line Pressure Control)
2 Line Pressure 353-2.206 kPa (52-320 psi)
3 Regulated Pressure 0-2.206 kPa (0-320 psi)
4 Compensator Pressure 62 kPa (9 psi)
5 Transmission Fluid Cooler Feed/Lubricant 0-758 kPa (0-110 psi)
6 Torque Converter Clutch (TCC) Pressure 0-1.138 kPa (0-165 psi)
7 No Pressure
8 Exhaust Circuit Approximately 21 kPa (3 psi)
9 Solenoid Feed Circuit/Full Solenoid Pressure 896 kPa (130 psi)
10 Variable Solenoid Pressure 0-896 kPa (0-130 psi)
11 Feddback Pressure 0-407 kPa (0-59 psi)
12 Valves/Pucks/Pistons
13 Ball Check
14 Shuttle Ball
15 Orifice
16 Fluid Direction

HYDRAULIC CIRCUIT IDENTIFICATION CHART

Circuit Name Description

CB1234 Regulated pressure from the forward (1, 2, 3, 4) clutch regulator valve to
the forward clutch.
CB1234 FDBK CB1234 pressure from the CB1234 boost valve supplied to the CB1234
clutch regulator valve to oppose movement of the valve from
{Acronym.SSA} SIG pressure during forward (1, 2, 3, 4) clutch application.
CB1234 SUP CB26FD/CB1234FD pressure supplied to the CB1234 regulator valve
downstream of the CB26FD/CB1234FD check ball.
CB26 Regulated pressure supplied to the intermediate (2, 6) clutch in 2nd and
6th gears.
CB26FD/CB1234FD DRIVE 2 or DRIVE B pressure directed to the CB26 and CB1234 regulator
valves by the DRIVE 2/DRIVE B shuttle ball.
C35R
Regulated C35R SUPPLY pressure from the direct (3, 5, R) regulator valve
that supplies the direct (3, 5, R) clutch.
C35R FDBK C35R pressure from the C35R boost valve supplied to the C35R clutch
regulator valve to oppose movement of the valve from {Acronym.SSB} SIG
pressure during direct (3, 5, R) clutch application.
C35R SUPPLY DRIVE 2 or REV SUPPLY pressure directed to the 3, 5, R clutch regulator
valve by the DRIVE 2/REV SUPPLY shuttle ball.
C456/C456 Regulated clutch pressure from the low/reverse/overdrive (4, 5, 6)
SUPPLY regulator valve directed to the overdrive (4, 5, 6) clutch in 4th, 5th, and
6th gears.
CBLR/C456 FDBK CBLR/C456 SUPPLY pressure from the CBLR/C456 boost valve supplied to
the CBLR/C456 regulator valve to oppose movement of the valve from
{Acronym.SSD} SIG pressure during low/reverse and overdrive (4, 5, 6)
clutch application.
CBLR/C456 Regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve
SUPPLY to the multiplex shift valve assembly. The multiplex shift valve directs it to
the overdrive clutch or the low/reverse clutch, depending on what position
it is in.
CBLR/CBLR Regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve
SUPPLY directed to the low/reverse clutch by the multiplex shift valve in LOW and
REVERSE.
COMP FEED Compensator feed pressure applied to the back side of clutches to keep the
clutches from centrifugally applying.
CONV FD Pressure from the pressure regulator valve to the torque converter clutch
control valve, which supplies the valve to apply and release the torque
converter clutch.
COOLER FEED Pressure supplied to the transmission fluid cooler from the torque converter
clutch control valve and feeds the LUBE circuit.
DECREASE Pressure from the pressure regulator valve to the pump that raises and
lowers the line pressure.
DRIVE 1 Line pressure directed to the multiplex shift valve by the manual valve in
DRIVE and LOW.
DRIVE 2 DRIVE 1 pressure from the multiplex shift valve to the torque converter
clutch regulator apply valve, DRIVE 2/DRIVE B shuttle ball, DRIVE 2/REV
SUPPLY shuttle ball and CBLR/C456 regulator valve.
DRIVE B REV DRIVE B pressure directed to the DRIVE 2/ DRIVE B shuttle ball by the
multiplex manual valve.
EXH Fluid exhausted from the valves that drains to the sump area.
EXH BF Fills the forward (1, 2, 3, 4), intermediate (2, 6) and low/reverse/overdrive
(4, 5, 6) regulator valves and the multiplex shift and manual valves with
fluid (no pressure).
LINE Line pressure from the pump to the manual valve, solenoid regulator valve,
fluid temperature sensor, low/reverse/overdrive (4, 5, 6) regulator valve,
COMP FEED circuit and EXH BF circuit.
LPC Full or regulated pressure from the {Acronym.LPC} solenoid to the
pressure regulator valve.
REG APPLY Regulated DRIVE 2 pressure from the torque converter clutch regulator
apply valve supplied to the torque converter clutch control valve to apply
the torque converter clutch.
REV DRIVE B DRIVE 1 pressure directed to the multiplex manual valve by the multiplex
shift valve.
REV/REV SUPPLY Pressure supplied to the multiplex shift valve assembly and the direct (3, 5,
R) clutch regulator valve from the manual valve in REVERSE only.
SOL FEED Regulated pressure from the solenoid regulator valve that supplies the
shift, TCC and {Acronym.LPC} solenoids, multiplex manual valve and the
direct (3, 5, R) clutch regulator valve.
SSA SIG Pressure supplied to the forward (1, 2, 3, 4) clutch regulator and boost
valves from {Acronym.SSA} to direct regulated pressure to the forward
clutch in 1st, 2nd, 3rd or 4th gears.
SSB SIG
Pressure supplied to the direct (3, 5, R) clutch regulator and boost valves
from {Acronym.SSB} to direct regulated pressure to the direct clutch in 3rd
and 5th gears and REVERSE.
SSC SIG Pressure supplied to the intermediate (2, 6) clutch regulator and boost
valves from {Acronym.SSC} to direct regulated pressure to the
intermediate clutch in 2nd and 6th gears.
SSD SIG Pressure supplied to the low/reverse/overdrive regulator and boost valves
from {Acronym.SSD} to direct regulated pressure to the multiplex shift
valve in LOW or REVERSE position or 4th, 5th and 6th gear.
SSE Full solenoid pressure from {Acronym.SSE} to the torque converter clutch
regulator valve and multiplex shift valve.
TCC APPLY Pressure supplied to the torque converter from the TCC control valve to
apply the torque converter clutch.
TCC RELEASE Pressure supplied to the torque converter from the TCC control valve to
release the torque converter clutch.
TCC SOL SIG Full or regulated pressure from the TCC solenoid to the torque converter
clutch regulator and control valves.
TFT Line pressure directed to TFT sensor.
Valve Body Maps for Solenoid and Line Pressure
Solenoid Body Hydraulic Passages
Cover Plate Hydraulic Passages
Transfer Plate Hydraulic Passages (Top View)
Transfer Plate Hydraulic Passages (Bottom View)
Center Spacer Plate Hydraulic Passages
Valve Body Hydraulic Passages (Top View)
Valve Body Hydraulic Passages (Bottom View)
Lower Spacer Plate Hydraulic Passages
Lower Valve Body Hydraulic Passages
Transmission Case Hydraulic Passages
Line Pressure Hydraulic Circuits (Shown with the Manual Valve in the DRIVE
Position)
Line Pressure Hydraulic Circuits
The TCM controls line pressure with the {Acronym.LPC} solenoid. This affects shift feel and
apply component operation.
When the engine is running, the pump supplies pressure to the pressure regulator valve,
which is controlled by the {Acronym.LPC} solenoid. The pressure regulator valve controls
the line pressure.
The line pressure circuit supplies the manual valve. The manual valve directs the line
pressure to either the REV/REV SUPPLY circuit when the manual control lever is in the
REVERSE position or the DRIVE 1 circuit when the manual control lever is in the DRIVE or
LOW position.
Lubrication Circuits (Torque Converter Clutch (TCC) Released)

Lubrication Circuits (Torque Converter Clutch [TCC] Applied)

Lubrication Hydraulic Circuits
Lubrication for the transmission is supplied by the transmission fluid cooler return tube.
Transmission fluid is sent to the transmission fluid cooler from the TCC control valve.
LINE pressure supplied to the pressure regulator valve is sent to the TCC control valve as
CONV FD pressure. During TCC release, the TCC control valve sends the transmission fluid
to the torque converter to release the clutch. The transmission fluid returns to the TCC
control valve from the torque converter and is directed to the transmission fluid cooler on
the COOLER FEED circuit.
Torque Converter Hydraulic Circuits (Torque Converter Clutch [TCC] Applied)

Torque Converter Hydraulic Circuits

The TCM controls the TCC solenoid. The TCC solenoid applies hydraulic pressure to the TCC
control and regulator apply valves through the TCC SOL SIG circuit. Regulated DRIVE 2
pressure from the multiplex shift valve is directed to the TCC control valve by the TCC
regulator apply valve through the REG APPLY circuit. The TCC control valve directs pressure
from the REG APPLY circuit to the TCC APPLY circuit to apply the clutch.
The transmission fluid returns to the TCC control valve through the TCC RELEASE hydraulic
circuit. The TCC control valve opens the TCC RELEASE circuit to exhaust, so the TCC
RELEASE circuit is not pressurized when the TCC is applied.
Torque Converter Hydraulic Circuits (Torque Converter Clutch [TCC] Released)

When the TCC is released, The TCC solenoid does not apply hydraulic pressure to the TCC
control or regulator apply valves. The TCC control valve, in this position, directs hydraulic
pressure from the CONV FD circuit to the torque converter through the TCC RELEASE
hydraulic circuit and it returns to the TCC control valve through the TCC APPLY circuit.
Solenoid Hydraulic Circuits

Solenoid Hydraulic Circuits

LINE pressure from the pump is directed to the individual shift, TCC and {Acronym.LPC}
solenoids by the solenoid regulator valve on the SOL FEED circuit. The solenoids, controlled
by the TCM, direct the fluid to the valves that they control.
The {Acronym.LPC} solenoid sends varying pressure to the line pressure regulator valve to
control line pressure.
Solenoid Body

Item Description
1 Solenoid body
2 Solenoid body filter
3 Seal-solenoid body electrical connector
4 Internal wiring harness frame

Item Description
1 {Acronym.SSE}
2 {Acronym.SSD}
3 {Acronym.SSA}
4 TCC solenoid
5 {Acronym.SSB}
6 {Acronym.SSC}
7 {Acronym.LPC} solenoid
Solenoid Body
The solenoid body contains 7 solenoids: 5 shift solenoids {Acronym.SSA}, {Acronym.SSB},
{Acronym.SSC}, {Acronym.SSD} and {Acronym.SSE}, 1 TCC solenoid and 1
{Acronym.LPC} solenoid. The TFT sensor is located in the solenoid body. The solenoid body
is serviced as an assembly.
The solenoid body has a unique strategy data file that must be downloaded to the TCM.
There is a 7- digit solenoid body identification and a 13-digit solenoid body strategy for
each solenoid body. When a new solenoid body or transmission is installed, the scan tool
must be used to get the solenoid body strategy data file and download it into the TCM.
If the TCM is replaced and the TCM data cannot be inhaled or exhaled, the solenoid body
identification and solenoid body strategy must be downloaded into the TCM.
This transmission uses 3 types of solenoids: On/Off, normally low and normally high.
On/Off solenoids open or close hydraulic passages based on the voltage signal it receives.
Normally low solenoids provide hydraulic pressure proportional to supplied current. A
normally low solenoid will not provide pressure without current, while it will supply high
pressure with high current. Normally high solenoids provide pressure inversely proportional
to supplied current. Normally high solenoids provide full output of pressure with no current
and very low pressure with high current.
Solenoid Body Electrical Connector Identification

Item Description
1 TR connector
2 OSS connector
3 Solenoid Body Connector C168
4 TSS connector
ON/OFF Solenoids
Item Description
{Acronym.SSE}Normally closed solenoid that blocks SOL FEED pressure from the
{Acronym.SSE} circuit. When energized, pressure from the {Acronym.SSE}
circuit positions the multiplex shift valve to direct CBLR/C456 SUPPLY pressure
to the low reverse clutch.
Normally Low Solenoids

Item Description
{Acronym.SSA} {Acronym.SSA} blocks SOL FEED pressure from the {Acronym.SSA} SIG
circuit when low current is supplied. When energized, {Acronym.SSA} SIG
pressure positions the CB1234 clutch regulator and boost valves to direct
CB1234 SUP pressure to apply the forward clutch.
{Acronym.SSC}{Acronym.SSC} blocks SOL FEED pressure to the {Acronym.SSC} SIG circuit
when low current is supplied. When energized, {Acronym.SSC} SIG pressure
positions the CB26 clutch regulator valve to direct CB26FD/CB1234FD pressure
to apply the intermediate clutch.
TCC solenoid The TCC solenoid is used in the transmission control system to control the
application, modulation and release of the torque converter clutch. The TCC
solenoid blocks SOL FEED pressure to the TCC SOL SIG circuit when low
current is supplied. When energized, TCC SOL SIG pressure positions the TCC
reg apply and control valves to direct REG APPLY pressure to apply the torque
converter.
Normally High Solenoids
Item Description
{Acronym.SSB} {Acronym.SSB} feeds SOL FEED pressure to the {Acronym.SSB} SIG circuit
to position the direct (3,5,R) clutch regulator and boost valves to apply the
direct (3,5,R) clutch. When energized, {Acronym.SSB} blocks
{Acronym.SSB} SIG to position the direct clutch (3,5,R) regulator and boost
valves to release the direct (3,5,R) clutch.
{Acronym.SSD} {Acronym.SSD} feeds SOL FEED pressure to the {Acronym.SSD} SIG circuit
to position the CBLR/C456 regulator and boost valves to apply either the
low/reverse clutch or the overdrive (4,5,6) clutch. When energized,
{Acronym.SSD} blocks {Acronym.SSD} SIG to position the CBLR/C456
regulator and boost valves to release either the low/reverse clutch or the
overdrive (4,5,6) clutch.
{Acronym.LPC} The {Acronym.LPC} solenoid is used to apply resistive force to the main
solenoid regulator valve to adjust line pressure. Line pressure is inversely proportional
to the current supplied to the {Acronym.LPC} solenoid. As current decreases,
line pressure increases.
Park

PARK CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
Park H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding

PARK POSITION SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
P P Off On Off Off On Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• With the selector lever in PARK, the low/reverse clutch holds the rear planetary
carrier/center ring gear stationary.
• The park pawl holds the rear ring/front planetary carrier stationary.
• The turbine shaft drives the center sun gear.
Reverse

REVERSE CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
Reverse D H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding
D = Driving

REVERSE POSITION SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
R R Off Off Off Off On Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• With the selector lever in REVERSE, the low/reverse clutch holds the rear planetary
carrier/center ring gear stationary.
• The direct clutch drives the rear sun gear.
• The rear ring/front planetary carrier transfers torque to the output hub in a reverse
direction with a ratio of 2.88.
Neutral

NEUTRAL CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
Neutral H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding

NEUTRAL POSITION SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
N N Off On Off Off On Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• With the selector lever in NEUTRAL, the low/reverse clutch holds the rear planetary
carrier/center ring gear stationary.
• The turbine shaft drives the center sun gear.

1st Gear
NOTE: The transmission operates differently in 1st gear above and below 8 km/h (5
mph). Transmission operation is the same below 8 km/h (5 mph) and in the LOW
position.

1ST GEAR ABOVE 8 KM/H (5 MPH) CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
1st Gear D H H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding

1ST GEAR LOW POSITION AND BELOW 8 KM/H (5 MPH) CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
1st Gear D H H H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding

1ST GEAR ABOVE 8 KM/H (5 MPH) SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
D 1 On On Off On Off Off
NC = Normally Closed
NH = Normally High
NL = Normally Low

1ST GEAR LOW POSITION AND BELOW 8 KM/H (5 MPH) SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
L 1 On On Off Off On Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In first gear, the forward clutch holds the front sun gear stationary.
• The rear planetary carrier/center ring gear is held stationary by the low One-Way Clutch
(OWC) and/or the low reverse (1, R) clutch.
• The turbine shaft transfers torque to the center sun gear. The center sun gear transfers
the torque to the center planetary carrier/front ring gear. The front ring gear transfers
torque to the front planetary carrier/rear ring gear and the output hub to produce a ratio
of 4.48.
2nd Gear

2ND GEAR CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
2nd Gear D H H
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding

2ND GEAR SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
D 2 On On On On Off Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In second gear the forward clutch holds the front sun gear stationary.
• The intermediate clutch holds the rear sun gear stationary.
• The turbine shaft transfers torque to the center sun gear. The center sun gear transfers
torque to the center ring gear/rear planetary carrier.
• The rear planetary carrier transfers the torque to the rear ring gear/front planetary
carrier and the output hub to produce a gear ratio of 2.87.
3rd Gear

3RD GEAR CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
3rd Gear D H D
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding
D = Driving

3RD GEAR SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Position Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Gear Off) NC
D 3 On Off Off On Off Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In third gear the forward clutch holds the front sun gear stationary.
• The direct clutch drives the rear sun gear.
• Power flows from the center sun gear to the center planetary carrier/front ring gear.
From there, torque is transferred to the rear ring gear/front planetary carrier.
• Power also flows from the rear sun gear to the rear ring gear/front planetary carrier.
• The two inputs to the front planetary carrier combine and transfer torque to the output
hub to produce a gear ratio of 1.84.
4th Gear

4TH GEAR CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
4th Gear D H D
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding
D = Driving

4TH GEAR SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Position Gear Off) NC
D 4 On On Off Off Off On/Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In fourth gear the forward clutch holds the front sun gear stationary.
• The overdrive clutch drives the rear planetary carrier/center ring gear.
• Power flows from turbine shaft to the center sun gear and center ring gear.
• The two inputs to the center planetary carrier combine and transfer torque to the front
ring gear.
• The front ring gear transfers the torque to the front planetary carrier and onto the output
hub to produce a gear ratio of 1.41.
5th Gear

5TH GEAR CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
5th Gear D D D
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
D = Driving

5TH GEAR SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Position Gear Off) NC
D 5 Off Off Off Off Off On/Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In fifth gear the overdrive clutch drives the rear planetary carrier/center ring gear.
• The direct clutch drives the rear sun gear.
• The turbine shaft transfers torque to the center sun gear, rear sun gear, and rear
planetary carrier/center ring gear.
• The torque from the three inputs locks the three planetary gearsets which produces a
gear ratio of 1 to 1

Fail-safe Mode

• Because both {Acronym.SSD} and {Acronym.SSB} apply the clutches they control when
they are turned OFF, 5th gear is the fail-safe.
6th Gear

6TH GEAR CLUTCH APPLICATION CHART

Gear Forward Direct Intermediate Low / Overdrive Low-OWC

(1,2,3,4) (3,5,R) (2,6) Reverse (4,5,6)
(1,R)
6th Gear D H D
Planetary Front sun Rear sun Rear sun Rear carrier/ Rear carrier/ Rear
Components center ring center ring carrier/
center ring
H = Holding
D = Driving

6TH GEAR SOLENOID OPERATION CHART

Base Selector PCM SSA NL SSB NH SSC NL SSD NH SSE TCC

Lever Commanded (1,2,3,4) (3,5,R) (2,6) (1,R,4,5,6) (On/ NL
Position Gear Off) NC
D 6 Off On On Off Off On/Off
NC = Normally Closed
NH = Normally High
NL = Normally Low
Powerflow

• In sixth gear the overdrive clutch drives the rear planetary carrier/center ring gear.
• The intermediate clutch holds the rear sun gear.
• The torque from the rear planetary carrier is transferred to the rear ring gear/front
planetary carrier and the output hub which produces a gear ratio of 0.74.
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Fluid Drain and Refill
Print

General Procedures
General Equipment
Ford Diagnostic Equipment

Materials
Name Specification
MERCON® LV
Automatic Transmission Fluid
WSS-M2C938-A

Draining
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. Remove engine undershield - If equipped.
3. NOTE: Be prepared to collect escaping fluid.

Filling
1. Torque: 12 Nm
2. Install engine undershield - If equipped.

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4.

5. Refer to: Specifications (307-01 Automatic Transmission, Specifications).

Material: MERCON® LV ; WSS-M2C938-A (Automatic Transmission Fluid)
6. Start and run the engine at idle.
7. Fully apply the brake pedal and parking brake.
8.

9. Use the General Equipment: Ford Diagnostic Equipment

10.

11.
1. Material: MERCON® LV ; WSS-M2C938-A (Automatic Transmission Fluid)

12.
13.
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Fluid Level Check
Print

General Procedures
General Equipment
Ford Diagnostic Equipment

Materials
Name Specification
MERCON® LV
Automatic Transmission Fluid
WSS-M2C938-A

Check
1. Start and run the engine at idle.
2. Fully apply the brake pedal and parking brake.
3.

4. Use the General Equipment: Ford Diagnostic Equipment

7.
1. Material: MERCON® LV ; WSS-M2C938-A (Automatic Transmission Fluid)

8.
9.
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Halfshaft Seal LH
Print

Removal and Installation

Special Tool(s) / General Equipment
204-609
Protection Cap, Ball Joint Gaiter

205-153
Handle

205-853
Protector, Halfshaft Seal

307-582A
Cover Axle Seal Installer

Lower Arm Down Force Lever

Slide Hammer Dent Puller
Tire Lever
Two Leg Puller

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. Remove engine undershield - If equipped.

3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

4. Loosen: 3 turn(s)
5.
1. Use the General Equipment: Two Leg Puller

6.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

7.
8. WARNING: Be prepared to collect escaping fluid.
NOTICE:

Take extra care not to damage the seal.

Take extra care not to damage the edges of the component.

Take extra care not to damage the mating faces.

Use the General Equipment: Tire Lever

9. NOTICE: Take extra care not to damage the seal.

Install Special Service Tool: 205-853.
10. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

11.

12. Use the General Equipment: Slide Hammer Dent Puller

Installation

1. NOTE: Use a new seal.

Use Special Service Tools: 205-153, 307-582A.

2. NOTE: Make sure that the component is correctly installed.

Use Special Service Tools: 205-153, 307-582A.

3. NOTE: Make sure that a new component is installed.

5. NOTICE: Take extra care not to damage the seal.

Install Special Service Tool: 205-853.
6. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
1.

2. 2. NOTICE: Take extra care not to damage the seal.

Remove the special tool before completely installing the halfshaft.

Remove Special Service Tool: 205-853.

7. NOTE: Make sure that the component is correctly installed.

8.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

9. Torque: 150 Nm

10. Refer to: Transmission Fluid Level Check (308-03 Manual Transmission, General
Procedures).

11. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
12. Install engine undershield - If equipped.

13. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

14. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Halfshaft
Seal RH
Print

Removal and Installation

Special Tool(s) / General Equipment
204-609
Protection Cap, Ball Joint Gaiter

205-153
Handle

205-853
Protector, Halfshaft Seal

307-582A
Cover Axle Seal Installer

Lower Arm Down Force Lever

Slide Hammer Dent Puller
Two Leg Puller

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. Remove engine undershield - If equipped.

3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

4. Loosen: 3 turn(s)
5.
1. Use the General Equipment: Two Leg Puller

6.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

7.
8. NOTICE: Take extra care not to damage the seal.
NOTE: Be prepared to collect escaping fluid.

9.
1. 1. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
NOTE: Be prepared to collect escaping fluid.

2. 2. NOTICE: Take extra care not to damage the seal.

Install Special Service Tool: 205-853.
10. Use the General Equipment: Slide Hammer Dent Puller

Installation

1. NOTE: Use a new seal.

Use Special Service Tools: 205-153, 307-582A.

2. NOTE: Make sure that the component is correctly installed.

Use Special Service Tools: 205-153, 307-582A.
3. Install Special Service Tool: 205-853.

5. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
1.

2. 2. NOTICE: Take extra care not to damage the seal.

Remove the special tool before completely installing the halfshaft.

Remove Special Service Tool: 205-853.

3.
6. 1. NOTE: Make sure that a new component is installed.

2. 2. NOTICE: Make sure that new nuts are installed.

Torque:
Stage 1:6 Nm
Stage 2:25 Nm

7.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

8. Torque: 150 Nm
9. Refer to: Transmission Fluid Level Check (308-03 Manual Transmission, General
Procedures).

10. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
11. Install engine undershield - If equipped.

12. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

13. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 - Main
Control Cover
Print

Removal and Installation

Removal

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
2.

4.
5. Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission, General
Procedures).
6. NOTE: Use suitable paper to absorb any escaping fluid.

9.
10.

11. NOTE: Be prepared to collect escaping fluid.

Installation
1. NOTE: The gasket is to be reused unless damaged.

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
Tighten the bolts diagonally.

Torque: 12 Nm

3. NOTE: Make sure that the component terminals are not bent or damaged.

4. Torque: 8 Nm
5.

6. Torque: 11 Nm

7. NOTE: The O-ring seals are to be reused unless damaged.

Torque: 30 Nm
8. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
9.

10. Torque: 12 Nm

11. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

12. Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission, General
Procedures).
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 - Main
Control Valve Body
Print

Removal and Installation

Removal

1. Refer to: Solenoid Body (307-01 Automatic Transmission, Removal and Installation).

2. NOTICE: Make sure that no component falls off during removal.

Installation

1. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Take extra care not to damage the wiring harnesses.

NOTE: Make sure that the components are correctly located.
NOTE: Only tighten the bolts finger tight at this stage.

2. Torque: 12 Nm
3. Refer to: Solenoid Body (307-01 Automatic Transmission, Removal and Installation).
Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Output
Shaft Speed (OSS) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Main Control Valve Body (307-01 Automatic Transmission, Removal and
Installation).

2. Torque: 12 Nm

Installation

1. To install, reverse the removal procedure.

Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Roll
Restrictor RH
Print

Removal and Installation

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. NOTE: Note the different lengths of the bolts.

Installation

1. NOTE: Note the different lengths of the bolts.

Torque: 175 Nm

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Selector
Shaft Seal
Print

Removal and Installation

General Equipment
Flat Headed Screw Driver

Materials
Name Specification
MERCON® LV
Automatic Transmission Fluid
WSS-M2C938-A

Removal

1. Refer to: Transmission Range (TR) Sensor (307-01 Automatic Transmission, Removal
and Installation).

2. NOTICE: Take extra care not to damage the mating faces.

Use the General Equipment: Flat Headed Screw Driver

Installation

1. 1. NOTE: Use a new seal.

Apply a thin coating.

Material: MERCON® LV ; WSS-M2C938-A (Automatic Transmission Fluid)

2. NOTE: Make sure that the component is correctly installed.
Use a suitable socket.
2. Refer to: Transmission Range (TR) Sensor (307-01 Automatic Transmission, Removal
and Installation).
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Solenoid Body
Print

Removal and Installation

General Equipment
Ford Diagnostic Equipment

Removal

1. Refer to: Main Control Cover (307-01 Automatic Transmission, Removal and
Installation).
2.

5. NOTICE: Make sure that no component falls off during removal.

NOTE: Note the different lengths of the bolts.
Installation

1. NOTICE:

Extreme cleanliness must be exercised when handling the component.

Take extra care not to damage the wiring harnesses.

NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Only tighten the bolts finger tight at this stage.

2. Torque: 12 Nm
3. Refer to: Main Control Cover (307-01 Automatic Transmission, Removal and
Installation).
4. NOTE: This step is only necessary when installing a new component.
NOTE: Make sure a new component is installed.
Upload the module information from the diagnostic tool to the module using the
Programmable Modules Installation routine.

Refer to: Transmission Description (307-01 Automatic Transmission, Description and

Operation).
Use the General Equipment: Ford Diagnostic Equipment
Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Torque
Converter
Print

Removal and Installation

Special Tool(s)
307-711
Handle, Torque Converter

Removal

1. Refer to: Transmission (307-01 Automatic Transmission, Removal).

NOTICE: Make sure that no component falls off during removal.

NOTE: Be prepared to collect escaping fluid.
Install Special Service Tool: 307-711.

Installation

1. NOTE: Install a new component if it is damaged or has excessive wear.

NOTICE: Take extra care not to damage the seal.

NOTE: Make sure that the component is correctly installed.
Remove Special Service Tool: 307-711.

3. Refer to: Transmission (307-01 Automatic Transmission, Installation).

Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 - Torque
Converter Seal
Print

Removal and Installation

Special Tool(s) / General Equipment
307-575
Converter Seal Installer

Slide Hammer Dent Puller

Removal

1. Refer to: Torque Converter (307-01 Automatic Transmission, Removal and Installation).

2. Use the General Equipment: Slide Hammer Dent Puller

Installation

1. NOTE: Use a new seal.

Use Special Service Tool: 307-575.

2. NOTE: Make sure that the component is correctly installed.

Use Special Service Tool: 307-575.
3. Refer to: Torque Converter (307-01 Automatic Transmission, Removal and Installation).
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Fluid Auxiliary Pump
Print

Removal and Installation

General Equipment
Hot Air Gun

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. Remove engine undershield - If equipped.
3.

4. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Hot Air Gun

5.
Installation

2. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Make sure that new bolts are installed.
Torque: 13 Nm

3.
4. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission Range (TR) Sensor
Print

Removal and Installation

Special Tool(s) / General Equipment
307-696
Remover, TRS Retaining Pin

Punch

Removal

1. Refer to: Main Control Valve Body (307-01 Automatic Transmission, Removal and
Installation).
2.

3.
4. Install Special Service Tool: 307-696.

5. Remove Special Service Tool: 307-696.

6. NOTICE: Take extra care when handling the component.

Installation

1. NOTE: Make sure that the component is correctly installed.

2. NOTICE: Take extra care not to damage the edges of the component.
Use the General Equipment: Punch

3. Torque: 17 Nm
4.

5. Refer to: Main Control Valve Body (307-01 Automatic Transmission, Removal and
Installation).

6. Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission External
Controls, General Procedures).
Automatic Transmission - 6-Speed
Automatic Transmission - 6F55 -
Transmission Support Insulator
Print

Removal and Installation

General Equipment
Trolley Jack
Wooden Block

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque: 133 Nm

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

4. Use the General Equipments: Trolley Jack, Wooden Block

5. Torque: 133 Nm
6. Torque: 20 Nm

7. Torque: 70 Nm

control module (TCM) and the TCM electrical connector are not bent or damaged.
NOTE: Make sure that the component is correctly installed.
2.

3. Tighten the shear bolt until the head is sheared off.

5.
6. Left-hand side only.

Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

7. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
8. NOTE: This step is only necessary when installing a new component.
Upload the module information from the diagnostic tool to the module using the
Programmable Modules Installation routine.

Refer to: Transmission Description (307-01 Automatic Transmission, Description and

Operation).
Use the General Equipment: Ford Diagnostic Equipment
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission
Print

Removal
Special Tool(s) / General Equipment
204-609
Protection Cap, Ball Joint Gaiter

205-1048
Protector, Driveshaft Seal

303-1196
Holding Wrench, Pulley

303-1554
Engine Support Bar

303-1554-09
Adapter for 303-1554, Engine Support Bar

303-290A-15
Adapter for 303-290A

307-569
Disconnect Tool TOC Line (1/2)

Lower Arm Down Force Lever

Retaining Strap
Tire Lever
Transmission Jack
Two Leg Puller
Wooden Block

1. Right-hand side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
2.

4.
5.

6.
7.

8. Remove engine undershield - If equipped.

9. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).
10.
11. NOTE: Note the different lengths of the bolts.

12. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

13. Loosen: 3 turn(s)

14.
1. Use the General Equipment: Two Leg Puller

2.
15.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

16.
17. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the mating faces.

Take extra care not to damage the seal.

1. Use the General Equipment: Tire Lever

18. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the seal.

1. Use Special Service Tool: 205-1048.
19. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

20.
21. Loosen: 3 turn(s)

22.
1. Use the General Equipment: Two Leg Puller

23.
1. Use the General Equipment: Lower Arm Down Force Lever

2. Install Special Service Tool: 204-609.

24.

25. NOTICE: Take extra care not to damage the seal.

NOTE: Be prepared to collect escaping fluid.
26.
1. 1. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
Use Special Service Tool: 205-1048.

2. 2. NOTICE: Take extra care not to damage the seal.

27. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or
twisted.

28.
1. If equipped.

Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-
00 Climate Control System - General Information, General Procedures).
2. If equipped.

29.
30.

31.
32. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.

33. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.

34.
35.

36.
37.

38. 1.

2. 2. NOTICE: Only rotate the crankshaft clockwise.

39.

40. Install Special Service Tools: 303-1554-09, 303-1554.

41. Install Special Service Tool: 303-1554.

42. Install Special Service Tool: 303-1554.

43. Install Special Service Tool: 303-290A-15.

44.

45. Use Special Service Tool: 303-1554.

46. Use the General Equipments: Transmission Jack, Wooden Block, Retaining Strap

47.

48. NOTICE:

Make sure that the torque converter remains in the transmission.

Make sure that no components catch.

49. NOTICE: Make sure that the locating dowels remain installed.
50. NOTICE: Make sure that the torque converter remains in the transmission.
Install Suggested Tool: 303-1196. Tool shown or a commercially available equivalent
can be used.
Automatic Transmission - 6-Speed Automatic Transmission - 6F55 -
Transmission
Print

Installation
Special Tool(s) / General Equipment
204-609
Protection Cap, Ball Joint Gaiter

205-1048
Protector, Driveshaft Seal

303-1196
Holding Wrench, Pulley

303-1554
Engine Support Bar

303-1554-09
Adapter for 303-1554, Engine Support Bar

303-290A-15
Adapter for 303-290A

Lower Arm Down Force Lever

Retaining Strap
Transmission Jack
Wooden Block

1. NOTICE: Make sure that the torque converter remains in the transmission.
Apply a thin coating.

Refer to: Specifications (307-01 Automatic Transmission, Specifications).

Remove Suggested Tool: 303-1196.

2. NOTICE:

Make sure that the component is correctly located on the locating dowels.

Make sure that no part of the wiring harness is trapped.

NOTE: Make sure that the installation marks are aligned.
NOTE: Make sure that the retaining strap is not trapped.

3. Torque: 48 Nm
4. NOTICE: Only rotate the crankshaft clockwise.
Torque: 48 Nm

5.
6. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).
7.
1. Torque: 95 Nm

2. Torque: 133 Nm

8. Use Special Service Tool: 303-1554.

9. NOTE: Make sure that the component is correctly installed.
Torque: 11 Nm

10. Torque: 48 Nm
11.

12. Torque: 48 Nm
13. Remove the General Equipments: Retaining Strap, Wooden Block, Transmission Jack

Vehicles With: Rear Climate Control

14.
1. Torque: 20 Nm

2. Torque: 15 Nm

3. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-
00 Climate Control System - General Information, General Procedures).

All vehicles
15. NOTE: Make sure that the components are correctly installed.
16.

17. NOTE: Make sure that the component terminals are not bent or damaged.

18.
19. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or
twisted.
NOTE: Use a new seal.
Torque: 25 Nm

20. Torque: 175 Nm

21. Refer to: Halfshaft Seal LH (307-01 Automatic Transmission, Removal and Installation).

22. Refer to: Halfshaft Seal RH (307-01 Automatic Transmission, Removal and Installation).
23. NOTE: Install a new component if it is damaged or has excessive wear.

24. NOTE: Make sure that a new component is installed.

25. NOTICE:

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.

Take extra care not to damage the seal.

1.
2. Remove the special tool before completely installing the halfshaft.

Use Special Service Tool: 205-1048.

26. NOTICE: Take extra care not to damage the seal.

NOTE: Make sure that the component is correctly installed.
Remove the special tool before completely installing the halfshaft.

27.

28.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

29. If equipped.

Torque: 215 Nm

30. If equipped.

Torque: 150 Nm
31. NOTE: Install a new component if it is damaged or has excessive wear.
1.
2. If equipped.

32. NOTE: Install a new component if it is damaged or has excessive wear.

33. NOTICE:

Make sure that the strut is not moved more than necessary to prevent
damage to top mount.

The inner constant velocity (CV) joint must not be bent more than 18°.

The outer constant velocity (CV) joint must not be bent more than 45°.
1.

2. 2. NOTICE: Take extra care not to damage the seal.

Remove the special tool before completely installing the halfshaft.

Use Special Service Tool: 205-1048.

34. NOTE: Make sure that the component is correctly installed.

35. NOTE: Make sure that the components are correctly installed.
1. NOTE: Make sure that a new component is installed.
2. NOTE: Make sure a new nut is installed.
Torque: 6 Nm

3. NOTE: Make sure a new nut is installed.

Torque: 6 Nm

4. Torque: 25 Nm

5. Torque: 25 Nm
36.

37.
1. Remove Special Service Tool: 204-609.

2. Use the General Equipment: Lower Arm Down Force Lever

38. If equipped.

Torque: 215 Nm
39. If equipped.

Torque: 150 Nm

40. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
41.
1. Torque: 63 Nm

2. Torque: 133 Nm
42. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

43. Remove Special Service Tools: 303-290A-15, 303-1554-09, 303-1554.

44. Torque: 7 Nm

45. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

46. Torque: 48 Nm
47. Torque: 25 Nm

48.
49. Torque: 12 Nm

50. Torque: 11 Nm
51. Right-hand side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

52. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
53. NOTE: This step is only necessary when installing a new transmission.
Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission External
Controls, General Procedures).

54. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Transmission Cooling - 6-Speed Automatic Transmission - 6F55 -
Transmission Cooling - Component Location
Print

Description and Operation

Item Description
1 Transmission fluid cooler inlet tube
2 Transmission fluid cooler
3 Transmission cooler outlet tube
4 Transmission fluid outlet tube
5 Transmission fluid cooler bypass valve
6 Transmission fluid inlet tube
Transmission Cooling - 6-Speed Automatic
Transmission - 6F55 - Transmission
Cooling - Overview
Print

Description and Operation

The transmission fluid cooling system consists of the following:

• An oil-to-air transmission fluid cooler integrated with the A/C (air conditioning) condenser
• A transmission fluid cooler bypass valve
• If equipped, a transmission fluid warmer
• Tubes to all fluid to flow to the various components

The transmission fluid flows from the transmission to the cooler bypass valve. When the
transmission fluid is below normal operating temperature, the bypass valve directs the flow
back to the transmission. When the transmission fluid is at or above normal operating
temperature, the bypass valve directs the flow through the transmission fluid cooler, which
transfers heat from the fluid to the air passing over the cooler. The transmission fluid then
returns to the transmission.
The transmission fluid warmer optimized transmission fluid temperature. The transmission
fluid warmer transfers heat either from the coolant to the transmission fluid or from the
transmission fluid to the coolant. If equipped, the transmission fluid flows through the
warmer. When the coolant is warmer than the transmission fluid, heat is transferred from
the coolant to the transmission fluid, warming the transmission fluid quickly to improve
efficiency. When the transmission fluid is warmer than the coolant, heat is transferred from
the transmission fluid to the coolant, providing additional transmission fluid cooling.
Transmission Cooling - 6-Speed Automatic Transmission - 6F55 -
Transmission Fluid Cooler - Air to Oil
Print

Removal and Installation

Removal

1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2. 1.
2. NOTE: Make sure that no component falls off during removal.

4. 1.
2. NOTE: Make sure that no components catch.
3.
Installation

1. 1.
2. NOTE: Make sure that no components catch.
3.
2. NOTE: Make sure that the component is correctly installed.

3. 1. NOTE: Make sure that the seal is correctly located.

Apply a thin coating.

Refer to: Specifications (307-01 Automatic Transmission, Specifications).

2. Torque: 11 Nm

4. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).

5. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Transmission Cooling - 6-Speed Automatic Transmission - 6F55 -
Transmission Fluid Cooler Tubes
Print

Removal and Installation

Special Tool(s)
307-569
Disconnect Tool TOC Line (1/2)

Removal

NOTICE: Make sure that all openings are sealed with clean blanking caps.
NOTE: Be prepared to collect escaping fluid.
1.

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. Remove engine undershield - If equipped.
4.

5. 1.
2. NOTE: Make sure that no component falls off during removal.
6.

8. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
10.

11. 1.
2. NOTE: Make sure that no component falls off during removal.
12. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
13.

14. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.
15. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.

16.

17. 1.
2. NOTE: Make sure that no component falls off during removal.
18. NOTE: Make sure that no components catch.

Installation

1. NOTE: Make sure that the components are correctly located.

2. 1. NOTE: Make sure that the seal is correctly located.
Apply a thin coating.

Refer to: Specifications (307-01 Automatic Transmission, Specifications).

2. Torque: 11 Nm

3. Torque: 11 Nm
4.
1. Apply a thin coating.

Refer to: Specifications (307-01 Automatic Transmission, Specifications).

2. Torque: 11 Nm

5. Torque: 30 Nm
6.
1. Torque: 35 Nm

7.
1. Apply a thin coating.

Refer to: Specifications (307-01 Automatic Transmission, Specifications).

2. Torque: 11 Nm

3. Torque: 30 Nm
8.

9. NOTE: Make sure that the components are correctly installed.

10.
11. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).

12. Torque: 8 Nm

13.

14. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Transmission Cooling - 6-Speed Automatic Transmission - 6F55 - Cooler
Bypass Valve
Print

Removal and Installation

Special Tool(s)
307-569
Disconnect Tool TOC Line (1/2)

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. Remove engine undershield - If equipped.
3.

4. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.
5. 1.
2. Use Special Service Tool: 307-569.

3. NOTE: Be prepared to collect escaping fluid.

Remove Special Service Tool: 307-569.

6. NOTE: Use suitable paper to absorb any escaping fluid.

7.
Installation

1. Torque: 9 Nm

2. NOTE: The O-ring seals are to be reused unless damaged.

Torque: 30 Nm

3. NOTE: Make sure that the components are correctly installed.

5. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - External Controls - Component Location
Print

Description and Operation

External Controls

Item Description
1 Selector lever cable adjuster
2 Selector lever cable
3 Selector lever assembly
4 Brake shift interlock actuator
5 Selector lever bezel
6 Selector lever knob
Automatic Transmission External Controls
- 6-Speed Automatic Transmission - 6F55
- External Controls - Overview
Print

Description and Operation

Overview
The transmission selector lever linkage consists of:

• a selector lever cable that connects the transmission manual control lever to the selector
lever assembly.
• a brake shift interlock actuator that is integral to the selector lever assembly.

The selector lever assembly:

• locks the transmission selector lever in the P (Park) position when the ignition switch is in
the LOCK position.
• requires the transmission selector lever to be in the P position to turn the ignition switch
to the LOCK position.
Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Brake Shift Interlock Actuator Manual Override
Print

General Procedures
General Equipment
Flat Headed Screw Driver

Activation
1.

3.
1. Use the General Equipment: Flat Headed Screw Driver

2.
Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Selector Lever Cable Adjustment
Print

General Procedures

Adjustment
1.

2. NOTE: Make sure that the ignition key is in the ON position.

4.
5.

6.
7.

8.
9. Verify the engine starts only in park (P) and neutral (N) and the reverse lamps
illuminate only in reverse (R).
Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Selector Lever Bezel
Print

Removal and Installation

Removal

2. NOTE: Make sure that the ignition key is in the ON position.

4.
5.

7.
8.

Installation

1. To install, reverse the removal procedure.

Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Selector Lever Cable
Print

Removal and Installation

General Equipment
Adhesive Tape
Draw Cord
Interior Trim Remover

Removal
NOTE: Removal steps in this procedure may contain installation details.
All vehicles
1.
1. On both sides.

Use the General Equipment: Interior Trim Remover

2.
3.

4.
5. If equipped.

All vehicles

6. Torque: 12 Nm

7. Attach a pull cord to the selector lever cable.

Use the General Equipments: Draw Cord, Adhesive Tape

8. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

Installation
1. Attach a pull cord to the selector lever cable.

Use the General Equipments: Draw Cord, Adhesive Tape

Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Selector Lever Knob
Print

Removal and Installation

Removal

2. NOTE: Make sure that the ignition key is in the ON position.

4.
5.

7.
8.

Installation

1. To install, reverse the removal procedure.

Automatic Transmission External Controls - 6-Speed Automatic
Transmission - 6F55 - Selector Lever Assembly
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
All vehicles
1.

3. Torque: 9 Nm
Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission External
Controls, General Procedures).
Manual Transmission and Clutch - General
Information - Manual Transmission and
Clutch
Print

Diagnosis and Testing

General Equipment
Ultraviolet fluid leak detection equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Oil leaks.
• Visibly damaged or worn components.
• Loose or missing nuts or bolts.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not evident, verify the symptom and REFER to the Symptom Chart.

The following checks should be carried out before repairing or installing a new transmission.
The inspection and verification of manual transmission concerns can be considered in three
main areas.
Gear shifting concerns

1. Check the operation of the clutch: Position a block of wood approximately 25 mm

thick under the clutch pedal and depress the clutch pedal as far as possible. If first
or second gear can be selected with the engine running and the parking brake
applied, without any concerns, the clutch is OK.

2. If the gear(s) cannot be selected, REFER to the Symptom Chart.

Transmission noise concerns

1. Check the engine and transmission support for insufficient gap between the
transmission and the body.

2. If a noise occurs in various gears at the same engine speed, check if the noise also
occurs in the neutral position. If it does, the noise is not caused by the
transmission.

3. REFER to the Symptom Chart.

Oil leakage concerns

1. Check the transmission fluid level. If necessary, drain off any excess fluid.

2. Clean the transmission and the adjacent areas carefully and road test the vehicle.
REFER to: Road/Roller Testing (100-00 General Information, Description and
Operation).

3. Using suitable ultraviolet fluid leak detection equipment, locate the leak and check
whether the leaking fluid is transmission fluid, brake fluid (from the hydraulically
operated clutch) or engine oil.
4. REFER to the Symptom Chart.

Symptom Chart
The following table provides all the possible symptoms and sources related to Manual
Transmission and Clutch. For the actual diagnostics, proceed to use the Ford diagnostic
equipment.

Symptom Chart Possible Sources

Clutch slippage Clutch master cylinder
Clutch slave cylinder
Clutch pressure plate
Clutch disc
Clutch slippage Crankshaft rear seal
Clutch slippage Transmission input shaft seal
Clutch chatter or shudder Engine and transaxle mounts
Clutch pressure plate
Clutch disc
Flywheel
Clutch drag Insufficient brake fluid
Air in the clutch hydraulic system
Clutch pedal free travel
Clutch pressure plate
Clutch disc
Crankshaft end play
Clutch drag Pilot bearing
Clutch pedal pulsation Clutch pressure plate
Clutch disc
Crankshaft end play
Excessive noise Engine vibrations inadequately damped
Transaxle fluid level low
Engine or transaxle is in contact with the chassis or body
Engine and transaxle out of alignment
External controls
Gear wheels and bearings
Clutch pedal
Excessive noise Clutch release bearing
Fluid leakage Clutch master cylinder
Clutch slave cylinder
Clutch hydraulic lines
Transmission Halfshaft seal
Fluid leak between the transaxle housing sections
Fluid leakage Transmission input shaft seal
Manual Transmission and Clutch - General Information - Gearshift Cable
Adjustment
Print

General Procedures
Special Tool(s)
308-650
Aligner, Gearshift Lever

Adjustment
1.

2.
3.

4.
5. NOTE: Make sure that the 4th gear is engaged.

6. NOTE: Make sure that the 4th gear is engaged.

Install Special Service Tool: 308-650.
7. NOTE: Make sure that the 4th gear is engaged.

8. NOTE: Make sure that the 4th gear is engaged.

9. Remove Special Service Tool: 308-650.
10.

11. To install, reverse the removal procedure.

Manual Transmission and Clutch - General
Information - Clutch System Bleeding
Print

General Procedures
Special Tool(s)
416-D001
Hand Vacuum Pump/Pressure Pump

Materials
Name Specification
Brake Fluid WSS-M6C65-A2
1.

2. NOTE: Make sure that the brake fluid level does not drop below the MIN mark.

Use Special Service Tool: 416-D001.

Material: WSS-M6C65-A2 (Brake Fluid)

3. Use Special Service Tool: 416-D001.

Material: WSS-M6C65-A2 (Brake Fluid)
4.
1. Install Special Service Tool: 416-D001.

5. Use Special Service Tool: 416-D001.

6. 1.

2. Remove Special Service Tool: 416-D001.

8. In order to remove any small amounts of trapped air remaining in the system, operate
the clutch pedal several times (max. 4-5 times), using the full clutch pedal travel.

9. Material: WSS-M6C65-A2 (Brake Fluid)

10. • Carefully engage reverse gear.

• Start the engine, depress the clutch pedal and wait approx. 2 seconds before
carefully engaging reverse gear.
• If gear engagement is excessively noisy, remove the small amounts of trapped air
remaining in the system by operating the clutch pedal several times (max. 4-5
times), using the full clutch pedal travel.
• After waiting approx. 30 seconds, check the operation of the clutch again.
• If gear engagement is still excessively noisy, repeat the previous steps.
Exhaust System - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Catalytic
Converter
Print

Removal and Installation

Removal

1. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).

Installation

1. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).
Exhaust System - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Diesel
Particulate Filter (DPF)
Print

Removal and Installation

General Equipment
Snap Ring Pliers

Removal

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).

2. NOTICE: Gearshift cables must not be kinked or bent.

3.
4.

5.
6.

7. Use the General Equipment: Snap Ring Pliers

8. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
9.

10.
11.

12.
13.

14. NOTE: This step is only necessary when installing a new component.
Installation

1. NOTE: This step is only necessary when installing a new component.

Torque:
1: 42 Nm
2: 35 Nm

2. NOTE: Use a new seal.

NOTE: Make sure that the seal is correctly located.
3. NOTE: Only tighten the nuts finger tight at this stage.

4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
5.
6. Torque: 25 Nm

7. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

8. Torque: 25 Nm
9. Torque:
1: 15 Nm
2: 9 Nm

10. Torque:
1: 10 Nm
2: 15 Nm
11. Torque: 52 Nm

12. Torque:
1: 15 Nm
2: 35 Nm
13. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

14. Torque: 10 Nm

15.
16.

17. NOTICE: Gearshift cables must not be kinked or bent.

18. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
Exhaust System - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Rear Muffler
Print

Removal and Installation

Special Tool(s)
309-005
Pliers, Exhaust Hangers

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Use Suggested Tool: 309-005. Tool shown or a commercially available equivalent can be
used.
Torque: 48 Nm

Installation

1. To install, reverse the removal procedure.

Exhaust System - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Selective
Catalytic Reduction System Catalyst
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque:
1: 48 Nm

3. Torque:
1: 48 Nm
2: 48 Nm
Installation

1. To install, reverse the removal procedure.

Fuel System - General Information - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN) - Diesel Filter Water Drain-Off
Print

General Procedures
General Equipment
Fluid Container

Draining

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. NOTE: Be prepared to collect escaping fluids.
Please tighten/untighten the drain valve just by hand. Do not use any tool

Use the General Equipment: Fluid Container

4. Please tighten/untighten the drain valve just by hand. Do not use any tool
Fuel System - General Information - 2.0L
EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Fuel
System Bleeding
Print

General Procedures

Bleeding

1. NOTICE: Make sure that the ignition is in the ON position for 30 seconds to
allow the fuel system to be primed.

3. Repeat steps 1+2 for 3 times before starting the engine – giving 120 seconds total
priming time.
Fuel System - General Information - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN) - Fuel Tank Draining
Print

General Procedures
General Equipment
Fuel Drain Tank
Fuel Tank Draining Equipment
Hose Clamp(s)
Transmission Jack

Draining

NOTICE: If the fuel tank has been filled with the wrong type of fuel, the engine must
not be started before the fuel system is cleaned.
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4. NOTE: Be prepared to collect escaping fluids.
Use the General Equipment: Hose Clamp(s)

5. Use the General Equipment: Transmission Jack

Torque: 35 Nm
6. Use the General Equipment: Transmission Jack

7. NOTE: Be prepared to collect escaping fluids.

Make sure, that the fuel filler pipe is above the fuel level.

Use the General Equipments: Fuel Tank Draining Equipment, Fuel Drain Tank
Fuel System - General Information - 2.0L
EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Quick
Release Coupling
Print

General Procedures

Disconnect
1. Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00, Description and Operation).
Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).
2.

5.
6.

Connect
1. To connect, reverse the disconnect procedure.
Fuel Tank and Lines - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel Filter
Print

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

4. Torque: 15 Nm
Installation

1. To install, reverse the removal procedure.

2. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).
Fuel Tank and Lines - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel Filter
Element
Print

Removal and Installation

General Equipment
Fluid Container

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

4. NOTE: Be prepared to collect escaping fluid.

Please tighten/untighten the drain valve just by hand. Do not use any tool

Use the General Equipment: Fluid Container

5. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container
Loosen: 2 turn(s)

6.
Installation

1. To install, reverse the removal procedure.

3. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).
Fuel Tank and Lines - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel Pump
and Sender Unit
Print

Removal and Installation

General Equipment
Punch

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Fuel Tank (310-01A Fuel Tank and Lines, Removal and Installation).

3. Use the General Equipment: Punch

4. NOTICE:

Take extra care not to damage the fuel tank level sensor float and arm.

Make sure that the installation marks are aligned.

NOTE: Use a new seal.
NOTE: Make sure that the seal is correctly located.
5. NOTE: Be prepared to collect escaping fluid.
NOTE: Use suitable paper to absorb any escaping fluid.

6.
Installation

1. To install, reverse the removal procedure.

Fuel Tank and Lines - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS) (YN) - Fuel Tank
Print

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Fuel Tank Draining (310-00A Fuel System - General Information, General
Procedures).

3. NOTICE: Make sure that no strain is placed on the fuel lines and wiring
harnesses.

4. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
5.

Installation

1. To install, reverse the removal procedure.

Fuel Tank and Lines - 2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue
(96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Fuel Tank Filler
Pipe
Print

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. NOTE: Be prepared to collect escaping fluid.
Torque: 6 Nm

4. Torque: 20 Nm

Installation

1. To install, reverse the removal procedure.

Acceleration Control - Acceleration
Control
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Accelerator pedal • Wiring harness(s)
• Throttle body • Wiring harness retaining clips
• Electrical connector(s)
• Accelerator pedal
• Powertrain control module (PCM)
• Electronic throttle body

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab
within the Ford diagnostic equipment.
Acceleration Control - Accelerator Pedal
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque: 8 Nm

Installation

1. To install, reverse the removal procedure.

Climate Control System - General Information - Specifications
Print

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

VAN SPECIFICATION

Refrigerant R134a WSH-M17B19-A

Refrigerant oil WSH-M1C231-B

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

BUS SPECIFICATION

Refrigerant R1234yf WSS-M17B21-A

Refrigerant oil WSS-M2C300-A2

REFRIGERANT CAPACITIES (TOTAL REQUIRED REFRIGERANT CHARGE)

VAN GRAMS

Air Conditioning 740 ± 15

A/C system with Auxiliary A/C system 1150 ± 15

REFRIGERANT CAPACITIES (TOTAL REQUIRED REFRIGERANT CHARGE)

BUS GRAMS

Air Conditioning 740 ± 15

A/C system with Auxiliary A/C system 1050 ± 15

REFRIGERANT OIL CAPACITIES (TOTAL REQUIRED REFRIGERANT OIL CHARGE)

MILLILITRES

Air Conditioning 160

A/C system with Auxiliary A/C system 245

ADDITION OF REFRIGERANT OIL (WHEN NEW COMPONENTS ARE INSTALLED)

NOTICE: The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.
MILLILITRES

After renewal of all lines and components, or if system gets flushed add the total required oil
charge (new compressor
as delivered ie. 160 or
245).
MILLILITRES

After renewal of A/C compressor without system flush add the same drained
quantity

Air conditioning compressor (if the amount of refrigerant oil drained from the Drain 50 from new
faulty compressor is less than 150 ml) compressor.

Air conditioning compressor (if the amount of refrigerant oil drained from the add the total required oil
faulty compressor is more than 150 ml) charge (new compressor
as delivered ie. 160 or
245).

A/C condenser add 30.

A/C evaporator add 30.

A/C receiver drier add 90.

Always, if refrigerant was drained. Add the same quantity as

the quantity that was
collected.

CLUTCH AIR GAP

Compressor clutch air gap 0,35 - 0,85

TORQUE SPECIFICATIONS

ITEM NM LB-FT LB-IN

Compressor drive plate retaining bolt 13 10 -

Climate Control System - General
Information - Climate Control System
Print

Diagnosis and Testing

General Equipment
Digital Multimeter (compatible with K-type thermocouple)
Ford diagnostic equipment
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260 4102 001 07)
Refer to Wiring Diagram Section 054-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION

Mechanical Electrical
• Coolant level • Fuse(s)
• Pollen filter • Relay(s)
• Refrigerant lines • Wiring harness
• Drive belt • Electrical connector(s)
• Thermostatic expansion valve • Front blower motor
• Receiver drier • Front blower motor switch
• Condenser • Front blower motor resistor
• Air conditioning (A/C) compressor • Rear blower motor (if fitted)
• Rear blower motor switch (if fitted)
• Rear blower motor resistor (if fitted)
• Rear blower controller (if fitted)
• Air inlet door actuator
• Defrost vent/register door actuator
• Temperature door actuator
• Recirculation door actuator
• Ambient air temperature sensor
• Front evaporator temperature sensor
• Rear evaporator temperature sensor (if
fitted)
• Refridgerant valve (if fitted)
• Auxiliary blower switch (if fitted)
• Air conditioning (A/C) clutch and air
conditioning (A/C) clutch field coil
• Air conditioning (A/C) clutch relay
• Air conditioning (A/C) pressure
transducer
• Fuel-fired heater control module (if
fitted)
• Fuel-fired heater coolant pump motor (if
fitted)
• Fuel-fired heater fuel pump motor (if
fitted)
• PTC heater control module (if fitted)
• Auxiliary heater control module (AHCM)
• Auxiliary junction box (AJB)
• Battery Junction Box (BJB)
• Body control module (BCM)
• Powertrain control module (PCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Diagnostic
tab within the Ford diagnostic equipment.

Refrigerant Circuit - Quick Check

WARNING: The air conditioning system is filled with refrigerant R134a. Observe
"Health and Safety Precautions". For further information

REFER to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
Refrigerant circuit check

WARNING: Under certain circumstances, refrigerant lines and A/C components may
be extremely hot or cold. Exercising care, touch the refrigerant lines or A/C components
in order to check this. Failure to observe this instruction can lead to injury.

• The refrigerant line from the refrigerant compressor to the condenser must be hot.
• The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but
not so hot as the refrigerant line mentioned above.
• Determine the difference in temperature upstream and downstream of the A/C condenser
by measuring the temperatures at the refrigerant lines. The temperature difference
should be more than 20° C, depending on the ambient temperature. If the temperature
difference is less, check the condenser for contamination or damage to the fins as well as
operation of the radiator fan.
• The refrigerant line between the fixed orifice tube and the evaporator must be cold from
the point where the fixed orifice tube is installed. Depending on the weather, the line
may also be iced up on the outside.
• The refrigerant line between the evaporator and the A/C compressor including the
accumulator must be cold.

Evaporator outlet temperature test

To test the power of the A/C system, the temperature of the evaporator outlet line must be
measured. To do this, the following preconditions must be met:

• Open all windows.

• Set the air distribution to the defrost/dashboard position and open all the ventilation
nozzles.
• Deactivate recirculated air function.
• Select lowest blower switch setting.
• Select lowest temperature setting.

NOTE: The temperature measurement cannot be done with a thermometer which makes
no contact. Incorrect readings could be made because of reflections from surfaces.
Connect temperature sensor (Fluke 80 PK-8) to the refrigerant line from the evaporator to
the accumulator in the area of the accumulator (metal line). Connect the temperature
sensor to the multimeter.
Start the engine and allow it to run at idle speed for several minutes.
Switch on the air-conditioning system.
After three minutes, measure the surface temperature of the evaporator outlet line.
If the temperature measured is 2° C or lower (vehicles with automatic transmission: 5° C
or lower) the A/C system is OK. If the temperature is higher, the A/C system may be
under-filled.
Frequent faults and their causes
Should a customer express concern about poor cooling performance of the A/C system it
must be ensured that the temperature control valve actuation is OK.

• No or poor cooling performance:

- Blockage or narrowing in a refrigerant line or in the accumulator: The location of the
blockage or narrowing can easily be found by comparing temperatures at the refrigerant
lines and at the accumulator. The blockage or restriction is located at the point where the
temperature difference is identified. Note: A temperature difference in the area of
the fixed orifice tube is normal. Once the location of the blockage or restriction has
been detected, check the relevant component and renew if necessary.
• Cooling power suddenly deteriorates (returns to normal after the compressor has been
switched off for about 5 minutes):
- The cause is an iced-up fixed orifice tube because of moisture in the refrigerant circuit.
In order to ensure that moisture is completely removed from the refrigerant circuit,
evacuation time must be extended to 2-3 hours and the dehydrator must be renewed.
For further information
REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).

Component Tests
Air conditioning (A/C) clutch relay

1. Check the normally open contact in the unswitched state:

• Measure the resistance at the air conditioning clutch relay, between pin 3 and pin
5, component side.
• Is a resistance of more than 10,000 Ohm measured?
1. If yes, go to 2.
2. If no, RENEW the air conditioning clutch relay.

2. Check the normally open contact in the switched state:

• Use a fused test cable (1 A) to connect pin 1 of the air conditioning clutch relay,
component side, to the battery positive terminal.
• Use a test cable to connect pin 2 of the air conditioning clutch relay, component
side, to the battery negative terminal.
• Measure the resistance at the air conditioning clutch relay, between pin 3 and pin
5, component side.
• Is a resistance of less than 2 Ohm registered?
1. If yes, then the air conditioning clutch relay is OK.
2. If no, RENEW the air conditioning clutch relay.
Climate Control System - General
Information - Air Conditioning (A/C)
Clutch Air Gap Adjustment
Print

General Procedures
Special Tool(s)
412-134
Holding Tool, Compressor Clutch

Activation
1. Operate the air conditioning clutch several times with the aid of a 5 A fused cable. Refer
to the relevant wiring diagram for the correct electrical connection. Check the gap A at
60° intervals around the circumference of the pulley.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).

2. Use Special Service Tool: 412-134.

3. If necessary correct the gap A using only one spacer washers.

4. Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Use Special Service Tool: 412-134.
5. Check the gap A as described in step 1. If necessary, repeat steps 2-5.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Climate Control System - General Information - Air Conditioning (A/C)
System Flushing
Print

General Procedures
Special Tool(s) / General Equipment
412-100
Hose Kit for R134a, Flush Filter

412-151
Adapters, Air Conditioning

Air Conditioning Service Unit

Activation
1. This procedure is only used for vehicles with R134A refrigerant
2. 1. Air conditioning (A/C) compressor
2. Condenser
3. Receiver drier
4. Thermostatic expansion valve
5. Evaporator
6. Adapter clamps
7. Thermostatic expansion valve adapter
8. AC service unit
9. Flushing kit
Vehicles with auxiliary climate control
3. 1. Air conditioning (A/C) compressor
2. Condenser
3. Receiver drier
4. Thermostatic expansion valve
5. Evaporator
6. Auxiliary evaporator with auxiliary thermostatic expansion valve
7. Adapter clamps
8. Thermostatic expansion valve adapter
9. Adapter clamps
10. AC service unit
11. Flushing kit
All vehicles

4. Refer to: Thermostatic Expansion Valve (412-01 Climate Control, Removal and
Installation).

5. Install the expansion valve adapter.

Use Special Service Tool: 412-151.

Torque: 4 Nm

6. Install the refrigerant lines to the expansion valve adapter.

Torque: 8 Nm
7. Refer to: Air Conditioning (A/C) Compressor (412-01 Climate Control, Removal and
Installation).

8. Install the high-pressure compressor line adapter.

Use Special Service Tool: 412-151.

9. Install the low-pressure compressor line adapter.

Use Special Service Tool: 412-151.

10. Refer to: Receiver Drier (412-01 Climate Control, Removal and Installation).
11.
12. Install the receiver drier plug.

Vehicles with auxiliary climate control

13. Torque: 8 Nm

14. Use Special Service Tools: 412-100, 412-151.

All vehicles

15. Install the flushing kit to the air conditioning service unit in accordance with the service
unit manufacturer instructions.

Use the General Equipment: Air Conditioning Service Unit

16. Connect the low-pressure service unit line to the filter line adapter.

17. • Connect the high-pressure connection line (red) to the air conditioning compressor
low-pressure line adapter.
• Connect the low-pressure connection line (blue) to the air conditioning compressor
high-pressure line adapter.

18. Flush the air conditioning system in accordance with the service unit manufacturer
instructions.
19. Install a new receiver drier with filter plug.
20. NOTICE: The following step is mandatory if the air conditioning compressor is
damaged due to metal abrasion.
Install a new air conditioning compressor, thermostatic expansion valve and receiver
drier.
21. Install all components in reverse order.
Climate Control System - General Information - Air Conditioning (A/C)
System Leak Test Using Forming Gas
Print

General Procedures
General Equipment
Air Conditioning Service Unit
Forming Gas Pressure Gauge and Leak Detector
Forming Gas Pressure Gauge and Leak Detector Set
Hydrogen Leak Detector
Refrigerant Identification Equipment

Materials
Name Specification
Forming Gas -

Activation
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Unscrew and remove the protective caps from the A/C charging connections.

Use the General Equipments: Air Conditioning Service Unit, Refrigerant Identification
Equipment

3. 1. Low-pressure connection
2. High-pressure connection

4. Use the refrigerant analyzer before recovery, otherwise the refrigerant center may
become contaminated. Dispose of contaminated refrigerant as hazardous waste. Always
follow the manufacturer's instructions when using the refrigerant center and the
refrigerant analyzer.

5. Connect the service unit lines to the filling connections of the air conditioning system.
6. Drain the air conditioning system in accordance with the service unit manufacturer
instructions.
7. Evacuate the air conditioning system in accordance with the service unit manufacturer
instructions.
8. Perform the vacuum leak test in accordance with the service unit manufacturer
instructions.
9. Disconnect the service unit from the air conditioning system in accordance with the
manufacturer instructions.
NOTE: The following steps are only necessary when using the forming gas pressure gauge
and leak detector.
10. Connect the forming gas pressure gauge and leak detector service hose to the low-
pressure port of the air conditioning system in accordance with the manufacturer
instructions.

Use the General Equipment: Forming Gas Pressure Gauge and Leak Detector
Material: - (Forming Gas)

11.
1. 1. NOTICE: Make sure that the pressure reducer (2) is closed.
Open the bottle valve.
2. Slowly turn the pressure reducer until a pressure of 10 bar is reached.
3. Close the bottle valve.
NOTE: The following steps are only necessary when using the forming gas pressure gauge
and leak detector set.
12. Connect the forming gas pressure gauge and leak detector set service hoses to the high-
pressure and low-pressure port of the air conditioning system in accordance with the
service unit manufacturer instructions.

Use the General Equipment: Forming Gas Pressure Gauge and Leak Detector Set
Material: - (Forming Gas)

13.
1. 1. NOTICE: Make sure that the cut-off valve (2) is closed.
Turn the pressure reducer until a pressure of 8 bar is reached.
2. Slowly open the cut-off valve.
3. Close the cut-off valve.
All vehicles

14. Locate and rectify any leaks in the A/C refrigerant circuit in accordance with the
hydrogen leak detector manufacturer instructions.

Use the General Equipment: Hydrogen Leak Detector

15. Disconnect the forming gas pressure gauge and leak detector from the air conditioning
system in accordance with the manufacturer instructions.
16. Connect the service unit lines to the filling connections of the air conditioning system.

17. NOTICE:

Make sure that the specified amount of refrigerant oil is added.

Make sure that tracer dye is added.

NOTE: After adding tracer dye into the air conditioning (A/C) system, the decal
supplied with the tracer dye must be positioned.
Fill the air conditioning system in accordance with the service unit manufacturer
instructions.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate Control System - General Information,
General Procedures).
18. Disconnect the service unit in from the air conditioning system in accordance with the
manufacturer instructions.
19. Screw the protective caps onto the charging connections.
Climate Control System - General Information - Air Conditioning (A/C)
System Leak Test Using Nitrogen Gas
Print

General Procedures
General Equipment
Air Conditioning Service Unit
Nitrogen Pressure Gauge and Leak Detector
Refrigerant Identification Equipment

Materials
Name Specification
Nitrogen -
Leak Detection Spray -

Activation
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Unscrew and remove the protective caps from the A/C charging connections.

Use the General Equipments: Air Conditioning Service Unit, Refrigerant Identification
Equipment

3. 1. Low-pressure connection
2. High-pressure connection

10. Connect the nitrogen gas pressure gauge and leak detector service hose to the low-
pressure port of the air conditioning system in accordance with the manufacturer
instructions.

Use the General Equipment: Nitrogen Pressure Gauge and Leak Detector
Material: - (Nitrogen)

Material: - (Leak Detection Spray)

13. Disconnect the nitrogen gas pressure gauge and leak detector from the air conditioning
system in accordance with the manufacturer instructions.
14. Connect the service unit lines to the filling connections of the air conditioning system.

15. NOTICE:

Make sure that the specified amount of refrigerant oil is added.

Make sure that tracer dye is added.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate Control System - General Information,
General Procedures).
16. Disconnect the service unit from the air conditioning system in accordance with the
manufacturer instructions.
17. Screw the protective caps onto the charging connections.
Climate Control System - General Information - Air Conditioning (A/C)
System Recovery, Evacuation and Charging
Print

General Procedures
General Equipment
Air Conditioning Service Unit
Refrigerant Identification Equipment

Activation
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Unscrew and remove the protective caps from the A/C charging connections.

Use the General Equipments: Air Conditioning Service Unit, Refrigerant Identification
Equipment

3. 1. Low-pressure connection
2. High-pressure connection

5. Connect the service unit lines to the filling connection of the air conditioning system.
6. Drain the air conditioning system via the low-pressure port in accordance with the
service unit manufacturer instructions.

7. NOTICE: Make sure that the specified amount of refrigerant oil is added.
NOTE: Make sure that a new component is installed.
Fill up with refrigerant oil.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
8. Evacuate the air conditioning system in accordance with the service unit manufacturer
instructions.
9. NOTE: Filling port valve leakage cannot be detected during test due to the valve is
bypassed by service unit.
NOTE: Make sure that there is no leakage on the filling port valve area.
Perform the leak test in accordance with the service unit manufacturer instructions.
10. Locate and rectify any leaks in the A/C refrigerant circuit, if necessary using a leak
tester.

11. Add refrigerant oil to the air conditioning system.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).

12. Fill the air conditioning system with liquid through the high-pressure connection.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
13. 1. Open the shut-off valve on the high-pressure side.
2. Switch the service unit to "Fill" mode and fill the system with the specified
quantity of liquid refrigerant.

14. Fill the air conditioning system with gas through the low-pressure connection.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
15. 1. Open the shut-off valve on the low-pressure side.
2. Switch the service unit to "Fill" mode and fill the system with the specified
quantity of gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To
do so run the engine at about 1200-1500 rev/min. Set the air conditioning system
to full cooling power and fresh air mode. Set the blower motor to the highest
setting. Fill with the remainder of the specified fill capacity.
16. Disconnect the service unit.
17. 1. Close the shut-off valve.
2. Switch off the service unit.
3. Disconnect the service unit lines from the filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging connections.
18. Install all components in reverse order.
Climate Control System - General
Information - Contaminated Refrigerant
Handling
Print

General Procedures
General Equipment
Refrigerant Identification Equipment

Activation
1. Use the refrigerant identification equipment to check that there is contaminated
refrigerant in the air conditioning system.

Use the General Equipment: Refrigerant Identification Equipment

2. 2. Inform the customer about the additional costs involved to repair the system because
of the contamination.
3. 3.Use a suitable A/C service unit designed for the purpose of collecting and storing
contaminated refrigerant and dispose of the contaminated refrigerant as hazardous
waste. Follow the manufacturer's instructions when working with the A/C service unit.
Climate Control System - General
Information - Fluorescent Dye Leak
Detection
Print

General Procedures
General Equipment
UV Leak Detector

Activation
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).
2. NOTE: Make sure that protective caps and test equipment adaptors are
disassembled during the detection.
Locate the leaks. Check all components, fittings and lines of the A/C system for leaks.

Use the General Equipment: UV Leak Detector

3. 3. After the leak is found and rectified, remove any traces of dye with a general purpose
solvent.
4. 4. Check the repair by operating the system for some minutes and inspecting with the
UV lamp again.
Climate Control System - General
Information - Refrigerant Oil Adding
Print

General Procedures

Activation

1. NOTICE: Make sure that the equipment is clean and free of foreign material.
Collect the refrigerant oil in a clean measuring cylinder.
2. NOTE: This step only needs to be carried out when removing the A/C compressor.
Rotate the compressor shaft at least 6 to 8 turns when draining the refrigerant oil.
3. NOTE: This step only needs to be carried out when removing the A/C compressor.
Drain the refrigerant oil from the defective A/C compressor and dispose of it.

4. Top up with the calculated quantity of new refrigerant oil in accordance with the A/C
service unit manufacturer instructions.

Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Climate Control System - General
Information - Vacuum Leak Detection
Print

General Procedures

Activation
1. 1. Carry out the air conditioning (A/C) system recovery procedure.

Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).
Climate Control - Specifications
Print

A/C COMPRESSOR

DESCRIPTION

A/C compressor Visteon VS19

Climate Control - Climate Control -
Overview
Print

Description and Operation

Pollen filter

The pollen filter must be changed at intervals in accordance with the service schedule. A
special production pollen filter is installed in the factory, and this must be cut through when
the filter is changed. The service pollen filter is flexible and can be pushed together during
installation or removal.
Heat exchanger

The heat exchanger is accessible from the right-hand side of the climate control housing
(LHD and RHD). It can be removed and installed with the climate control housing still
installed in the vehicle. During removal, the coolant pipes of the production heater core
must be sawn through. During servicing, a heater core with separate coolant pipes is
installed.
Evaporator assembly

The evaporator is located on the right-hand side of the climate control housing (LHD and
RHD). It can only be removed and installed with the climate control housing still installed in
the vehicle, and the heat exchanger must be removed at the same time.
Blower motor
NOTICE: Make sure that the blower motor and fan assembly is placed on the bench
with the fan pointing upwards.

To prevent damage to the fan wheel vanes, the fan wheel must not be touched. For this
reason, a special tool (412-131) has been introduced for removal and installation of the
blower motor. This tool is pushed onto the central shaft in order to lift out the blower
motor.
Fault Memory Interrogation without diagnostics unit - vehicles with automatic
temperature control
NOTE: On vehicles equipped with a DVD navigation system with touchscreen, the fault
memory can only be interrogated using the Ford diagnostic tool.
The climate control and heating system features a on-board diagnosis function which can
detect and store both current permanent faults as well as intermittent faults which have
occurred during normal operation of the vehicle. It is also possible to read out these faults
via the display on the control panel of the climate control system. To read out the fault
memory, the ignition key must be turned to the "ON" position and the battery voltage must
be between 9 V and 16 V.
To activate the on-board diagnosis at the control panel for the climate control system,
PRESS the "OFF" and "FOOTWELL" buttons simultaneously for exactly 2 seconds, then
PRESS "AUTO" within 1.5 seconds. The on-board diagnosis which then starts lasts a few
seconds. An animated display appears in the display of the control panel for the climate
control system during this time. Any faults found are displayed on both displays of the
control panel for the climate control system in the form of trouble codes.
To read out saved errors at the control panel for the climate control system, PRESS the
"OFF" and "FOOTWELL" buttons simultaneously for exactly 2 seconds, then PRESS "HEAD
AREA" within 1.5 seconds. Any stored faults are shown on the display of the control panel
for the climate control system and should be noted for safety reasons. By PRESSING the
"DEFROST" button, the fault memory is cleared and diagnosis mode is ended. To end the
diagnostic mode without clearing the DTCs, PRESS any other operating button on the
control panel for the climate control system.
To read out the software version at the control panel for the climate control system, PRESS
the "OFF" and "FOOTWELL" buttons simultaneously for exactly 2 seconds, then PRESS "A/C"
within 1.5 seconds. The software version is shown on the display of the control panel for
the climate control system. The output mode can be exited by PRESSING any button on the
control panel for the climate control system.
Switch over from Celsius to Fahrenheit
The switch from Celsius to Fahrenheit is performed on the display of the instrument cluster
and is then transmitted via the CAN bus to the module of the two-zone air conditioning
system.
Climate Control - Climate Control - System Operation and Component
Description
Print

Description and Operation

System Diagram
Climate control system - vehicles with manual temperature control

Item Description
1 Climate control system control assembly
Refer to Component Description: Control assembly, climate control - vehicles with
manual temperature control
2 Air flap actuator
3 Blower motor resistor
4 Blower motor
Climate control system - vehicles with automatic temperature control
Item Description
1 Climate control system control assembly
Refer to Component Description: Control assembly, climate control - vehicles with
automatic temperature control
2 Blower control module
Refer to Component Description: Blower control module - vehicles equipped with
automatic temperature control
3 Blower motor
Refer to Component Description:
4 Air flap actuator
5 Actuator - right-hand temperature control flap
6 Actuator - left-hand temperature control flap
7 Actuator - air distribution flap - demister vents
8 Actuator - air distribution flap - center vents
9 Genetic electronic module (GEM).
10 Ambient air temperature sensor
Refer to Component Description: Ambient temperature sensor
11 Air outlet temperature sensor - left-hand center vents
12 Air outlet temperature sensor - right-hand center vents
13 Air outlet temperature sensor - left-hand footwell
14 Air outlet temperature sensor - right-hand footwell
15 Solar sensor
Refer to Component Description: Sun sensor - vehicles with automatic temperature
control
16 In-vehicle temperature sensor
Refer to Component Description:
Climate control system - vehicles with DVD navigation system with a touch screen

Item Description
1 Climate control module
Refer to Component Description: Climate control module - vehicles with DVD navigation
system with a touch screen
2 Blower control module
Refer to Component Description: Blower control module - vehicles equipped with
automatic temperature control
3 Blower motor
Refer to Component Description:
4 Air flap actuator
5 Actuator - right-hand temperature control flap
6 Actuator - left-hand temperature control flap
7 Actuator - air distribution flap - demister vents
8 Actuator - air distribution flap - center vents
9 Genetic electronic module (GEM).
10 Ambient air temperature sensor
Refer to Component Description: Ambient temperature sensor
11 DVD navigation system with touchscreen
12 Left-hand air outlet temperature sensor - left-hand center vents
13 Air outlet temperature sensor - right-hand center vents
14 Air outlet temperature sensor - left-hand footwell
15 Air outlet temperature sensor - right-hand footwell
16 Solar sensor
Refer to Component Description: Sun sensor - vehicles with automatic temperature
control
17 In-vehicle temperature sensor
Refer to Component Description:
Air conditioning system - vehicles with manual temperature control
Item Description
1 Air conditioning compressor
2 Climate control system control assembly
Refer to Component Description: Control assembly, climate control - vehicles with
manual temperature control
3 Genetic electronic module (GEM).
4 Ambient air temperature sensor
Refer to Component Description: Ambient temperature sensor
5 instrument cluster
6 High pressure limiting switch
7 Dual pressure switch
8 Powertrain control module (PCM)
9 Air conditioning clutch relay
Air conditioning system - vehicles with automatic temperature control
Item Description
1 Air conditioning compressor
2 Climate control system control assembly
Refer to Component Description: Control assembly, climate control - vehicles with
automatic temperature control
3 Genetic electronic module (GEM).
4 Ambient air temperature sensor
Refer to Component Description: Ambient temperature sensor
5 instrument cluster
6 High pressure limiting switch
7 Dual pressure switch
8 Powertrain control module (PCM)
9 Air conditioning clutch relay

System Operation
Climate control housing
General overview
Item Description
1 Blower motor
Refer to Component Description:
2 Pollen filter
Refer to Component Description:
3 Evaporator assembly
4 Heat exchanger
5 Electric booster heater (if equipped)
6 Temperature blend door motor
7 Air distribution flap, demister vents
8 Air distribution door - center vents
9 Air distribution door - footwell
10 Air intake door
11 Air duct, demister vents
12 Air passages - center vents
13 Air ducts, rear footwell
Air flow - defroster vents
Item Description
1 Warm air
2 Cold air
Air flow - center vents

Item Description
1 Warm air
2 Cold air
Air flow – footwell
Item Description
1 Warm air
2 Cold air

Climate control

Two options are available:

• manual climate control
• Air conditioning system with automatic temperature control (DEATC)

Item Description
1 Condenser
2 Air conditioning compressor
3 Suction accumulator
4 Evaporator assembly
5 Blower motor
6 Evaporator Core Orifice Tube
7 Cooling fans.
8 High - pressure (liquid and warm)
9 Low - pressure (liquid and cool)
10 Low pressure (gaseous and cold)
11 High pressure (gaseous and hot)
The engine driven refrigerant compressor (2) sucks in gaseous refrigerant from the suction
accumulator and compresses it. The temperature of the refrigerant rises to a value between
70 °C and 110 °C. It passes to the condenser (1) under high pressure.
At this point heat is drawn from the refrigerant by the air being forced past the cooling fins.
Because of this heat loss, the refrigerant liquefies and leaves the condenser.
A fixed orifice tube (6), which separates the refrigerant at high pressure from that at low
pressure, is located between the condenser and the evaporator (5). This fixed orifice tube
slows down the flow of the refrigerant from the compressor, so that pressure builds up in
the condenser.
After passing through the fixed orifice tube the liquid refrigerant expands in the circuit to
the evaporator, where it becomes gaseous. This causes heat to be extracted from the air
coming into the vehicle. The air cools down, and excess moisture contained in it is
condensed and is drained off. The refrigerant coming from the evaporator flows into the
refrigerant accumulator and is again sucked in by the refrigerant compressor.
The system is protected by a high-pressure limiting switch, in order to prevent damage by
excessive pressure (e.g. because of overfilling with refrigerant). If the pressure exceeds the
maximum permitted, the high-pressure switch turns off the refrigerant compressor.
The compressor on-off cycle is controlled by the dual pressure switch depending on the
pressure in the refrigerant accumulator. The dual pressure switch turns the refrigerant
compressor off permanently if the pressure falls below a permitted value (e.g. if there is a
leak).

Component Description
Air conditioning compressor

The special feature of a compressor with variable swash plate is that the stroke of the
pistons can be varied by means of the variable swash plate. The swash plate is mounted on
a slide rail in the axial direction.
The piston stroke and thus the delivery rate are determined by means of the variable
obliqueness of the swash plate.
The obliqueness of the swash plate is dependent upon the chamber pressure and thus on
the pressure conditions at the top and bottom of the piston. This is supported by springs in
front of and behind the swash plate.
The chamber pressure is determined by the high and low pressure applied to the control
valve and by a calibrated orifice bore. If the low pressure is relatively high, the control
valve is opened and the chamber pressure is reduced.
If the low pressure is relatively low, the control valve is closed and the chamber pressure is
increased. The force due to the chamber pressure exerted on the piston bottom, is higher
than the sum of the force due to the low pressure on the piston top and the spring force.
Pollen filter

The fresh air flowing into the vehicle through the air inlet housing passes through a pollen
filter which is located on the left-hand side of the climate control housing (LHD and RHD)
and removes pollen and dust particles measuring 0.003 mm or more.
Control assembly, climate control - vehicles with manual temperature control

In vehicles with manual temperature control, the heating and air conditioning are operated
using three rotary switches. The air distribution flaps are actuated via the air distribution
flap/temperature control flap actuating unit, which is connected via a rod to the control
assembly for the climate control. The temperature control flap is also actuated via the air
distribution flap/temperature control flap actuating unit, which is connected via a cable to
the control assembly. In addition, the operating switch for recirculated air mode and the
on/off switch for the air conditioning are located on the control assembly.
Control assembly, climate control - vehicles with automatic temperature control

Vehicles with automatic temperature control have a control assembly with the
following button operated functions:
• Switching the air conditioning system on and off
• Temperature adjustment for the driver's side/front passenger's side
• Switching the windshield defrost function on and off
• Switching the electronic automatic climate control and the dual mode on and off
• Air distribution
• Blower Control
• Switching off the dual automatic climate control
• Recirculated air control

Control assembly, climate control - vehicles with DVD navigation system with a
touch screen

On vehicles with a DVD navigation system with a touch screen, the control buttons for the
automatic temperature control (climate control) are integrated in this unit. In addition, all
heating and air conditioning functions can be controlled via the touchscreen. The
information exchange takes place on the mid-speed CAN bus (MS-CAN).
Climate control module - vehicles with DVD navigation system with a touch screen

On vehicles with a DVD navigation system with a touch screen, the climate control module
is provided as a separate component underneath the DVD navigation unit. It is actuated via
control buttons or via the navigation touch screen.
Sun sensor - vehicles with automatic temperature control

For vehicles with automatic temperature control the sun sensor determines the intensity of
the sunload. The sunload serves as an additional parameter for determining the blower air
temperature, the air distribution and the blower speed.
In-vehicle temperature sensor
The interior temperature sensor measures the temperature in the passenger compartment
and thereby also helps to control the pre-selected interior temperature. This is an NTC
resistor.
In order to achieve optimum measurement values, an integrated blower draws air from the
interior into the in-vehicle temperature sensor.
Ambient temperature sensor

The outside-temperature sensor measures the ambient temperature outside the vehicle.
The resistance, and so the voltage drop at the sensor, alter depending on the outside-air
temperature. This is an NTC resistor.
Blower motor

On vehicles with electronic automatic temperature control (EATC), a blower motor with
brushes is used.
Blower control module - vehicles equipped with automatic temperature control
On vehicles with electronic automatic temperature control (EATC) a blower control module
is fitted instead of the conventional blower motor resistor. This is located in the usual
position next to the blower motor, so that the cooling fins of the module are cooled by the
air flow.
The climate control module regulates the blower control module via a PWM signal, which in
turn regulates the voltage at the blower motor to between 3 V and 12.8 V, in an infinitely
variable manner.
The blower control module is fitted with a temperature monitor which continuously monitors
the internal temperature of the module. If the temperature rises above 105°C, the blower
motor is switched off until the temperature in the module falls to below 100°C.
If the current rises above the value of 26 A ± 3 A defined in the blower control module (e.g.
high dynamic pressure in blower housing during fast motorway driving), the current flow
through the blower motor is limited by the blower control module, until a safe value is
reached. If this value cannot be achieved (e.g. blower motor blocked or partially seized or
dynamic pressure in the blower housing permanently too high), the value is limited to 6 A ±
2 A.
Under normal conditions, the blower motor control returns to the normal state.
Climate Control - Climate Control Housing
Print

Removal and Installation

Special Tool(s) / General Equipment
303-435
Mounting Stand

501-125
Remover, Grab Handle Cover

501-404
Holding Tool, Instrument Panel

Hose Clamp(s)

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

Vehicles with air conditioning

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).

3. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
4.
5.

6.
7. NOTICE: Make sure that all openings are sealed.
Use the General Equipment: Hose Clamp(s)
Torque: 8 Nm

Vehicles without air conditioning

8. NOTICE: Make sure that all openings are sealed.

Use the General Equipment: Hose Clamp(s)
All vehicles

9. Remove both front doors.

Refer to: Front Door (501-03 Body Closures, Removal and Installation).

10. On both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
11.

12.
13.

14.
15.

16.
17.

18.
19.

20.
21.
1. On both sides.

Use Special Service Tool: 501-125.

22. NOTE: Note the position of the component before removal.

If equipped.
23. WARNING: Make sure that a new bolt is installed.

NOTICE: Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 28 Nm

24.

25. 1.
26.

27.
28.

29. Remove the driver seat.

Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

30. Torque: 25 Nm
31. Torque: 25 Nm

32. On both sides.

33. On both sides.

Torque: 40 Nm

34. Torque: 25 Nm

35. Torque: 25 Nm
Left-hand drive vehicles
36.
1. Use Special Service Tools: 303-435, 501-404.

2. Torque: 10 Nm
Right-hand drive vehicles
37. 1. Remove the tolerance absorber.
2. Use Special Service Tools: 303-435, 501-404.

3. Torque: 10 Nm
All vehicles
38.
40.

41.
42.

43.
44. Torque: 10 Nm

Installation

Removal

1. Refer to: Climate Control Housing (412-01 Climate Control, Removal and Installation).
2.

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3.

5.
1. Torque: 15 Nm

2. Torque: 25 Nm
6. NOTICE: Make sure that all openings are sealed.
1. Torque: 15 Nm

2. Torque: 20 Nm

3. Torque: 25 Nm

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.
Material: WSH-M1C231-B (Refrigerant Oil)
Climate Control - Air Conditioning (A/C) Compressor to Condenser Line
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

Removal

1. Refer to: Air Conditioning (A/C) Compressor Manifold and Tube Assembly (412-01
Climate Control, Removal and Installation).
2.

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Air Conditioning (A/C) Compressor Manifold and Tube
Assembly
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Conditioning (A/C) Compressor (412-01 Climate Control, Removal and
Installation).

Vehicles with auxiliary climate control

2. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm

All vehicles
4. NOTICE: Make sure that all openings are sealed.
1. Torque: 8 Nm

2. Torque: 8 Nm

General Equipment
Cable Ties

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).

3. Use the General Equipment: Cable Ties

4. On both sides.
5.

6. Torque: 25 Nm

7.
8. NOTICE: Make sure that all openings are sealed.
1. Torque: 8 Nm

2. Torque: 8 Nm

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Thermostatic Expansion Valve
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
3.

4. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm

5. NOTICE: Make sure that all openings are sealed.

Torque: 4 Nm
Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Thermostatic Expansion Valve Manifold and Tube
Assembly
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
3.

4. Remove the left handed headlamp.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

5. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

6. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
7.
8. NOTICE: Make sure that all openings are sealed.
Torque: 8 Nm

9.
1. Torque: 10 Nm
10.

11. Torque: 8 Nm
12. NOTICE: Make sure that all openings are sealed.
Torque: 8 Nm

13.
1. 1. NOTICE: Make sure that all openings are sealed.
If equipped.

Torque: 8 Nm
2. Torque: 8 Nm

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Receiver Drier
Print

Removal and Installation

General Equipment
Cable Ties

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Use the General Equipment: Cable Ties

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4.

5. NOTICE: Make sure that all openings are sealed.

Torque: 25 Nm
6.

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Air Conditioning (A/C)
Clutch and Air Conditioning (A/C) Clutch
Field Coil
Print

Removal and Installation

Special Tool(s) / General Equipment
412-134
Holding Tool, Compressor Clutch

412-157
Holding Fixture, Compressor Clutch

Puller

Removal

1. Refer to: Air Conditioning (A/C) Compressor (412-01 Climate Control, Removal and
Installation).

2. Refer to: Specifications (412-00 Climate Control System - General Information,

Specifications).
Use Special Service Tools: 412-134, 412-157.

3. Use the General Equipment: Puller

4. NOTE: Note the position of the component before removal.

Installation

1. NOTE: Make sure that the component is installed to the position noted before
removal.
To install, reverse the removal procedure.

2. Refer to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control
System - General Information, General Procedures).
Climate Control - Ambient Air Temperature Sensor
Print

Removal and Installation

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

Installation

1. To install, reverse the removal procedure.

Climate Control - High-Pressure Cutoff
Switch
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

3. WARNING: Make sure that the high-pressure cutoff switch valve closes
completely after removal of the high-pressure cutoff switch.
Torque: 8 Nm

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Climate Control - Climate Control Housing
Print

Disassembly and Assembly

Disassembly
NOTE: Removal steps in this procedure may contain installation details.
1.

3.
4. Torque: 4 Nm

5.
Assembly

6. To assemble, reverse the disassembly procedure.

Auxiliary Climate Control - Auxiliary
Climate Control - Overview
Print

Description and Operation

Initial start-up of the fuel-fired booster heater

The fuel-fired booster heater needs to be filled before being taken into operation for the
first time. Activation of the fuel pump for the fuel-fired booster heater is controlled by the
Ford diagnostic unit.
Lockout
Flame sensor
If the flame goes out independently during operation of the booster heater, a restart is
carried out. If the booster heater does not ignite within 90 seconds of fuel delivery or if the
flame goes out within 15 minutes of starting, a lockout will be implemented by the flame
sensor.
Lockout can be cancelled by switching the booster heater off then on again, although this
may only be repeated at most 2 times.
Overheating sensor
In the event of overheating (water shortage, poorly ventilated coolant circuit), the fuel
supply to the booster heater is interrupted and a lockout occurs. After the cause of the
overheating has been eliminated, the booster heater can be started again by switching it off
and on, if the coolant temperature is below 70°C. If the booster heater overheats ten times
in a row, the control unit will be locked.
Unlocking the control unit
Delete the fault memory of the fuel-fired booster heater after eliminating the cause of the
fault using the Ford diagnostic unit.
Auxiliary Climate Control - Auxiliary Climate Control - System Operation
and Component Description
Print

Description and Operation

System Diagram
Electric booster heater - vehicles with manual temperature control

Item Description
1 Electric Booster Heater
Refer to Component Description:
2 GEM (generic electronic module)
3 Outside temperature sensor
4 Climate control system control assembly
5 Generator and Alternator
6 PCM (powertrain control module)
7 Coolant temperature sensor (ECT (engine coolant temperature) sensor)
Refer to Component Description: ECT
8 instrument cluster
Electric booster heater - vehicles with automatic temperature control

Item Description
1 Electric Booster Heater
Refer to Component Description:
2 GEM
3 Outside temperature sensor
4 Climate control system control assembly
5 Generator and Alternator
6 PCM
7 Coolant temperature sensor (ECT sensor)
Refer to Component Description: ECT
8 instrument cluster
Programmable fuel fired booster heater

Item Description
1 Fuel powered booster heater
Refer to Component Description: Detailed illustration of fuel-fired heater
2 GEM
3 Outside temperature sensor
4 Climate control system control assembly
5 Blower control module
6 Blower motor
7 Crankshaft position (CKP) sensor
8 PCM
9 Coolant temperature sensor (ECT sensor)
Refer to Component Description: ECT
10 instrument cluster
11 Fuel level sensor
12 Fuel pump
Refer to Component Description:
13 Water pump
Refer to Component Description:
Coolant circuit - Programmable fuel fired booster heater

Item Description
1 Engine
2 Water pump
3 Fuel pump
4 Fuel tank
5 Blower motor
6 Heat exchanger
7 Air Intake
8 Exhaust pipe
9 Auxiliary Heaters

System Operation
Electric Booster Heater
In diesel vehicles which give off little residual heat, a booster heater is used to heat the
passenger compartment rapidly in the case of low ambient temperatures.
If the interior temperature has been set to HI, or if the heater controls have been switched
to the highest setting, the two-zone air conditioning system sends an "electric booster
heater ON" request signal to the CAN (controller area network) via the medium speed GEM
bus. If a manual air conditioning system is installed, the signal is transmitted via a
conventional cable connection.

The GEM switches on the electric booster heater depending on the following
parameters:
• Engine coolant temperature is below 60 °C.
• Ambient air temperature is below 10 °C.
• Sufficient generator capacity is available.

The electric booster heater electronics activate three output stages as a function of a pulse
width modulated signal PWM (pulse width modulation) generated by the GEM. The output
stages switch the three heating elements of the electric booster heater ON or OFF
individually, whereby the heating periods of the individual elements can overlap. Due to the
variable switch-on duration, continuously variable temperature control is possible. The
overall heating power of the three heating elements is linearly proportional to the PWM
signal. If the PWM signal is below 10% or above 95%, the electric booster heater is not
activated.
The electric booster heater is switched off when an engine coolant temperature of 70°C or
an ambient air temperature of 20°C is exceeded.
Fuel-fired heater - function diagram

Item Description
1 Glow plug
2 Combustion Air Blower
3 Fuel pump
4 Fuel-fired heater on
5 Fuel-fired heater - large regulating step
6 Fuel-fired heater - small regulating step
7 Fuel-fired heater off
8 Blower motor on
9 Flame detection
10 Blower motor off
11 Large regulating step
12 Small regulating step

Boost heat mode

When the engine is running, the booster heater helps the engine to heat the passenger
compartment at low ambient temperatures.
When the coolant temperature reaches 30 °C, the control unit transmits a switch-on signal
for the passenger compartment blower via the CAN bus. When the coolant temperature
drops, the blower remains on until the temperature reaches 20 °C whereupon it is
deactivated.
The fuel tank must be filled to at least 14% for the system to be switched on. If the fuel
level drops below 8% then the system is switched off.

In boost mode, the fuel fired booster heater is only switched on if all of the following
criteria are met:
• Engine speed above 500 rpm. The fuel fired booster heater is not allowed to start up
while the engine is being cranked; this prevents a shut-down due to low voltage if the
battery charge is low.
• Ambient temperature below 5 °C.
• Fuel level above 14% of total capacity.
• Function is active on the trip computer menu.

One of the following conditions is sufficient to switch off the booster heater in boost
heat mode:
• Engine speed below 500 rpm.
• Ambient temperature above 11 °C.
• Function is active on the trip computer menu.
• Fuel level below 8% of total capacity.

Programmable fuel fired booster heater

The programmable fuel fired booster heater has two operating modes:
• Instant start
• Programmed start

The heater status is displayed on the instrument cluster display. The parking heater mode
is controlled via a menu in the message centre. The fuel fired booster heater can be
activated and deactivated via the message centre. (If set to 'Auto' the system is activated,
if set to 'Off' the system is completely deactivated)
Immediate start-up of the booster heater
This function enables the fuel-fired booster heater to be switched on manually when the
engine is not running. This function is activated via the menu on the driver information
system.
The ignition key must be in the II" position before this menu can be accessed. The timer
function of the booster heater remains active when the ignition key is in position "0".
After an immediate start-up of the booster heater it is switched off again after 30 minutes
(or if the fuel level in the fuel tank drops below 8%). The booster heater stops within 2
minutes of the engine starting. This leaves enough time to check whether the switch-on
conditions for boost heat mode have been met, thus preventing the booster heater from
having to switch off and switch back on again. The heater can be switched off manually at
any time from the menu.
Programmed start-up of the booster heater

The driver can use a menu to adjust the time at which the vehicle is to be pre-heated.
The following options are available:
• Time setting. One or two times can be programmed for each day of the week. It is
possible to program days either individually or together in groups (Mon-Sun/Mon-
Sat/Mon-Fri).
• Time and data setting

With the first option, the fuel-fired booster heater will start repeatedly without needing to
be reprogrammed. However, if the engine hasn't been run since the last programmed start,
the fuel-fired booster heater will not start up the second time so as to prevent the battery
from being discharged.

The length of time required to pre-heat the vehicle is calculated in the control unit of
the fuel-fired booster heater and is based on two temperature values:
• Ambient air temperature: this message is taken from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster
heater.

The maximum heating time is 30 minutes at an outside air temperature of -10 °C or lower.
The heating time decreases proportionally with increasing ambient temperature until the
ambient temperature reaches +15 °C. Then the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures above +15 °C.

The sequence for a programmed start of the booster heater is as follows:

• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation message to the fuel-fired booster heater
via the CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary,
sends a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up
are: engine not running and amount of fuel in the fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster
heater sends a request to switch on the passenger compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating
mode and starts a run-on operation to clean the system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides some leeway in case the driver is late
arriving.

After a programmed start-up of the booster heater it is switched off again after the heating
time has elapsed (or if the fuel level in the fuel tank drops below 8%). The booster heater
stops within 2 minutes of the engine starting. This leaves enough time to check whether the
switch-on conditions for boost heat mode have been met, thus preventing the booster
heater from having to switch off and switch back on again. The heater can be switched off
manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional heating mode and/or parking heating
mode, the instrument cluster receives a fuel consumption signal; this is used to re-calculate
the vehicle's remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags are deployed, the control unit of the fuel-
fired booster heater receives a message on the CAN bus from the restraints control module
(RCM). When this message is received, the booster heater system switches off immediately.
The booster heater control module deactivates the system and does not respond to further
messages on the CAN bus. The booster heater control module needs to be activated with
WDS.

Component Description
Electric Booster Heater
The electric booster heater consists of three individual heating elements, which are
incorporated into a single housing. It is controlled by the generic electronic module (GEM),
taking into account the following factors:
Detailed illustration of fuel-fired heater

Item Description
1 Cooling sleeve cover
2 Combustion air blower cover
3 Fuel fired additional heater module
4 Combustion Air Blower
5 Cooling sleeve
6 Glow plug
7 Flame sensor
8 Overheat Sensor
9 ECT
10 Compression spring
11 'O' Ring
12 Internal wiring harness - fuel fired additional heater
13 Gasket
14 Gasket
15 Heat exchanger
16 Combustion chamber
17 'O' Ring
18 Combustion blower motor cover
19 Glow plug wiring harness

Flame sensor
If the flame goes out independently during operation of the booster heater, a restart is
carried out. If the booster heater does not ignite within 90 seconds of fuel delivery or if the
flame goes out within 15 minutes of starting, a lockout will be implemented by the flame
sensor.
Lockout can be cancelled by switching the booster heater off then on again, although this
may only be repeated at most 2 times.
Overheat Sensor
The overheating sensor enables the fuel-fired booster heater module to determine the
coolant temperature, protecting the heater from overheating. The overheating sensor is
installed next to the coolant temperature sensor under a cover on the top of the fuel-fired
heater.
In the event of overheating (lack of water, poorly ventilated coolant circuit), the fuel supply
to the heater is interrupted and a lockout occurs. After the cause of the overheating has
been eliminated, the heater can be restarted by switching it off and on again, if the coolant
temperature is below 70°C. If the heater overheats ten times in a row, the control unit is
locked.
ECT
The fuel-fired booster heater module uses the temperature sensor to determine the coolant
temperature, which it then uses to set the starting and stopping time. The coolant
temperature sensor is installed next to the overheating sensor under a cover on the top of
the fuel-fired heater.
Water pump

The coolant pump is located on the holder for the fuel-fired heater on the bulkhead in the
rear of the engine compartment. The coolant pump is driven by a built-in electric motor and
circulates the coolant in the engine cooling system. The delivery rate for the pump is 820l/h
at a delivery pressure of 0.1 bar.
Fuel pump

The fuel required for the fuel-fired heater is taken from the fuel system by a fuel pump
fitted in the fuel tank and is delivered to the heater via a fuel line.
The fuel pump is an electric piston pump which meters the corresponding fuel volume for
the fuel-fired heater according to a cycle set by the fuel-fired heater module.
Auxiliary Climate Control - Electric Booster Heater—RHD FWD
Print

Removal and Installation

Removal

1. Refer to: Climate Control Housing (412-01 Climate Control, Removal and Installation).
2.

Installation

1. To install, reverse the removal procedure.

Auxiliary Climate Control - Fuel Fired Booster Heater
Print

Removal and Installation

General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General
Information, Description and Operation).

3. Use the General Equipment: Hose Clamp(s)

4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Use the General Equipment: Hose Clamp(s)

6. NOTICE: Make sure that all openings are sealed.

Use the General Equipment: Hose Clamp Remover/Installer
Torque: 8 Nm
7. NOTE: This step is not necessary when installing a new component.
Torque: 8 Nm

General Equipment
Hose Clamp(s)

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

Removal
Vehicles with auxiliary climate control

1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).

All vehicles

2. Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and
Installation).

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

Vehicles with auxiliary heating

4. NOTICE: Make sure that all openings are sealed.

Use the General Equipment: Hose Clamp(s)
Torque: 8 Nm

Vehicles with auxiliary climate control

5. NOTICE: Make sure that all openings are sealed.

Use the General Equipment: Hose Clamp(s)
Torque: 8 Nm
6.

All vehicles
7.
NOTE: The following steps are only necessary when installing a new component.
8.

9.
10. NOTICE: Make sure that all openings are sealed.
Torque: 4 Nm

11.
12.

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Auxiliary Climate Control - Auxiliary Heater Core
Print

Removal and Installation

Removal

1. Refer to: Auxiliary Climate Control Housing (412-02A Auxiliary Climate Control, Removal
and Installation).
2.

Torque: 4 Nm

Installation

1. To install, reverse the removal procedure.

Auxiliary Climate Control - Auxiliary Evaporator Rear Outlet and Inlet
Line
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

3. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm

4. Torque: 8 Nm

5. Torque: 8 Nm
6. NOTICE: Make sure that all openings are sealed.
Torque: 8 Nm

Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Auxiliary Climate Control - Auxiliary Evaporator Front Outlet and Inlet
Line
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

3. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm

4. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm
Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Auxiliary Climate Control - Fuel Fired Booster Heater
Print

Disassembly and Assembly

General Equipment
Terminal Release Tool

Disassembly
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Fuel Fired Booster Heater (412-02A Auxiliary Climate Control, Removal and
Installation).

3. Torque: 4 Nm

4. Torque: 4 Nm
5. Torque: 6 Nm

6.
7.
1. Torque: 3 Nm

2. Torque: 6 Nm

8.
9.

10. Use the General Equipment: Terminal Release Tool

11. NOTICE: Use an open-ended wrench to prevent the component from turning.
Use the General Equipment: Terminal Release Tool
Torque: 6 Nm

12. Use the General Equipment: Terminal Release Tool

Torque: 3 Nm
13.

14. Use the General Equipment: Terminal Release Tool

Torque: 5 Nm
15.

16.
Assembly

17. To assemble, reverse the disassembly procedure.

Rear Climate Control - Rear Evaporator Inlet Line
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B
Refrigerant Oil WSS-M2C300-A2

2. NOTICE: Make sure that all openings are sealed.

1. Torque: 6 Nm

2. Torque: 8 Nm

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

4. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm
Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Material: WSS-M2C300-A2 (Refrigerant Oil)
Rear Climate Control - Rear Evaporator Outlet Line
Print

Removal and Installation

Materials
Name Specification
Refrigerant Oil WSH-M1C231-B

2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. Remove engine undershield - If equipped.

4. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm

5. NOTICE: Make sure that all openings are sealed.

Torque: 8 Nm
Installation

1. NOTICE: Only use the specified material to lubricate the seals.

To install, reverse the removal procedure.

Material: WSH-M1C231-B (Refrigerant Oil)

Instrument Panel Cluster (IPC) -
Instrument Panel Cluster (IPC) -
Overview
Print

Description and Operation

Replacing the instrument cluster

When installing a new instrument cluster, the Ford diagnostics device must be connected
before dismantling the instrument cluster, in order to load the configuration data of the
defective instrument cluster using the "Installation of programmable modules" routine. In
addition, the value on the odometer of the defective instrument cluster must be noted, as
this is required for configuration of the new instrument cluster. If the odometer value
cannot be obtained from the instrument cluster (display failure), the customer should
supply the approximate value.
When installing a new instrument cluster, the Ford diagnostics device must be connected
after installation in order to download the configuration data of the defective instrument
cluster into the new instrument cluster using the "Installation of programmable modules"
routine, and to configure the newly installed instrument cluster to the PATS system.
Self-diagnostic mode

• To enter the instrument cluster self-diagnostic mode, simultaneously press and hold the
set button and turn the ignition switch from position 0 to position II.
• Entry to self-diagnostic mode is confirmed when 'TEST' is displayed in the odometer's
liquid crystal display (LCD). The instrument cluster set button must be released within 3
seconds of TEST being displayed in the tripmeter LCD (liquid crystal display) display.
Otherwise the system will exit self-diagnostic mode.
• To navigate through or skip any of the instrument cluster self-diagnostic mode tests,
press the SET button. If the SET button is pressed for more than 3 seconds between
tests, the instrument cluster will exit self-diagnostic mode.
• Self-diagnostic mode is deactivated when the ignition switch is turned to the OFF position
or low battery voltage is detected.
• If input data to the instrument cluster is missing or invalid, the tripmeter LCD will display
'----'.
• If the self-diagnostic mode cannot be activated, test the instrument cluster using the
Ford diagnostic device.
Instrument Panel Cluster (IPC) - Instrument Panel Cluster (IPC) -
System Operation and Component Description
Print

Description and Operation

System Diagram

Item Description
1 Instrument Cluster
2 PCM (powertrain control module)
3 {Acronym.EHPS} ({Acronym.EHPS}) control module
4 Audio unit
5 GEM (generic electronic module)
6 RCM (restraints control module)
7 PATS transceiver
8 Steering wheel lock module
9 Left-hand steering column switch
10 Fuel level sensor
11 Washer water level warning lamp switch
12 Accelerator pedal position sensor
13 CPP (clutch pedal position) sensor/BPP (brake pedal position) sensor
14 Lighting control switch

System Operation
Instrument Cluster
The instrument cluster contains analog displays as well as warning and control lamps for
displaying the system status; in addiiton, there is an LCD (liquid crystal display) indicator
field for driver information.
The instrument cluster receives the following signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):

• Vehicle speed
- The PCM receives the necessary signals from the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed

The instrument cluster receives the following signals from the GEM via the medium speed
CAN Bus (MS-CAN):

• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control

The fuel level signal is sent by the two fuel level sensors in the fuel pumps in the semitrailer
tank, which is wired to the instrument cluster. The sensors are connected in series, and the
total resistance is determined from the two individual resistors. The instrument cluster
converts the raw fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled by the vehicle and is based on the same
signal as is processed for the daily mileage counter. The value is recorded by the
instrument cluster and stored in a protected EEPROM (Electronically Erasable Programmable
Read Only Memory) area. This area is a memory protected against manipulation. If the
instrument cluster detects an error in this memory area, e.g. through damage, the driver is
notified with the "Odometer error" message.
Message center
The message center is operated using the left-hand switch on the steering column.
The SET/RESET button is activated to select a submenu and change the settings. If signal
tones have been activated, a short acoustic signal will sound each time a button is pressed.
By turning the rotary switch, the different menu displays can be scrolled through or a
setting selected.
In this display, the navigation system can also display direction and distance information.
In addition, safety and warning messages can be displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer fluid level too low". In addition to a safety
message, a general warning light (red/yellow) lights up.

Component Description
Vehicles with low series instrument cluster

Item Description
1 Glow plug indicator
2 Speed control system indicator
3 Gear shift indicator
4 Air bag warning indicator
5 Left-hand turn signal indicator
6 Coolant temperature gauge
7 Generic warning indicator (red/amber)
8 PATS (passive anti-theft system) control
9 Fuel Level Gauge
10 Right-hand turn signal indicator
11 Malfunction Indicator Lamp (MIL)
12 Low fuel warning indicator
13 Anti-lock Braking system (ABS) Warning Indicator
14 Stability assist indicator
15 Brake warning indicator
16 Speedometer
17 Charging system indicator
18 Low oil pressure warning indicator
19 Message center
20 Seat belt indicator
21 Ice warning indicator
22 Rear Fog Lamp Indicator
23 Front fog lamp indicator
24 Headlamp indicator
25 High beam indicator
26 Tachometer

Vehicles with high series instrument cluster

Item Description
1 Glow plug indicator
2 Speed control system indicator
3 Gear shift indicator
4 Air bag warning indicator
5 Left-hand turn signal indicator
6 Coolant temperature gauge
7 Generic warning indicator (red/amber)
8 PATS control
9 Fuel Level Gauge
10 Right-hand turn signal indicator
11 Malfunction Indicator Lamp (MIL)
12 Low fuel warning indicator
13 Anti-lock Braking system (ABS) Warning Indicator
14 Stability assist indicator
15 Brake warning indicator
16 Speedometer
17 Charging system indicator
18 Low oil pressure warning indicator
19 Message center
20 Seat belt indicator
21 Ice warning indicator
22 Rear Fog Lamp Indicator
23 Front fog lamp indicator
24 Headlamp indicator
25 High beam indicator
26 Tachometer
Instrument Panel Cluster (IPC) -
Instrument Panel Cluster (IPC)
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 060-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Engine oil level • Fuse(s)
• Oil pressure (EOP) switch • Wiring harness
• Engine coolant level • Electrical connector(s)
• Coolant level indicator switch • Light emitting diode(s) (LED)
• Coolant thermostat • Engine coolant temperature (ECT) sensor
• Fuel gauge • Brake pad wear sensor(s)
• Collapsed or damaged fuel tank • Ambient air temperature sensor
• Fuel pump and sender unit • Vehicle speed sensor (VSS)
• Indicated fuel level • Instrument cluster
• Brake fluid level indicator switch • Tachograph
• Parking brake indicator switch • Multi-function display module
• Washer fluid level switch • Body control module (BCM)
• Steering wheel control(s) • Steering column control module (SCCM)
• Passenger air bag deactivation (PAD) • Restraints control module (RCM)
switch • Powertrain control module (PCM)
• Door adjustment

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

5. If the cause is still evident, refer to the Diagnostic tab within the Ford diagnostic
equipment.

Symptom Chart

Symptom Sources
The fuel gauge is inoperative or erratic Circuit(s)
Fuel pump and sender unit
Instrument cluster
BCM
Configuration of the Instrument Cluster
The instrument cluster is a programmable module, which must be configured by selecting
the Programmable Module Installation Routine on the Ford diagnostic equipment.
NOTE: When the new instrument cluster has been configured with the odometer value, its
configuration cannot be decreased or matched. A new configuration will result in an
increase in the displayed odometer value by a minimum of two units.
NOTE: The odometer value must be recorded from the original instrument cluster before
removal.
If the odometer value cannot be obtained from the original instrument cluster (display
failure) the customer should supply the approximate value.
In addition, the new instrument cluster will require the original odometer value to be
entered.
After the installation and configuration of a new instrument cluster. The passive anti-theft
system (PATS) will require programming by selecting the Security Access routine on the
Ford diagnostic equipment.
Instrument Panel Cluster (IPC) - Instrument Panel Cluster (IPC)
Print

Removal and Installation

General Equipment
Ford approved diagnostic tool

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. NOTE: This step is only necessary when installing a new component.
Upload the instrument cluster configuration information using the Programmable
Modules Installation Routine.

Use the General Equipment: Ford approved diagnostic tool

2. NOTE: This step is only necessary when installing a new component.
Record the odometer value from the original instrument cluster. If the odometer value
cannot be obtained from the instrument cluster (display failure), perform the diagnostic
routine. If the value cannot be obtained after the diagnostic routine, the customer
should supply the approximate odometer value.
3.

5.
6.

7.
Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
Download the instrument cluster configuration information to the newly installed
instrument cluster using the programmable modules installation routine.
3. NOTE: This step is only necessary when installing a new component.
Write the odometer value from the original instrument cluster to the new instrument
cluster.
Instrumentation, Message Center and
Warning Chimes - Seatbelt Minder
Deactivating/Activating
Print

General Procedures

Activation

WARNING: Before beginning any service procedure in this section, refer to Safety
Warnings in section 100-00 General Information. Failure to follow this instruction may
result in serious personal injury.
NOTE: The driver and passenger seat Belt-Minder® deactivating/activating can be carried
out using a diagnostic scan tool.
NOTE: If you are using a MyKey® programmed key, the Belt-Minder® cannot be disabled
and does not time out after 5 minutes. If the Belt-Minder® has been previously disabled,
it is re-enabled when a MyKey® programmed key is used.
NOTE: The driver and front passenger Belt-Minder® are deactivated/activated
independently. When deactivating/activating one seating position, do not buckle the other
position.
1. Apply the parking brake before deactivating/activating the Belt-Minder®.
2. Place the selector lever in Park (P) (automatic transmission) or Neutral (N) (manual
transmission).
3. Place the ignition OFF.
4. Unbuckle the driver and the front passenger safety belts.
5. Place the ignition in RUN (do not start the engine).
6. Wait until the safety belt warning indicator turns off (approximately 1 minute).
7. NOTE: Steps 7 and 8 must be completed within 30 seconds after the safety belt
warning indicator turns off (step 6).
NOTE: Buckle and unbuckle the safety belt at a moderate rate. If the safety belt
buckle/unbuckle/buckle sequence is carried out too quickly, the RCM (restraints
control module) can fail to recognize one of the sequences and the procedure must
be repeated.
For the seating position to be disabled, buckle then unbuckle the safety belt 3 times at a
moderate speed, ending with the safety belt in the unbuckled state. After this step the
safety belt warning indicator turns off.
8. NOTE: As confirmation of enabling or disabling the Belt-Minder®, the safety belt
warning indicator, beginning with the safety belt warning indicator in the off state,
flashes for 4.5 seconds.
Within 7 seconds of the indicator turning off, buckle then unbuckle the safety belt at a
moderate speed.
9. After confirmation, the deactivation/activation procedure is complete.
Horn - Horn
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Principles of Operation
The horn system consists of a relay, a steering wheel switch and either one or two horns.
The horn(s) receives voltage from the switched side of the relay, and the relay switch is
controlled on its ground side by the steering wheel switch.
The horn relay, is located in the engine junction box (EJB) and is supplied with a permanent
voltage from the battery.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Horn(s)
• Steering wheel module
• Horn switch
• Horn relay
• Generic electronic module(GEM)
• EJB

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the symptom
based diagnostic tab within the Ford diagnostic equipment.
Horn - Horn
Print

Removal and Installation

Removal

1. NOTE: Removal steps in this procedure may contain installation details.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

2. If equipped.

Torque: 23 Nm

3. If equipped.

Torque: 23 Nm
Installation

1. To install, reverse the removal procedure.

Warning Chimes - Image Processing Module A (IPMA)
Print

Removal and Installation

General Equipment
Ford approved diagnostic tool
Interior Trim Remover

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. NOTICE: Make sure that the cable cannot be damaged or cause a noise,
vibration or harshness (NVH) concern.
Use the General Equipment: Interior Trim Remover
Installation

1. NOTICE: Make sure that the surface is clean and free of foreign material.
To install, reverse the removal procedure.
2. NOTE: This step is only necessary when installing a new component.
Calibrate the front view camera using the diagnostic tool.

Use the General Equipment: Ford approved diagnostic tool

Parking Aid - Parking Aid - Overview
Print

Description and Operation

Parking aid sensors

NOTICE:

Always keep sensors free from dirt, ice and snow. Do not use any sharp objects to
clean the sensors.

If a high-pressure cleaner is used to wash the vehicle, the jet must only be aimed at
the sensors briefly at a distance of at least 20 cm.
The parking aid sensors have a separate decoupling ring, which must be removed before
painting the sensors, and then refitted.
Front sensors detection range

Rear sensors detection range

Parking aid camera module
It is not necessary to programme the module after changing it.
Parking Aid Camera
NOTICE:

Always keep the reversing camera free from dirt, ice and snow. Do not clean with
sharp objects, fat solvents, wax or organic media. Only use a damp cloth for cleaning.

If a high-pressure cleaner is used to wash the vehicle, the jet must only be aimed at
the reversing camera briefly at a distance of at least 20 cm.

The reversing camera is sensitive to pressure. The position and angle of the camera
can be changed with increased pressure.
It is not necessary to programme the camera after changing it.
Parking Aid - Parking Aid - System Operation and Component
Description
Print

Description and Operation

System Diagram
Vehicles with rear parking aid

Item Description
1 Parking aid module
Refer to Component Description:
2 Rear parking aid speaker
Refer to Component Description:
3 Generic Electronic Module (GEM)
4 Reverse gear switch
5 Instrument cluster
6 ABS sensor assembly
7 ABS
8 Trailer relay
9 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
10 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
11 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
12 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
Vehicles with front and rear parking aid

Item Description
1 Parking aid module
Refer to Component Description:
2 Front parking aid speaker
Refer to Component Description:
3 Rear parking aid speaker
Refer to Component Description:
4 Generic Electronic Module (GEM)
5 Reverse gear switch
6 Instrument cluster
7 ABS sensor assembly
8 ABS
9 Trailer relay
10 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
11 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
12 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
13 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
14 Front parking aid sensor
Refer to Component Description: Parking aid sensors
15 Front parking aid sensor
Refer to Component Description: Parking aid sensors
16 Front parking aid sensor
Refer to Component Description: Parking aid sensors
17 Front parking aid sensor
Refer to Component Description: Parking aid sensors
18 Parking aid switch (with light emitting diode (LED))
Refer to Component Description: Parking aid switch
Vehicles with parking aid camera
Item Description
1 Parking aid camera module
Refer to Component Description: Parking aid camera module
2 Parking Aid Camera
Refer to Component Description: Parking aid camera module
3 Generic Electronic Module (GEM)
4 Reverse gear switch
5 Parking aid module
Refer to Component Description:
6 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
7 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
8 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
9 Rear parking aid sensor
Refer to Component Description: Parking aid sensors
10 steering angle sensor
11 Navigation device

System Operation
Parking Aid
WARNING: It is the driver's responsibility to stay alert during reversing procedures.
The system may fail to detect small children or animals.

NOTICE: The driver is responsible for detecting obstacles and judging the distance
between these and the vehicle. The system may fail to detect some hanging objects,
barriers, narrow obstacles or painted surfaces, which could damage the vehicle. Always
pay attention when parking.
The parking aid provides an audible warning to the driver if there are any obstacles in front
of or behind the vehicle during reverse parking maneuvers.
At low speeds, the parking aid module uses the parking aid sensors to monitor the area
around the vehicle. If an object is detected within a monitored area, the parking aid module
emits a warning tone using the respective parking aid speaker.
The rear parking aid is switched on with the ignition. However, it is only enabled when
reverse gear is selected.
The front and rear parking aid is always switched off when the ignition is switched on. It is
switched on when reverse gear is selected or if the parking aid switch in the center console
is actuated up to a speed of 16 km/h.
The parking aid is switched off when the vehicle is travelling forwards at more than 16
km/h or if the parking aid switch in the center console is actuated again.
When the parking aid module activates the system, the parking aid switch LED is
illuminated. If the vehicle is only fitted with the rear parking aid, there is no switch.
The parking aid sensors emit a series of ultrasonic impulses and switch to receiver mode to
receive the echo reflected by an obstacle within the detection range. The received echo
signals are amplified and converted from an analog signal to a digital signal by the sensor.
The digital signal is passed to the parking aid module and compared with pre-programmed
data stored in an EEPROM within the module. The module calculates the distance to the
obstacle by measuring the time taken between the emitted and received impulses.
If no objects are detected there are no further warning tones. If an object is detected,
repeated audible tones are emitted from either parking aid speaker(s) as appropriate. The
time delay between the tones decreases as the distance between the object and the vehicle
decreases, until at approximately 250 mm (10 inches), the audible tone becomes
continuous.
If the distance between the obstacle and the vehicle does not decrease, the warning tone
remains constant if the object has been detected by an internal parking aid sensor. If the
obstacle was detected by an external sensor and the distance remains unchanged, the
warning tone stops after 3 seconds.
The parking aid module continues to monitor the distance and will resume the warning
tones if a decrease in distance is detected.
If a trailer is connected to the vehicle, a signal is sent to the GEM (generic electronic
module) via the trailer relay. This signal is sent to the parking aid module via the MS CAN
bus. When the parking aid module detects that a trailer is connected to the vehicle, the rear
parking aid sensors are disabled to prevent constant warnings due to the close proximity of
the trailer.
Parking Aid Camera
For vehicles with a DVD navigation system with a touch screen, the parking aid camera is
supplied as standard. For vehicles with a standard navigation system, the camera can be
ordered as an optional extra. The system essentially consists of a camera with a wide angle
lens, a control unit and a wiring harness which is not integrated in the vehicle wiring
harness.
On the navigation display screen, the drivers sees a video image of the area behind the
vehicle. Guides integrated in the camera images by the parking aid camera module and
displayed on the screen help the driver to find out about the steering angle, vehicle width,
cornering and driving straight ahead. The system generates these guides using:

• Vehicle parameters (length, width)

• Steering Angle
• Vehicle position during the parking maneuver

Item Description
1 Monitoring angle
If the vehicle is also fitted with a rear parking aid, the distances to the obstacle are
displayed as a 3D illustration.

The area behind the vehicle is shown on the navigation display screen when the ignition is
switched on and reverse gear is engaged (1). The rear view is always given priority,
regardless of what is currently being shown on the display.
The camera view is automatically disabled 10 seconds after disengaging reverse gear (2).
If the blue button is pressed during operation of the reversing camera, the camera view
disappears from the screen. When reverse gear is engaged again, the system returns to the
camera view. Exception: For incoming telephone calls, the screen shows the corresponding
menu and then automatically returns to the camera view.
The green buttons can be pressed during operation of the reversing camera, and the screen
retains the camera view.

Component Description
Rear parking aid speaker
The rear parking aid speaker, in addition to its actual function, is also used for audible
indication of various types of error in the front and rear parking aids. If the rear parking aid
speaker becomes defective, the front parking aid speaker will then be used to indicate
failure modes.
If an error is detected in the system, a signal tone is emitted via the speaker for 3 seconds.
Parking aid sensors
NOTICE:

Always keep sensors free from dirt, ice and snow. Do not use any sharp objects to
clean the sensors.

If a high-pressure cleaner is used to wash the vehicle, the jet must only be aimed at
the sensors briefly at a distance of at least 20 cm.

The parking aid sensor consists of the following:

• Plastic housing
• Aluminum membrane with Piezo disc
• Decoupling ring
• Printed circuit board (PCB)

The parking aid sensor consists of a sensor and a holder. The holder makes sure that each
parking aid sensor is correctly orientated in relation to its location in the rear bumper.
The sensors have a 3-pin connector which is connected to the wiring harness of the front
bumper. This in turn is connected to the main body wiring harness. Three pins provide for
power supply, ground and signal lines to and from the parking aid module.
The disc resonates at a frequency of ca. 50kHz, producing the ultrasonic output. The disc
also receives the reflected echo signal from any objects within range.
Parking aid module

The parking aid module has three connectors which provide for power, ground and MS CAN
bus connections, as well as the front and rear parking aid sensors, the parking aid switch
and parking aid speaker.
The parking aid module carries out self-check routines and when the parking aid is active,
checks the parking aid sensor wiring for short or open circuits. If a concern is detected, a
diagnostic trouble code (DTC) is stored in a memory in the parking aid module and the
front and rear parking aid sensors will be disabled until the DTC is cleared and the ignition
cycled. The driver recognizes a problem through the flashing LED and a shrill continuous
tone, which is emitted for 3 seconds when the parking aid is activated. If the parking aid is
working properly, short tones are emitted instead of this continuous tone. DTCs can be read
using the Ford approved diagnostic tool through the data link connector (DLC).
Front parking aid speaker

The front parking aid speaker, in addition to its actual function, is also used for audible
indication of various types of error in the front and rear parking aids when the rear parking
aid speaker fails.
Parking aid switch

The parking aid switch is a non-locking switch with an integrated LED for switching the
parking aid on and off. When pressed, the parking aid switch momentarily connects a
ground to the parking aid module. The LED indicates when the parking aid is active. The
LED is controlled by the parking aid module.
The parking aid switch allows the driver to disable the parking aid when reverse gear is
selected or to activate the parking aid sensors when not in reverse gear.
If a high tone is emitted for 3 seconds and the lights in the switch flash, this indicates that
there is a fault. The system is then deactivated.
Parking aid camera module

The data from the optional parking aid is sent to the module via the Mid Speed CAN data
bus. The signals from the steering angle sensor are sent to the module via cable. The
module is connected to the navigation device via a video-in/out cable.
Parking Aid Camera
The wide angle lens camera is fixed in the handle strip of the tailgate. It is connected to the
parking aid camera module via a separate line.
Parking Aid - Parking Aid
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 131-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION CHART

Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Front parking aid sensor(s)
• Rear parking aid sensor(s)
• Rear parking aid camera
• Parking aid switch
• Front parking aid speaker
• Rear parking aid speaker
• Auto-dimming interior mirror
• Auxiliary junction box (AJB)
• Image processing module B (IPMB)
• Body control module (BCM)
• Parking assist control module (PAM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Self-
Diagnostic Mode.

Self-Diagnostic Mode

1. NOTE: Self-Diagnostic Mode is always carried out when the parking aid system is
activated.
To enter the parking aid module Self-Diagnostic Mode, turn the ignition key to
position 0 and make sure that the vehicle is in neutral gear.

2. Make sure that there are no obstacles within 2 meters of the front or rear of the
vehicle.

3. Turn the ignition key to position II and select reverse gear.

4. If there is a concern, the Self-Diagnostic Mode will be indicated by an audible tone for
3 seconds from the parking aid system, and is paused for 1 second, otherwise the
system proceeds with normal operation.

5. If a concern is detected, the 3 seconds prelude tone will be followed by a tone

sequence indicationg the highest priority error. After a 1 second delay, the concern
is identified with a 1 to 8 beep tone.

6. To exit the Self-Diagnostic Mode, select neutral gear, turn the ignition key to position
0.

7. Carry out the Self-Daignostic Mode again to confirm that there are no further errors
present.
AUDIBLE TONE SEQUENCE FROM REAR SYSTEM

Audible Tone Sequence From Description Action

Rear System
ON for 3 seconds, pause for 1 Opening sequence for concern -
second diagnostics
3 second prelude tone + 1 Rear left-hand outer sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 2 Rear left-hand inner sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 3 Rear right-hand inner sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 4 Rear right-hand outer sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 5 ECU errors REFER to the Ford diagnostic
beep tone from rear system equipment
3 second prelude tone + 6 Common sensor VBatt circuit REFER to the Wiring Diagrams
beep tone from rear system and CHECK the VBatt circuit(s)
3 second prelude tone + 7 All rear sensors REFER to the Wiring Diagrams
beep tone from rear system and CHECK S406 and S407 and
associated circuit(s)

AUDIBLE TONE SEQUENCE FROM FRONT SYSTEM

Audible Tone Sequence From Description Action

Front System
ON for 3 seconds, pause for 1 Opening sequence for concern -
second diagnostics
3 second prelude tone + 1 Front left-hand outer sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 2 Front left-hand inner sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 3 Front right-hand inner sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 4 Front right-hand outer sensor REFER to the Component Test
beep tone concern in this procedure.
3 second prelude tone + 5 Switch failure REFER to the Ford diagnostic
beep tone from front system equipment
3 second prelude tone + 6 LED indicator failure REFER to the Ford diagnostic
beep tone from front system equipment
3 second prelude tone + 7 All front sensors REFER to the Wiring Diagrams
beep tone from front system and CHECK S195 and S196 and
associated circuit(s)
Component Tests
Parking Aid Sensor Wiring Harness
NOTE: Refer to the Wiring Diagram, Section 131-1 for Schematic and Connector
information.
NOTE: Check the parking aid wiring harness for short to ground, short to battery or
damage.

1. Test the parking aid sensor wiring harness using the following table as a guide to
meter lead placement as well as expected values.

REAR LEFT-HAND OUTER PARKING AID SENSOR

Rear Left-Hand Outer Parking Assist Control Expected Value Action

Parking Aid Sensor Module C9071C
C4009
Pin 1 Pin 11 Less than 5 ohms If the resistance is
greater than 5 ohms,
Rear Left-Hand Outer Parking Assist Control Expected Value Action
Parking Aid Sensor Module C9071C
C4009
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 5 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 8 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

REAR LEFT-HAND INNER PARKING AID SENSOR

Rear Left-Hand Inner Parking Assist Control Expected Value Action

Parking Aid Sensor Module C9071C
C4010
Pin 1 Pin 11 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 3 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 8 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

REAR RIGHT-HAND INNER PARKING AID SENSOR

Rear Right-Hand Inner Parking Assist Control Expected Value Action

Parking Aid Sensor Module C9071C
C4012
Pin 1 Pin 11 Less than 5 ohms
Rear Right-Hand Inner Parking Assist Control Expected Value Action
Parking Aid Sensor Module C9071C
C4012
If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 2 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 8 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

REAR RIGHT-HAND OUTER PARKING AID SENSOR

Rear Right-Hand Parking Assist Control Expected Value Action

Outer Parking Aid Module C9071C
Sensor C4011
Pin 1 Pin 11 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 4 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 8 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

2. Test the parking aid system using the following table as a guide to meter lead
placement as well as expected values.

FRONT LEFT-HAND OUTER PARKING AID SENSOR

Rear Left-Hand Outer Parking Assist Control Expected Value Action
Parking Aid Sensor Module C9071B
C1428
Pin 1 Pin 2 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 5 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 1 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

FRONT LEFT-HAND INNER PARKING AID SENSOR

Rear Left-Hand Inner Parking Assist Control Expected Value Action

Parking Aid Sensor Module C9071B
C1429
Pin 1 Pin 2 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 6 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 1 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

FRONT RIGHT-HAND INNER PARKING AID SENSOR

Rear Right-Hand Inner Parking Assist Control Expected Value Action
Parking Aid Sensor Module C9071B
C1430
Pin 1 Pin 2 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 7 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 1 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

FRONT RIGHT-HAND OUTER PARKING AID SENSOR

Rear Right-Hand Parking Assist Control Expected Value Action

Outer Parking Aid Module C9071B
Sensor C1431
Pin 1 Pin 2 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 2 Pin 8 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation
Pin 3 Pin 1 Less than 5 ohms If the resistance is
greater than 5 ohms,
CHECK and REPAIR the
circuit. If the circuit is
OK, INSTALL a new
parking aid sensor.
TEST the system for
normal operation

PARKING AID SPEAKER

Parking Aid Speaker Parking Aid Speaker Expected Value Action

(component side) (component side)
Parking Aid Speaker Parking Aid Speaker Expected Value Action
(component side) (component side)
Pin 1 Pin 2 50 ohms If the resistance value
is not approximately 50
ohms, INSTALL a new
parking aid speaker.
REFER to: (413-13
Parking Aid)
Front Parking Aid
Speaker (Removal
and Installation),
Rear Parking Aid
Speaker (Removal
and Installation).
If the speaker is OK
but no audible error
output, INSTALL a new
parking assist control
module.
REFER to: Parking
Assist Control Module
(PAM) (413-13 Parking
Aid, Removal and
Installation).
TEST the system for
normal operation
Parking Aid - Parking Aid Camera
Print

Removal and Installation

Removal

1. Refer to: Liftgate Release Handle (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
2.

4.
Installation

1. To install, reverse the removal procedure.

Parking Aid - Image Processing Module B (IPMB)
Print

Removal and Installation

Removal

1. NOTE: This step is only necessary when installing a new component.

It is recommended that any vehicle that requires a tachograph replacement is sent to an
authorised Continental VDO Tachograph Service Center for system installation and
calibration. For further information see the Body & Equipment Mounting Manual (BEMM).

2. Remove Special Service Tool: 415-001.

Installation

1. To install, reverse the removal procedure.

Charging System - General Information - Charging System
Print

Diagnosis and Testing

Refer to Wiring Diagrams Cell 012-1, for schematic and connector information.
General Equipment
Midtronics EXP-1050 battery tester
Midtronics GRX-3590 battery diagnostic station
Ford diagnostic equipment

Inspection and Verification

WARNINGS:

Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also,
shield your eyes when working near batteries to protect against possible splashing of the
acid solution. In case of acid contact with 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. Failure to follow these instructions may result in personal injury.

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. Failure to follow these instructions may result in personal
injury.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Accessory drive belt • Fuse(s)
• Generator • Relay(s)
• Wiring harness
• Electrical connector(s)
• Charging system warning indicator
• Generator
• Battery
• Battery cables
• Battery monitoring sensor
• Auxiliary battery
• Auxiliary battery relay
• Auxiliary junction box (AJB)
• Auxiliary battery monitoring sensor
• Battery junction box (BJB)
• Body control module (BCM)
• Powertrain control module (PCM)

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. Check the operation of the charging system warning indicator lamp, located in the
instrument cluster. Normal operation is as follows:

NORMAL CHARGING SYSTEM VOLTAGES

Ignition Switch I Circuit Generator Battery Engine to Charging System

Position B+ Circuit battery ground Warning Indicator
Operation
Ignition Switch I Circuit Generator Battery Engine to Charging System
Position B+ Circuit battery ground Warning Indicator
Operation
Position 0 0V 10-12V 10-12V 0V OFF
Position II 0V 10-12V 10-12V 0V Illuminated
Position II with 13-15V 13-15V 13-15V 0V OFF
the engine
running

5. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Action

Sources
The charging system * Accessory * CHECK the accessory drive belt condition, REFER
warning indicator is on drive belt. to: (303-05B Accessory Drive)
with the engine running Accessory Drive (Diagnosis and Testing),
(The charging system Accessory Drive (Diagnosis and Testing).
voltage does not * Circuit. * CARRY OUT the generator tests, REFER to the
increase) * Generator. Generator On-Vehicle Tests in Component Tests in
* Voltage this section.
regulator.
The charging system * Bulb. * INSTALL a new bulb.
warning indicator is off * Ignition * CHECK the ignition switch.
with the ignition switch in switch.
the RUN position and the * Circuit. * CARRY OUT the generator tests, REFER to the
engine off * Generator. Generator On-Vehicle Tests in Component Tests in
this section.
Radio interference * Circuit. * REFER to the Ford diagnostic equipment
* Generator.
The generator is noisy * Accessory * REFER to: (303-05B Accessory Drive)
drive belt. Accessory Drive (Diagnosis and Testing),
Accessory Drive (Diagnosis and Testing).
* Loose * TIGHTEN the generator mounting bolts.
generator
mounting
bolts.
* Generator. * INSTALL a new generator. REFER to:
Generator - 2.2L Duratorq-TDCi
(74kW/100PS) - Puma/2.2L Duratorq-TDCi
(92kW/125PS) - Puma/2.2L Duratorq-TDCi
(114kW/155PS) - Puma, Vehicles With: Air
Conditioning (414-02 Generator and
Regulator, Removal and Installation),
Vehicle electrical systems * Battery. * CARRY OUT the battery tests, REFER to the
inoperative Battery Tests in Component Tests in this section.
The engine cranks slowly * Battery. * CARRY OUT the battery tests, REFER to the
Battery Tests in Component Tests in this section.
* Battery cable * REFER to: (303-06B Starting System)
(s). Starting System (Diagnosis and Testing),
* Starter Starting System (Diagnosis and Testing).
motor.

Component Tests
Generator On-Vehicle Tests - No-Load Test

1. Turn off all electrical loads and the ignition switch.

2. Switch the multimeter to the voltage function.

3. Connect the leads of the multimeter across the battery terminals.

4. Read the voltage (base voltage).

5. Start the engine.

6. Run the engine at 1500 rpm with no electrical load.

7. Read the voltage. The voltage should be in the range of 14.1 volts to 15.1 volts. If
the voltage increase is less than 2.5 volts above the base voltage, carry out the
Load Test. If the voltage increase is greater than 2.5 volts, REFER to the Ford
diagnostic equipment.

Generator On-Vehicle Tests - Load Test

1. With the engine running, turn on the air conditioning (if equipped), turn the blower
motor to high speed and the headlamps to high beam.

2. Increase the engine speed to 2000 rpm. The voltage should increase a minimum of
0.5 volts above the base voltage. If the voltage does not increase as specified,
REFER to the Ford diagnostic equipment. If the voltage increases as specified, the
charging system is charging correctly.

Battery Tests

Battery Identification

Item Description
1 Cold crank amp (CCA) rating
2 Reserve capacity (RC) rating (minutes)
3 Battery voltage
4 Ford Part number
5 FINIS code
6 EN number (European Norm)
7 Battery type: Ca = Silver/Calcium; Sb = Lead/Antimony
8 Amp hour rating
Item Description
1 Battery performance data
2 Motorcraft internal labelling
3 DIN labelling
Battery Performance Data

NOTE: The data only applies to a new fully-charged battery.

• The first group of digits (12V) indicates the battery voltage (12 volts).
• The second group of digits (590A) indicates that the battery delivers a current of 590
amps at -18°C without the terminal voltage falling below 7.2 volts.
• The third group of digits (90RC) indicates the time in minutes in which the battery
voltage falls to 10.5 volts in the case of a 25 amp load and an ambient temperature of
22°C.

DIN Labelling

• The first group of letters (WF) indicates that the battery is maintenance-free.
• The first digit (5) indicates that the battery is 12 volts.
• The second and third digits (58) indicates the battery capacity is 58 Ah, which means it
could power a 58 amp load for 1 hour.
• The last two digits (11) is a sequential serial number.

Midtronics EXP-1050 Battery Tester

The Midtronics EXP-1050 battery tester is the only battery tester recommended by Ford to
test latest technology batteries including Absorbent Glass Mat (AGM) and Enhanced Flooded
Battery (EFB), previously known as Improved Flooded Battery (IFB) used on Ford Start-
Stop vehicles.
Main specifications of the Midtronics EXP-1050 battery tester
• Tests 6/12V batteries
• Tests discharged batteries down to 1V both in and out of the vehicle
• Ratings in battery tester: CCA, JIS, EN, DIN, IEC, SAE
• CCA range: By Ford battery type 100-1700 A SAE / EN / CCA 100-1000 A DIN / IEC All
current JIS codes
• Large LCD display with adjustable backlight
• Detects short-circuited cells
• Surface charge removal procedure
• Dynamic Response procedure for refined decisiveness on battery diagnostics
• Upgradeable by SD card
• Export data feature to send data to infra red printer
• Voltmeter function
• Date and time indication with every test
• 23 languages included within the battery tester

Using the Midtronics EXP-1050 Battery Tester

• Disconnect the battery ground cable at the battery negative (-) post. Note: if using this
battery tester on models where the ground cable is not accessible, the battery does not
have to be removed from the vehicle and may be tested using the vehicle's 'jump start
post' if the battery tester is set to the correct mode. In this case, the battery must be
disconnected at the positive (+) post before testing.
• Connect the positive red clamp of the Midtronics EXP-1050 battery tester to the battery
positive (+) post.
• Connect the negative black clamp of the Midtronics EXP-1050 battery tester to the
battery negative (-) post or jump start post as appropriate.

A poor connection will prevent testing and the battery tester will display the message
CHECK CONNECTION. If this message appears after you have correctly reconnected the
clamps, clean the terminals and reconnect.
It is recommended that batteries are always tested using both battery posts. However, if
used in 'jump start post' mode, the Midtronics EXP-1050 battery tester will compensate for
the extra resistance of the additional cable.

• Select BATTERY TEST or START-STOP BATTERY TEST.

- Press the NEXT key to continue.
• Select the BATTERY LOCATION
- UNDER HOOD
- UNDER SEAT
- OUT OF VEHICLE
- Press the NEXT key to continue.
• Select the negative POST TYPE (IN-VEHICLE ONLY)
- BATTERY POST
- JUMP START POST
- JUMP START POST (Battery Monitoring Sensor)
- Press the NEXT key to continue.
• Select the BATTERY RATING from the drop down list.
- Press the NEXT key to test the battery.
• If the battery under test is not listed in the drop down list, it can still be selected with the
MANUAL ENTRY mode. This is item 11 of 11 in the list.

The Midtronics EXP-1050 battery tester will display the word TESTING while it evaluates the
battery.

BATTERY TESTER RESULTS AND REQUIRED ACTIONS

Battery Tester Action

Reading
GOOD BATTERY Return the battery to service
GOOD - Fully recharge the battery and return it to service
RECHARGE
CHARGE & RETEST Fully charge the battery and retest (failure to fully charge the battery before
retesting may cause false readings)
REPLACE BATTERY
or BAD CELL WARNING: Do not recharge the battery.
BATTERY Make sure that the surface charge was removed. A "REPLACE BATTERY"
result could also mean a poor connection between the battery cables and
the battery. Check the connections are OK and retest. If the result remains
the same, INSTALL a NEW battery
In addition it is advisable to check the vehicle electrical system. Check that the generator is
functioning correctly and the vehicle does not have an excessive key-off load (in general this
should be under 20mA after 40 minutes of key off).
Midtronics EXP-1050 Battery Tester Test Code
At the end of the test, use the arrow keys to scroll down the screens to see additional
information. One of these is the TEST CODE.
The TEST CODE has 11 digits, for example: 0021U-B88WKX.
Midtronics GRX-3590 Battery Diagnostic Station

Using the Midtronics GRX-3590

Item Description
1 GRX-3590 stand-alone version with integrated keypad and display
2 GRX-3590 docking station

The Midtronics GRX-3590 is both a battery charger and battery tester and automatically
removes the surface charge as part of the normal operating procedure.
The Midtronics GRX-3590 can be used on a battery in-vehicle or out-of-vehicle.

• Disconnect the battery ground cable.

• Connect the positive red clamp from the Midtronics GRX-3590 to the battery positive
terminal.
• Connect the negative black clamp from the Midtronics GRX-3590 to the battery negative
terminal.
• Connect the AC power cable to the mains outlet and switch ON.
Part Number
• Follow the instructions supplied with the Midtronics GRX-3590 to charge the battery.
-
• To disconnect the Midtronics GRX-3590, reverse the connection procedure.
-
The Midtronics GRX-3590 will automatically carry out a charge cycle before giving the
resulting test- code. The TEST CODE has 13 digits, for example: Y74NH-58R36-ESV. It will
bring the battery
- into a serviceable condition and if required can proceed to fully charge the
battery.
-
-
-
-
Part Number
-
-
-
Battery, Mounting and Cables - Battery Disconnect and Connect
Print

General Procedures

Disconnect
1. Refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General
Information, Description and Operation).
2.

3. If equipped.

4. If equipped.
5.

6. Torque: 8 Nm
Connect
1. To connect, reverse the disconnect procedure.
2. Reset the clock and Date to the correct time.
Battery, Mounting and Cables - Battery
Print

Removal and Installation

Removal

1. Refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

Single cab

3. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

All vehicles

4. Torque: 10 Nm

5.
6. Torque: 10 Nm

8. Torque:
1: 6 Nm
2: 6 Nm
9.

Installation

1. To install, reverse the removal procedure.

Generator and Regulator - Generator—2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue (125kW/170PS)
(YN)
Print

Removal and Installation

Removal

1. Right side.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
2.

3.
4.

6. Loosen: 5 turn(s)
7.

8.
9.

Installation

1. Torque: 48 Nm
2. Torque:
1: 48 Nm
2: 48 Nm

3. Torque: 15 Nm
4. Torque: 10 Nm

5.
6. Torque: 10 Nm

7. Right side.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
Generator and Regulator - Generator Pulley—2.0L EcoBlue
(77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN)
Print

Removal and Installation

Special Tool(s) / General Equipment
414-009
Remover/Installer Generator Pulley

Round-Ended Steel Rule

Removal

1. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)

(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
2.

3.
4. Use Special Service Tool: 414-009.

5. Use Special Service Tool: 414-009.

6. Use Special Service Tool: 414-009.
Loosen: 3 turn(s)

7. Remove Special Service Tool: 414-009.

8.
Installation

1. NOTE: The component must be installed by hand before final tightening.

2. NOTICE: Do not insert anything into the fins of the generator to prevent the
rotor inside the generator from turning. Inserting items into the generator could
result in damage to the generator.
NOTE: The shaft and rotor will turn during installation.
Use Special Service Tool: 414-009.
Torque: 80 Nm
3. NOTE: Make sure that a new component is installed.

4. Use the General Equipment: Round-Ended Steel Rule

6. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)

Removal and Installation

Removal

1. Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and
Installation).
2.

Installation
1. To install, reverse the removal procedure.
Information and Entertainment System - General Information - Information
and Entertainment System - Component Location
Print

Description and Operation

Item Description
1 AM (amplitude modulation)/FM (frequency modulation) antenna coaxial cable
2 AM/FM antenna
3 ACM (audio front control module)
4 Right Rear (RR) door speaker (Left Rear (LR) also shown)
Comments:
Wagon models only
5 Audio input jack
6 Left Front (LF) door speaker (Right Front (RF) also shown)
Information and Entertainment System - General Information -
Information and Entertainment System - System Operation and
Component Description
Print

Description and Operation

System Operation
My Connection Audio System

Item Description
1 Audio AM/FM/USB and DAB+ (optional)
2 Speakers
3 Antenna (According to the features)
4 Radio remote control
5 Audio Input Jack

Enable Diagnostic Mode

1. Turn ignition on
2. Press button 1 and 6 simultanously.
3. Speaker self test will start automatically.
4. Don't press any button whilst self test is carry out.
5. After self test has finished press button 2 to get a list of DTCs
6. Use arrow keys to navigate through the list of DTCs
DTC Chart "My Connection" Audio System
DTC Display Root Description Failure Type
B1A01-01 Speaker #1 (LF) General Electrical Failure
B1A01-11 Speaker #1 (LF) Circuit Short To Ground
B1A01-12 Speaker #1 (LF) Circuit Short To Battery
B1A01-13 Speaker #1 (LF) Circuit Open
B1A02-01 Speaker #2 (RF) General Electrical Failure
B1A02-11 Speaker #2 (RF) Circuit Short To Ground
B1A02-12 Speaker #2 (RF) Circuit Short To Battery
B1A02-13 Speaker #2 (RF) Circuit Open
B1A03-11 Speaker #3 (RR) General Electrical Failure
B1A03-12 Speaker #3 (RR) Circuit Short To Ground
B1A03-13 Speaker #3 (RR) Circuit Short To Battery
B1A04-01 Speaker #3 (RR) Circuit Open
B1A04-11 Speaker #4 (RR) General Electrical Failure
B1A04-12 Speaker #4 (RR) Circuit Short To Ground
B1A04-13 Speaker #4 (RR) Circuit Short To Battery
U2013-63 Speaker #4 (RR) Circuit Open
B11BA-11 Bezel Buttons) Stuck Button
B11BA-63 SWC Input) Circuit Short To Ground
B1252-11 SWC Input Circuit Short To Ground
B13C3-11 Switched B+ output General Checksum Failure
U3000-41 Control Module) General Checksum Failure
U3000-42 Control Module General Memory Failure
U3000-96 Control Module Component Internal Failure
9A05-13 Left Front Tweeter Circuit Open
9A05-13 Right Front Tweeter Circuit Open
B116A Ext. Microphone Circuit Open
Accessory Delay Feature
The accessory delay feature allows the audio system to be operated for a preset period of
time after the ignition is turned off and a front door has not been opened.
AM (amplitude modulation)/FM (frequency modulation) Radio
The AM/FM roof-mounted antenna receives analog radio waves and sends them through the
AM/FM antenna coaxial cable to the ACM (audio front control module). The radio waves are
converted into fluctuating AC (alternating current) voltage and sent as left and right analog
audio signals to the speakers.
Audio Extended Play
This feature allows the audio system to operate with the ignition OFF, regardless of door
latch position. When the power button on the ACM is pressed, audio system functionality is
enabled and remains active for a period of 60 minutes, depending on sufficient battery
voltage. To turn the audio system off, press the ACM power button.
Audio Input Jack Mode
When a portable audio device, such as an iPod® with its available cable, is connected to the
vehicle audio system through the audio input jack, audio from the device can be played
through the vehicle speakers. Only the volume can be controlled by the vehicle audio
controls. All other functions such as seek, fast forward, pause, etc. must be carried out on
the device itself.
No metadata (information such as artist, album title, song title, and genre) is transferred
when a device is connected to the audio input jack.

Component Description
ACM
The ACM can be operated with the ignition in RUN, ACC, or OFF.
The ACM receives radio waves containing audio from the antenna coaxial cable and
converts them into fluctuating AC voltage. The ACM processes these inputs, and sends
stereo analog audio signals to the speakers as fluctuating AC voltage.
Antenna
The AM/FM radio uses the fixed-mast roof-mounted AM/FM antenna to receive radio waves
containing audio. The radio waves are sent through the AM/FM antenna coaxial cable to the
ACM, where they are amplified.
Audio Input Jack
The audio input jack can be used to play audio files from an audio device connected
through the 1/8-inch (3 mm) audio jack.
Audio signals are sent from the audio input jack to the ACM.
There are no power or ground circuits to the audio input jack.
Information and Entertainment System -
General Information - Audio System
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 130-1 for schematic and connector information.
Inspection and Verification
NOTE: If the keycode is entered incorrectly 3 times, the system will lock out and not
allow the next keycode to be entered for a period of 30 minutes. After entering the
keycode the 10th time incorrectly, the system will lock out. The component can only be
unlocked by using the Ford diagnostic equipment.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Antenna • Fuse(s)
• Foreign objects contacting speaker • Wiring harness
• Trim poorly fitted/resonance • Electrical connector(s)
• Speaker(s)
• Audio input socket
• Antenna cable(s)
• Microphone
• Steering wheel switch(es)
• Clockspring
• Steering column control module (SCCM)
• Front controls interface module (FCIM)
• SYNC module (APIM)
• Univeral serial bus (USB) module
• Global positioning system module
(GPSM)
• Front control/display interface module
(FCDIM)
• Auxiliary junction box (AJB)
• Instrument panel cluster (IPC)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, refer to the Ford diagnostic equipment to
diagnose the system.
Information and Entertainment System - General Information - Front
Door Speaker
Print

Removal and Installation

Removal

1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

Installation

1. To install, reverse the removal procedure.

Information and Entertainment System - General Information - SYNC
Module [APIM]
Print

Information and Entertainment System - Speech Recognition Module
(SPRM)
Print

Removal and Installation

Removal

1. To install, reverse the removal procedure.

Information and Entertainment System - Navigation System Antenna
Print

Removal and Installation

Removal

Installation

1. To install, reverse the removal procedure.

Information and Entertainment System - Navigation System Display
Module
Print

Removal and Installation

Removal

3.
4.

5.
6.

7.
8.

9.
10.

11.
12.

13.
14.

15.
Installation

1. To install, reverse the removal procedure.

Information and Entertainment System - Cellular Phone Microphone
Print

Removal and Installation

Special Tool(s)
415-001
Remover, Audio Unit

501-125
Remover, Grab Handle Cover

Removal
Vehicles with tachograph

1. Remove Special Service Tool: 415-001.

Vehicles without tachograph

2. Remove Special Service Tool: 501-125.

All vehicles
3.

4.
Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Specifications
Print

HEADLAMP ADJUSTMENT SETTING

ADJUST

Headlamp X = 12 cm/10 m = 0 degrees, 41 minutes =

1.2%

FRONT FOG LAMP ADJUSTMENT SETTING

Electrical
• Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Switch
• Lamp(s)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Exterior Lighting - Parking, Rear and
License Plate Lamps
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 092-1 for schematic and connector information.
Inspection and Verification
NOTE: Before retrieving the vehicle-specific data make sure that all electrical connections
in the vehicle are reconnected so that the module and the Ford diagnostic equipment can
communicate correctly.

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION CHART

Electrical
• Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Bulb(s)
• Switch(es)
• Lamp(s)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Exterior Lighting - Reversing Lamps
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 093-1 for schematic and connector information.
Inspection and Varification
NOTE: Before retrieving the vehicle-specific data make sure that all electrical connections
in the vehicle are reconnected so that the module and the Ford diagnostic equipment can
communicate correctly.
NOTE: If a new body control module (BCM) is being installed, the new module must be
configured following installation. For this purpose, the vehicle-specific data is retrieved
from the module to be changed using the Ford diagnostic equipment and is transferred to
the new module.

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION

Electrical
• Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Bulb(s)
• Switch
• Lamp(s)
• Auto-dimming interior mirror
• Body control module (BCM)
• Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Exterior Lighting - Stoplamps
Print

Diagnosis and Testing

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical or mechanical damage.

VISUAL INSPECTION

Mechanical Electrical
• Stop lamp switch adjustment • Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Bulb(s)
• Switch(es)
• Lamp(s)
• Body control module (BCM)
• Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Exterior Lighting - Turn Signal and Hazard
Lamps
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 090-1 for schematic and connector information.
Inspection and Verification
NOTE: Before retrieving the vehicle-specific data make sure that all electrical connections
in the vehicle are reconnected so that the module and the Ford diagnostic equipment can
communicate correctly.
NOTE: If a new body control module (BCM) is being installed, the new module must be
configured following installation. For this purpose, the vehicle-specific data is retrieved
from the module to be changed using the Ford diagnostic equipment and is transferred to
the new module.

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION

Electrical
• Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Bulb(s)
• Switch(es)
• Lamp(s)
• Exterior mirror(s)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Exterior Lighting - Front Fog Lamp Adjustment
Print

General Procedures
General Equipment
Headlamp Beam Setter

Adjustment
All vehicles
1. NOTE: Make sure that the tire pressures are to specification and that the vehicle is
unladen.
Ensure that the adjustment is made with the suspension set up.
2. Place the vehicle on a level surface.

Vehicles with load-leveling shock absorbers

3. Set the suspension at normal ride height. Refer to the Owner's Literature.

All vehicles
4. NOTE: Always follow the manufacturer's instructions when handling the
equipment.
Set the measuring screen of the beam setting equipment to the correct front fog lamp
adjustment setting.

Refer to: Specifications (417-01 Exterior Lighting, Specifications).

Use the General Equipment: Headlamp Beam Setter
5. Switch on the front fog lamps.
6. Adjust the fog lamp so that the cut-off line touches the horizontal line.
Exterior Lighting - Headlamp Adjustment
Print

General Procedures
General Equipment
Headlamp Beam Setter

Adjustment
All vehicles
1. NOTE: Make sure that the tire pressures are to specification and that the vehicle is
unladen.
NOTE: Only use a damp cloth to clean the headlamp lens to avoid any electrostatic
charging.
Ensure that the adjustment is made with the suspension set up.
2. Place the vehicle on a level surface.

Vehicles with load-leveling shock absorbers

3. Set the suspension at normal ride height. Refer to the Owner's Literature.

Vehicles with conventional headlamps

4. Repeatedly operate the headlamp leveling switch and then set it to "0".

Vehicles with adaptive front lighting

5. Use the diagnostic tool to make certain that the front wheels are in the straight ahead
position.

All vehicles
6. NOTE: Always follow the manufacturer's instructions when handling the
equipment.
Set the measuring screen of the beam setting equipment to the correct headlamp
adjustment setting.

Refer to: Specifications (417-01 Exterior Lighting, Specifications).

Use the General Equipment: Headlamp Beam Setter
7. Switch on dipped beam.
8. Adjust the dipped beams so that the light/dark boundary touches the horizontal line.
9. NOTE: It is acceptable for a stray portion of the low beam to cross the 15° line.
Adjust the headlamps so that the rising line of the boundary line lies at the intersection
of horizontal line and the 15 degree line (left-hand drive vehicle shown).
Exterior Lighting - Headlamp Masking
Print

General Procedures
General Equipment
Adhesive Tape
Round-Ended Steel Rule

Adjustment
Left-hand drive vehicles

1. NOTICE: Take extra care not to scratch the headlamp lens.

Mask the marked areas with opaque black adhesive tape.

2. Left headlamp.

Use the General Equipments: Round-Ended Steel Rule, Adhesive Tape

3. Right headlamp.

Use the General Equipments: Round-Ended Steel Rule, Adhesive Tape

Vehicles with cornering lamps
4. On both sides.

5. On both sides.
Right-hand drive vehicles

6. NOTICE: Take extra care not to scratch the headlamp lens.

Mask the marked areas with opaque black adhesive tape.

7. Right headlamp.

Use the General Equipments: Round-Ended Steel Rule, Adhesive Tape

8. Left headlamp.

Use the General Equipments: Round-Ended Steel Rule, Adhesive Tape

Vehicles with cornering lamps

9. On both sides.
10. On both sides.
Exterior Lighting - Headlamp Assembly
Print

Removal and Installation

Removal

1. NOTICE: Take extra care when removing the headlamp assembly as the
fixings are easily damaged.

Installation

1. To install, reverse the removal procedure.

2. Refer to: Headlamp Adjustment (417-01 Exterior Lighting, General Procedures).

Exterior Lighting - Headlamp Switch
Print

Removal and Installation

Removal

3.
Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Front Fog Lamp
Print

Removal and Installation

Removal

2. On both sides.

Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Side Turn Signal Lamp
Print

Removal and Installation

General Equipment
Flat Headed Screw Driver

Removal

3. Use the General Equipment: Flat Headed Screw Driver

Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Stoplamp Switch
Print

Removal and Installation

Removal

1. NOTICE: Make sure that the brake pedal remains in the rest position.

Installation

1. NOTE: Make sure that the ignition key is in the OFF position.

2. NOTICE: Make sure that the brake pedal remains in the rest position.
NOTE: Allow the brake pedal to return to it's natural off position, do not lift the
brake pedal.
Exterior Lighting - Trailer Module (TRM)
Print

Removal and Installation

Removal

1. Refer to: B-Pillar Trim Panel - Bus (501-05 Interior Trim and Ornamentation, Removal
and Installation).
Refer to: B-Pillar Trim Panel - Van (501-05 Interior Trim and Ornamentation, Removal
and Installation).

2. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
Refer to: Front Bench Seat (501-10A Front Seats, Removal and Installation).
3.

4. Torque: 10.5 Nm
Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Rear Lamp Assembly
Print

Removal and Installation

Removal

Installation

1. To install, reverse the removal procedure.

Exterior Lighting - High Mounted Stoplamp
Print

Removal and Installation

Removal
Vehicles with liftgate
1.

3.
All vehicles
4. On both sides.

5. On both sides.
Installation

1. To install, reverse the removal procedure.

Exterior Lighting - Reversing Lamp Switch
Print

Removal and Installation

Materials
Name Specification
Manual Transmission Fluid - SAE 75W WSS-M2C200-D2

Removal

1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2.

Installation

1. Material: WSS-M2C200-D2 (Manual Transmission Fluid - SAE 75W)

2. Torque: 20 Nm

3.
Interior Lighting - Interior Lighting
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 089-1 for schematic and connector information.
Inspection and Verification
NOTE: If a new body control module (BCM) is being installed, the new module must be
configured following installation. For this purpose, the vehicle-specific data is retrieved
from the module to be changed using the Ford diagnostic equipment and is transferred to
the new module.

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION

Electrical
• Fuse(s)
• Transportation fuse pack
• Wiring harness
• Electrical connector(s)
• Bulb(s)
• Switch(es)
• Lamp(s)
• Door latch(es)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Module Communications Network - Communications Network - System
Operation and Component Description
Print

Description and Operation

System Diagram

Item Description
A HS-CAN (controller area network) data bus (multimedia)
B MS-CAN databus
C HS-CAN databus
D Terminating resistor
E LIN (local interconnect network) databus
F ISO data bus
G Private HS-CAN data bus
1 audio unit
2 Multi-function display
3 Audio system control unit
4 SYNC module
5 Battery-operated siren
6 Intrusion sensor
7 Instrument Panel Cluster
8 Tachograph
9 GPS (global positioning system) module
10 Interior rear view mirror
11 Fuel fired booster heater
12 Module, trailer towbar
13 IPMB (image processing module B) module
14 Reversing camera
15 Rain sensor
16 Battery monitoring sensor, second battery
17 Battery monitoring sensor, first battery
18 Wiper motor, master
19 Wiper motor, slave
20 Module, speed control system
21 Steering wheel rotation sensor.
22 Front view camera module
23 Parking Aid Module
24 Light control module
25 Vibration motor module
26 Steering wheel module
27 Light switch module
28 BCM (body control module)
29 RCM (restraints control module) module
30 ABS (anti-lock brake system) module
31 PCM (powertrain control module)
32 RKE (remote keyless entry) module
33 Generator module
34 PATS (passive anti-theft system) module

System Operation
Data bus systems

The following data bus systems are used:

• HS-CAN databus
• HS-CAN data bus (multimedia)
• Private HS-CAN data bus
• MS-CAN databus
• LIN databus
• ISO data bus

Gateway modules

Gateway modules act as the interface between the different data bus systems. To do this
on the new Transit Custom, the instrument panel cluster act as gateway between the HS-
CAN data bus (multimedia) and the MS-CAN data bus, and also the BCM as gateway
between the HS-CAN data bus and the MS-CAN data bus.

Component Description
Terminating resistors
8 terminating resistors are installed in total.
The two terminating resistors, 120 ohms each, of the HS-CAN data bus are integrated into
the PCM and the BCM. Because the two 120 ohm resistors are connected in parallel, the
total resistance is 60 ohms (measured at the DLC). If a control unit is disconnected from
the network, 120 ohms must be present between pin 6 and 14DLC (data link connector).
The terminating resistors of the HS-CAN data bus (multimedia) are in the instrument panel
cluster and in the audio unit.
The HS-CAN data bus (multimedia) can be tested via pins 1 and 8.
The RCM module is connected via a private HS-CAN data bus with the ABS module. Two
separate termination resistors are installed here.
The terminating resistors of the MS-CAN data bus are in the instrument panel cluster and in
the BCM. The total resistance can be measured at the DLC between pins 3 and 11 and
should be 60 ohms.
HS CAN

The following HS-CAN data buses are used:

• HS-CAN data bus:
- Front camera module
- Proximity warning system module
- RCM
- ABS module
- Steering wheel rotation sensor
- Parking Aid Module
- PCM
- SYNC module
- BCM
• HS-CAN data bus (multimedia):
- SYNC module
- audio unit
- Audio system control unit
- Multi-function display
- Instrument Panel Cluster
• Private HS-CAN data bus:
- RCM
- ABS module

The private HS-CAN is used for fast, interference-free data exchange.

The HS-CAN data bus, the HS-CAN data bus (multimedia) and the private HS-CAN data bus
have a speed of 500 kBit/s.
MS-CAN databus

• MS-CAN data bus:

- BCM
- Instrument Panel Cluster
- Fuel fired booster heater
- Trailer Module
- GPS module
- Reversing camera module

The MS-CAN bus has a speed of 125 kBit/s.

LIN databus

The following systems are connected to the LIN bus:

• Audio system control unit
• Reversing camera
• Light switch unit
• Steering wheel module
• Vibration motor module
• Intrusion sensors
• Anti-theft alarm horn with own battery
• Battery monitoring sensors
• Rain sensor
• Wiper motor module
• alternator

The transmission speed within the LIN databus system is 9.6 kBit/s. A LIN databus system
consists of a LIN master and one or more LIN slaves. The LIN master knows the time
sequence of all data which are to be transmitted.
This data is transferred by the corresponding LIN slaves when they are prompted by the
LIN master.
The LIN bus is a single conductor databus system, i.e. the data is transmitted on one cable.
No terminating resistors are used in the LIN network.
ISO data bus

• RKE module
• Wiper motor, slave
Module Communications Network -
Communications Network
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION

Electrical
• Fuse(s).
• Wiring harness.
• Electrical connectors.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Diagnostic
tab within the Ford diagnostic equipment.
Wiring Harnesses - Instrument Panel Wiring Harness
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and
Installation).

2. Torque: 12 Nm

3.
4. Torque: 12 Nm

5. Torque: 12 Nm

6.
7.

8. Torque: 12 Nm
9.

10.
Installation

1. To install, reverse the removal procedure.

Wiring Harnesses - Passenger Compartment Wiring Harness
Print

Removal and Installation

Special Tool(s) / General Equipment
303-435
Mounting Stand

501-125
Remover, Grab Handle Cover

501-404
Holding Tool, Instrument Panel

Hose Clamp(s)

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

Vehicles with air conditioning

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).

3. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
4.
5.

6.
7. NOTICE: Make sure that all openings are sealed.
Use the General Equipment: Hose Clamp(s)
Torque: 8 Nm

Vehicles without air conditioning

8. NOTICE: Make sure that all openings are sealed.

Use the General Equipment: Hose Clamp(s)
All vehicles

9. Remove both front doors.

Refer to: Front Door (501-03 Body Closures, Removal and Installation).

10. On both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

11. On both sides.

Refer to: B-Pillar Trim Panel - Bus (501-05 Interior Trim and Ornamentation, Removal
and Installation).
Refer to: B-Pillar Trim Panel - Van (501-05 Interior Trim and Ornamentation, Removal
and Installation).

12. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
Refer to: Front Bench Seat (501-10A Front Seats, Removal and Installation).
13.
14.

15.
16.

17.
18.

19.
20.

21.
22.

23.
1. On both sides.

Use Special Service Tool: 501-125.

24. NOTE: Note the position of the component before removal.
If equipped.

25. WARNING: Make sure that a new bolt is installed.

NOTICE: Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 28 Nm

26.
27. 1.

28.
29.

30.
31. Torque: 25 Nm

32. Torque: 25 Nm
33. On both sides.

34. On both sides.

Torque: 40 Nm
35. Torque: 25 Nm

36. Torque: 25 Nm
Left-hand drive vehicles
37.
1. Use Special Service Tools: 303-435, 501-404.

2. Torque: 10 Nm
Right-hand drive vehicles
38. 1. Remove the tolerance absorber.
2. Use Special Service Tools: 303-435, 501-404.

3. Torque: 10 Nm
All vehicles

39. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
40.
41. • On both sides.

42.
43.

44. On both sides.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
45.
46.

47.
49.

50. On both sides.

51. 1.
2.
3.
4. Torque: 55 Nm

52.
53.

54.
55.

56.
57.

58.
Installation

1. To install, reverse the removal procedure.

2. Refer to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General
Procedures).
Wiring Harnesses - Passenger Compartment and Loadspace Wiring
Harness LH
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and
Installation).

2. Refer to: Auxiliary Climate Control Housing (412-02A Auxiliary Climate Control, Removal
and Installation).

3. Refer to: Front Headliner - Bus (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Refer to: Front Headliner - Van (501-05 Interior Trim and Ornamentation, Removal and
Installation).

Van

4. Refer to: Rear Headliner (501-05 Interior Trim and Ornamentation, Removal and
Installation).

All vehicles
5.

6.
Installation

1. To install, reverse the removal procedure.

Wiring Harnesses - Passenger Compartment and Loadspace Wiring Harness RH
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and
Installation).

2. Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and Ornamentation, Removal
and Installation).

Van

4. Refer to: Rear Headliner (501-05 Interior Trim and Ornamentation, Removal and
Installation).

All vehicles
5.

6.
Installation

1. To install, reverse the removal procedure.

Wiring Harnesses - Liftgate Wiring Harness
Print

Removal and Installation

Removal

1. If equipped.

3.
4.

5. Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
6.
7. Refer to: High Mounted Stoplamp (417-01 Exterior Lighting, Removal and Installation).
8.

9.
Installation

1. To install, reverse the removal procedure.

Wiring Harnesses - Front Door Wiring Harness
Print

Removal and Installation

Removal

1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

4.
Installation

1. To install, reverse the removal procedure.

Wiring Harnesses - Front Bumper Wiring Harness
Print

Removal and Installation

Removal

1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2.

9. Left-hand side only.

Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
10.

11. Torque: 8 Nm
12. If equipped.

Use the General Equipments: Center Punch, 3.5 mm Drill Bit

13.
14.

15.
16.

17.
18.

19.
20.

21.
22.

Installation

1. To install, reverse the removal procedure.

2. Tighten the shear bolt until the head is sheared off.
Perimeter Anti-Theft Alarm - Perimeter
Anti-Theft Alarm
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 117-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Misaligned door(s), hood or liftgate • Fuse(s)
• Door latch(es) • Relay(s)
• Liftgate latch • Wiring harness
• Hood latch • Electrical connector(s)
• Switch(es) • Door latch(es)
• Sliding door ajar switch(es)
• Sliding door latch(es)
• Sliding door contact plate(s)
• Liftgate latch
• Hood switch
• Remote transmitter batteries
• Remote transmitter
• RF receiver
• Intrusion sensor
• Anti-theft alarm horn(s)
• Anti-theft alarm horn with integral
battery (if equipped)
• Auxiliary junction box (AJB)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, refer to the Ford diagnostic equipment to
diagnose the system.
Perimeter Anti-Theft Alarm - Anti-Theft
Alarm Horn
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. 1. If equipped.

2. Torque: 35 Nm

3. 1.
4. Torque: 10.5 Nm

Installation

1. To install, reverse the removal procedure.

Passive Anti-Theft System (PATS) - Passive
Anti-Theft System (PATS)
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 112-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Ignition lock cylinder • Fuse(s)
• Passive anti-theft system (PATS) ignition • Wiring harness(s)
key (blue dot) • Electrical connector(s)
• Non-PATS ignition key • Relay(s)
• Use of a non-progammed PATS ignition • PATS transceiver
key • Body control module (BCM)
• Use of a non-encoded PATS ignition key • Powertrain control module (PCM)
• More than one PATS key in close
proximity of the PATS transceiver

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, use Ford diagnostic equipment to retrieve any
DTCs and refer to the Diagnostic Trouble Code (DTC) Index.

DIAGNOSTIC TROUBLE CODE (DTC) INDEX

DTC Indicator Description/Condition Possible Source

Flash Code
B1681 11 PATS transceiver signal is not received PATS transceiver
wiring, PATS
transceiver connector,
PATS transceiver, PCM
or BCM
B1232 and B2103 12 PATS transceiver antenna coil fault, PATS transceiver,
vehicle does not start PATS transceiver
mounting
B1600 13 Non-PATS key or damaged encoded PATS encoded ignition
ignition key, or no key code received, key
vehicle does not start
B2431 13 PATS transponder programming failed Ignition key
crypto transponder only, vehicle does not
start
B1602 14 Partial key read of PATS key, vehicle does PATS encoded ignition
not start key, PATS transceiver
B1601 15 Incorrect key code, Unprogrammed PATS PATS encoded ignition
key (keycode format OK), vehicle does key
not start (20 second anti-scan invoked)
U2510 16 CAN communication link between the Circuit, PCM or BCM
PCM and body control module (BCM),
vehicle does not start
B1213 21 Incorrect number of
keys programmed or
DTC Indicator Description/Condition Possible Source
Flash Code
Number of programmed PATS encoded PATS encoded ignition
keys below minimum, vehicle does not key
start
B2141 22 NVM Configuration failure. No security ID Circuit, PCM or BCM
exchange between PCM and body control
module (BCM), vehicle does not start
B2139 23 Data mismatch (received data does not Circuit, PCM or BCM
match what was expected). Security
messages do not match between PCM
and body control module (BCM), vehicle
does not start
P1260 - PCM disabled PCM
Multifunction Electronic Modules - Body
Control Module (BCM)
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment

Inspection and Verification

NOTE: Diagnosis of the body control module (BCM) must be carried out using the Ford
diagnostic equipment.

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

VISUAL INSPECTION

Electrical
Fuse(s)
Electrical connectors
Circuit(s)
Wiring harness
BCM

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab
within the Ford diagnostic equipment.
Multifunction Electronic Modules - Body Control Module (BCM)
Print

Removal and Installation

General Equipment
Ford approved diagnostic tool

Removal
NOTICE:

Modules are not interchangeable between vehicles.

When installing a new junction box, make sure that the contents match those of the
removed junction box.
1. NOTE: This step is only necessary when installing a new component.
Download the module information to the diagnostic tool using the Programmable
Modules Installation routine.

Use the General Equipment: Ford approved diagnostic tool

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
3.

4.
5.

7.
8.

9.
10.

11.
Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
Upload the module information from the diagnostic tool to the module using the
Programmable Modules Installation routine.

Use the General Equipment: Ford approved diagnostic tool

Multifunction Electronic Modules - Lighting Control Module (LCM)
Print

Removal and Installation

Removal

3.
4.

5.
6.

7.
8.

9.
10.

Installation

1. To install, reverse the removal procedure.

Front End Body Panels - Cowl Panel Grille
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
Installation

1. NOTICE: Make sure that the motor is in the park position.

To install, reverse the removal procedure.
Front End Body Panels - Fender
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

4. Torque: 9 Nm
5. Torque: 9 Nm

6.
7.

8. Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and
Installation).

9. Torque: 9 Nm
10. Torque: 9 Nm

11. NOTE: Make sure that no component falls off during removal.
Torque: 9 Nm
12. NOTICE: Make sure that the component paintwork is not damaged.

Installation

1. NOTE: Adjust the fender to a minimum gap of 6 mm to the front door.

For additional information regarding gap and flushness:

Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
2. To install, reverse the removal procedure.
Front End Body Panels - Radiator Grille Opening Panel
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).

2. Torque: 25 Nm

4.
5. Torque: 25 Nm

6.
7.

8.
9. On both sides.

10. NOTE: This step requires the aid of another technician.

NOTE: The following steps are only necessary when installing a new component.
11. Refer to: Hood Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).

12. Refer to: Hood Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).

13. Refer to: Horn (413-06 Horn, Removal and Installation).

Installation

1. To install, reverse the removal procedure.

Front End Body Panels - Hood
Print

Removal and Installation

Removal

1. NOTE: Removal steps in this procedure may contain installation details.

3. Torque: 11 Nm

Installation

1. To install, reverse the removal procedure.

Front End Body Panels - Fender Splash Shield

Removal and Installation

Removal

1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
2. Vehicles built up to 2015-07-31

3. Vehicles built from 2015-07-31

5.
6.

Installation

1. To install, reverse the removal procedure.

Body Closures - Front Door Alignment
Print

General Procedures

Check
1. 1. 0mm +/- 2mm
2. 5mm +/- 2mm
3. 0mm + 1mm /- 0,6mm
4. 6mm +1,5mm /- 0mm

2. 1. -2mm +/- 2mm

2. 5mm +/- 1,5mm

3.
1. -4 mm +/- 1,5 mm
2. 5,5 mm +/- 2,5 mm

Adjustment
1.

2.
1. Loosen:
2 turn(s)

2. Loosen:
2 turn(s)
3. 1. NOTE: Only tighten the bolts finger tight at this stage.
2. NOTE: Only tighten the bolts finger tight at this stage.

4.
5.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

6.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

Check
1. 1.
2. 5mm +/- 2mm
3.
4. 6mm +1,5mm /- 0mm
2. 1.
2. 5mm +/- 1,5mm

3. 1.
2. 5,5 mm +/- 2,5 mm
Adjustment
1.
1. Torque: 35 Nm

2. Torque: 10 Nm

2. Torque: 35 Nm
3. Torque: 25 Nm

4.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

5.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

6.
Check
1. 1. 0mm +/- 2mm
2.
3. 0mm + 1mm /-0,6mm
4.

2. 1. -2mm +/- 2mm

2.
3. 1. -4 mm +/- 1,5 mm
2.

Adjustment
1. Torque: 62.5 Nm
2. Torque: 62.5 Nm

3.
4.
Body Closures - Sliding Door Alignment
Print

General Procedures

Check
1. 1. 0mm +/- 2mm
2. 5mm +/- 2mm
3. 0mm +/- 2mm
4. 5mm +/- 2mm

2. 1. -2,1 mm +/- 2,3mm

2. 5mm +/- 1,7mm

3.
1. -4,5 mm +/- 2,5 mm
2. 5,5 mm +/- 2 mm

Adjustment
1.
1. Loosen:
2 turn(s)

2. Loosen:
2 turn(s)

2. 1. NOTE: Only tighten the bolts finger tight at this stage.

2. NOTE: Only tighten the bolts finger tight at this stage.
3.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

4.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

5.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

6.
Check
1. 1.
2. 5mm +/- 1,7mm

2. 1.
2. 5,5 mm +/- 2 mm
Adjustment
1.
1. Torque: 35 Nm

2. Torque: 10 Nm

2. Torque: 35 Nm
3. Torque: 35 Nm

4.
5.

Check
1. 1.
2. 5mm +/- 2mm
3.
4. 5mm +/- 2mm
Adjustment
1. Torque: 10 Nm

2.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

3.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

4.
1. Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

Check
1. 1. 0mm +/- 2mm
2.
3. 0mm +/- 2mm
4.
2. 1. -2,1 mm +/- 2,3mm
2.

3. 1. -4,5 mm +/- 2,5 mm

2.
Adjustment
1. Torque: 24 Nm

2. Torque: 24 Nm
3. Torque: 30 Nm

4. Torque: 25 Nm
Body Closures - Hood Alignment
Print

General Procedures

Adjustment
1. Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and
Tolerance Checks, Description and Operation).
2. 1. NOTE: Only tighten the bolts finger tight at this stage.
Loosen:
2 turn(s)

2. After operation check the alignment and correct if necessary.

Torque: 25 Nm

3.
4. After operation check the alignment and correct if necessary.
Body Closures - Rear Door Alignment
Print

General Procedures

Adjustment
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and
Tolerance Checks, Description and Operation).
2.

3. • NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

• Torque: 25 Nm
4. • NOTE: Only tighten the bolts finger tight at this stage.
Loosen:
2 turn(s)

• Torque: 25 Nm

5. After operation check the alignment and correct if necessary.

7. • NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

• Torque: 25 Nm
8. 1. NOTE: Only tighten the nuts finger tight at this stage.
Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

3. NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

9. After operation check the alignment and correct if necessary.

10.
1. Torque: 25 Nm

2. Torque: 10 Nm

3. Torque: 25 Nm

11. • NOTE: Only tighten the bolts finger tight at this stage.
Loosen:
2 turn(s)

• Torque: 25 Nm
12. After operation check the alignment and correct if necessary.

13.
14. • NOTE: Only tighten the bolts finger tight at this stage.
Loosen:
2 turn(s)

• Torque: 25 Nm

15. 1. NOTE: Only tighten the nuts finger tight at this stage.
Loosen:
2 turn(s)

2. NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

3. NOTE: Only tighten the bolts finger tight at this stage.

Loosen:
2 turn(s)

16. After operation check the alignment and correct if necessary.

17.
1. Torque: 25 Nm

2. Torque: 10 Nm

3. Torque: 25 Nm
18. After operation check the alignment and correct if necessary.
Body Closures - Liftgate Alignment
Print

General Procedures

Check
1. Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and
Tolerance Checks, Description and Operation).
2. On both sides.

3. 1. Spotting the latch cover with chalk before closing and opening the liftgate.
2. Check the footprint of the striker bumpstops to the latch cover. If measurement X
differs more than 2 mm, correct the alignment of the ligtgate.
Adjustment
1. Refer to: Headliner - Lowering (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. Do not loosen the bolts more than 2 turns.

3. Do not loosen the bolts more than 2 turns.

4.
5. Torque: 51 Nm

6. Do not loosen the bolts more than 2 turns.

8. Torque: 25 Nm
9. After operation check the alignment and correct if necessary.

10. Torque: 25 Nm
11. After operation check the alignment and correct if necessary.

12. After operation check the alignment and correct if necessary.

13. NOTE: Make sure that the component is in the end position.
On both sides.

14. NOTE: Make sure that new components are installed.

On both sides.

Torque: 11 Nm
15.
1. 1. NOTICE: Make sure that equal force is applied to the underside of the
body panel.
On both sides.
2. Carefully close the liftgate until the secondary locking noise of the latch is heard.

16. NOTICE: Make sure that equal force is applied to the underside of the body
panel.
After operation check the alignment and correct if necessary.
17. On both sides.

18. After operation check the alignment and correct if necessary.

Body Closures - Front Door
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3. Torque: 30 Nm
4. NOTE: Make sure that no component falls off during removal.
NOTE: This step requires the aid of another technician.
Torque: 25 Nm

5. NOTE: This step requires the aid of another technician.

Installation

NOTE: This step requires the aid of another technician.
Torque: 26 Nm
Installation
NOTE: The following steps are only necessary if the component is damaged.

1. NOTICE: Take extra care not to damage the seal.

NOTE: This step requires the aid of another technician.

All vehicles
2. To install, reverse the removal procedure.
Body Closures - Sliding Door
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Torque: 11 Nm

3. Torque: 9 Nm
4.

5.
6.

Installation

1. To install, reverse the removal procedure.

Body Closures - Rear Door
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. On both sides.

2. On both sides.

3. On both sides.

Torque: 25 Nm
Installation

1. To install, reverse the removal procedure.

Body Closures - Front Door Check Arm
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: Front Door Speaker (415-00 Information and Entertainment System - General
Information, Removal and Installation).

3. Torque: 30 Nm

4. Torque: 11 Nm
5.

Installation

1. To install, reverse the removal procedure.

Body Closures - Fuel Filler Door
Print

Removal and Installation

General Equipment
Flat Headed Screw Driver

Removal

1. Use the General Equipment: Flat Headed Screw Driver

Installation

1. To install, reverse the removal procedure.

Body Closures - Fuel Filler Door Assembly
Print

Removal and Installation

General Equipment
4 mm Drill Bit
Blind Rivet Gun
Electric Drill

Removal

2. Use the General Equipments: 4 mm Drill Bit, Electric Drill

Installation

1. Use the General Equipment: Blind Rivet Gun

Removal

3.
4.

5.
6.

Removal

1. Refer to: C-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: D-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3.

Short wheelbase
4.
Long wheelbase
5.

Installation

1. To install, reverse the removal procedure.

Interior Trim and Ornamentation - Front Headliner—Bus
Print

Removal and Installation

Special Tool(s) / General Equipment
415-001
Remover, Audio Unit

501-125
Remover, Grab Handle Cover

Hot Glue Gun

Interior Trim Remover

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. On both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: Rear Headliner (501-05 Interior Trim and Ornamentation, Removal and
Installation).

Vehicles with tachograph

3. Remove Special Service Tool: 415-001.

Vehicles without tachograph

5. Remove Special Service Tool: 501-125.

All vehicles
6.
7. On both sides.

8. On both sides.
Vehicles without front view camera
9.

10.

Vehicles with front view camera

11.
12. Use the General Equipment: Interior Trim Remover

13.
All vehicles
14. On both sides.

15.

16. NOTICE: Take extra care not to crease the headliner.

17. NOTICE: Take extra care not to crease the headliner.

NOTE: The following steps are only necessary when installing a new component.

18. NOTICE: Replace interior lamp bulbs only from the back side of the lamp,
removing the glass causes malfunction.
19.

20.

21.
22.

23. On both sides.

24. NOTE: Note the position of the components before removal.

Use the General Equipment: Hot Glue Gun
Installation

1. NOTE: Make sure that the components are installed to the position noted before
removal.
To install, reverse the removal procedure.
Interior Trim and Ornamentation - Front Headliner—Van
Print

Removal and Installation

Special Tool(s) / General Equipment
415-001
Remover, Audio Unit

501-125
Remover, Grab Handle Cover

Hot Glue Gun

Interior Trim Remover

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. On both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. On both sides.

3. On both sides.
Torque: 35 Nm

4. On both sides.

5.
6.

7.
Vehicles with tachograph

8. Remove Special Service Tool: 415-001.

9.
10.

Vehicles without tachograph

11. Remove Special Service Tool: 501-125.

All vehicles
12.

13.

14. On both sides.

15. On both sides.

Vehicles without front view camera

16.
17.

Vehicles with front view camera

18.

19. Use the General Equipment: Interior Trim Remover

20.

All vehicles
21.

22. NOTICE: Take extra care not to crease the headliner.

23. NOTICE: Take extra care not to crease the headliner.

NOTE: The following steps are only necessary when installing a new component.
24. NOTICE: Replace interior lamp bulbs only from the back side of the lamp,
removing the glass causes malfunction.

25.

26.
27.

28.

29. All.
30. NOTE: Note the position of the components before removal.
Use the General Equipment: Hot Glue Gun

Installation

1. NOTE: Make sure that the components are installed to the position noted before
removal.
To install, reverse the removal procedure.
Interior Trim and Ornamentation - Rear Headliner
Print

Removal and Installation

General Equipment
Hot Glue Gun

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. • On both sides.
1. If equipped.

2. On both sides.

Torque: 35 Nm

3. 1. On both sides.
4.

5. On both sides.
6. On both sides.

7.
8.

9. On both sides.
11. NOTICE: Take extra care not to crease the headliner.

NOTE: The following steps are only necessary when installing a new component.
12.
13. On both sides.

14.
Vehicles with auxiliary climate control
16. All.

17. NOTE: Note the position of the components before removal.

Use the General Equipment: Hot Glue Gun
All vehicles
18. NOTE: Note the position of the components before removal.
Use the General Equipment: Hot Glue Gun

Installation

1. NOTE: Make sure that the components are installed to the position noted before
removal.
To install, reverse the removal procedure.
Interior Trim and Ornamentation - Floor Covering—Transit
Print

Removal and Installation

General Equipment
Knife

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Both sides, If equipped.

Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

2. If equipped.

Refer to: Front Bench Seat (501-10A Front Seats, Removal and Installation).

3. Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and
Installation).

4. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

5. Torque: 55 Nm

6. Torque: 55 Nm
7.

8.
9.

10.
11.

12.
13.

14.
15.

16.
17. 1. On both sides.

18. NOTE: Note the position of the components before removal.

If equipped.
19. NOTICE:

Make sure that a new bolt is installed.

Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 28 Nm

20. Refer to: Accelerator Pedal (310-02 Acceleration Control, Removal and Installation).
21.

22. Torque: 25 Nm
23. Torque: 25 Nm

24. On both sides.

25. On both sides.

26. On both sides.

27.
Use the General Equipment: Knife

Installation

1. To install, reverse the removal procedure.

2. Refer to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General
Procedures).
Interior Trim and Ornamentation - Sliding Door Trim Panel
Print

Removal and Installation

Removal

3. NOTICE: Take extra care not to damage the edges of the component.
4.

5.
6.

7.
Installation

1. To install, reverse the removal procedure.

Interior Trim and Ornamentation - Headliner
Print

Removal and Installation

Removal

1. Refer to: C-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: D-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3.

4.
Short wheelbase
5.

Long wheelbase
6.

Installation

1. To install, reverse the removal procedure.

Exterior Trim and Ornamentation - Exterior Trim - Overview
Print

Description and Operation

Built-in roof rack

Folding mechanism

Item Description
1 Roof mounting
2 Bracket, cross brace
3 Locking and unlocking lever
4 Locking bolt
A further new feature for low-roof models is the built-in retractable roof rack with a payload
of up to 130 kg.
This roof rack can be lowered into the roof outline when not in use. On the one hand, this
contributes to a reduction in fuel consumption, on the other hand it also reduces the vehicle
height to below two meters.
Exterior Trim and Ornamentation - Radiator Grille
Print

Removal and Installation

Removal

1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2.

1. To install, reverse the removal procedure.

Exterior Trim and Ornamentation - Roof Rack
Print

Removal and Installation

Removal

1. On both sides.

2. On both sides.

3.
Installation

2. On both sides.
3. On both sides.

Torque: 24 Nm

4. After operation check the alignment and correct if necessary.

5. On both sides.
Rear View Mirrors - Rear View Mirrors - Overview
Print

Description and Operation

Door mirror

The new Transit Custom is optionally equipped with electrically adjustable and heated
exterior rear view mirrors. Furthermore, for the first time these are now equipped with side
turn signal lamps.
The mirrors can be electrically folded in with the aid of a switch in the driver door. This
function is available both when the ignition is switched on and when it is switched off.
Rear View Mirrors - Rear View Mirrors
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 124-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Exterior mirror(s) • Fuse(s)
• Relay(s)
• Wiring harness
• Electrical connector(s)
• Exterior mirror control switch
• Exterior mirror(s)
• Auto dimming interior mirror
• Auxiliary junction box (AJB)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, refer to the Ford diagnostic equipment to
diagnose the system.
Rear View Mirrors - Exterior Mirror
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

3. Torque: 10 Nm
Installation

1. To install, reverse the removal procedure.

Rear View Mirrors - Exterior Mirror Cover
Print

Removal and Installation

Special Tool(s)
501-125
Remover, Grab Handle Cover

Removal

1. Use Special Service Tool: 501-125.

Installation

1. To install, reverse the removal procedure.

Rear View Mirrors - Exterior Mirror Glass
Print

Removal and Installation

Special Tool(s)
501-125
Remover, Grab Handle Cover

Removal

2. Use Special Service Tool: 501-125.

Installation

1. To install, reverse the removal procedure.

Rear View Mirrors - Interior Rear View Mirror
Print

Removal and Installation

Removal
Vehicles without parking aid camera
1.

Vehicles with parking aid camera

3.
4.

5.
Installation

1. To install, reverse the removal procedure.

Rear View Mirrors - Exterior Mirror Motor
Print

Removal and Installation

Special Tool(s)
501-125
Remover, Grab Handle Cover

Removal

2. Use Special Service Tool: 501-125.

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Seats
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
For power seats, refer to Wiring Diagram Section 120-1 for schematic and connector
information.
For heated seats, refer to Wiring Diagram Section 119-1 for schematic and connector
information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Seat tracks • Fuse(s)
• Seat latch • Relay(s)
• Hinge(s) • Wiring harness
• Electrical connector(s)
• Seat control switch
• Heated seat switch
• Seat height adjustment motor(s)
• Seat tilt motor(s)
• Seat track motor(s)
• Seat recliner motor(s)
• Seat power lumbar motor(s)
• Cushion heater mat
• Backrest heater mat
• Auxiliary junction box (AJB)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Diagnostic
tab within the Ford diagnostic equipment.
Front Seats - Front Head Restraint Guide
Sleeve
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Seat
Print

Removal and Installation

Removal
WARNINGS:

The following procedure prescribes critical repair steps required for correct restraint
system operation during a crash. Follow all notes and steps carefully. Failure to follow
step instructions may result in incorrect operation of the restraint system and increases
the risk of serious personal injury or death in a crash.

Incorrect repair techniques or actions can cause an accidental Supplemental

Restraint System deployment. Make sure the restraint system is depowered before
reconnecting the component. Refer to the Supplemental Restraint System depowering
General Procedure in section 501-20B. Failure to precisely follow depowering instructions
could result in serious personal injury from an accidental deployment.
NOTE: Removal steps in this procedure may contain installation details.
1. Fabricate spacers.

2. Torque: 40 Nm

3.
4.

5. Torque: 25 Nm

6. Torque: 25 Nm
7. Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental
Restraint System, General Procedures).

9.
Installation

1. To install, reverse the removal procedure.

Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental

Restraint System, General Procedures).
Front Seats - Front Seat Armrest
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Seat Backrest Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

2. Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and
Installation).
3.

5. If equipped.
6.

7. If equipped.

8. If equipped.
9.

Installation

1. To install, reverse the removal procedure.

1. 1. NOTE: Make sure that the component is installed to the position noted before
removal.
2. NOTE: Touching the adhesive surface will impair rebonding.

2. Refer to: Front Seat Cushion Cover (501-10A Front Seats, Removal and Installation).
Front Seats - Front Seat Cushion Heater
Mat
Print

Removal and Installation

Removal

Installation

1. 1. NOTE: Make sure that the component is installed to the position noted before
removal.
2. NOTE: Touching the adhesive surface will impair rebonding.

2. Refer to: Front Seat Cushion Cover (501-10A Front Seats, Removal and Installation).
Front Seats - Front Seat Cushion Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

Vehicles without power seats

3. Torque: 3 Nm
Vehicles with power seats

4. Torque: 3 Nm

All vehicles

5. Torque: 3 Nm
6.

7. If equipped.

8.
9.

Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Front Seats - Front Seat Lumbar Assembly
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Seat Backrest Cover (501-10A Front Seats, Removal and Installation).
2. If equipped.

Vehicles without power seats

4.
Vehicles with power seats
5.

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Seat Track
Print

Removal and Installation

General Equipment
Blind Rivet Gun
Electric Drill

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Seat (501-10A Front Seats, Removal and Installation).

Vehicles without power seats

2. Torque: 3 Nm

3. Torque: 3 Nm
Vehicles with power seats

4. Torque: 3 Nm

All vehicles

5. Torque: 3 Nm
6.

7. Torque: 47 Nm

8.
9.

10. If equipped.

11.
12. Torque: 47 Nm

13.

14. Use the General Equipments: Electric Drill, Blind Rivet Gun
15. Use the General Equipments: Electric Drill, Blind Rivet Gun

16. Use the General Equipments: Electric Drill, Blind Rivet Gun

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Bench Seat
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque: 40 Nm

3. Torque: 48 Nm
Installation

1. To install, reverse the removal procedure.

Front Seats - Front Bench Seat Cushion Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. 1. If equipped.

3. 1. If equipped.
4.

Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Front Seats - Front Bench Seat Cushion
Heater Mat
Print

Removal and Installation

Removal

1. Refer to: Front Bench Seat Cushion Cover (501-10A Front Seats, Removal and
Installation).
2. 1. NOTE: Note the position of the component before removal.
2. NOTE: Touching the adhesive surface will impair rebonding.

Installation

1. 1. NOTE: Make sure that the component is installed to the position noted before
removal.
2. NOTE: Touching the adhesive surface will impair rebonding.

2. Refer to: Front Bench Seat Cushion Cover (501-10A Front Seats, Removal and
Installation).
Front Seats - Front Bench Seat Backrest
Print

Removal and Installation

General Equipment
Blind Rivet Gun
Electric Drill

Removal
WARNINGS:

After the power supply has been disconnected, wait for a minimum of 3 minutes
before disconnecting or removing any pyrotechnic components.

2. Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and
Installation).

3. Torque: 40 Nm

4. Torque: 47 Nm
5. Torque: 2 Nm

7.
8.

9.
10.

11. If equipped.

12.
13.

14.
15.
Torque: 6 Nm

16. Torque: 47 Nm
17. Torque: 47 Nm

18. Use the General Equipments: Electric Drill, Blind Rivet Gun

Installation

1. To install, reverse the removal procedure.

Front Seats - Front Bench Seat Backrest Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and
Installation).

2. Torque: 40 Nm

3. Torque: 40 Nm

4. Torque: 3 Nm
5.

7.
8.

10. If equipped.
11.

12.
Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Front Seats - Front Bench Seat Backrest Heater Mat
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and
Installation).

2. Torque: 40 Nm

3. Torque: 40 Nm

4. Torque: 3 Nm
5.

7.
8.

10. If equipped.
11.

12.
13. NOTE: Touching the adhesive surface will impair rebonding.

Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Front Seats - Front Bench Seat Cushion
Print

Removal and Installation

Removal

Installation

1. 1. NOTE: Make sure that the component is installed to the position noted before
removal.
2. NOTE: Touching the adhesive surface will impair rebonding.

2. Refer to: Front Bench Seat Cushion Cover (501-10A Front Seats, Removal and
Installation).
Second Row Seats - Second Row Seats
Print

Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

VISUAL INSPECTION CHART

Mechanical
• Control lever(s)
• Seat tracks
• Seat latch
• Hinge(s)
• Operating cable(s)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

The second row * Control cables. * CHECK the control cables are connected and routed
seat is inoperative * Seat adjuster correctly. CONNECT and SECURE the control cable or
or jams mechanism. INSTALL a new control cable if necessary. TEST the
system for normal operation.
* CHECK the seat adjuster mechanism is not obstructed
or damaged. INSTALL a new seat adjuster mechanism
as necessary. TEST the system for normal operation.
Second Row Seats - Second Row Double Seat Cushion Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque: 3 Nm

3. Torque: 40 Nm
4. Torque: 3 Nm

5. Torque: 3 Nm

6.
7.

8.
Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Second Row Seats - Second Row Double Seat Backrest Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Second Row Seat Head Restraint Guide Sleeve (501-10B Second Row Seats,
Removal and Installation).
2.

3. Torque: 40 Nm

4. Torque: 3 Nm
5.

6. Torque: 3 Nm

7.
8.

10.
11. Torque: 40 Nm

12.

Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Second Row Seats - Second Row Seat
Head Restraint Guide Sleeve
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Installation

1. To install, reverse the removal procedure.

Second Row Seats - Second Row Single Seat Cushion Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Second Row Seat Head Restraint Guide Sleeve (501-10B Second Row Seats,
Removal and Installation).

2. Torque: 3 Nm

4. Torque: 40 Nm
5. Torque: 3 Nm

6. Torque: 3 Nm
8.

9.
Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Second Row Seats - Second Row Single Seat Backrest Cover
Print

Removal and Installation

General Equipment
Hog Ring Plier

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Second Row Seat Head Restraint Guide Sleeve (501-10B Second Row Seats,
Removal and Installation).
2.

3. Torque: 40 Nm

4. Torque: 3 Nm
5.

6. Torque: 3 Nm

7.
8.

10.

11.
Installation

1. To install, reverse the removal procedure.

2. Use the General Equipment: Hog Ring Plier

Second Row Seats - Second Row Seat Latch
Print

Removal and Installation

Removal
NOTE: Front latch shown, rear latch similar.
NOTE: Removal steps in this procedure may contain installation details.
1.

3.
4. Torque: 65 Nm

Installation
NOTE: Front latch shown, rear latch similar.
1. To install, reverse the removal procedure.
2. Fabricate a spacer.
3.
Second Row Seats - Rear Seat Front Latch Actuator and Cable
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. On both sides.

3. On both sides.
4.

5. Torque: 10 Nm
6.

Installation

1. To install, reverse the removal procedure.

2.
3. Fabricate a spacer.

4. On both sides.
Glass, Frames and Mechanisms - Glass,
Frames and Mechanisms
Print

Diagnosis and Testing

General Equipment
The Ford diagnostic equipment
For heated windows, refer to Wiring Diagram Section 056-1 for schematic and connector
information.
For power windows, refer to Wiring Diagram Section 100-1 for schematic and connector
information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Window seal • Fuse(s)
• Door window frame • Electrical connector(s)
• Switch(es)
• Circuit(s)
• Window regulator motor(s)
• Heated rear window relay
• Heated windshield relay
• Heated rear window grid wire
• Heated windshield grid wire
• Auxiliary junction box (AJB)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart
The table provides all possible Wheels ans Tires symptoms. For a detailed diagnostics,
proceed to the Ford diagnostic equipment.

Symptom Possible Sources

All power windows are inoperative Circuit(s)
A single power window is inoperative - driver side Circuit(s)
Driver power window control switch
Window regulator motor
A single power window is inoperative - passenger side Passenger power window control switch
Window regulator motor
Circuit(s)
The one-touch down window is inoperative Driver power window control switch
Body control module (BCM)
The defrost system is inoperative Rear Window Heater Relay
Body control module (BCM)
Heated rear window grid wire
Heated windshield grid wire
Circuit(s)
Heated rear window control switch
Heated front window control switch
The defrost system will not shut off automatically Front Window Heater Relay
Body control module (BCM)
Component Tests
Heated Rear Window Switch

1. Remove the heated rear window switch.

2. Measure the resistance between pins 1 and 2 of the switch while operating the switch.

3. The resistance should be less than 5 ohms when the switch is in the ON position and
greater than 10,000 ohms when in the OFF position.

4. If the resistances are not as specified, INSTALL a new heated rear window switch.

Heated Rear Window Grid Wire Test

1. Using a bright lamp inside the vehicle, visually inspect the wire grid from the outside.
A broken grid conductor will appear as a brown spot.

2. Start the engine and set the heated rear window switch to ON, the indicator light
should illuminate.

3. Work inside the vehicle with a 12 volt DC voltmeter. Contact the broad red-brown
strips on the rear window, positive lead to the battery side and the negative lead to
ground side. The meter reading should be 10-12 volts. A lower voltage reading
indicates a loose heated rear window ground wire connection at the heated rear
window ground wire screws.

4. Contact a ground point with the negative lead of the meter. The voltage reading
should not change.

5. With the negative lead of the meter grounded, touch each grid line of the heated rear
window at its midpoint with the positive meter lead. A reading of approximately six
volts indicates that the line is good. A reading of zero volts indicates that the line is
broken between the midpoint and the B+ side of the grid line. A reading of 12 volts
indicates that the circuit is broken between the midpoint of the grid line and ground.

6. Install a new heated rear window using the procedures as described under the
general procedures if necessary.

Window Heater Relay

1. Remove the heated rear window relay.

2. Using a jumper wire, connect one end to terminal 1 of the relay. Connect the other
end to ground.

3. Using a second jumper wire, connect one end to terminal 2 of the relay.

4. Connect one lead of an ohmmeter to terminal 3 of the relay. Connect second lead to
terminal 5 of the relay. Observe the resistance.

5. Momentarily tap the unconnected end of the second jumper wire to the battery
power. An audible click should be heard and the resistance on the ohmmeter should
drop to zero.

6. If the relay does not click and the resistance does not drop to zero, INSTALL a new
relay.
Glass, Frames and Mechanisms - Power
Door Window Initialization
Print

General Procedures

Initialization

1. WARNING: Keep objects and body parts clear of the glass panel when carrying
out the initialization procedure. During the initialization procedure, the glass panel
closes with high force and cannot detect objects in its path. Failure to follow this
instruction may result in serious personal injury.
NOTE: Make sure that the window runs are correctly installed and free of foreign
material.
NOTE: If the power to a window regulator motor has been disconnected, it is
necessary to initialize that window regulator motor.
NOTE: Wait for a minimum of 1 minute before connecting the battery, fuse or
electrical connector.
Start the engine.
2.

3.
4.

5.
6.

7.
8.
Glass, Frames and Mechanisms - Front Door Window Control Switch
Print

Removal and Installation

Special Tool(s)
501-125
Remover, Grab Handle Cover

Removal

1. Use Special Service Tool: 501-125.

Installation

1. To install, reverse the removal procedure.

2. If the door is equipped with one touch up/down, perform the power door window
initialization.

Refer to: Power Door Window Initialization (501-11 Glass, Frames and Mechanisms,
General Procedures).
Glass, Frames and Mechanisms - Front Door Window Regulator and
Motor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

3.
5.

6. Torque: 7 Nm
Installation

1. To install, reverse the removal procedure.

Glass, Frames and Mechanisms - Liftgate Window Glass
Print

Removal and Installation

General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Laminated Card

Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5

Removal

1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)

2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a
minimum of 30 minutes.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:

Material: WSS-M11P57-A5 (Adhesive)

3. Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and
Installation).

Vehicles with heated rear window

4.
All vehicles

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

6.
WARNING: Make sure that the component paintwork is not damaged.
Use a suitable brace to prevent paintwork damages.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

7. WARNING: Make sure that the component paintwork is not damaged.

NOTE: Some resistance may be encountered when cutting through the glass
locating spacers.
Use suitable adhesive tape or a laminated card to prevent paintwork damages.

Use the General Equipments: Direct Glazing Removal/Replacement Equipment, Adhesive

Tape, Laminated Card
Installation

1. 1. NOTE: Minimum 1 mm bead thickness.

Use the General Equipment: Knife

2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
3. NOTE: Touching the adhesive surface will impair rebonding.
Prepare the liftgate window glass, liftgate window glass flange and trimmed PU
adhesive in accordance with the instructions supplied with the glass adhesive kit.

2. NOTE: Make sure that new components are installed.

3. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.
4. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.

5. NOTE: Discard the first 100 mm of adhesive as this may have a reduced working
time.
NOTE: Make sure that any breakage in the continuous bead of adhesive is
overlapped by 20 mm.
Use the General Equipment: Direct Glazing Removal/Replacement Equipment
Material: WSK-M11P57-A3 (Adhesive)
Material: WSS-M11P57-A5 (Adhesive)
6.
• Press firmly and evenly into position.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

• NOTICE: During the curing time of the polyurethane (PU) adhesive, the
door windows must be left open.
Using tape, secure the liftgate window glass in the correct position until the PU
adhesive has cured.

Use the General Equipment: Adhesive Tape

Vehicles with heated rear window

7.
All vehicles

8. Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and
Installation).
Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Glass, Frames and Mechanisms - Rear Door Window Glass
Print

Removal and Installation

General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Laminated Card

Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5

Removal

1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)

2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a
minimum of 30 minutes.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:

Material: WSS-M11P57-A5 (Adhesive)

Vehicles with rear window wiper

3.
4.

5. Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and
Installation).

Vehicles with heated rear window

6.
All vehicles

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

8.
WARNING: Make sure that the component paintwork is not damaged.
Use a suitable brace to prevent paintwork damages.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

WARNING: Make sure that the component paintwork is not damaged.

NOTICE: If the original window glass is to be installed, take care not to

damage the electrical connectors and the weatherstrip (if equipped).
• Use a suitable brace to prevent trim damages.
• Use suitable adhesive tape or a laminated card to prevent paintwork damages.

Use the General Equipments: Direct Glazing Removal/Replacement Equipment,

Adhesive Tape, Laminated Card
Installation

1. 1. NOTE: Minimum 1 mm bead thickness.

Use the General Equipment: Knife

2. NOTE: Make sure that new components are installed.

3. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.

4. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.
5. NOTE: Discard the first 100 mm of adhesive as this may have a reduced working
time.
NOTE: Make sure that any breakage in the continuous bead of adhesive is
overlapped by 20 mm.
Use the General Equipment: Direct Glazing Removal/Replacement Equipment
Material: WSK-M11P57-A3 (Adhesive)
Material: WSS-M11P57-A5 (Adhesive)

6.
• Press firmly and evenly into position.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

Use the General Equipment: Adhesive Tape

Vehicles with heated rear window

Vehicles with rear window wiper

8. Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and
Installation).
9.

10.
Glass, Frames and Mechanisms - Windshield Glass
Print

Removal and Installation

General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Laminated Card

Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5

Removal

1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)

2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a
minimum of 30 minutes.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:

Material: WSS-M11P57-A5 (Adhesive)

3. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

4. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors, Removal and
Installation).

5. Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

Vehicles with autolamps and rain sensor

6. Refer to: Rain Sensor - Vehicles Without: Front View Camera (501-16 Wipers and
Washers, Removal and Installation).

Vehicles with front view camera

7. Refer to: Rain Sensor - Vehicles With: Front View Camera (501-16 Wipers and Washers,
Removal and Installation).

Vehicles with heated windshield

All vehicles

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

10.

WARNING: Make sure that the component paintwork is not damaged.

NOTICE: If the original window glass is to be installed, take care not to

damage the electrical connectors and the weatherstrip (if equipped).
• Use a suitable brace to prevent trim damages.
• Use suitable adhesive tape or a laminated card to prevent paintwork damages.

Use the General Equipments: Direct Glazing Removal/Replacement Equipment,

Adhesive Tape, Laminated Card
11.

Installation

1. 1. NOTE: Minimum 1 mm bead thickness.

Use the General Equipment: Knife

2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
3. NOTE: Touching the adhesive surface will impair rebonding.
Prepare the windshield glass, windshield glass flange and trimmed PU adhesive in
accordance with the instructions supplied with the glass adhesive kit.

2. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.
3. NOTE: Touching the adhesive surface will impair rebonding.
NOTE: Make sure that the mating faces are clean and free of foreign material.

4. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.

6.
• Press firmly and evenly into position.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

• NOTICE: During the curing time of the polyurethane (PU) adhesive, the
door windows must be left open.
Using tape, secure the windshield glass in the correct position until the PU
adhesive has cured.

Use the General Equipment: Adhesive Tape

Vehicles with heated windshield
7.

Vehicles with front view camera

8. Refer to: Rain Sensor - Vehicles With: Front View Camera (501-16 Wipers and Washers,
Removal and Installation).

Vehicles with autolamps and rain sensor

9. Refer to: Rain Sensor - Vehicles Without: Front View Camera (501-16 Wipers and
Washers, Removal and Installation).

All vehicles
10. Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

11. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors, Removal and
Installation).

12. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
Glass, Frames and Mechanisms - Sliding Door Window Glass
Print

Removal and Installation

General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Laminated Card

Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5

Removal

1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)

2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a
minimum of 30 minutes.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:

Material: WSS-M11P57-A5 (Adhesive)

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable brace to prevent paintwork damages.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

5. WARNING: Make sure that the component paintwork is not damaged.

NOTE: This step requires the aid of another technician.
NOTE: Some resistance may be encountered when cutting through the glass
locating spacers.
Use suitable adhesive tape or a laminated card to prevent paintwork damages.

Use the General Equipments: Direct Glazing Removal/Replacement Equipment, Adhesive

Tape, Laminated Card

Installation

1. 1. NOTE: Minimum 1 mm bead thickness.

Use the General Equipment: Knife

2. NOTE: Make sure that new components are installed.

3. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.

6.
• Press firmly and evenly into position.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

Use the General Equipment: Adhesive Tape

Glass, Frames and Mechanisms - Front Door Window Glass
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: Front Door Window Control Switch (501-11 Glass, Frames and Mechanisms,
Removal and Installation).
3.

4. Torque: 9 Nm
5.

6.
7.

8.
9.

10. Torque: 9 Nm
11.

12.
Installation

1. To install, reverse the removal procedure.

Glass, Frames and Mechanisms - Second Row Side Window Glass
Print

Removal and Installation

General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Laminated Card

Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5

Removal

1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information,
Description and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)

2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a
minimum of 30 minutes.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:

Material: WSS-M11P57-A5 (Adhesive)

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

WARNING: Make sure that the component paintwork is not damaged.

Use a suitable brace to prevent paintwork damages.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

5. WARNING: Make sure that the component paintwork is not damaged.

Use the General Equipments: Direct Glazing Removal/Replacement Equipment, Adhesive

Tape, Laminated Card

Installation

1. 1. NOTE: Minimum 1 mm bead thickness.

Use the General Equipment: Knife

2. NOTE: Make sure that new components are installed.

3. Apply the activator/ primer in accordance with the instructions supplied with the glass
adhesive kit.

6.
• Press firmly and evenly into position.

Use the General Equipment: Direct Glazing Removal/Replacement Equipment

Use the General Equipment: Adhesive Tape

Glass, Frames and Mechanisms - Front Door Fixed Window Glass
Print

Removal and Installation

Removal

1. Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal
and Installation).
2.

Installation

1. To install, reverse the removal procedure.

Instrument Panel and Console - Instrument Panel
Print

Removal and Installation

General Equipment
Flat Headed Screw Driver

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. On both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

4.
5.

6.
7.

8.
9.

10.
11.

12.
13.

14.
15.

16.
17.

18.
19.

20.
21.

22. Use the General Equipment: Flat Headed Screw Driver

23.

24.
25.

26.
27.

28.
29.

30. Torque: 25 Nm
31.

32.
Installation

1. To install, reverse the removal procedure.

Instrument Panel and Console - In-Vehicle Crossbeam
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Instrument Panel Wiring Harness (418-02 Wiring Harnesses, Removal and
Installation).
2. NOTE: Note the position of the component before removal.
If equipped.

3.
1. 1. WARNING: Make sure that a new bolt is installed.

NOTICE: Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 28 Nm

2. 2. WARNING: Make sure that new nuts are installed.

Torque: 25 Nm

4. 1. On both sides.
5. Torque: 9 Nm

6. Torque: 25 Nm
7. Torque: 25 Nm

8. Torque: 10 Nm
9. On both sides.

Refer to: Front Door (501-03 Body Closures, Removal and Installation).
10. On both sides.

11. On both sides.

Torque: 40 Nm
12. Torque: 25 Nm

Installation

1. To install, reverse the removal procedure.

Instrument Panel and Console - Floor Console
Print

Removal and Installation

Removal

3.
Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry
Systems - Locks, Latches and Entry
Systems
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 117-1 for schematic and connector information.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Misaligned door(s), hood or liftgate • Fuse(s)
• Door latch(es) • Relay(s)
• Liftgate latch • Wiring harness
• Hood latch • Electrical connector(s)
• Actuating Cable(s) • Door switch(es)
• Exterior door handle(s) • Door latch(es)
• Door latch remote control(s) • Door latch motor(s)
• Door lock cylinder(s) • Sliding door ajar switch(es)
• Sliding door track(s) • Sliding door latch(es)
• Sliding door contact plate(s)
• Liftgate latch
• Liftgate release switch
• Hood switch
• Vehicle battery
• Remote transmitter batteries
• Remote transmitter
• RF receiver
• Intrusion sensor
• Anti-theft alarm horn(s)
• Anti-theft alarm horn with integral
battery
• Auxiliary junction box (AJB)
• Body control module (BCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, refer to the Ford diagnostic equipment to
diagnose the system.
Handles, Locks, Latches and Entry Systems - Radio Frequency (RF)
Receiver
Print

Removal and Installation

Special Tool(s)
415-001
Remover, Audio Unit

501-125
Remover, Grab Handle Cover

Removal
Vehicles with tachograph

1. Remove Special Service Tool: 415-001.

Vehicles without tachograph

2. Remove Special Service Tool: 501-125.

All vehicles
3.

4.
Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Ignition Lock Cylinder
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

3.
4.

Removal

1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Refer to: Front Door Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).

3. Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry
Systems, Removal and Installation).

4. Torque: 9 Nm

5.
6. Torque: 8 Nm

7.
8.

NOTE: The following steps are only necessary when installing a new component.
9.
10.

Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Hood Lock Cylinder
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2. If equipped.

4.
5. Torque: 9 Nm

Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Rear Door Lower Latch
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Torque: 12 Nm

3.
Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Rear Door Upper Latch
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Torque: 12 Nm

3.
Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Sliding Door Latch
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Sliding Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal
and Installation).

2. Torque: 8 Nm

3.
5.

6.
7.

Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Exterior Sliding Door
Handle
Print

Removal and Installation

Removal

1. Refer to: Sliding Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal
and Installation).
2.

4.
5.

Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Interior Sliding Door
Handle
Print

Removal and Installation

Removal

1. NOTICE: Take extra care not to damage the edges of the component.

3. Refer to: Sliding Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal
and Installation).
5.

6.
7.

8.
Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Rear Door Latch
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Rear Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

2. Torque: 8 Nm

3.
4. If equipped.

Installation

1. To install, reverse the removal procedure.

Handles, Locks, Latches and Entry Systems - Ignition Lock Cylinder
Print

Disassembly and Assembly

Materials
Name Specification
Grease - Electrical Contact WSB-M1C239-A

Disassembly

1. Refer to: Ignition Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
2.

4.
5.

7. NOTICE: Note the position of the components before removal.

8. NOTE: Make sure to read the key code from the key entry to the end of the lock
barrel in sequence.
1. Key code

Assembly

9. NOTICE: Make sure that the components are installed to the position noted
before removal.
The digit numbering starts allways with a 2 digit and follows the sequence as shown.
10. Material: WSB-M1C239-A (Grease - Electrical Contact)

11.

12.

13.
14.

15.
17. Refer to: Ignition Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
Handles, Locks, Latches and Entry Systems - Door Lock Cylinder
Print

Disassembly and Assembly

General Equipment
2 mm Punch

Materials
Name Specification
Multi-Purpose Grease WSD-M1C234-A

Disassembly

1. Refer to: Front Door Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
2.

3. NOTE: This step requires considerable force.

4.
5.

6. Use the General Equipment: 2 mm Punch

7. NOTE: Make sure that no component falls off during removal.

9. NOTICE: Note the position of the components before removal.

Assembly
NOTE: Make sure that new components are installed.

10. NOTICE: Make sure that the components are installed to the position noted
before removal.
11. Material: WSD-M1C234-A (Multi-Purpose Grease)

12.

13.
14. Use the General Equipment: 2 mm Punch

15. NOTE: The component can only be installed in 1 position.

16. NOTE: The component can only be installed in 1 position.

17. NOTE: This step is only necessary when installing a new component.

18. NOTE: This step requires considerable force.

19.
20. Refer to: Front Door Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
Handles, Locks, Latches and Entry Systems - Hood Lock Cylinder
Print

Disassembly and Assembly

General Equipment
2 mm Punch

Materials
Name Specification
Multi-Purpose Grease WSD-M1C234-A

Disassembly

1. Refer to: Hood Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
2.

3. NOTE: This step requires considerable force.

6. Use the General Equipment: 2 mm Punch

8. NOTICE: Note the position of the components before removal.

9. NOTE: Make sure to read the key code from the key entry to the end of the lock
barrel in sequence.
1. Key code

Assembly

10. NOTICE: Make sure that the components are installed to the position noted
before removal.

11. Material: WSD-M1C234-A (Multi-Purpose Grease)

12.

13. Use the General Equipment: 2 mm Punch

14. NOTE: The component can only be installed in 1 position.

15. NOTE: The component can only be installed in 1 position.

16. NOTE: This step requires considerable force.

17.
18. Refer to: Hood Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).
Wipers and Washers - Wipers and Washers - Overview
Print

Description and Operation

General information
Illustration shows LHD (left-hand drive)

Item Description
1 Driveshaft, front windshield wiper arm
2 Wiper motor bracket
3 Wiper motor
4 Electrical connection (4-pin)
5 Integral electronics
The drive of the front windshield wiper arms is provided directly (direct drive) via two
separate, counter-rotating wiper motors. An additional wiper linkage is therefore dispensed
with.
Electronics are integrated in each wiper motor. The BCM (body control module) controls the
driver side wiper motor via the LIN (local interconnect network) databus.

The driver side wiper motor communicates with the passenger side wiper motor via a
separate data cable. Here,
• the wiper motor on the driver side is the master and
• the wiper motor on the passenger side is the slave.

Both wiper motors look identical from the outside. The software for both motors is also
almost identical, apart from the difference in design with regards to the direction of
rotation. However, the left and right-hand wiper motors do differ in terms of the shape of
the bracket. The bracket and wiper motor are only available as a single component in
service. This eliminates the risk of any mix-up.

When the wiper motors are first take into operation the master/slave assignment is
performed automatically. This is defined by the pin allocation of the relevant wiring
harness connector:
• On the master (driver side), all of the pins of the 4-pin connector are assigned. In the
process, pin 1 provides the LIN connection to the BCM.
• On the slave, pin 1 (LIN) is not assigned.

The wiper blade on the driver side is 750 mm long while that on the passenger side is only
700 mm long.
Service instructions
Service position

In order to replace the windshield wiper blades, both wiper arms need to be moved to the
service position.
Alignment of the windshield wiper arms during assembly

NOTICE: Before the windshield wiper arms are installed, the ignition must be
switched on and the windshield wipers must pass through one wipe cycle. This is done by
pressing the wiper lever once downwards. This ensures that the wiper motors are in the
starting position (park position). The ignition must remain on during the process of
installing new wiper arms. During installation of the wiper arms, the wiper arm on the
driver side must be set to the mark and installed above the wiper arm on the passenger
side.
During installation of the windshield wiper arms the driver side wiper arm must be
mounted horizontally and above the passenger side arm.
NOTE: On both LHD and RHD vehicles, there is a marking on the windshield for the
alignment of the wipers.
Wipers and Washers - Wipers and
Washers
Print

Diagnosis and Testing

General Equipment
Ford diagnostic equipment
Refer to Wiring Diagram Section 081-1 for schematic and connector information.
Inspection and Verification
NOTE: Before retrieving the vehicle-specific data make sure that all electrical connections
in the vehicle are reconnected so that the module and the Ford diagnostic equipment can
communicate correctly.
NOTE: If a new body control module (BCM) is being installed, the new module must be
configured following installation. For this purpose, the vehicle-specific data is retrieved
from the module to be changed using the Ford diagnostic equipment and is transferred to
the new module.

1. Verify the customer concern.

2. Visually check for any obvious mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Wiper blade(s) • Fuse(s)
• Rotating shaft – wiper arm • Relay(s)
• Wiper linkage • Wiring harness
• Washer reservoir • Electrical connector(s)
• Hose(s) • Washer pump
• Nozzles • Windshield wiper motor
• Check the windshield wiper for residue- • Rear window wiper motor
free wiping in the vicinity of the • Autolamp and rain sensor
autolamp and rain sensor. • Battery junction box (BJB)
• Check the adhesive pad between the • Auxiliary junction box (AJB)
autolamp and rain sensor and the • Body control module (BCM)
windshield for trapped air.
• Clean wax residues from the windshield
in the vicinity of the autolamp and rain
sensor.
• Check the windshield for damage/cracks
in the vicinity of the autolamp and rain
sensor.
• Check that the autolamp and rain sensor
retaining frame is correctly attached to
the windshield.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Ford
diagnostic equipment to diagnose the system.
Wipers and Washers - Rain
Sensor—Vehicles Without: Front View
Camera
Print

Removal and Installation

Removal

2. NOTICE: After removing the bracket, wait for a minimum of 3 minutes before
removing the rain sensor.

Installation
1. NOTICE:

Make sure that the surface is clean and free of foreign material.

Make sure that the insulator pads are correctly positioned to prevent direct
contact with other components.
To install, reverse the removal procedure.
Wipers and Washers - Rain Sensor—Vehicles With: Front View Camera
Print

Removal and Installation

General Equipment
Interior Trim Remover

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Left-hand drive vehicles

2. NOTICE: Make sure that the cable cannot be damaged or cause a noise,
vibration or harshness (NVH) concern.
Use the General Equipment: Interior Trim Remover
All vehicles

3. NOTICE: After removing the bracket, wait for a minimum of 3 minutes before
removing the rain sensor.

Installation

1. NOTICE:

Make sure that the surface is clean and free of foreign material.

Make sure that the insulator pads are correctly positioned to prevent direct
contact with other components.
To install, reverse the removal procedure.
Wipers and Washers - Rear Window Wiper
Motor
Print

Removal and Installation

General Equipment
Two Leg Puller

Removal

1. NOTICE: Make sure that the motor is in the park position.

NOTE: Removal steps in this procedure may contain installation details.
Use the General Equipment: Two Leg Puller
Torque: 15 Nm

2. Refer to: Liftgate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).

3. Torque: 8 Nm

Installation

1. To install, reverse the removal procedure.

Wipers and Washers - Windshield Wiper Motor
Print

Removal and Installation

Removal

1. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

2. Torque: 10 Nm

Installation

1. To install, reverse the removal procedure.

Wipers and Washers - Windshield Washer Pump
Print

Removal and Installation

Removal

1. NOTE: Be prepared to collect escaping fluid.

Installation

1. To install, reverse the removal procedure.

Wipers and Washers - Windshield Washer Pump and Reservoir
Print

Removal and Installation

Removal

1. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Refer to: Windshield Washer Pump (501-16 Wipers and Washers, Removal and
Installation).
2. NOTE: Be prepared to collect escaping fluid.

3.
5. If equipped.

6.
7.

8.
9.

Installation

1. To install, reverse the removal procedure.

Bumpers - Front Bumper
Print

Removal and Installation

Removal

1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2.

3. On both sides.

4. On both sides.
Installation

1. To install, reverse the removal procedure.

Bumpers - Rear Bumper
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).

2. Torque: 20 Nm

NOTE: The component can be reused unless it has been subjected to abnormal
mechanical stress, damage or oil contamination.
3.
1. Torque: 105 Nm

2. Torque: 30 Nm
Installation

1. To install, reverse the removal procedure.

Bumpers - Front Bumper Cover
Print

Removal and Installation

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

2. Torque: 6 Nm

3. On both sides.

Vehicles with front fog lamps

4. On both sides.

Vehicles with parking aid

All vehicles
6.
7. Torque: 30 Nm

8. On both sides.
9.

Installation

1. To install, reverse the removal procedure.

Bumpers - Rear Bumper Cover
Print

Removal and Installation

General Equipment
Blind Rivet Gun

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

Vehicles with parking aid

2. Torque: 3 Nm
3. On both sides.

Torque: 3 Nm

All vehicles

4. Torque: 3 Nm
5. On both sides.

Torque: 3 Nm

6. Both sides, If equipped.

7. On both sides.

8. On both sides.
Installation

1. On both sides.

2. On both sides.

Use the General Equipment: Blind Rivet Gun

3. Both sides, If equipped.

Use the General Equipment: Blind Rivet Gun

4. To install, reverse the removal procedure.

Bumpers - Front Bumper Cover
Print

Disassembly and Assembly

Special Tool(s) / General Equipment
501-193
Punching Tool, Parking Aid Sensor

15 mm Drill Bit
Electric Drill
Flat File

Disassembly

1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Refer to: Front Bumper Wiring Harness (418-02 Wiring Harnesses, Removal and
Installation).
2.

3.
4.

5.
6.

Vehicles with front fog lamps

7.
Vehicles with front parking aid

8. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.
All vehicles
9.
Assembly

11.

12.
Vehicles with front fog lamps
13.

14.
15.

16.
17.

18.
Vehicles with front parking aid

19. Use the General Equipments: Electric Drill, 15 mm Drill Bit

20. 1. Align the flattened side horizontal upwards, before punching each hole.
2. Use Special Service Tool: 501-193.
21. Use the General Equipment: Flat File

22. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.
23. Refer to: Front Bumper Wiring Harness (418-02 Wiring Harnesses, Removal and
Installation).
Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Bumpers - Rear Bumper Cover
Print

Disassembly and Assembly

Special Tool(s) / General Equipment
501-130
Punching Tool, Parking Aid Sensor

501-138
Punching Tool, Parking Aid Sensor

12 mm Drill Bit
15 mm Drill Bit
Electric Drill
Flat File

Disassembly

1. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
2.

Vehicles with rear parking aid

3. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.
4. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.

Assembly

5.
Vehicles with rear parking aid

6. Use the General Equipments: Electric Drill, 15 mm Drill Bit

7.
1. Align the flattened side horizontal upwards, before punching each hole.

Use Special Service Tool: 501-130.

8. Use the General Equipment: Flat File

9. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.
10. Use the General Equipments: Electric Drill, 12 mm Drill Bit

11. Use Special Service Tool: 501-138.

12. Use the General Equipment: Flat File

13. NOTICE: Pressure must not be applied to the outer face of the parking aid
sensor.
14. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
Seatbelt Systems - Seatbelt Systems
Print

Diagnosis and Testing

General Equipment
The Ford diagnostic equipment
Refer to Wiring Diagram Section 046-1 for schematic and connector information.
Principles of Operations
WARNINGS:

All safety belt components including retractors, buckles, child safety seat tether
brackets and attaching hardware in use during a collision must be removed and new
components installed. New safety belt components should also be installed where safety
belts not in use during a collision, are inspected and found to be damaged or operate
incorrectly. Failure to follow these instructions may result in personal injury.

All vehicles equipped with a passenger air bag have a WARNING sticker attached to
the instrument panel PROHIBITING the use of rear facing child seats in the front seating
positions. Failure to follow this instruction may result in personal injury.

NOTICE: Do not attempt to repair or lubricate the retractor / buckle mechanisms or

modify the belts.
The safety belt system utilizes a combination of two point lap safety belts and three point
lap and diagonal safety belts, depending on the individual vehicle specifications.
The driver front seat safety belt, and passenger front seat safety belt if also equipped with
passenger air bag, incorporate retractor pretensioners. The safety belt pretensioners are
controlled as part of the supplementary restraint system (SRS). When the ignition is turned
on the RUN position the SRS warning indicator will illuminate for three seconds. If the SRS,
including the safety belt electrical system, is operating correctly the SRS warning indicator
will be extinguished. If a fault is detected the SRS warning indicator will illuminate the air
bag warning indicator located in the instrument cluster.
REFER to: Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) (501-
20B Supplemental Restraint System, Diagnosis and Testing).
Emergency Locking Retractor (ELR)

The ELR is part of the safety belt system that in normal operation allows free movement of
the belted occupant. In an emergency the ELR will lock, preventing webbing payout and
hence forward movement of the occupant. Locking may be achieved by one of two
mechanisms:
Vehicle Motion Sensor (VMS)
The VMS is operated by sudden deceleration of the vehicle or excessive tilt. Once operated,
it causes a locking pawl to be engaged, thus locking the retractor, preventing webbing
payout. When the vehicle is stationary the VMS stabilizes causing the pawl to disengage
and unlock the retractor allowing webbing payout.
Webbing Motion Sensor (WMS)
The WMS is operated by rapid acceleration of the webbing. Once operated, it causes a
locking pawl to be engaged thus locking the retractor. When the vehicle is stationary the
VMS stabilizes causing the pawl to disengage and unlock the retractor allowing webbing
payout.
Seatbelt Retractor Webbing does not Extract from Stowed Position
Some of the 2012 Transit and Transit Custom vehicles may have a concern where the
seatbelt retractor webbing does not extract from the stowed position. This may be due to a
normal condition which happens when the seatbelt retracts at a high speed. To release the
seat belt:

1. Lower the shoulder height adjuster, if available or slowly extract the seatbelt webbing
to tighten the roll on the retractor. Only a few millimeters are required to release
the locked retractor.

2. Allow the extracted webbing to retract and the locked condition will release. By
following these instructions, the webbing will once again extract freely.

If a seatbelt concern still exists, refer to the normal diagnostics under Seatbelt Systems.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Safety belt retractor • Fuse(s)
• Safety belt buckle • Electrical connector(s)
• Safety belt shoulder height adjuster • Circuit(s)
• Safety belt retractor pretensioner(s)
• Restraints control module

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Normal mode - occupant restraint * Safety belt * CARRY OUT the Safety Belt
system inoperative retractor. Component Test in this section.

Component Test
Poor Retraction
If a safety belt does not retract correctly, check that the anchor covers and trim are
correctly installed and not rubbing against the safety belt webbing. Where necessary, check
that the safety belt webbing is not rubbing at one end of the retractor cover slot and if so,
correct by loosening the retaining bolt, aligning the retractor to centralize the safety belt
webbing and tightening the bolt.
The safety belt retractors are dual sensitive, which means that they have:

• a vehicle motion sensor, which locks the safety belt webbing under braking, cornering, on
steep hills and in adverse camber conditions.
• a webbing motion sensor, which locks when the safety belt webbing is quickly extracted.

Both systems should be fully operational and can be checked by the tests below:
Vehicle Motion Sensor Test

Either of the following two procedures may be used to check correct operation of the
vehicle motion sensor. Both methods require two technicians, but note that technicians of
larger than normal build should not be asked to conduct these tests. This is to avoid the
possibility of a fully unrolled safety belt webbing being mistaken for a correctly locked
safety belt retractor.
Test Method 1 (braking)
WARNING: It is important that during this test, the wearers allow the safety belt to
provide the restraint and do not attempt to anticipate the sudden deceleration. The
steering wheel should not be used as a brace. However, both driver and passenger should
prepare themselves for the possibility that the safety belts will not lock. The passenger
should hold their hands in front of them, just clear of the instrument panel or front seat
backrest, depending on which safety belt is being tested. Failure to follow these
instructions may result in personal injury.
This method requires a quiet or private stretch of road.

• Make sure that the road is clear and that full visibility is maintained at all times.
• Both driver and passenger should adopt a normal, comfortable seating position. Both
occupants should wear the safety belts and the safety belt webbing must be correctly
adjusted, with no slack.
• Proceed at a speed of 10 km/h (6 mph). Do not exceed 10 km/h (6 mph) for this test.
• Apply the foot brake sharply to stop the vehicle. If the vehicle motion sensor lock
mechanism is operating correctly, the safety belt webbing will lock and restrain the
wearer.
• Conduct the test twice in each passenger seat position.
• Any safety belt retractor which does not restrain the wearer must not be used. A new
safety belt must be installed. REFER to: (501-20A Seatbelt Systems)
Front Seatbelt Retractor (Removal and Installation),
Front Center Seatbelt Retractor - Vehicles With: Double Passenger Seat (Removal
and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation).

Test Method 2 (turning circle)

This method requires a flat open area of private road, sufficient for the vehicle to be driven
in a continuous circle on full steering lock.

• The driver should wear the safety belt provided and the belt webbing must be correctly
adjusted, with no slack.
• The passenger should occupy a rear seat with the safety belt correctly adjusted.
• Start the engine and, with the steering on full right-hand lock, drive the vehicle in a
continuous circle at 16 km/h (10 mph). Do not exceed 16 km/h (10 mph) for this test.
• When the speed is stable, the passenger should attempt to slowly extract the safety belt
webbing from the safety belt retractor. If the vehicle motion sensor lock mechanism is
operating correctly, it will not be possible to extract the webbing. This test should be
repeated for each passenger seating position.
• Any safety belt retractor from which it is possible to extract the webbing during this test
must not be used, a new safety belt must be installed. REFER to: (501-20A Seatbelt
Systems)
Front Seatbelt Retractor (Removal and Installation),
Front Center Seatbelt Retractor - Vehicles With: Double Passenger Seat (Removal
and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation).

Static Test
With the vehicle stationary and on level ground, take firm hold of the safety belt webbing
(on the tongue side of the upper safety belt anchor) and pull quickly. The retractor should
lock within 0.25 meters (10 inches), preventing further webbing payout. Any safety belt
retractor from which it is possible to extract further webbing must not be used. A new
safety belt must be installed. REFER to: (501-20A Seatbelt Systems)
Front Seatbelt Retractor (Removal and Installation),
Front Center Seatbelt Retractor - Vehicles With: Double Passenger Seat (Removal and
Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Center Seatbelt Retractor (Removal and Installation),
Second Row Double Seat Outer Seatbelt Retractor (Removal and Installation).
Seatbelt Systems - Front Seatbelt
Retractor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2. 1. If equipped.

3. 1.
4. 1.
2. Torque: 40 Nm

5. 1.

6. 1.
7.
1. Torque: 40 Nm

8.
1. Torque: 40 Nm
9. 1.

Installation

1. To install, reverse the removal procedure.

Seatbelt Systems - Seatbelt Shoulder
Height Adjuster
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2. 1. If equipped.

General Equipment
Blind Rivet Gun
Electric Drill

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Second Row Double Seat Backrest Cover (501-10B Second Row Seats,
Removal and Installation).

2. Torque: 3 Nm

3. Torque: 3 Nm

4.
5. Use the General Equipments: Electric Drill, Blind Rivet Gun

6. Torque: 40 Nm

Installation

1. To install, reverse the removal procedure.

Seatbelt Systems - Second Row Double Seat Center Seatbelt Retractor
Print

Removal and Installation

General Equipment
Blind Rivet Gun
Electric Drill

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Second Row Double Seat Backrest Cover (501-10B Second Row Seats,
Removal and Installation).

2. Torque: 3 Nm

3. Torque: 3 Nm

4.
5. Use the General Equipments: Electric Drill, Blind Rivet Gun

6. Torque: 40 Nm

Installation

1. To install, reverse the removal procedure.

Seatbelt Systems - Second Row Single
Seat Seatbelt Buckle
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Torque: 40 Nm

Installation

1. To install, reverse the removal procedure.

5. Torque: 40 Nm

Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Airbag and Seatbelt Pretensioner
Supplemental Restraint System (SRS) - Component Location
Print

Description and Operation

Item Description
1 Front impact sensor
2 PAD (passenger airbag deactivation) switch
3 Front passenger airbag
4 PAD indicator light
5 Side air curtain
6 Side air bag
7 Driver air bag
8 Safety belt retractor, 3rd row of seats
9 Safety belt retractor, 2nd row of seats
10 Safety belt retractor, driver seat and passenger seat
11 Driver and passenger side impact sensor
12 RCM (restraints control module)
Supplemental Restraint System - Airbag
and Seatbelt Pretensioner Supplemental
Restraint System (SRS) - Overview
Print

Description and Operation

General information
The air bag systems listed below are available for the new Transit Custom:

• Driver air bag

• Passenger air bag
• Side air bag
• Side air curtain

As an option there will be the facility for aftermarket installation of a deactivation switch for
the passenger air bag. There is an appropriate warning indicator available for this in the
instrument panel cluster.
Supplemental Restraint System - Airbag
and Seatbelt Pretensioner Supplemental
Restraint System (SRS)
Print

Diagnosis and Testing

Special Tool(s) / General Equipment
Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt
418-S055

Test and Deployment Lead; Driver, Driver Lower and Passenger Air Bags and
Side Air Curtain Module
418–525

Test and Deployment Lead, Side Air Bag Module

418–555

Simulator, Driver, Driver Lower and Passenger Air Bags and Side Air Curtain
Module
418-160

Simulator, Occupant Restraint Systems

501–077

Simulator, Passenger Safety Belt Retractor and Pretensioner

418-138

Ford diagnostic equipment

Refer to Wiring Diagram Section 046-1 for schematic and connector information.
For SRS Depowering and Repowering,
REFER to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental
Restraint System, General Procedures).
Principles of Operation
SRS Operation

The vehicle is equipped with a DC fired sensing system.

In the event of a severe frontal or three-quarter frontal impact, in excess of a
predetermined limit, the driver and passenger front air bags and safety belt retractor
pretensioners and driver knee air bag (if equipped) will deploy.
In the event of a severe full side impact, in excess of a predetermined limit, either the
driver or passenger side air bag, side air curtain (if equipped) will deploy.
Air bag deployment will only occur, in the event of a severe collision, when the ignition key
is in the RUN position. The passenger air bag deactivation (PAD) switch (if equipped) will
deactivate the passenger frontal air bag in the event of a severe frontal impact; it will not
deactivate any other deployable device.
RCM

The RCM retains full control of the whole system, providing continual system checks and full
diagnostic capabilities. The non-volatile memory stores the diagnostic trouble codes, which
can then be downloaded through the data link connector (DLC) to the Ford diagnostic
equipment.
In the event of a failure in the vehicle supply during an accident, the RCM provides a
backup power supply, sufficient to deploy the air bag(s) for a minimum of 150 ms. The
backup power supply is discharged by the RCM within 60 seconds of the battery ground
cable being disconnected.
The RCM contains electronic acceleration sensors which measure the longitudinal
acceleration and the lateral acceleration and provide both signals to the micro-controller
proportional to the amount of acceleration measured. The RCM also contains a safing
sensor, which prevents unintentional deployment of the front air bags and safety belt
retractor pretensioners and knee air bag (if equipped) in the event of a fault within the
electronic acceleration sensor(s). The RCM compares the values it receives from the crash
sensor, side impact sensors, safing sensor and the internal electronic sensors. If the
deceleration due to a frontal or side impact exceeds a stored threshold value then the RCM
triggers the air bags and safety belt pretensioners as required.
Air Bag Warning Indicator

The air bag warning indicator is incorporated into the instrument cluster, together with the
automatic detach detect circuit. The air bag warning indicator illuminates for 3.2 seconds at
key ON and goes OFF for 4.8 seconds. If the system self-tests OK the indicator will stay
OFF, but if there is a fault condition, the air bag warning indicator will come ON again and
stay illuminated.
The system is designed to illuminate the air bag warning indicator continuously if the RCM
circuit is broken, either by loss of power, ground supply, module disconnect or CAN BUS
failure.
Diagnostic evaluation of the SRS should be made through the DLC using the Ford diagnostic
equipment to establish the nature of the concern.
Front Crash Sensor

The front crash sensor contains an acceleration sensor, filter, amplifier and an application
specific integrated circuit for signal transmitting and is mounted on the radiator grille
opening panel reinforcement. The crash sensor sends a signal at a level determined by the
crash severity to the RCM. The RCM will evaluate the signal against stored data and deploy
the frontal air bags and safety belt retractor pretensioners and knee air bag (if equipped)
when required. Both the crash sensor and the internal RCM longitudinal acceleration sensor
must exceed a preset limit to initiate the air bag.
Side Impact Sensor

The side impact sensors are mounted at the base of the B-pillar on either side of the
vehicle, to facilitate remote lateral impact sensing. Each side impact sensor contains an
acceleration sensor, filter, amplifier and an application specific integrated circuit for signal
transmitting. In the event of an impact, in excess of a predetermined limit, the side impact
sensor sends a signal at a level determined by the crash severity to the RCM. The RCM will
evaluate the signal against stored data and deploy the side air bag on the side the
deployment request was initiated. Both the side impact sensor and the internal RCM lateral
acceleration sensor must exceed a preset limit to initiate the air bag. The RCM retains
control of the side air bags, side air curtains.
Diagnosing Customer Concerns Without Hard DTCs

WARNING: To avoid accidental deployment, the restraints control module (RCM)

backup power supply must be depleted. Wait at least one minute after disconnecting the
battery ground cable(s) before commencing any repair or adjustment to the supplemental
restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to
follow these instructions may result in personal injury.
NOTE: Following the pinpoint tests when a diagnostic trouble code (DTC) is not present,
or the air bag warning lamp is not permanently illuminated, will result in needless
replacement of air bag system components and repeat repairs.
Speak with the customer to determine if a particular set of conditions must be met in order
for a fault to occur. If an illuminated air bag warning lamp is reported by the customer but
is not present when the vehicle comes in for repair, pinpoint test diagnostics cannot be
used.
Diagnosing Customer Concerns with Hard DTCs

WARNING: Do not use substitute air bag simulators when working on the SRS. Use
only the appropriate tool. Failure to follow these instructions may result in personal
injury.
Most air bag system diagnostic procedures require the use of system deactivation and
system reactivation procedures. These procedures require the air bag module(s) and safety
belt retractor pretensioners to be disconnected from the SRS, thereby removing the risk of
air bag deployment while diagnostics are carried out.
Air bag simulators are required to carry out diagnosis and testing of the air bag system.
The simulator contains a resistor, used to simulate an air bag module connection to the
system. It is not acceptable to short-circuit the air bag module connections with a 0 ohm
jumper wire. If a 0 ohm jumper wire is used to short-circuit the air bag module
connections, an illuminated air bag warning lamp will be displayed and a DTC logged by the
RCM.
Glossary
Air Bag Simulator
Air bag simulators are used to simulate air bag module connections to the system.
Prove Out the System
The air bag warning indicator will illuminate for three seconds. If there is a fault condition,
the air bag warning indicator will stay illuminated or illuminate after a five second delay.
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical Electrical
• Safety belt retractor pretensioner(s) • Fuse(s)
• Driver frontal air bag • Wiring harness
• Passenger frontal air bag • Electrical connector(s)
• Driver and passenger side air bags • Driver safety belt buckle switch
• Driver and passenger side air curtains • Safety belt retractor pretensioner(s)
• Impact sensor(s) • Passenger seat occupant sensor
• Passenger air bag deactivation (PAD)
switch
• PAD indicator
• Clockspring
• Impact sensor(s)
• Message center switch
• Front impact severity sensor
• Auxiliary junction box (AJB)
• Body control module (BCM)
• Anti-Lock Brake System (ABS) module
• Restraints control module (RCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab
within the Ford Diagnostic Equipment.
Supplemental Restraint System - Clockspring Adjustment
Print

General Procedures
General Equipment
Adhesive Tape

Adjustment
NOTICE:

If there is a break between installing the clockspring and steering wheel rotation
sensor assembly and installing the steering wheel, the centralizing of the clockspring
must be repeated.

If the centralization of the clockspring is in doubt, the centralizing of the clockspring

must be repeated.
1. 1. Turn the clockspring rotor in a counterclockwise direction until a resistance is felt.
2. Turn the clockspring rotor in a clockwise direction, until the arrow marked on the
clockspring rotor aligns with the raised ‘V’ section on the clockspring body.
3. Turn the clockspring rotor in a clockwise direction three turns.

2. NOTICE: Make sure that the clockspring rotor does not rotate.
Use the General Equipment: Adhesive Tape
Supplemental Restraint System -
Deployed Airbag Disposal
Print

General Procedures

WARNING: After deployment, the air bag module surface may contain deposits of
sodium hydroxide, a product of the gas generate combustion, that is irritating to the skin.
Use protective gloves when handling any deployed air bag module. Failure to follow this
instruction may result in personal injury.

1. Remove the deployed air bag module(s). For additional information, refer to the
relevant procedure in this section.

2. Seal the deployed air bag module(s) in the packaging from the new air bag module(s)
or a suitable polythene bag, and then dispose of in accordance with local
contaminated waste regulations.
Supplemental Restraint System -
Inspection and Repair after a
Supplemental Restraint System (SRS)
Deployment
Print

General Procedures

Inspection
NOTE: Deployable devices such as airbags, pretensioners and inflatable belt inflators,
may deploy alone or in various combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out
vehicle repairs affecting the SRS (supplemental restraint system) and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to
the customer.
1. NOTE: Refer to the correct removal and installation procedure for all SRS
components being installed.
When any deployable device or combination of devices have deployed the RCM
(restraints control module) can be reused up to five times after a crash. The repair of
the vehicle SRS is to include the removal of all deployed devices, the installation of new
deployable devices and the removal and installation of new impact sensors. Diagnostic
Trouble Codes (DTCs) must be cleared from all required modules after repairs are
carried out.
2. When any damage to the impact sensor mounting points or mounting hardware has
occurred, repair or install new mounting points and mounting hardware as needed.
3. When the driver airbag has deployed, install a new clockspring.
4. New driver and/or front passenger safety belt systems (including retractors, buckles and
height adjusters) must be installed if the vehicle is involved in a collision that results in
deployment of the driver and/or front passenger safety belt pretensioners.
5. New second/third row safety belt systems (including retractors, buckles and inflators)
must be installed if the vehicle is involved in a collision that results in deployment of the
rear inflatable safety belt system, if equipped.
6. Inspect the entire vehicle for damage, including the following components:

7. • Steering column (deployable column if equipped)

• Instrument panel knee bolsters and mounting points
• Instrument panel braces and brackets
• Instrument panel and mounting points
• Seats and seat mounting points
• Safety belts, safety belt buckles, safety belt retractors and safety belt anchors
• SRS wiring, wiring harnesses and connectors
8. After carrying out the review and inspection of the entire vehicle for damage, repair or
install new components as needed.
9. Inspect the fuel system for damage or leaks. Repair the system and install new
components as necessary.
10. • Connect a diagnostic scan tool and view the BCM (body control module) CRASH
PID (parameter identification).
• If the BCM CRASH PID is present and reads 'Yes', use the diagnostic scan tool to
carry out the BCM Crash Status Reset under "Electrical - Service Functions".
• If the BCM CRASH PID reads 'No' or is not present, complete any necessary
repairs before returning the vehicle to the customer.
Supplemental Restraint System - Scrapped Vehicle Airbag and Seatbelt
Pretensioner Disposal - In-Vehicle Disposal
Print

General Procedures
Special Tool(s)
418-143
Adapter Box (AC)

418-S055C
Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt

Activation
WARNINGS:

To avoid accidental deployment, the restraints control module (RCM) backup power
supply must be depleted. Wait at least one minute after disconnecting the battery ground
cable(s) before commencing any repair or adjustment to the supplemental restraint
system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
instructions may result in personal injury.

To minimize the possibility of premature deployment, do not use radio key code
savers when working on the SRS. Failure to follow this instruction may result in personal
injury.

Before deploying the air bag module or safety belt pretensioner pyrotechnic make
sure that all personnel in the vicinity are aware that a loud noise (bang) is about to occur.
Do not let anybody approach closer than 6 meters. Failure to follow this instruction may
result in personal injury.

The air bag module or the safety belt pretensioner should not be handled
immediately following deployment as the air bag module will be very hot. Failure to follow
this instruction may result in personal injury.

After deployment, the inflator(s) becomes inert, direct contact to the skin or eyes of
any free pyrotechnic residues should be avoided. Failure to follow this instruction may
result in personal injury.

Always wear gloves and safety glasses when handling deployed air bag modules and
safety belt pretensioners, Failure to follow this instruction may result in personal injury.

If the air bag module or safety belt pretensioner pyrotechnic residue should contact
the eyes, wash the eyes with clean water and seek medical assistance. Failure to follow
this instruction may result in personal injury.

If a large amount of air bag or safety belt pretensioner pyrotechnic residue is

inhaled, seek medical assistance. Failure to follow this instruction may result in personal
injury.
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and
Installation).
3.

4.
1. Use Special Service Tools: 418-143, 418-S055C.

5.
6. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.

7. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.
8. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.

9. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.
10. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.

11. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.
12. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.

13. 1.

2. 2. WARNING: Make sure to be a minimum distance of 6 meters from

pyrotechnic components during deployment. If possible stand behind a wall.
14. Deployed air bag module(s) and safety belt pretensioners should be sealed in suitable
bags and then disposed of in accordance with local contaminated waste regulations.
15. NOTE: All unserviceable air bag modules have been placed on the Mandatory
Return List. All discolored or damaged air bag modules should be treated the same
as any unserviceable live air bag module being returned.
Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
Refer to: Passenger Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
Refer to: Side Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
Refer to: Side Airbag - Vehicles With: Double Passenger Seat (501-20B Supplemental
Restraint System, Removal and Installation).
Refer to: Front Side Curtain Airbag (501-20B Supplemental Restraint System, Removal
and Installation).

16. WARNING: Under no circumstances is an unserviceable air bag module or

safety belt pretensioner to be returned through the local mailing system. Failure to
follow this instruction may result in personal injury.
If an air bag module or safety belt pretensioner fails to deploy, seal the unserviceable
air bag module or safety belt pretensioner in suitable packaging and return to the
Exchange Plan Center, as appointed through the local National Sales Company
Supplemental Restraint System -
Supplemental Restraint System (SRS)
Depowering
Print

General Procedures

Depower

WARNING: Incorrect repair techniques or actions can cause an accidental

1. WARNING: Before beginning any service procedure in this section, refer to

Safety Warnings in section 100-00 General Information. Failure to follow this
instruction may result in serious personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2. Determine if a SRS (supplemental restraint system) fault is present. Turn the ignition
OFF and wait 10 seconds, then turn the ignition ON and monitor the airbag warning
indicator. The airbag warning indicator illuminates continuously for approximately 6
seconds and then turns off. Continue to monitor the airbag warning indicator for
approximately 30 seconds as this is the time required for the RCM (restraints control
module) to complete testing of the SRS.
3. • If a SRS fault is present the airbag warning indicator either fails to light, remains
lit continuously or flashes. The flashing may not occur until approximately 30
seconds after the ignition has been turned from OFF to ON. If this occurs,
diagnose and repair any SRS faults before proceeding with other repairs.
• If after the ignition has been turned ON for 30 seconds the airbag warning
indicator remains unlit with no chime or SRS message displayed in the message
center, no SRS fault is present.
• If the airbag warning indicator is inoperative and a SRS fault exists, a chime
sounds in a pattern of 5 sets of 5 beeps or a message displays in the message
center. If this occurs, diagnose and repair the airbag warning indicator and any
SRS faults before proceeding with other repairs.

No SRS Fault Present (with ignition ON, airbag warning

indicator stays off after prove out)

4. WARNING: Turn the ignition OFF and wait one minute to deplete the backup
power supply. Ignition must remain OFF until repair is complete. Failure to follow
this instruction may result in serious personal injury or death in the event of an
accidental deployment.
Turn the ignition OFF and wait one minute before continuing vehicle service.

SRS Fault Present

5. Turn the ignition OFF.
6. Remove the RCM fuse and, if equipped, {Acronym.BECMB} ({Acronym.BECMB}) fuse
(s). Refer to Wiring Diagram Cell 11/Section 700-01 for fuse and relay information.
7. For a vehicle equipped with a 3 blade {Acronym.BECMB}/GWM (gateway module A)
fuse, install a 2 blade 10A fuse at the GWM position to allow the scan tool to
communicate with the vehicle network.
8. Turn the ignition ON.
9. Using a diagnostic scan tool, carry out a Network Test. Verify that the RCM and, if
equipped, {Acronym.BECMB} does not respond to the Network Test. If the RCM or
{Acronym.BECMB} pass the Network Test, remove the correct RCM or
{Acronym.BECMB} fuse and repeat the Network Test to verify before proceeding.
10. Turn the ignition OFF.

11. Disconnect the battery.

Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
12. Wait at least one minute before continuing vehicle service.
Supplemental Restraint System -
Supplemental Restraint System (SRS)
Repowering
Print

General Procedures

Repower

WARNING: Incorrect repair techniques or actions can cause an accidental

Supplemental Restraint System (SRS) deployment. Never compromise or depart from
these instructions. Failure to precisely follow all instructions could result in serious
personal injury from an accidental deployment.
NOTE: The SRS (supplemental restraint system) must be fully operational and free of
faults before releasing the vehicle to the customer.

1. WARNING: Before beginning any service procedure in this section, refer to

No SRS Fault Present At Beginning of Repair

2. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF.
Wait 10 seconds then turn the ignition ON and monitor the airbag warning indicator. The
airbag warning indicator illuminates continuously for approximately 6 seconds and turns
off. Continue to monitor the airbag warning indicator for approximately 30 seconds as
this is the time required for the RCM (restraints control module) to complete testing of
the SRS.
3. • If a SRS fault is present, the airbag warning indicator either fails to light, remains
lit continuously or flashes. The flashing may not occur until approximately 30
seconds after the ignition has been turned from OFF to ON. If this occurs,
diagnose and repair any SRS faults before proceeding with other repairs.
• If, after the ignition has been turned on for 30 seconds, the airbag warning
indicator remains unlit with no chime or SRS message displayed in the message
center, no SRS fault is present.
• If the airbag warning indicator is inoperative and a SRS fault exists, a chime
sounds in a pattern of 5 sets of 5 beeps or a message displays in the message
center. If this occurs, diagnose and repair the airbag warning indicator and any
SRS faults before proceeding with other repairs.

SRS Fault Present At Beginning of Repair

4. Verify the ignition is OFF.
5. For a vehicle equipped with a 3 blade {Acronym.BECMB} ({Acronym.BECMB})/GWM
(gateway module A) fuse, remove the 2 blade 10A fuse at the GWM position.
6. Install the RCM and, if equipped, {Acronym.BECMB} fuse(s). Refer to Wiring Diagram
Cell 11/Section 700-01 for fuse and relay information.

7. Connect the battery.

Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
8. Sit in the driver seat in an upright position. Make sure no objects are between you and
any pyrotechnic device. Move the driver seat to the rearmost position to maintain the
maximum possible distance from the driver airbag.
9. Turn the ignition from OFF to ON.
10. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF.
Wait 10 seconds, then turn the ignition ON and monitor the airbag warning indicator.
The airbag warning indicator illuminates continuously for approximately 6 seconds and
then turns off. Continue to monitor the airbag warning indicator for approximately 30
seconds, as this is the time required for the RCM to complete testing of the SRS.
11. • If a SRS fault is present, the airbag warning indicator either fails to light, remains
lit continuously or flashes. The flashing may not occur until approximately 30
seconds after the ignition has been turned from OFF to ON. If this occurs,
diagnose and repair any SRS faults before proceeding with other repairs.
• If, after the ignition has been turned on for 30 seconds, the airbag warning
indicator remains unlit with no chime or SRS message displayed in the message
center, no SRS fault is present.
• If the airbag warning indicator is inoperative and a SRS fault exists, a chime
sounds in a pattern of 5 sets of 5 beeps or a message displays in the message
center. If this occurs, diagnose and repair the airbag warning indicator and any
SRS faults before proceeding with other repairs.
12. Using a scan tool, clear all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from
all modules.
Supplemental Restraint System -
Unserviceable Airbag Disposal
Print

General Procedures

NOTE: Unserviceable Airbags cannot be deployed and are inoperative because of internal
technical failure.

1. WARNINGS:

To minimize the possibility of injury in the event of premature deployment,

always carry a live air bag module with the bag and trim cover pointed away from
the body. Failure to follow this instruction may result in personal injury.

To prevent premature deployment, live air bag modules must only be placed
on work benches which have been ground bonded. Failure to follow this instruction
may result in personal injury.
NOTE: All unserviceable air bag modules have been placed on the Mandatory
Return List. All discolored or damaged air bag modules should be treated the same
as any unserviceable live air bag module being returned.
Remove the unserviceable air bag module. For additional information, refer to the
relevant procedure in this section.

2. WARNING: Under no circumstances is an unserviceable air bag module(s) to be

returned through the local mailing system. Failure to follow this instruction may
result in personal injury.
Seal the unserviceable air bag module(s) in the packaging from the new air bag
module(s) and address to the appropriate manufacturer. The package should then
be forwarded to the Exchange Plan Center (as appointed through the national sales
company) who will arrange forwarding to the manufacturer.

3. NOTE: Autoliv air bag modules and seat belt pretensioners.

Autoliv Gmbh, Theodor Heuss Strasse 2, 85221, Dachau, Germany.

4. NOTE: TRW air bag modules.

TRW Occupant Restraint Systems, FAO Rene Getto, Industriestr 20, 73551, Aldorf,
Germany.

5. NOTE: TRW seat belt pretensioners.

TRW Occupant Restraint Systems, FAO Helmut Goss, Industriestr 20, 73551,
Aldorf, Germany.

6. NOTE: Takata Petri air bag modules.

Takata Petri AG, Grossostheimer Strasse 223, D-63741 Aschaffenburg, (Supplier
Code P790M) Germany.
Supplemental Restraint System - Restraints Control Module (RCM)
Print

Removal and Installation

General Equipment
Ford approved diagnostic tool

Removal

WARNING: The following procedure prescribes critical repair steps required for
correct restraint system operation during a crash. Follow all notes and steps carefully.
Failure to follow step instructions may result in incorrect operation of the restraint system
and increases the risk of serious personal injury or death in a crash.
NOTE: After an impact, the RCM can be used again up to 5 times if it is not physically
damaged and if it passes a self-test without any faults.
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Parking Brake Control (206-05 Parking Brake and Actuation, Removal and
Installation).

2. Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental

Restraint System, General Procedures).
3.

4.
Installation

1. To install, reverse the removal procedure.

2.
Torque: 10 Nm

3. After an impact, connect the diagnostic scan tool to carry out the BCM Crash Status
Reset under "Electrical - Service Functions", if the BCM CRASH PID is present and reads
'Yes'.
Refer to: Inspection and Repair after a Supplemental Restraint System (SRS)
Deployment (501-20B Supplemental Restraint System, General Procedures).

4. When a new RCM is installed, configure the RCM using the diagnostic tool.

Use the General Equipment: Ford approved diagnostic tool

5. Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental

Restraint System, General Procedures).
Supplemental Restraint System - Clockspring
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation).

2. NOTICE: Make sure that the clockspring pins are not bent or damaged.

Installation

1.
2. NOTE: This step is only necessary if adjustment is required.
Refer to: Clockspring Adjustment (501-20B Supplemental Restraint System, General
Procedures).

3. Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation).
4. NOTE: This step is only necessary when installing a new component.
Supplemental Restraint System - Driver Airbag
Print

Removal and Installation

Removal
WARNINGS:

After the power supply has been disconnected, wait for a minimum of 3 minutes
before disconnecting or removing any pyrotechnic components.

Make sure that the vehicle electrical system is fully depowered and no other power
source is connected.
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Pyrotechnic Device Health and Safety Precautions (100-00 General
Information, Description and Operation).
NOTE: Make sure that the steering column lock is not engaged.
2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
3.

5.
6.

7.
Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Passenger Airbag
Print

Removal and Installation

Removal
WARNINGS:

After the power supply has been disconnected, wait for a minimum of 3 minutes
before disconnecting or removing any pyrotechnic components.

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
3.

4. Torque: 8 Nm

5.
1. Torque: 4 Nm
2. Torque: 25 Nm

6.
Torque: 4 Nm

7.
Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Side
Airbag
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Front Seat Backrest Cover (501-10A Front Seats, Removal and Installation).
2.

4.
Torque: 7 Nm
Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Side Airbag—Vehicles With: Double
Passenger Seat
Print

Removal and Installation

Removal
WARNINGS:

After the power supply has been disconnected, wait for a minimum of 3 minutes
before disconnecting or removing any pyrotechnic components.

2. Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and
Installation).

3. Torque: 40 Nm

4. Torque: 40 Nm
5. Torque: 3 Nm

7.
8.

9.
10.

11. If equipped.

12.
13.

14.
15.
Torque: 7 Nm

Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Front Side Curtain Airbag
Print

Removal and Installation

Removal
WARNINGS:

After the power supply has been disconnected, wait for a minimum of 3 minutes
before disconnecting or removing any pyrotechnic components.

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

3. Refer to: Front Headliner - Bus (501-05 Interior Trim and Ornamentation, Removal and
Installation).

4. Refer to: Front Headliner - Van (501-05 Interior Trim and Ornamentation, Removal and
Installation).

5.
Torque: 9 Nm

Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Front Impact Severity Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2. Refer to: Hood Latch Release Cable (501-14 Handles, Locks, Latches and Entry Systems,
Removal and Installation).

3. Torque: 10 Nm

Installation

1. To install, reverse the removal procedure.

Supplemental Restraint System - Side Impact Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Pyrotechnic Device Health and Safety Precautions (100-00 General
Information, Description and Operation).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
3.

4. NOTE: This step is only necessary when installing a new component to the left-
hand side.
If equipped.

Torque: 11 Nm
5. Torque: 10 Nm

Installation

1. To install, reverse the removal procedure.

Uni-Body, Subframe and Mounting System - Front Axle Crossmember
Print

Removal and Installation

General Equipment
Transmission Jack
Two Leg Puller

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).

2. NOTICE: Make sure that the steering column lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
NOTE: This step is not necessary when installing a new component.

3. NOTICE: The steering column is designed to absorb energy in a crash and

must be handled carefully. The energy-absorbing steering column shaft cannot be
subjected to force or impact shocks. Follow the removal procedure instructions
carefully to avoid damage.
Torque: 27 Nm

4.
5. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

6. On both sides.

Loosen: 3 turn(s)

7.
1. On both sides.

Use the General Equipment: Two Leg Puller

2. On both sides.

8.
9. Torque: 17 Nm

10.
1. 1. NOTICE: Make sure a new bolt is installed.
Torque: 133 Nm

2. 2. NOTICE: Make sure a new bolt is installed.

If equipped. W706661-S442 / M14x1,5

Torque: 150 Nm

3. 3. NOTICE: Make sure a new bolt is installed.

If equipped. W718556-S439 / M14x2,0

Torque: 175 Nm

11. Torque: 62 Nm

12.
13. Use the General Equipment: Transmission Jack

14.
1. 1. NOTICE: Support the cage nut through the access hole using a
spanner to prevent damage to the side member.
On both sides.
2. On both sides.

Torque: 275 Nm
15.
1. Torque: 175 Nm

2. 2. NOTICE: Make sure that no components catch.

16. Torque: 3 Nm
17. Torque: 115 Nm

18. NOTICE: Make sure that no components catch.

19. NOTE: This step is only necessary when installing a new component.
NOTE: Only tighten the bolts finger tight at this stage.

Installation

1. To install, reverse the removal procedure.

2. On both sides.

Torque: 150 Nm
3. NOTE: This step is only necessary when installing a new component.
On both sides.

4. NOTE: This step is only necessary when installing a new component.

On both sides.

Torque: 275 Nm
5. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).

6. Refer to: Front Toe Adjustment (204-00 Suspension System - General Information,
General Procedures).
Note
All wiring connections between components are shown exactly as they
exist in the vehicles. It is important to realize, however, that no attempt
has been made on the schematics to represent components and wiring
as they physically appear on the vehicle.
For example, a 4-foot length of wire is treated no differently in a
schematic from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside
complicated components has been simplified.

Complete Circuit Operation

Each circuit is shown completely and independently in one cell. Other
components that are connected to the circuits may not be shown unless
they influence the circuit operation.
Current Flow (1) Hot at all times
Each cell normally starts with the component that powers the circuit, such as a fuse CENTRAL
or the ignition switch. Current flow is shown from the power source at the top of the JUNCTION
page to ground at the bottom of the page. A full representation of the power supply F41 F39 F37 BOX (CJB)
of a fuse or the power distribution from a fuse to various components is given in 20A 20A 20A 11-1
151-12
cell 13 "Power Distribution." Full representation of the ground connections are 13-5 13-5 13-6
shown in cell 10 "Grounds."

Switch Positions (2)

Within a schematic, all switches, sensors and relays are shown "at rest" (ignition 6
switch OFF).
6 4 C270H
Splices (3) 1

LB-WH
Splices directly connecting to the power distribution are best represented on the MODULE COMMUNICATIONS

40
power distribution schematic in cell 13 "Power Distribution." Splices connected to NETWORK
grounds can be seen completely in cell 10 "Grounds." For all other splices, a
reference is given to each off page where that particular splice can be best viewed. 14-1 S289
S279
64S-LK11
Component Referencing (4) 71-1
OG
Components on a schematic have a reference to a component location view

LB-RD

BN-PK
CLUSTER
or the page where it is shown completely. The reference is located to the 5

1049
AND PANEL

19
right of each component. ILLUMINATION
2 1
Component Names (5) C2031 1 C2033

Component names are placed on the right hand side of each component when POWER
CIGAR POINT
possible. Descriptions of the internals of the component are also included when 7b LIGHTER 151-9
available. The page where the component appears in full is listed in the Index. 151-10 1 2
1) Off
The base part number for a component is listed in cell 150 "Connector Views." 2) On
3 C2031 3 C2033
Internal Name and Function Identification Numbers (6)
Some components on each page have internal symbols with an identification
number located within it. You can identify the internal symbol or function by 2
finding the corresponding number under the component name. 4
6

GD133
Circuit Numbering and Wire Identification (7)

BK
BK
57
Ford Motor Company uses three different circuit numbering conventions: 7a 7c
Standard Circuit Numbering System, Global Circuit Numbering System, and
New Global Circuit Numbering System (NGCNS). With each, the circuit number
(which identifies a specific circuit function) is followed by the wire color. S203
Examples:
31S-AC3A
WH-VT

CRW12
GY-OG
BK-RD
218

3
Standard (a) Global (b) NGCNS (c)

NOTE: Refer to cell 150 "Connector Views" for circuit functions.

The wire identification consists of a basic color and possibly a stripe, and is
G202
determined directly from the wire's circuit number. In the schematics, the wire 10-5
colors are indicated next to the wires. The colors are abbreviated using the
international norm IEC 757. The abbreviations are listed in cell 4 "Symbols."
Fuse and Relay Information
F7
Cell 11 "Fuse and Relay Information" contains 87 87 87 F27
a view of the fuse/relay box in which fuses and 87A 87A 87A
relays are identified, numbered and named. F8
Fuse and relay numbering and naming R04 R05 R06 F28
85 86 85 86 85 86
follow the indication of the fuse panel cover.
In addition, for all removable relays, pin positions 30 30 30
are added to illustrate proper orientation.
F10

F29
F11

F17
F13

F15

F18
F14

F16

F19

F20

F21
CENTRAL JUNCTION
BOX (CJB) C220B INSTRUMENT
11-3 151-1 CLUSTER
C270F 17 60-1
F1 10A 489 PK-BK
C125
Power Distribution 2 65 DG WINDSHIELD
WIPER MOTOR
6 297 BK-LG
Cell 13 "Power Distribution" shows the current 8 81-1
12 IGNITION SWITCH
feed circuits. The current path is shown from
151-10
the battery to the ignition switch and to all fuses.
It also shows the circuits protected by SOL
each fuse. The circuit is traced from the fuse to OFF C250
the component. All details (wires, splices, F102 20A C270G 1050 LG-PK C250 POWER DISTRIBUTION
ACC
6 964 DB-LG
connectors) between the fuse and the first B 13-2

PWR
4 4 RUN
1 32 RD-LB
component are shown. START
7 158 BK-PK
C 13-3
POWER DISTRIBUTION
HI BEAM
KEY_IN
5
RELAY C270H C202B 20-1
275 YE MULTIFUNCTION
SWITCH STARTING SYSTEM
85 86
2 9 85-1
87 F35 12 LG-BK
30 D 13-3
20A 6 C205A
188 WH-BK MAIN LIGHT POWER DISTRIBUTION
SWITCH
2 1
5 5 86-1
C270A C152 FOG LAMP,
F17 5 478 TN-OG
3
LEFT
12 S108 2 86-1
15A
FOG LAMP C162
RELAY A FOG LAMP,
13-3 RIGHT
2 86-1
Ground Distribution 1204 BK-OG SUBWOOFER
130-1
Cell 10 "Grounds" contains the schematic that shows the complete
details for each ground connection or main ground splice. This is 1204 BK-OG
S329
useful in diagnosing a problem affecting several components at
once (poor ground connection or ground splice).
All details (wires, splices, connectors) between the ground point
and the component are shown. These ground connection details
are shown here in order to keep the individual cell schematics as DVD/RSC
uncluttered as possible. C315-2 1204 BK-OG

BK-OG
130-4

1204
G310
10-7

Component and Connector Information C904 (GY)

Cell 150 "Connector Views" show the views of the pins and/or 3
cavities of all connectors. The pin and cavity sides are shown 14290
2
separately as if the connector were disconnected. REAR DOME/MAP LAMP (13M614)
The color of the connector housing is indicated next to the connector 1
number when available. The harness causal number is located
above the connector view and below the connector number.
The circuit function charts are located below each connector.
The wiring harness designations are listed in cell 152 "Component
Location Charts."
Cell 151 "Component Location Views" shows the components
and their connecting wires as they can be found on the vehicle.
Pin Circuit Gauge Circuit Function Qualifier
Cell 152 "Component Location Charts" helps the user find where
thevarious items depicted on the schematic can physically be 1 53 (BK-LB) 20 Courtesy lamp switch to courtesy lamp
found on the vehicle. 2 57 (BK) 20 Ground circuit
A brief written description of the location is given, along 3 705 (LG-OG) 20 Battery saver lamp feed
with a reference to the component location views.
WARNINGS

!
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires being under a
vehicle.
Be sure that the IGNITION SWITCH is always in the OFF position, unless
otherwise required by the procedure.
Set the parking brake when working on any vehicle. An automatic
transmission should be in PARK. A manual transmission should be in
NEUTRAL.
Operate the engine only in a well-ventilated area to avoid danger of
carbon monoxide.
Keep away from moving parts, especially the fan and belts, when the
engine is running.
To prevent serious burns, avoid contact with hot metal parts such as
the radiator, exhaust manifold, tail pipe, catalytic converter and
muffler.
Do not allow flame or sparks near the battery. Gases are always
present in and around the battery cell. An explosion could occur.
Do not smoke when working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry
and avoid wearing loose clothing.
Entire component Resistor
Crossed wiring without
connection

Part of a component Potentiometer (pressure

Splice or temperature)

Ground
Potentiometer (outside
influence)
Component case directly
attached to metal part of vehicle
(ground)
High voltage line
(+)
Battery

(-)
Connector attached to
component
Connector
Fuse

Female connector
Connector attached to
component lead (pigtail)
Circuit breaker

Male connector

Positive Temperature Heating element,

Twisted pair Coefficient (PTC) Conductor loop
Ignition coil assembly Hall sensor Antenna

+ Solenoid controlled valve Clockspring Permanent magnet,

or clutch solenoid one-speed-motor
M

Light emitting diode

(LED) Diode, current flows in Permanent magnet,
direction of arrow two-speed-motor
M

Capacitor
Switch Rotational sensor

Horn or speaker
Multipole switch Lamp

Fusible link
Bifilament lamp
Piezoelectric sensor

Shield
From off-page Reference
Buzzer

To off-page Reference Warning

!
Wire insulation Connector reference
is one color (BK) number for component Shorting Bar
Circuit Number with another location chart
color stripe (OG)

PASS
Pin number 13 AIR BAG
151-10
C290B C256A
AUDIO 1204 BK-OG C315-4 COMPONENT
UNIT
130-1 17
Ground numbered for
reference to component
location chart
G301
Reference to another 10-7
Cell where circuit is 14
also shown

Wire colors
BK Black
1175 TN-RD
BN Brown Busbar Optional content
BU Blue 1174 WH-RD
DB Dark blue
6 2 C314 SUPER CAB
DG Dark green C912 4 9 ONLY
GN Green
C315 Two connections (pins)
GY Grey Fuse Number 9 1 in the same connector
and Fuse rating Dashed line indicates
LB Light blue terminals for the same
LG Light green connector

NA Natural

WH-RD

TN-RD
1175
1174
OG Orange
F106 COMPONENT
PK Pink
RD Red 30A
SR Silver
TN Tan
VT Violet C921
13-3
COMPONENT
WH White
A 5
YE Yellow
10

Cut wire reference

between pages.
Arrows show current
flow from power to
ground
Busbar Name of component
Name of component Hot at all times
CENTRAL
Details of component JUNCTION
IGNITION operation
SWITCH 151-10 F41 F39 F37 BOX (CJB)
20A 20A 20A 11-1
151-12
13-5 13-5 13-6
SOL
Circuit number
OFF Fuse number
C250 and fuse rating Wire insulation
is one color
C250 ACC 4 with another
color stripe
PWR

7 RUN Component connector

3
number 6 4 2 C270H
131 PK-OG S338

LB-WH
START 2
MODULE COMMUNICATIONS Component connector Optional content

40
KEY_IN 1 NETWORK number 37 C238
14-1 S289

19 S276
Dashed line indicates 5 C3007
71-1
LB-RD terminals for the same

PK-OG
LB-RD

BN-PK
CLUSTER connector
Dashed line shows a mechanical

1049
AND PANEL

131
connection between switches

19
(Switches that move together) ILLUMINATION
2 1 C2031 1 C2033 1 C3063
Two connections (pins)
in the same connector POWER CENTER
HI FTP HI FTP CIGAR CONSOLE
LIGHTER POINT
151-9 POWER POINT
151-10 151-18
LOW LOW
Reference to another
MULTIFUNCTION Cell where circuit is
SWITCH also shown 3 C2031 3 C2033 3 C3063

Pin number
Reference description
to switch position

BK
57
57

57
RELAY Wire insulation is one color
Normally open contact S203
When coil is energized
switch is activated Connector reference
number for component
Splice numbered for location chart
reference in component
location chart
57 BK C3007-8
S380
SWITCH
One pole, two S205
position switch Ground numbered for
reference to component
G202 location chart
10-5
Each connector, ground, and splice number used in this publication references an area of the vehicle.
The chart below describes the different areas of the vehicle, and lists the numbers associated with each.

NUMBER LOCATION

100-199 Engine compartment, powertrain (including transmission and

1000-1999 front wheel drive axle/differential)
200-299 Instrument panel and console, steering wheel assembly
2000-2999
300-399 From instrument panel to rear seat, up to, and including, door trim panel
3000-3999
400-499 Behind rear seats to rear bumper, truck bed
4000-4999
500-599 Driver door
600-699 Passenger door, front
700-799 Rear door, left
800-899 Rear door, right
900-999 Above door trim panel and headliner
G101, G102, G103, G104, G105 2.2L

REVERSING
GD121 BK-YE C169 LAMP SWITCH
2 93-2

8 C133

BK-YE
GD121
34 C134

BK-YE
GD121
POWERTRAIN
CONTROL
S118 GD121 BK-YE C175B MODULE (PCM)
23-2
7
GD120 BK-GN
2
COOLING
C1074 FAN GD120 BK-GN
MOTOR
1 33-1 3
GD120 BK-GN
S101 42
BK-YE
GD121

GD120 BK-GN
53
BK-BU
GD119

GLOW PLUG
GD120 BK-GN C1273A MODULE
23-1
3
BK-GN
GD120
BK-GY
GD163

G103 G101 G102 G104 G105

151-2 151-1 151-1 151-2 151-2
G106, G107 2.2L

GD187 BK-GN C1010 - 2

Not used

ANTI-LOCK
BRAKE SYSTEM
GD187 BK-GN C135 (ABS) MODULE
42-1
13
GD187 BK-GN
S120
38

Not used

BK-GN
GD187
16 C133

AIR CONDITIONING (A/C)

C100 CLUTCH AND
AIR CONDITIONING (A/C)
2 CLUTCH
FIELD COIL
54-9
GD122

GD122
BK

G106 G107
151-10 151-6
G108, G109 2.2L

heated windshield

LOW WASHER
GD125 BK C138 FLUID WARNING
front fog lamps INDICATOR
1 SWITCH
60-3
FRONT
FOG LAMP RH
86-2

C162 GD123 BK-GY

FRONT BRAKE
GD125 YE C1688 PAD WEAR
S131 SENSOR RH
2 60-5
HEADLAMP
ASSEMBLY RH
85-4 85-5
85-6 90-4
92-2

anti-theft alarm system

C1041 GD123 BK-GY
4
HOOD
GD123 BK-GY GD125 BK C127 SWITCH
S132 117-13
7 1

6 C192
BK-GY
GD123

GD125

Thatcham category 1 alarm

ANTI-THEFT
ALARM HORN
WITH INTEGRAL
BATTERY
GD125

117-14
BK

C154 GD123 BK-GY

G108 G109
151-6 151-6
G110, G111 2.2L

front fog lamps

WINDSHIELD
WIPER
MOTOR FRONT
81-3 GD129 BK-YE C152 FOG LAMP LH
86-2
C1655 GD129 BK-YE 2

HEADLAMP
AUXILIARY ASSEMBLY LH
WINDSHIELD GD129 BK-YE C1021 85-3 85-5
WIPER 85-6 90-3
MOTOR 4 92-2
81-3 GD129 BK-YE
S125
C1656 GD129 BK-YE 7
S126
2

HORN
GD129 BK-YE C131 44-1
1

emission requirements: stage V

BK-YE

BK-YE
GD129

GD129

FUEL
C1263 VAPORIZER
SYSTEM
1 GLOW PLUG
23-4

BK-YE
GD109
G111
G110 151-12
151-6
G200 2.2L

AUXILIARY
POWER
C2031 POINT
1 44-4

FRONT POWER
OUTLET
C2033 SOCKET
44-4
1

AUDIO
FRONT
BK-BU

BK-BU

C240A
GD114

GD114

CONTROL
13 MODULE (ACM)
130-1 130-4

multi-function
display
1 8 C265
BK-BU

BK-BU

BK-BU
GD114

GD114

SYNC

SYNC
MODULE
GD114 BK-BU C2383 [APIM]
37 130-7

S201 GD114 BK-BU

38
BK-BU
GD114

G200
151-14 151-18
G201 ,G202 2.2L
SYNC

GLOBAL POSITIONING
GD116 BK-VT C2398 SYSTEM MODULE (GPSM)
130-7
6

MESSAGE
1 C263 GD116 BK-VT C253 CENTER
SWITCH
6 46-6
multi-function 60-6
display
BK-VT
GD116

multi-function
display

FRONT CONTROL/
DISPLAY INTERFACE
GD116 BK-VT C2123 MODULE (FCDIM)
130-3
11
GD116 BK-VT
9

INSTRUMENT
GD116 BK-VT C220 PANEL
S222 CLUSTER (IPC)
10 60-1

without:
multi-function
display
AUDIO
GD116 BK-VT C240A FRONT
CONTROL
15 MODULE (ACM)
130-1
BK-VT
GD116

DATA LINK
CONNECTOR
GD116 BK-VT C251 (DLC)
5 14-1

GD167 BK-BU
4

G201 G202
151-14 151-18 151-14 151-18
G203, G204 2.2L

BLOWER MOTOR SWITCH

GD185 BK-WH C271A 54-2 54-3
5

fuel fired booster heater

38 C210
AUXILIARY
JUNCTION
BOX (AJB)
FUEL FIRED 11-1
GD185 BK-WH BOOSTER
5 HEATER RELAY
54-3
without:
BK-WH

fuel fired
GD185

booster heater
GD185 BK-WH
3

33 C210

electric booster heater

BK-WH
GD185

ELECTRIC
GD285 BK-WH C2603B BOOSTER
HEATER
1 54-8

G203 G204
151-14 151-18 151-14 151-18
G205 2.2L

HEADLAMP
GD165 BK C205 SWITCH
71-1 85-1
7 86-1 89-1
92-1

lane departure warning STEERING COLUMN

CONTROL
GD165 BK C2414 MODULE (SCCM)
31-4 81-1
10 85-2 90-1
GD165 BK 136-1

PASSIVE
GD165 BK C252 ANTI-THEFT
S219 SYSTEM (PATS)
2 TRANSCEIVER
112-1

cornering lamps

ADAPTIVE
GD165 BK C2800 FRONT
LIGHTING
GD165

4
MODULE
BK

85-6

G205
151-14 151-18
G206 2.2L
CLOCKSPRING STEERING WHEEL
31-5 31-6 C2998 SWITCH LH UPPER
44-1 60-2 60-2 71-3
71-3 130-10 4
heated windshield
130-11 130-12
STEERING WHEEL
HEATED C218A C218B BN C2366 SWITCH LH LOWER
WINDSHIELD 31-5 31-6
SWITCH 5 10 S2010 5 71-3
56-1 71-4
STEERING WHEEL
C2999 SWITCH RH UPPER
C2025 GD184 BK-GY 71-3 130-10
3 130-11
2
GD184 BK-GY
STEERING WHEEL
5 C2367 SWITCH RH LOWER
71-3 71-10
4 130-12

HORN
heated mirror C217B SWITCH
44-1

BK-GY
GD184
1
HEATED
REAR
WINDOW START
GD184 BK-GY C2195 CONTROL
SWITCH
UNIT
56-3 71-4 2 40-1
GD184 BK-GY 71-2
C241 GD184 BK-GY 5
2 HAZARD
GD184 BK-GY GD184 BK-GY C2039 FLASHER
SWITCH
5 5 71-2 90-2
117-6

GLOVE COMPARTMENT
GD184 BK-GY C254 LAMP
S226 89-2
2
front parking aid

PARKING
AID
SWITCH BLOWER MOTOR SWITCH
71-4 131-3 GD184 BK-GY C271B 54-5
17
C2035 GD184 BK-GY GD184 BK-GY
2 4
BK-GY
GD184

GD184 BK-GY
5

G206
151-14 151-18
G207, F13, F14, F15, F16, F17 CUSTOMER ACCESS 2.2L
Emergency Services

roof mounted turn signals

ROOF MOUNTED ROOF MOUNTED

INDICATORS INDICATORS
LHS RHS
140-8 140-13 140-9 140-13
C9091 GD285 BK-WH S9014 GD285 BK-WH C9092

2 2

BK-WH
GD285
Not used Not used Not used Not used
SVO
AUXILIARY
FUSE 6 5 3 4 2 C2237
PANEL
11-9

BK-WH

BK-WH
GD285

GD285

GD285
INTERIOR
LAMP RELAY
140-11 SUPPLEMENTARY
2 FUSE BOX
F13 F14 F15 F16 F17 11-10 151-57
20A 20A 20A 20A 20A 151-60
BK-WH
GD238

BK-WH

BK-WH
GD285

GD285

GD285
C C2238
BK-WH
GD285

S248

BK-WH
GD285
Camper Conversions

C215
GD285 BK-WH
Not used
B
G207
151-55 151-56
151-57 151-60
G300 2.2L

liftgate

LIFTGATE
GD150 BK-WH C4216 RELEASE
SWITCH
2 117-11

4 C494
tachograph

TACHOGRAPH
GD133 BK C9068A 60-7
5
GD133

GD133 BK S911 GD133 BK

1 C406

auxiliary climate control

GD133
BK

late production: high roof

AUXILIARY
GD133 BK C938 C937 BLOWER
MOTOR
15 8 SWITCH
1 C935 16 C9027 15 C9028 52-2
GD133

GD133

GD133
BK

parking aid camera

IMAGE
GD133 BK C9058 PROCESSING
MODULE B (IPMB)
1 131-6

G300
151-24
G301 2.2L

FRONT
GD238 BK-WH C929B INTERIOR LAMP
89-2 89-9
2

without: Base

FRONT
GD238 BK-WH C931B INTERIOR LAMP
S906 89-3 89-10
2

illuminated vanity mirrors

VANITY
GD238 BK-WH C906 MIRROR
LAMP RH
3 89-3 89-10

VANITY
MIRROR
BK-WH

GD238 BK-WH C907

GD238

LAMP LH
3 89-3 89-10

1 C900
BK-WH
GD238

G301
151-25
G302 2.2L
left hand drive

power mirrors

EXTERIOR
GD134 BK C527 MIRROR
CONTROL
4 SWITCH
124-1

EXTERIOR
GD134 BK C521 MIRROR
S505 LH
2 56-6 90-3
124-1
GD134
BK

DRIVER DOOR
GD134 BK C535A WINDOW
S504 CONTROL SWITCH
2 100-1
GD134
BK

right hand drive

EXTERIOR
GD134 BK C663 MIRROR
LH
2 56-6 90-3
124-3

PASSENGER DOOR
GD134 BK C604 WINDOW
S603 CONTROL SWITCH
4 100-2
GD134
BK

late production

BATTERY
JUNCTION
REAR WINDOW BOX (BJB)
B11 C339 B11 C340 GD134 BK-VT WIPER 11-3
4 RELAY
81-5
4 C139
BK-VT

BK-VT
GD134

GD134

BK-VT
GD134

G302
151-30 151-32
G303 2.2L

AUXILIARY
JUNCTION
AUXILIARY BOX (AJB)
POWER 11-1
2 POINT RELAY
44-2 44-3

early production

BATTERY
JUNCTION
REAR WINDOW BOX (BJB)
WIPER 11-3
4 RELAY
81-5
BK-WH
GD137

BK-WH
GD137

4 C139
BODY
GD137 BK-WH C2280B CONTROL
MODULE (BCM)
BK-WH

23 11-5
GD137

S256 GD137 BK-WH

24
BK-WH
GD137

GD137 BK-WH
31

G303
151-30 151-32
G304 SLIDING DOOR 2.2L
GD135 BK-GY C958 AJAR SWITCH
LH
2 117-6

left hand drive

DRIVER
GD135 BK C505 DOOR
LOCK CONTROL
2 SWITCH
71-5 117-1

DRIVER
GD135 BK C525 DOOR
S502 LATCH
5 117-2
GD135

22 C300
BK

right hand drive

PASSENGER
GD135 BK C609 DOOR
B12 C339 LATCH
5 117-3

PASSENGER
BK-GY

DOOR
GD135

GD135 BK C605
S602 LOCK CONTROL
2 SWITCH
71-5 117-1
BK-GY
GD135

GD135
BK

B12 C340
BK-GY
GD135

G304 GROUNDING
151-30 151-32 10-16
G304 2.2L
trailer tow

TRAILER
GD135 BK-GY C3548C MODULE
95-1
4

PARKING BRAKE
GD135 BK-GY C3663 - 3 GD135 BK-GY C306 WARNING
INDICATOR SWITCH
2 60-4

FUEL SUPPLY
GD135 BK-GY C145 - 12 GD135 BK-GY C4432 LINE PRESSURE
SENSOR
2 23-5

LOW BRAKE
GD135 BK-GY C124 FLUID WARNING
S270 INDICATOR SWITCH
1 60-4

BRAKE PEDAL
GD135 BK-GY C278 POSITION (BPP)
SWITCH
2 23-12 31-1
90-6

CLUTCH PEDAL
GD135 BK-GY C260 - 6 GD135 BK-GY S208 GD135 BK-GY C2354 POSITION (CPP)
TOP OF
3 TRAVEL SWITCH
23-13 31-2
early production: auto-start-stop
GD135 BK-GY
A 10-17 CLUTCH PEDAL
GD135 BK-GY C257 POSITION (CPP)
GROUNDING BOTTOM OF
2 TRAVEL SWITCH
GD135 BK-GY 23-13 31-2
B 10-17

late production: auto-start-stop

CLUTCH PEDAL
GD135 BK-GY C257 POSITION (CPP)
BK-GY
GD135

BOTTOM OF
2 TRAVEL SWITCH
23-13 31-2

G304 GROUNDING
151-30 151-32 10-15
2.2L

left hand drive

PASSENGER
GD135 BK C609 DOOR
LATCH
4 117-3

PASSENGER
GD135 BK C605 DOOR
S602 LOCK CONTROL
3 SWITCH
71-5 117-1
GD135
BK

B12 C340

right hand drive

BK-GY
GD135

DRIVER
GD135 BK C505 DOOR
LOCK CONTROL
3 SWITCH
71-5 117-1

DRIVER
GD135 BK C525 DOOR
S502 LATCH
4 117-2
GD135
BK

B12 C339
GROUNDING
10-16 A
BK-GY
GD135

GROUNDING
10-16 B
G305 2.2L

power seats

FRONT SEAT
GD182 BK-GY C341E - 2 7 BK C369 CONTROL
SWITCH
3 120-1 120-2

heated seats

FRONT SEAT
GD182 BK-GY C341F - 2 4 BK C364 CUSHION
S302 HEATER MAT
2 119-1

FRONT SEAT
GD182 BK-GY C3660C - 2 4 BK C334 CUSHION
HEATER MAT
2 119-1
BK-GY
GD182

Direct Current/Alternating Current (DC/AC) inverter

DIRECT CURRENT/
GD182 BK-GY C3664 - 4 GD182 BK-GY C3501 ALTERNATING CURRENT
(DC/AC) INVERTER
2 44-5

G305
151-30 151-32
G306 2.2L
parking aid camera

REAR
C4357 PARKING AID
CAMERA
5 131-8
RMP19
BN-VT

RADIO
GD140 BK-GN C9026 FREQUENCY
rear doors (RF) RECEIVER
2 117-12 118-1
7 C495
parking aid camera
7 C494
AUTO-DIMMING
GD140 BK-GN C911 INTERIOR
MIRROR
BK-GN
GD140

3 124-5 131-7
BK

rear doors
Thatcham category 1 alarm
4 C406 INTRUSION
GD140 BK-GN C9800 SENSOR
4 C422 S909 117-14
1
rear doors
BK-GN

rain sensor
GD140
BK

lane departure warning

rear doors AUTOLAMP
GD140 BK-GN C919 - 1 GD140 BK-BU C914 AND
4 C935 RAIN SENSOR
2 81-4 85-7
BK-GN
GD140
BK-GN
GD140

lane departure warning

7 C913
8 C300 IMAGE
C919 - 7 PROCESSING
GD140 BK-GN GD140 BK-BU C9039
MODULE A (IPMA)
22 C311 5 136-2
BK-GN
GD140

BK-GN

FUEL FIRED
GD140

GD140 BK-GN C2806 BOOSTER HEATER

CONTROL MODULE
6 54-4

G306
151-33 151-35
G307 2.2L
left hand drive

EXTERIOR
GD240 BK C626 MIRROR
RH
2 56-6 90-4
124-1

PASSENGER DOOR
GD240 BK C604 WINDOW
S603 CONTROL SWITCH
4 100-2

right hand drive

GD240
BK

power mirrors

EXTERIOR
GD240 BK C527 MIRROR
CONTROL
4 SWITCH
124-3

EXTERIOR
C596 MIRROR
GD240 BK
S505 RH
2 56-6 90-4
124-3
GD240
BK

DRIVER DOOR
GD240 BK C535A WINDOW
B11 C340 S504 CONTROL SWITCH
2 100-1
BK-GN
GD240

GD240
BK

B11 C339
BK-GN
GD240

G307
151-33 151-35
G308 auxiliary AUXILIARY 2.2L
climate control JUNCTION
BOX (AJB)
11-1
AUXILIARY
GD241 BK-BU BLOWER
2 MOTOR
RELAY
52-1

fuel fired
booster heater

FUEL FIRED
GD241 BK-BU BOOSTER
1 HEATER
RELAY
54-3

AUXILIARY
GD241 BK-BU IGNITION RELAY 2
S274 2 13-14

AUXILIARY
GD241 BK-BU IGNITION RELAY 1
2 13-14
BK-BU
GD241

BATTERY
JUNCTION
5 C139 BOX (BJB)
IGNITION
GD241 BK-BU RELAY 11-3
2
BK-BU
GD241

BK-BU
GD241

13-6
without:
Econetic

Econetic WINDSHIELD
WIPER
GD241 BK-BU MOTOR
S117 2 RELAY
81-2

COOLANT
GD241 BK-BU C1912 - 1 GD129 BK-YE C1913 BYPASS VALVE
23-16
1

G308
151-33 151-35
G309 2.2L

(+) BATTERY (+) AUXILIARY

12-1 13-1 BATTERY
12-1 13-1
(-) (-)

BATTERY AUXILIARY
MONITORING BATTERY
SENSOR MONITORING
12-1 13-1 SENSOR
12-1 13-1

1 C3666C 1 C3667C 1 C3667D

GD108 BK

GD175
BK

G309
151-30 151-34
G310 CUSTOMER ACCESS 2.2L

REAR
GD285 BK-WH C9090 BEACON
140-4
GD285 BK-WH GROUNDING 1
C
10-24
1 C9411 FRONT
2 WAY GD285 BK-WH C9089 BEACON
GD285 BK-WH C3438 RADIO 140-4
140-2 1
2

BEACON
GD285 BK-WH C2239 - 2 GD285 BK-WH S9002 GD285 BK-WH C9434 SWITCH
S3011 71-7 140-4
4

auxiliary heater

WATER
GD285 BK-WH C9435 HEATER
BK-WH
GD285

SWITCH
4 71-7 140-5

E C2238
utility package

AUXILIARY
GD285 BK-WH C9436 SWITCH 1
71-7 140-6
4
BK-WH
GD285

AUXILIARY
GD285 BK-WH C9437 SWITCH 2
71-7 140-7
OG-YE
ZA102

AUXILIARY
ZA102 OG-YE C9441 POWER
SOCKET 1
S9020 2 140-6

AUXILIARY
ZA104 OG-GN C9442 POWER
SOCKET 2
2 140-7

auxiliary heater

WATER
GD285 BK-WH C9439B HEATER
140-5
1
G310
151-58 151-59
CUSTOMER ACCESS 2.2L
SVO
AUXILIARY
FUSE
TURN PANEL
GD285 BK-WH SIGNAL
2 11-9
RELAY RH
140-9

utility package

AUXILIARY
RELAY 1
2 140-6

GD285 BK-WH

roof mounted turn signals

TURN
SIGNAL
2 RELAY LH
140-8

WORK
GD285 BK-WH LAMP RELAY
2 140-10

IGNITION
GD285 BK-WH RELAY
S3012 2 13-61 140-3

BEACON
GD285 BK-WH RELAY
2 140-4
BK-WH
GD285

10-23 C

GROUNDING
G400 2.2L

trailer tow

C438 TRAILER
GD132 BK-VT GD132 BK-VT C439 SOCKET
95-2
1 3

S412 GD132 BK-VT GD132 BK-VT

8 11

GD132 BK-VT GD132 BK-VT

16 13

FUEL PUMP AND

GD132 BK-VT C463 SENDER UNIT
23-6 60-3
3
BK-VT
GD132

fuel fired booster heater

AUXILIARY HEATER
S410 GD132 BK-VT C4429 CONTROL
MODULE (AHCM)
2 54-4
BK-VT
GD132

G400
151-3
G401 LIFTGATE LICENSE
2.2L
GD149 BK-GY C452 PLATE
LAMP LH
2 92-6

LICENSE
C494 - 3 GD149 BK-GY S416 GD149 BK-GY C462 PLATE
LAMP RH
2 92-6
GD149
BK

HIGH
GD149 BK C475 MOUNTED
S400 STOPLAMP
2 90-9 90-11

rear window wipers

REAR
GD149 BK C4218 WINDOW
WIPER MOTOR
GD149

1 81-6
BK

heated rear window

HEATED REAR
GD149 BK C402B WINDOW
ELEMENT
1 56-4

LIFTGATE
GD149 BK C4339 LATCH
S401 117-11
2

2 C406
GD149
BK

2 C935

REAR LAMP
BK-GY
GD149

GD149 BK-GY C412 ASSEMBLY LH

86-3 90-5
6 90-7 92-3
93-1

G401
151-36
G401 REAR DOORS LICENSE
2.2L
GD149 BK-GY C452 PLATE
LAMP LH
2 92-5

LICENSE
C495 - 3 GD149 BK-GY S416 GD149 BK-GY C462 PLATE
LAMP RH
2 92-5
BK-GY
GD149

late production: high roof

HIGH
GD149 BK-GY C4131 - 3 GD149 BK-GY C4431 MOUNTED
S403 STOPLAMP LH
2 90-8 90-10

rear window wipers

REAR
GD149 BK-GY C476 WINDOW
WIPER MOTOR
BK-GY
GD149

1 LH
81-7

heated rear window

HEATED REAR
GD149 BK-GY C4425B WINDOW
S402 ELEMENT LH
1 56-5
BK-GY
GD149

2 C422
BK-GY
GD149

2 C935

REAR LAMP
BK-GY
GD149

GD149 BK-GY C412 ASSEMBLY LH

86-3 90-5
6 90-7 92-3
93-1

G401
151-36
G402, G403 2.2L

auxiliary climate control

AUXILIARY
C940A BLOWER MOTOR
CONTROL
2 MODULE
52-1

THIRD ROW
GD150 BK-WH C9054B INTERIOR LAMP
89-6 89-8
2 89-13 89-15

Bus, Kombi

FOURTH ROW
GD150 BK-WH C9055B INTERIOR LAMP
89-8 89-15
BK-VT
GD147

S902 2
BK-WH
GD150

Bus (low roof), Kombi (low roof)

6 C922 Double Cab in Van
6 C9060

Bus (low roof), Kombi (low roof)

BK-GY
GD149

early production - Double Cab in Van

BK-WH
GD150
BK-VT
GD147

6 C9076
BK-WH
GD150

G402 G403
151-36 151-36
G404 2.2L

rear doors

heated rear window

HIGH
GD351 BK C4430 MOUNTED
S405 STOPLAMP RH
2 90-8 90-10

rear window wipers

GD351

REAR
BK

GD351 BK C4171 WINDOW

WIPER MOTOR
1 RH
81-8

heated rear window

HEATED REAR
GD351 BK C4426B WINDOW
S404 ELEMENT RH
1 56-5
GD351
BK

rear passenger power outlet socket

2 C411
REAR
GD351 BK-GN C979 PASSENGER
POWER
GD351

1 OUTLET SOCKET
44-4
BK

2 C991

REAR LAMP
BK-GN
GD351

GD351 BK-GN C415 ASSEMBLY RH

86-3 90-5
1 90-7 92-4
93-1

G404
151-37
G405 2.2L

rear doors

REAR
GD352 BK C486 DOOR
LATCH
4 117-9 117-10

1 C411
GD352
BK

SLIDING DOOR
GD352 BK-BU C959 AJAR SWITCH
1 C991 RH
2 117-6

rear parking aid

PARKING ASSIST
GD352 BK-BU S923 GD352 BK-BU C9071A CONTROL
MODULE (PAM)
8 131-1
BK-BU

BK-BU
GD352

GD352

without:
rear parking aid

G405
151-37
G0101, G0102, G0103 2.0L

twin fans

BATTERY
JUNCTION
BOX (BJB)
HIGH SPEED 11-15
GD119 BK-BU COOLING FAN
5 RELAY
33-3

COOLING
GD119 BK-BU C01078 FAN
MOTOR 2
S115 2 33-3

single fan

COOLING
C01074 FAN
MOTOR
1 33-2

manual transmission
BK-BU

BK-BU
GD119

GD119
GD003
BK
BK-GY
GD163

G0103
G0101 G0102 151-66
151-65 151-65
G0104, G0105, G0106 manual transmission 2.0L
REVERSING
GD121 BK-YE C0169 LAMP SWITCH
2 93-4

8 C0133

BK-YE
GD121
AUXILIARY
JUNCTION
BOX (AJB)
REDUCTANT 11-11
GD121 BK-YE HEATER
1 RELAY
24-9

34 C0134
automatic transmission

TRANSMISSION

BK-YE
GD121
CONTROL
MODULE (TCM)
29-1 POWERTRAIN
C01822 CONTROL
GD121 BK-YE GD121 BK-YE C0175B MODULE (PCM)
41 24-1
S118 1
GD120 BK-GN
GD409 BK 96
GD120 BK-GN
39
97
GD409 BK GD120 BK-GN
S117
9 S101 98
BK-YE
GD121

GD120 BK-GN
99

GLOW PLUG
GD120 BK-GN C01273C MODULE
24-2
9
BK-GN
GD409

GD120
BK

G0106
151-66
G0104 G0105
151-66 151-66
G0107 2.0L

GD187 BK-GN C01010 - 2

Not used

ANTI-LOCK
BRAKE SYSTEM
GD187 BK-GN C0135 (ABS) MODULE
42-4
13
GD187 BK-GN
S120
38

BK-GN
GD187

G0107
151-68
G0108 2.0L

front fog lamps

FRONT
FOG LAMP LH
86-5

C0152 GD123 BK-GY

FRONT
FOG LAMP RH
86-5
without rear window wipers
C0162 GD123 BK-GY
S197
1
WINDSHIELD
GD123 BK-GY C0137 WASHER
2 PUMP
81-14

12 C0110
HEADLAMP
ASSEMBLY RH

BK-GY
GD123
85-11 85-12
85-13 90-15 right hand drive
92-8
AUXILIARY
C01041 GD123 BK-GY JUNCTION
BOX (AJB)
4 REAR WASHER 11-11
GD123 BK-GY GD123 BK-GY RELAY
4 81-18
7 S132

Thatcham category 1 alarm - right hand drive

G0108
151-69
G0109 2.0L

heated windshield

LOW WASHER
GD124 BK-VT C0138 FLUID WARNING
INDICATOR
1 SWITCH
60-11

FRONT BRAKE
S131 GD124 YE C01687 PAD WEAR
SENSOR LH
2 42-6 60-14

BK-VT
GD124

6 C0192

anti-theft alarm system

HOOD
S185 GD124 BK C0127 SWITCH
117-34
1
BK-VT
GD124

PROXIMITY WARNING
GD124 BK C01582 RADAR UNIT
31-13 31-14
4 146-3 146-4

G0109
151-69
G0110, G0111 2.0L
HEADLAMP
ASSEMBLY LH
GD129 BK-YE C01021 85-10 85-12
85-13 90-14
4 92-8
GD129 BK-YE
S125
7
WINDSHIELD
WIPER
MOTOR
81-12

C01655 GD129 BK-YE HORN

GD129 BK-YE C0131 44-6
6 1

AUXILIARY
WINDSHIELD
WIPER AIR CONDITIONING (A/C)
MOTOR GD121 BK C0100 CLUTCH AND
81-12 AIR CONDITIONING (A/C)
2 COMPRESSOR
C01656 GD129 BK-YE 54-19
S126
2
COOLANT
S150 GD121 BK C01812 WATER PUMP
24-5
1
left hand drive

AUXILIARY POSITIVE CRANKCASE

GD121 BK C01833 VENTILATION (PCV)
JUNCTION
BOX (AJB) VALVE HEATER ELEMENT
1 24-5
11-11
REAR WASHER
RELAY
81-18 automatic transmission
GD129 BK-YE TRANSMISSION
4 GD121 BK C01792 AUXILIARY
OIL PUMP
6 29-4
BK-YE

BK-YE
GD129

GD129

GD121
BK

G0110 G0111
151-69 151-72
G0200 2.0L

AUXILIARY
POWER
C02031 POINT
1 44-8

FRONT POWER
OUTLET
C02033 SOCKET
44-8
1

AUDIO
FRONT
BK-BU

BK-BU

C0240A
GD214

GD214

CONTROL
13 MODULE (ACM)
130-13 130-19

multi-function
display
1 8 C0265
BK-BU

BK-BU

BK-BU
GD214

GD214

SYNC

SYNC
MODULE
GD214 BK-BU C02383 [APIM]
37 130-24

S201 GD214 BK-BU

38
BK-BU
GD214

G0200
151-77 151-81
G0201 ,G0202 2.0L
WITHOUT MULTI-FUNCTION DISPLAY

parking aid camera

REAR
C04357 PARKING AID
CAMERA
5 145-8
RMP19
BN-VT

rear doors

7 C0495

7 C0494

MESSAGE
GD216 BK-VT C0253 CENTER
GD214

SWITCH
BK

6 46-12 60-15

4 C0406
INSTRUMENT
4 C0422 GD216 BK-VT C0220 PANEL
S222 CLUSTER (IPC)
rear doors 12 60-9
GD214
BK

AUDIO
GD216 BK-VT C0240A FRONT
CONTROL
4 C0935 15 MODULE (ACM)
130-13
BK-VT
GD216
BK-BU
GD214

GATEWAY
8 C0300 MODULE A
GD216 BK-VT C02431 (GWM)
14 14-8
GD216 BK-VT
GD266 BK-WH
1

G0201 G0202
151-77 151-81 151-77 151-81
G0201 ,G0202 2.0L
MULTI-FUNCTION DISPLAY

parking aid camera

REAR
C04357 PARKING AID
CAMERA
5 145-8 145-9
RMP19
BN-VT

HAZARD
GD216 BK-VT C02039 FLASHER
SWITCH
5 71-9 90-13
rear doors 117-27
SYNC without navigation
7 C0495 GLOBAL POSITIONING
GD216 BK-VT C02398 SYSTEM MODULE (GPSM)
7 C0494 S206 130-24
6
GD214
BK

MESSAGE
GD216 BK-VT C0253 CENTER
BK-VT
GD216

SWITCH
6 46-12 60-15
4 C0406

4 C0422 FRONT CONTROL/

DISPLAY INTERFACE
rear doors GD216 BK-VT C02123A MODULE (FCDIM)
1 C0263 130-18 145-7
11
GD216 BK-VT
GD214
BK

9
BK-VT
GD216

4 C0935 INSTRUMENT
GD216 BK-VT C0220 PANEL
S222 CLUSTER (IPC)
12 60-9
BK-BU
GD214

GATEWAY
8 C0300 MODULE A
BK-VT
GD216

GD216 BK-VT C02431 (GWM)

14 14-8
GD216 BK-VT
GD266 BK-WH
1

G0201 G0202
151-77 151-81 151-77 151-81
G0203, G0204 2.0L

HEATING,
GD215 BK-GY C02357B VENTILATION AND
AIR CONDITIONING (HVAC)
5 CONTROL MODULE
54-11 54-12

fuel fired booster heater

38 C0210
AUXILIARY
JUNCTION
BOX (AJB)
FUEL FIRED 11-11
GD215 BK-GY BOOSTER
5 HEATER RELAY
54-12
without:
BK-GY

fuel fired
GD215

booster heater
GD215 BK-GY
3

33 C0210

electric booster heater

BK-GY
GD215

ELECTRIC
GD285 BK-WH C02603B BOOSTER
HEATER
1 54-18

G0203 G0204
151-77 151-81 151-77 151-81
G0205 2.0L

HEADLAMP
GD265 BK C0205 SWITCH
71-8 85-8
4 86-4 89-16
GD265 BK 92-7

STEERING COLUMN
CONTROL
MODULE (SCCM)
31-10 81-10
85-9 90-12
146-1
PASSIVE
C02414 GD265 BK S219 GD265 BK C0252 ANTI-THEFT
SYSTEM (PATS)
14 4 TRANSCEIVER
GD265 BK 112-1

cornering lamps

ADAPTIVE
GD265 BK C02800 FRONT
LIGHTING
GD265

4
MODULE
BK

85-13

G0205
151-77 151-81
G0206 CLOCKSPRING
C02998
STEERING WHEEL
SWITCH LH UPPER 2.0L
31-11 31-12
44-6 60-10 60-10 71-10
4
71-10 130-17
130-27 130-28
STEERING WHEEL
heated windshield SWITCH LH LOWER
C0218A C0218B BN C02366
31-11 31-12
HEATED 5 10 S2010 5 71-10
WINDSHIELD
SWITCH
56-7 71-11 STEERING WHEEL
C02999 SWITCH RH UPPER
71-10 130-17
C02025 GD284 BK-GY 3 130-27

2 STEERING WHEEL
C02367 SWITCH RH LOWER
71-10 130-28
5 4

HORN
C0217B SWITCH
44-6
1

BK-GY
GD284
heated defrost

HEATED START
REAR GD284 BK-GY C02195 CONTROL
WINDOW UNIT
SWITCH 2 40-2 71-9
56-9 71-11
without 5
multi-function
C0241 GD284 BK-GY display
2 HAZARD
GD284 BK-GY C02039 FLASHER
SWITCH
5 5 71-9 90-13
117-27

HEATING,
GD284 BK-GY C02357A VENTILATION AND
S226 AIR CONDITIONING (HVAC)
5 CONTROL MODULE
front parking aid 54-14
GD284 BK-GY
PARKING
AID 10
SWITCH GD284 BK-GY
71-11 145-3
BK-GY
GD284

26
C02035 GD284 BK-GY
automatic transmission
2
SELECTOR LEVER
GD284 BK-GY C02810 ASSEMBLY
5 37-1
8
S227 GD284 BK-GY
11
G0206
151-77 151-81
G0300 2.0L

liftgate

LIFTGATE
GD150 BK-WH C04216 RELEASE
SWITCH
2 117-32

4 C0494
tachograph

TACHOGRAPH
GD236 BK-GN C09068A 60-16
5
GD236

GD236 BK-GN S911 GD236 BK-GN

1 C0406

auxiliary climate control

GD350
BK

AUXILIARY
GD307 BK-WH C0937 BLOWER
MOTOR
8 SWITCH
1 C0935 16 C09027 15 C09028 52-5 52-6
BK-GN

BK-GN

BK-GN
GD236

GD236

G0300
151-87
G0301 dome lamp 2 2.0L
FRONT INTERIOR
S906 GD241 BK C0931A LAMP
89-18
1

FRONT INTERIOR illuminated vanity mirrors

GD241
LAMP

BK
89-17 VANITY
GD241 BK C0906 MIRROR
LAMP RH
C0929A 3 89-18
1

VANITY
GD241 BK C0907 MIRROR

GD241
LAMP LH

BK
3 89-18

Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
GD306 BK C09447A COMPARTMENT
LAMP
1 89-22

Van - LHD (SWB without LED)

Van - LOW ROOF (LWB, SWB with LED)
Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
GD306 BK C09056A COMPARTMENT
LAMP
1 89-19 89-21
89-22

Not used
2 C0925 5 C0900 1 C0925
Double Cab in Van
Van - LHD (SWB without LED)
Van - LOW ROOF (LWB, SWB with LED)
LUGGAGE
BK-BU

BK-BU

BK-BU
GD241

GD241

GD306 BK C09057A COMPARTMENT

LAMP
1 89-19 89-21
89-23

1 C0936
S931
GD241 BK-BU
BK-BU
GD241

G0301
151-88
G0302 2.0L
LEFT HAND DRIVE

EXTERIOR
GD234 BK C0521 MIRROR
LH
2 56-12 90-14
124-6

DRIVER DOOR
GD234 BK C0535A WINDOW
S504 CONTROL SWITCH
2 100-3

GD234
BK

B11 C0339
BK-VT
GD234

G0302
151-93
G0302 2.0L
RIGHT HAND DRIVE

EXTERIOR
GD234 BK C0517 MIRROR
LH
2 56-12 90-14
124-8

PASSENGER DOOR
GD234 BK C0592 WINDOW
S513 CONTROL SWITCH
4 100-6

GD234
BK

B11 C0340
BK-VT
GD234

G0302
151-95
G0303 2.0L

LOW VOLTAGE
GD233 BK C02513 DIRECT CURRENT/
DIRECT CURRENT
6 (DC/DC) CONVERTER
40-3

BODY
GD233 BK C02280C CONTROL
MODULE (BCM)
10 11-17

G0303
151-93 151-95
G0304 2.0L
LEFT HAND DRIVE

BODY
GD235 BK-GY C02280C CONTROL
MODULE (BCM)
6 11-17
GD235 BK-GY
7

G0304
151-93
G0304 2.0L
RIGHT HAND DRIVE power mirrors

EXTERIOR
GD235 BK C0618 MIRROR
CONTROL
4 SWITCH
124-8

FRONT DOOR
GD235 BK C0632 LOCK
SWITCH RH
3 71-12 117-16

PARKING BRAKE
WARNING INDICATOR DRIVER
SWITCH GD235 BK C0603 DOOR
60-13 S612 LATCH
4 117-18
C0306 GD135 BK-GY
2
3 C03663

PASSENGER

GD235
GD235 BK C0502 DOOR
LATCH

BK
BK-GY
GD235

5 117-20

BRAKE PEDAL
POSITION
(BPP) SWITCH B12 C0339 FRONT DOOR
24-20 31-7 GD235 BK C0541 LOCK
90-17 S512 SWITCH LH
2 71-12 117-16
C0278 GD235 BK-GY

GD235
BK-GY
GD235

BK
SLIDING DOOR
GD235 BK-GY C0958 AJAR SWITCH
LH
B12 C0340 2 117-27
9 C0300
TRAILER
MODULE
95-3

BK-GY
C03548C GD235 BK-GY GD235
S286
BK-GY
GD235

1 AUXILIARY
JUNCTION
BOX (AJB)
BK-GY
GD235

EXTERNAL 11-11
GD235 BK-GY LOCKING
4 RELAY
117-30

G0304
151-95
G0305 2.0L
power seats

FRONT SEAT
GD382 BK-GY C0341E - 2 7 BK C0369 CONTROL
SWITCH
3 120-3 120-4

heated seats

FRONT SEAT
GD382 BK-GY C0341F - 2 4 BK C0364 CUSHION
S302 HEATER MAT
2 119-2

FRONT SEAT
GD382 BK-GY C03660C - 2 4 BK C0334 CUSHION
HEATER MAT
2 119-2
BK-GY
GD382

Direct Current/Alternating Current (DC/AC) inverter

DIRECT CURRENT/
GD382 BK-GY C03664 - 4 GD182 BK-GY C03501 ALTERNATING CURRENT
(DC/AC) INVERTER
2 44-9

C03665 - 8
GD382 BK-GY
Not used

G0305
151-93 151-95
G0306 2.0L

right hand drive

EXTERIOR
GD239 BK C0622 C0626 MIRROR
RH
2 2 56-12 90-15
124-6 124-8

right hand drive

DRIVER DOOR
GD239 BK C0648A WINDOW
S613 CONTROL SWITCH
2 100-5
GD239
BK

B11 C0340

B11 C0339 right hand drive

BK-YE
GD239

G0306
151-96 151-98
G0307 FRONT DOOR 2.0L
GD240 BK C0605 LOCK
SWITCH RH
LEFT HAND DRIVE 3 71-12 117-15

PASSENGER
GD240 BK C0609 DOOR
LATCH
4 117-19

PASSENGER DOOR
GD240 BK C0604 WINDOW
S603 CONTROL SWITCH
PARKING BRAKE 4 100-4
WARNING INDICATOR
SWITCH

GD240
60-13 power mirrors

BK
C0306 GD135 BK-GY EXTERIOR
GD240 BK C0527 MIRROR
2 CONTROL
B12 C0340 4 SWITCH
124-6
3 C03663
BRAKE PEDAL
POSITION

BK-GN
DRIVER

GD240
(BPP) SWITCH GD240 BK C0525 DOOR
24-20 31-7
BK-GN
LATCH
GD240

90-17 5 117-17
C0278 GD240 BK-GN
3 FRONT DOOR
GD240 BK C0505 LOCK
S502 SWITCH LH
2 71-12 117-15
TRAILER

GD240
MODULE
95-3

BK
fuel fired
C03548C GD240 BK-GN booster heater

1 B12 C0339 FUEL FIRED

BK-GN GD240 BK-GN C02806 BOOSTER HEATER
CONTROL MODULE
GD240

6 54-13
SLIDING DOOR
AJAR SWITCH
LH
117-27

C0958 GD235 BK-GY AUXILIARY

JUNCTION
2 S288 BOX (AJB)
22 C0300 EXTERNAL 11-11
GD240 BK-GN LOCKING
4 RELAY
BK-GN
GD240

117-30
BK-GN
GD240

G0307
151-96
G0307 2.0L
RIGHT HAND DRIVE

BODY
GD240 BK-GN C02280C CONTROL
MODULE (BCM)
6 11-17

GD240 BK-GN
7

G0307
151-98
G0308 2.0L

auxiliary AUXILIARY
climate control JUNCTION
BOX (AJB)
11-11
AUXILIARY
GD238 BK-WH BLOWER
2 MOTOR
RELAY
52-4

fuel fired
booster heater

FUEL FIRED
GD238 BK-WH BOOSTER
2 HEATER RELAY
54-12

EXTERNAL
GD238 BK-WH LOCKING
S287 1 RELAY
117-30

FOLD MIRROR
GD238 BK-WH MODULE RELAY
5 124-7 124-9
BK-WH
GD238

G0308
151-96 151-98
G0309 2.0L

(+) BATTERY
12-4 13-63

(-)

dual battery

BATTERY
MONITORING AUXILIARY
SENSOR (+)
BATTERY
12-4 13-63 12-4 13-63
(-)

1 C03666B 1 C03666C 1 C03364B

GD108 BK-VT
GD175
BK

right hand drive

GD375
BK

G0309
151-93 151-95
G0401 LIFTGATE LICENSE 2.0L
GD149 BK-GY C0452 PLATE
LAMP LH
1 92-12

LICENSE
C0494 - 3 GD149 BK-GY S426 GD149 BK-GY C0462 PLATE
LAMP RH
1 92-12
GD350
BK

HIGH
GD350 BK C0475 MOUNTED
S400 STOPLAMP
2 90-20

rear window wipers

REAR
GD350 BK C04218 WINDOW
WIPER MOTOR
GD350

3 81-15
BK

heated rear window

HEATED REAR
GD350 BK C0402B WINDOW
ELEMENT
1 56-10

LIFTGATE
GD350 BK C04339 LATCH
S401 117-32
2

2 C0406
GD350
BK

2 C0935
BK-WH

REAR LAMP
GD350

GD350 BK-WH C0412 ASSEMBLY LH

86-6 90-16
6 90-18 92-9
93-3

G0401
151-99
G0401 REAR DOORS LICENSE 2.0L
GD149 BK-GY C0452 PLATE
LAMP LH
1 92-11

LICENSE
C0495 - 3 GD149 BK-GY S426 GD149 BK-GY C0462 PLATE
LAMP RH
1 92-11
GD350

high roof
BK

GD350 BK-WH high roof

HIGH
GD350 BK C04001 - 3 GD350 BK C04431 MOUNTED
S403 STOPLAMP LH
2 90-19

rear window wipers

REAR
GD350 BK C0476 WINDOW
WIPER MOTOR
GD350

1 LH
81-16
BK

heated rear window

HEATED REAR
GD350 BK C04425B WINDOW
S402 ELEMENT LH
1 56-11
GD350
BK

2 C0422
GD350
BK

2 C0935
BK-WH

REAR LAMP
GD350

GD350 BK-WH C0412 ASSEMBLY LH

86-6 90-16
6 90-18 92-9
93-3

G0401
151-99
G0402 2.0L
AUXILIARY CLIMATE CONTROL

AUXILIARY
C0940A BLOWER MOTOR
CONTROL
2 MODULE
52-4

BK-GN
GD307
6 C09060

BK-WH
GD307

G0402
151-99
G0403 2.0L
Van - RHD (SWB without LED)
VAN Van - LOW ROOF (LWB, SWB with LED)

LUGGAGE
C09079A COMPARTMENT
LAMP
1 89-20 89-21

Van - RHD (SWB without LED)

Van - LOW ROOF (LWB, SWB with LED)
Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
C09078A COMPARTMENT
GD306

LAMP
BK

1 89-20 89-21
89-22

GD306
BK
1 C09077

Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
GD306 BK C09448A COMPARTMENT
LAMP
1 89-22
GD306

Not used
BK

2 C09076 1 C09076
GD306

GD306
BK

S915
GD306
BK

G0403
151-99
G0403 2.0L
DOUBLE CAB IN VAN

FOOTWELL
GD306 BK C02056B LAMP
LH
1 89-24

FOOTWELL
S943 GD306 BK C02057B LAMP
RH
1 89-24
GD306
BK

THIRD ROW
GD306 BK C0963A INTERIOR LAMP
1 C0922 89-24
1
GD306
BK

LUGGAGE
GD306 BK C09079A COMPARTMENT
2 C0922 LAMP
1 C09076 1 89-23

1 C09077
GD306
GD306

BK
BK

GD306 BK C09076 - 2
GD306
BK

S915
GD306
BK

G0403
151-99
G0403 2.0L
BUS, KOMBI

FOOTWELL
GD306 BK C02056B LAMP
LH
1 89-25

FOOTWELL
S941 GD306 BK C02057B LAMP
RH
1 89-25

LUGGAGE
GD306 BK C09075B COMPARTMENT
LAMP
GD306

1 89-26
BK

THIRD ROW
GD306 BK C09054A INTERIOR LAMP
1 C0922 89-27
1

FOURTH ROW
GD306

S942 GD306 BK C09055A INTERIOR LAMP

89-27
1
Not used

1 C09077 1 C09076 GD306

BK
GD306

GD306

2 C0922
BK

S915 GD306 BK C09076 - 2 GD306 BK

GD306
BK

G0403
151-99
G0404 2.0L

rear doors

heated rear window

HIGH
GD351 BK C04430 MOUNTED
S405 STOPLAMP RH
2 90-19

rear window wipers

GD351

REAR
BK

GD351 BK C04171 WINDOW

WIPER MOTOR
1 RH
81-17

heated rear window

HEATED REAR
GD351 BK C04426B WINDOW
S404 ELEMENT RH
1 56-11
GD351
BK

rear passenger power outlet socket

2 C0411
REAR
GD351 BK-GN C0979 PASSENGER
POWER
GD351

1 OUTLET SOCKET
44-8
BK

2 C0991

REAR LAMP
BK-GN
GD351

GD351 BK-GN C0415 ASSEMBLY RH

86-6 90-16
1 90-18 92-10
93-3

G0404
151-100
G0405 2.0L
Thatcham category 1 alarm

INTRUSION
GD308 BK-GN C09800 SENSOR
117-35
3

RADIO rain sensor

FREQUENCY
(RF) RECEIVER
117-33 118-2
AUTOLAMP
C09026 GD308 BK-GN S909 GD308 BK-GN C0914 AND
RAIN SENSOR
1 3 81-13 85-14

C09012 AUTO-DIMMING
GD308 BK-GN INTERIOR
MIRROR
7 124-10

BK-GN
GD308 rear doors

REAR
GD308 BK C0486 DOOR
11 C0900 LATCH
4 117-31

rear parking aid 1 C0411

GD308
PARKING ASSIST
BK-GN
GD308

CONTROL

BK
MODULE (PAM)
145-1

C09071A GD308 BK-GN 1 C0991

S923
8

SLIDING DOOR
GD308 BK-GN C0959 AJAR SWITCH
RH
BK-GN
GD308

S924 2 117-27
BK-GN
GD308

G0405
151-100
G0406, G0407 2.0L

VEHICLE AIR
GD406 BK-YE C04396 DYNAMICS C04620 SUSPENSION
MODULE (VDM) COMPRESSOR
1 41-1 3 41-2

GD406 BK-YE

S425 37
BK-YE
GD406

20 C0408

BK-GN
GD410
BK-YE
GD406

G0406 G0407
151-102 151-102
G0408, G0409 2.0L

FUEL FILTER
GD412 BK-VT C04350 HEATER/
3 WATER-IN-FUEL
SENSOR
24-11

fuel fired booster heater

AUXILIARY HEATER
GD412 BK-VT C04429 CONTROL
MODULE (AHCM)
2 54-13

GD412 BK-VT

S413 6

C0438 TRAILER
GD132 BK-VT C0439 SOCKET
1 3 95-4

GD132 BK-VT
8 11
GD132 BK-VT
16 13
GD480

GD480

GD480
BK

BK
BK-VT
GD412

S412
GD480
BK

G0408 G0409
151-103 151-103
G0410, G0411, G0412 2.0L

REDUCTANT
GD411 BK-BU C04470 TANK
24-7 24-8
1

GD411 BK-BU
8

GD411 BK-BU
S410
11

C04000 FUEL PUMP

GD413 BK-YE C0433 CONTROL
MODULE
7 4 24-12

NOx
C04373A SENSOR
MODULE GD413 BK-YE
4 24-3
8

SHIELD
BK-GN

BK-BU

BK-YE

BK-YE
GD481

GD411

GD413

G0410 G0411 G0412

151-102 151-102 151-103
AUXILIARY JUNCTION BOX (AJB) 2.2L

F10

F11

F12

F13

F14

F15

F16

F17

F18
F1

F9
C283A C283B

R1 2 R2 R3 2 R4 2 R5 2 R6 R7 R8
2 2
3 3
3 3 3 3 3 3 5 5
4 5 5 4 5 5 4 5 5

1 4 2 1 4 2
1 1 1 1 1 1

2 R9 R10 R11 R12 R13 F50

2 2 2 2
F19

F20

F21

F22

F23

F24

F25

3 3 3 3 3
4 5 4 5 4 5 4 5 4 5 F51
F26

F27

F28

F29

F30

F31

F32

1 1 1 1 1 F52

C283C
F53
F33

F34

F35

F36

F37

F38

F39

F40

F41

F42

F43

F44

F45

F46

F47

F48

F49
Relay Relay

R1 Fuel fired booster heater relay R8 Not used

R2 Auxiliary power point relay R9 Blower motor relay

R3 Not used R10 Auxiliary blower motor relay

R4 Auxiliary ignition relay 2 R11 Heated rear window relay

R5 Not used R12 Heated windshield element RH relay

R6 Auxiliary ignition relay 1 R13 Heated windshield element LH relay

R7 Horn relay
AUXILIARY JUNCTION BOX (AJB) 2.2L
Fuse Amps Circuit protected Fuse Amps Circuit protected

F1 10 Restraints Control Module (RCM) F28 20 Adaptive front lighting module

F2 - Not used F29 10 Image Processing Module B (IPMB)
Auto-dimming interior mirror
F3 10 Exterior mirrors Steering Column Control Module (SCCM)
Image Processing Module A (IPMA)
F4 - Not used
F30 5 Not used
F5 20 Auxiliary Heater Control
Module (AHCM) F31 - Not used

F6 5 Tachograph F32 10 Interior lamps

F7 - Not used F33 - Not used

F8 40 Direct Current/ Alternating Current (DC/AC) inverter F34 20 Rear window wiper relay
Rear window wiper motors
F9 - Not used
F35 5 Driver door window control switch
F10 30 Front seat control switch Exterior mirror control switch
F11 - Not used F36 20 Horn relay

F12 - Not used F37 7.5 SYNC module [APIM]

Global Positioning System Module (GPSM)
F13 - Not used
F38 5 Rear window wiper relay
F14 5 Powertrain Control Module (PCM) relay Horn relay
Blower motor relay
F15 40 Powertrain Control Module (PCM) relay
F39 7.5 Auxiliary blower motor switch
F16 40 Body Control Module (BCM) - F1, F2, F3 Radio Frequency (RF) receiver
Intrusion sensor
F17 - Not used
F40 40 Blower motor relay
F18 - Not used
F41 40 Auxiliary blower motor relay
F19 5 Tachograph
F42 30 Heated rear window relay
F20 5 Heated rear window relay
Heated windshield element LH relay F43 30 Trailer module
Heated windshield element RH relay Trailer socket
Direct Current/Alternating Current (DC/AC) inverter
F44 60 Auxiliary power point relay
F21 10 Customer access F45 - Not used
F22 15 Body Control Module (BCM) - F4, F5 F46 30 Driver door window control switch
Passenger door window control switch
F23 7.5 Fuel fired booster heater relay
Auxiliary blower motor switch F47 20 Auxiliary power point
Electric booster heater
Blower motor switch
Message center switch F48 20 Rear passenger power outlet socket

F24 5 Headlamp assemblies F49 20 Front power outlet socket

F25 7.5 Interior lamps F50 60 Auxiliary ignition relay 1

F26 - Not used F51 60 Auxiliary ignition relay 2

F27 20 Heated front seat switch F52 40 Heated windshield element LH relay

F53 40 Heated windshield element RH relay

BATTERY JUNCTION 2.2L
BOX (BJB)

C1035C C1035B C1035A

R1 R5 R9 R15
2 2 2 F8 F18 F30 2
3 3 3 3
5 4 5 4 5 5
F9 F19 F31

1 1 1 1
F10 F20 F32
R2 R6 R16
2 2 2
3 3 R10 F1 F11 F21 F33 3
4 5 4 5 3 4 5
5 F2 F12 F34
F22
1 1 F3 F13 F35 1
1 4 2
R3 R7 F4 F14 F23 F36 R17
2 2 R11 2
3 3 3 F5 F15 F24 F37 3
4 5 4 5 4 5
5
F6 F16 F25 F38

1 1 1 4 2 F7 F17 F26 F39 1

R4 R8 R12 R13 F27 R14 R18

2 2 3 2 3 2
3 3 5 3 F28 5 3
5 4 5 4 5 5

1 4 2 F29 1 4 2
1 1 1 1

Relay Relay Relay

R1 Ignition relay R7 Not used R13 Not used

R2 Starter relay (Early production) R8 Not used R14 Econetic coolant valve relay

R3 R15 Low speed cooling fan relay

Rear window wiper relay R9 Starter relay (Late production)
R16 Not used
R4 Windshield wiper motor relay R10 Air Conditioning (A/C) clutch relay
R17 Powertrain Control Module (PCM) relay
R5 Not used R11 Glow plug relay
R18 High speed cooling
R6 Not used R12 Fuel pump relay fan relay
BATTERY JUNCTION BOX (BJB) 2.2L
Fuse Amps Circuits protected Fuse Amps Circuits protected

F1 - Not used F21 60 Ignition relay

F2 - Not used F22 - Not used

F3 - Not used F23 25 Anti-lock Brake System

(ABS) module
F4 - Not used F24 7.5 Fuel pump relay

F5 3 Powertrain Control Module (PCM) F25 - Not used

Anti-lock Brake System
F6 3 (ABS) module F26 3 Econetic coolant valve relay

F7 7.5 Glow plug module F27 - Not used

Powertrain Control Module (PCM)
F28 - Not used
F8 - Not used
F29 3 Audio front Control Module (ACM)
F9 30 Windshield wiper motor
Auxiliary windshield F30 60 Low speed cooling fan relay
F10 30 wiper motor High speed cooling fan relay

F11 10 Air Conditioning (A/C) clutch relay F31 - Not used

F12 20 Glow plug relay F32 60 Windshield wiper motor relay

F13 - Not used F33 - Not used

F14 - Not used F34 - Not used

F15 - Not used F35 15 Powertrain Control Module (PCM)

F16 - Not used F36 7.5 Mass Air Flow (MAF) sensor

F17 - Not used F37 7.5 Fuel metering valve

Anti-lock Brake System
F18 40 (ABS) module F38 7.5 Air Conditioning (A/C) clutch relay
F19 30 Starter relay F39 15 Low speed cooling fan relay
High speed cooling fan relay
F20 60 Glow plug module Glow plug relay
Fuel vaporizer system fuel pump
Heated Oxygen Sensor (HO2S)
Econetic coolant valve relay
BODY CONTROL MODULE (BCM)
2.2L
C2280C

C2280B

C2280A

C2280D

F2 F12
F3 F13

F4 F14

F5 F15

F6 F16

F7 F17

F8 F18

F9 F19

F10 F20

F11 F21
BODY CONTROL MODULE (BCM) 2.2L

Fuse Amps Circuits protected Fuse Amps Circuits protected

F1 15 Passenger door latch F12 20 Anti-theft alarm horn with

Sliding door contact plate LH integral battery
Sliding door contact plate RH Anti-theft alarm horn LH
Rear door latch Anti-theft alarm horn RH

F2 15 Driver door latch F13 15 Data Link Connector (DLC)

Passenger door latch Glove compartment lamp
Sliding door contact plate LH Auxiliary power point relay
Sliding door contact plate RH Luggage compartment lamps
Rear door latch Interior lamps
Liftgate latch Illuminated vanity mirror lamps
Footwell lamps
F3 15 Ignition switch
Auxiliary battery relay F14 25 Headlamp assemblies
Rear lamp assemblies
Exterior mirrors
F4 5 Parking Assist Control
Module (PAM) F15 25 Headlamp assembly LH
Rear lamp assembly LH
F5 5 Autolamp and rain sensor License plate lamps
Trailer module
F6 15 Windshield washer pump Illumination lamps
F16 20 Audio front Control Module (ACM)
F7 7.5 Exterior mirrors
F17 7.5 Instrument Panel Cluster (IPC)
F8 15 Front fog lamps Blower motor switch
F18 10 Headlamp switch
F9 10 Headlamp assembly RH Brake Pedal Position (BPP) switch
Steering Column Control Module (SCCM)
F10 10 Headlamp assembly LH
F19 5 Front Control/Display Interface
Module (FCDIM)
F11 25 Headlamp assembly RH Message center switch
Rear lamp assembly LH
Rear lamp assembly RH
Auto-dimming F20 5 Passive Anti-theft System
interior mirror (PATS) transceiver

F21 3 Audio front Control Module (ACM)

HIGH CURRENT BATTERY JUNCTION BOX (BJB) 2.2L

F3 E
C3670A

F14 S N M L K J H G F C3670D F2 D

F11 F10 F9 F8 F7 F6 F5 F4
C3670C F1 C

F13 R

C3670T
AUXILIARY

C3670M
C3670N

C3670K

C3670H

C3670G
C3670L

C3670F
C3670J
BATTERY T
RELAY
F12 P

B
C3670B
HIGH CURRENT BATTERY JUNCTION BOX (BJB) 2.2L

Fuse Amps Circuits protected

F1 350 Generator
Starter motor
Battery Junction Box (BJB) - F18, F19, F20, F21, F23, F24, F26

F2 100 Auxiliary Junction Box (AJB) - F14, F15, F16

F3 40 Not used

F4 200 Auxiliary Junction Box (AJB) - F35, F36, F37, F38, F39, F40, F41, F42, F43, F44

F5 100 Auxiliary Junction Box (AJB) - F5, F6, F8, F10

F6 80 Electric booster heater

F7 80 Auxiliary Junction Box (AJB) - F52, F53

F8 100 Battery Junction Box (BJB) - F30, F32

F9 100 Auxiliary Junction Box (AJB) - F50, F51

F10 60 Body Control Module (BCM) - F6, F7, F8, F9, F10, F11

F11 60 Body Control Module (BCM) - F12, F13, F14, F15, F16, F17, F18, F19

F12 60 Customer access

F13 60 Not used

F14 60 Customer access

SVO AUXILIARY FUSE PANEL 2.2L

F12

F11

F10

F1
R7 2 R6 2 R5 2 R4
3
4 4 4
3 5 1 3 5 1 3 5 1 5

R3 2 R2 2 R1 2 1 4 2
4 4 4
3 5 1 3 5 1 3 5 1

Relay Fuse Amps Circuit protected

R1 Beacon relay F1 3 Beacon switch

Water heater switch
Auxiliary switch 1
R2 Ignition relay Auxiliary switch 2
R3 Water heater relay - auxiliary heater
F2 20 Not used
Auxiliary relay 2 - utility package
F3 20 Beacon relay
R4 Work lamp relay
F4 20 Ignition relay
R5 Turn signal relay LH - roof mounted turn signals
F5 15 Water heater relay
Auxiliary relay 1 - utility package Auxiliary relay 2
F6 15 Work lamp relay
R6 Turn signal relay RH
F7 15 Turn signal relay LH
R7 Interior lamp relay Turn signal relay RH
Auxiliary relay 1

F8 10 Interior lamp relay

F9 20 2 way radio

F10 5 Not used

F11 15 Not used

F12 - Not used

SUPPLEMENTARY FUSE BOX 2.2L

F11

F13

F15

F17
F10

F12

F14

F16

F18
F2

F8
F1

F9
Fuse Amps Circuit protected

F1 10 Not used
F2 5 Not used

F3 15 Not used

F4 15 Not used

F5 10 Not used

F6 7.5 Not used

F7 10 Not used

F8 7.5 Not used

F9 5 Not used

F10 5 Not used

F11 10 Not used

F12 5 Not used

F13 20 Roof mounted indicators LHS

Roof mounted indicators RHS

F14 20 Not used

F15 20 Not used

F16 20 Not used

F17 20 Not used

F18 - Not used

AUXILIARY JUNCTION BOX (AJB) 2.0L
C0283A C0283B C0283C

F30 F53
F1 F15 F38

F31 F54

F2 F16 F39

F55
F17 2 5 F40
F3 R1
3 1
F56
F18 F41
F4

F19 F42 F57

F5 F32

F20 F43 F58

F6
F21 F44
F33 F59

F7
F22 F45
F60

F8 F23 F46
F34

F9 F24 F47 F61

F10 F25 F35 F48 F62

F11 F26 F49 F63

F36
F12 F27 F50 F64

F13 F28 F51 F65

F37
F14 F29 F52 F66
AUXILIARY JUNCTION BOX (AJB) 2.0L

1 5 3 1 5 3 1 5 3 5 1 5 1
4 4 4 F67 F69
R15 R18
2 2 2 3
R2 R6 R10
2 3 2 3
1 2

5 1 5 1
1 5 3 1 5 3 1 5 3
5 F68 R16 F70 R19
4 4 4 R13
2 R3 2 R7 2 R11
2 3 2 3

1 5 3 1 5 3
4 4 5
1 F71
2 2 3
R4 R8

1 2
5 4 2 1
3
1 5 3 1 5 3 3
2 5 F72
4 4 R12 R14
R17
2 R5 2 R9

Relay Relay

R1 Horn relay R10 Blower motor relay

R2 Heated rear window relay R11 External locking relay

R3 Auxiliary blower motor relay R12 Fold mirror module relay

R4 Auxiliary power point relay R13 Run/start relay

R5 Power point relay R14 Fuel pump relay

R6 Heated windshield element LH relay R15 Not used

R7 Heated windshield element RH relay R16 Not used

R8 Rear washer relay R17 Front wiper relay

R9 Fuel fired booster heater relay R18 Not used

R19 Not used

AUXILIARY JUNCTION BOX (AJB) 2.0L
Fuse Amps Circuit protected Fuse Amps Circuit protected

F1 60 Front wiper relay F28 - Not used

F2 40 Blower motor relay F29 40 Auxiliary blower motor relay
F3 - Not used F30 20 Rear passenger power outlet socket

F4 40 Heated rear window relay F31 30 Heated rear window element

F5 40 Trailer module F32 60 Run/start relay

F6 40 Auxiliary power point relay F33 60 Fuel pump relay

F7 40 Power point relay F34 40 Heated windshield element LH relay
F8 20 Horn relay F35 40 Heated windshield element RH relay
F9 15 Rear washer relay
F36 50 Body Control Module (BCM)
F10 10 Horn relay
Blower motor relay F37 50 Body Control Module (BCM) - F1
Power point relay
Auxiliary power point relay F38 - Not used
Front wiper relay
F11 - Not used F39 20 Heated front seat switch

F12 - Not used F40 5 Glow plug module

Powertrain Control Module (PCM)
F13 20 Auxiliary power point
F41 5 Fuel fired booster heater relay
F14 20 Front power outlet socket
F42 5 Headlamp assembly LH
F15 50 Low voltage Direct Current/Direct Headlamp assembly RH
Current (DC/DC) converter Headlamp switch
Body Control Module (BCM) - F12, F13, F32, F33
F43 5 Transmission Control Module (TCM)
F16 25 Anti-lock Brake System Transmission auxiliary oil pump
(ABS) module
F44 10 Low voltage Direct Current/Direct Current (DC/DC) converter
Vehicle Dynamics Module (VDM)
F17 5 Fuel pump relay Proximity warning radar unit
Powertrain Control Module (PCM) power relay Auxiliary blower motor switch
Rear parking aid camera
F18 10 Brake Pedal Position (BPP) switch
F45 20 Adaptive front lighting module
F19 15 External locking relay
F46 5 Auxiliary blower motor relay
F20 5 Fuel fired booster heater Heated windshield element LH relay
control module Heated windshield element RH relay
F21 15 Transmission Control Module (TCM) Heated rear window relay

F22 25 Transmission auxiliary oil pump F47 5 Anti-lock Brake System (ABS) module

F23 - Not used F48 10 Customer access

F24 10 Exterior mirror LH F49 20 Rear window wiper motor

Exterior mirror RH

F25 7.5 Driver door latch

F26 7.5 Passenger door latch

F27 - Not used

AUXILIARY JUNCTION BOX (AJB) 2.0L

Fuse Amps Circuit protected

F50 5 Rear washer relay

Autolamp and rain sensor

F51 25 Windshield wiper motor - LHD

Auxiliary windshield wiper motor - RHD

F52 25 Windshield wiper motor - RHD

Auxiliary windshield wiper motor - LHD

F53 40 Rear air suspension relay

F54 15 Vehicle Dynamics Module (VDM)

F55 40 Anti-lock Brake System (ABS) module

F56 - Not used

F57 30 Front seat control switch

F58 - Not used

F59 30 Starter relay

F60 15 Trailer module

F61 15 Driver door latch - LHD
Passenger door latch - RHD
Sliding door contact plate LH

F62 15 Rear door latch

Passenger door latch - LHD
Driver door latch - RHD
Sliding door contact plate RH

F63 15 Driver door latch - LHD

Passenger door latch - RHD
Sliding door contact plate LH

F64 15 Rear door latch

Passenger door latch - LHD
Driver door latch - RHD
Sliding door contact plate RH

F65 20 Fuel pump control module

F66 40 Fuel filter heater/water-in-fuel sensor

F67 - Not used

F68 - Not used

F69 7.5 Tachograph

F70 - Not used

F71 40 Direct Current/Alternating Current (DC/AC) inverter

F72 30 Trailer socket

BATTERY JUNCTION 2.0L
BOX (BJB)

C01035C C01035B C01035A

R1 R5 R9 R15
2 2 2 F8 F18 F30 2
3 3 3 3
5 4 5 4 5 5
F9 F19 F31

1 1 1 4 2 F7 F17 F26 F39 1

R4 R8 R12 R13 F27 R14 R18

2 2 3 2 3 2
3 3 5 3 F28 5 3
5 4 5 4 5 5

1 4 2 F29 1 4 2
1 1 1 1

Relay Relay Relay

R1 High speed cooling R7 Not used R13 Reductant heater relay

fan relay
R8 Not used R14 Not used
R2 Not used
R9 Starter relay R15 Low speed cooling fan relay
R3 Rear window wiper relay
R10 Air Conditioning (A/C) clutch relay R16 Not used
R4 Rear air suspension relay
R11 Not used R17 Not used
R5 Cooling fan relay
R6 Not used R12 Not used R18 Powertrain Control Module (PCM) power relay
BATTERY JUNCTION BOX (BJB) 2.0L

Fuse Amps Circuits protected Fuse Amps Circuits protected

F1 5 Audio front Control Module (ACM) F21 40 Glow plug module

F2 - Not used F22 40 Glow plug module

F3 - Not used F23 10 Air Conditioning (A/C) clutch relay

F4 - Not used
F24 - Not used
F5 - Not used
F25 - Not used
F6 15 Not used
F26 - Not used

F7 15 Not used F27 - Not used

F28 5 Positive Crankcase Ventilation (PCV)

F8 20 Cooling fan relay valve heater element

F9 - Not used F29 15 Coolant water pump

F10 - Not used F30 60 Powertrain Control Module (PCM) power relay

F11 - Not used F31 20 Not used

F12 - Not used F32 20 Auxiliary Heater Control
Module (AHCM)
F13 - Not used
F33 - Not used
F14 - Not used
F34 - Not used
F15 - Not used
F35 20 Powertrain Control Module (PCM)
F16 - Not used
F36 20 Battery Junction BoX (BJB) - F28, F29
F17 - Not used

F18 40 Cooling fan relay F37 15 Reductant tank

Universal Heated Oxygen Sensor (HO2S) #11
Exhaust Gas Recirculation (EGR) cooler bypass valve solenoid
F19 40 Low speed cooling fan relay
(Twin fans) F38 10 High speed cooling fan relay
Cooling fan relay
60 Low speed cooling fan relay Air Conditioning (A/C) clutch relay
High speed cooling Low speed cooling fan relay
(Single fan)
fan relay
F39 10 Glow plug module
F20 40 Reductant heater relay NOx sensor module
BODY CONTROL MODULE (BCM) 2.0L
C02280E C02280F

C02280G

F38

F23 F1

F24 F2

F25 F3

C02280C F26

F27 F4

F28 F5

F29 F6 F7

F30 F8 F9
C02280B
F31 F10 F11

F32 F12 F13

F33 F14 F15

F34 F16

C02280A F35 F17 F18

F36 F19 F20

F37 F21 F22

C02280H
BODY CONTROL MODULE (BCM) 2.0L
Fuse Amps Circuits protected Fuse Amps Circuits protected

F1 10 Third row interior lamp F20 5 Tachograph

Fourth row interior lamp
Front interior lamp F21 5 Electric booster heater
Vanity mirror lamp RH
Vanity mirror lamp LH
F22 5 Not used
F2 7.5 Fold mirror module relay
Driver door window control switch F23 10 Audio front Control Module (ACM)
Exterior mirror control switch Direct Current/Alternating Current (DC/AC) inverter

F3 20 Auxiliary Junction Box (AJB) - F25, F26

F24 30 Auxiliary Junction Box (AJB) - F61, F62, F63, F64

F4 5 Not used
F25 30 Not used
F5 20 Not used
F26 30 Not used
F6 10 Not used
F27 30 Not used
F7 10 Not used
F28 20 Not used
F8 10 Anti-theft alarm horn LH
Anti-theft alarm horn RH F29 30 Not used

F9 10 Not used F30 30 Not used

F10 5 Not used F31 15 Not used

F11 5 Auxiliary blower motor switch F32 10 Radio Frequency (RF) receiver
Intrusion sensor Front Control/Display Interface Module (FCDIM)
SYNC module [APIM]
F12 7.5 Heating, Ventilation and Air Conditioning (HVAC) control module Global Positioning System Module (GPSM)
Message center switch

F13 7.5 Instrument Panel Cluster (IPC) F33 20 Audio front Control Module (ACM)
Steering Column Control Module (SCCM)
Gateway Module A (GWM)
F34 30 Body Control Module (BCM) - F19, F20, F21, F23, F35, F36
F14 10 Not used
F35 5 Restraints Control Module (RCM)

F15 10 Gateway Module A (GWM)

F36 15 Steering Column Control Module (SCCM)
Auto-dimming interior mirror
F16 15 Sliding door contact plate LH Parking Assist control Module (PAM)
Sliding door contact plate RH

F37 15 Not used

F17 5 Anti-theft alarm horn with integral battery
F38 30 Driver door window control switch
F18 5 Ignition switch Passenger door window control switch

F19 5 Message center switch

HIGH CURRENT BATTERY JUNCTION BOX (BJB) 2.0L

F3 E
C03670E
C03670A

S N M L K J H G F C03670D F2 D
C3670S F14
F11 F10 F9 F8 F7 F6 F5 F4
C03670C F1 C

C3670R F13 R
F17

C03670M
C03670N

C03670K

C03670H

C03670G
C03670L

C03670F
C03670J
F16

C3670P F12 P F15

B
C03670B
HIGH CURRENT BATTERY JUNCTION BOX (BJB) 2.0L

Fuse Amps Circuits protected

F1 470 Generator
Starter motor
Battery Junction Box (BJB) - F18, F19, F20, F21, F22, F23

F2 100 Body Control Module (BCM) - F2, F3, F8, F11, F15, F16, F17, F18, F24, F34, F38

F3 40 Auxiliary Junction Box (AJB) - F71

F4 200 Auxiliary Junction Box (AJB) - F53, F54, F55, F57, F59, F60

F5 100 Auxiliary Junction Box (AJB) - F15, F16, F17, F18, F19, F20, F21, F22

F6 100 Electric booster heater

F7 80 Auxiliary Junction Box (AJB) - F34, F35

F8 100 Auxiliary Junction Box (AJB) - F36, F37

F9 100 Auxiliary Junction Box (AJB) - F1, F2, F4, F5, F6, F7, F8, F9, F10

F10 100 Auxiliary Junction Box (AJB) - F32, F33

F11 100 Battery Junction Box (BJB) - F30, F32

F12 60 Customer access

F13 60 Customer access

F14 60 Customer access

F15 60 Auxiliary Junction Box (AJB) - F29

F16 100 Not used

F17 60 Customer access

CHARGING SYSTEM CHARGING SYSTEM
2.2L
A B
12-2 12-2

BODY
CONTROL
MODULE (BCM)
11-5
SDC02

SDC04
RD

RD
BMS
1 C3365A LIN 1 C3364A

3 C2280C

(+) BATTERY (+) AUXILIARY

151-28 151-29 BATTERY
151-28 151-29

CDC56
WH
(-) (-)

INLINE INLINE
FUSE 1 FUSE 2
F1 151-28 151-29 F2 151-28 151-29
3A 3A
13-1 13-1

S310
CDC56

CDC56

YE-RD
SDL01

SDL02
WH

WH
RD

2 1 C3666A 1 2 C3667A

BATTERY AUXILIARY
MONITORING BATTERY
SENSOR MONITORING
151-28 151-29 SENSOR
151-28 151-29

1 C3666C 1 C3667C 1 C3667D

GD108 BK

GD175
BK
G309
10-22
CHARGING SYSTEM CHARGING SYSTEM
12-1 A 12-1 B 2.2L
Hot at Hot at

SDC02

SDC04
all times all times

RD
1 C3670B 1 C3670A

HIGH CURRENT
BATTERY
JUNCTION
BOX (BJB)
11-7

AUXILIARY
BATTERY
RELAY
F2 F1
100A 350A
13-2 13-2

1 4 2 3 C3670T 1 C3670D 1 C3670C

SBF01
BU-RD

BU-RD
SBP03

SBP03

RD
BN-WH

BU-GN
CDC27

CDC24

YE-RD
SBF02
S311 C

CHARGING SYSTEM
20 C210 1 C283B 12-3

AUXILIARY
IGNITION JUNCTION
BU-RD
SBP03

SWITCH F16 BOX (AJB)

13-10 13-11 40A 11-1
13-7
C250
4
BU-RD

VT-RD
SBP03

SB116
65 C2280D 30 13 C2280C 28 C2280B

BODY
AUX AUX CONTROL
BATT ON BATT OFF F3 MODULE (BCM)
15A 11-5
13-10 13-11
CHARGING SYSTEM
12-2 C
2.2L
Hot at
all times

SBF01

RD
1 C1035B

BATTERY
JUNCTION
BOX (BJB)
11-3

1 C1035C

SBF01

1 C197A

STARTER
MOTOR
20-1

POWERTRAIN
CONTROL
MODULE (PCM)
SBF01

23-17
MODULE
RD

COMMUNICATIONS
NETWORK

VDB04 WH-BU C175B

1 C102A HS CAN +
10
GENERATOR 14-5
VDB05 WH
B+ 151-1 151-10 HS CAN -
11
REGULATOR

C102B
RC
Not used
2
LI VDC42 GN C175E
GENMON
1 30
A CHARGING SYSTEM
12-5
2.0L

SDC02

BODY
RD
CONTROL
MODULE (BCM)
LIN 3 SPL1 11-17
1 C03365A

4 C02280F

(+) BATTERY
151-91 151-92

VDN03
GY-VT
(-) dual battery

INLINE
FUSE 1 CHARGING SYSTEM
151-91 151-92 B
12-5
3A

SDC04
RD
SDL01

1 C03364A
RD

2 1 C03666A

BATTERY (+) AUXILIARY

MONITORING BATTERY
SENSOR 151-91 151-92
151-91 151-92 (-)

1 C03666B 1 C03666C 1 C03364B

GD108 BK-VT
GD175
BK

right hand drive

GD375
BK

G0309
10-55
dual battery
2.0L
CHARGING SYSTEM CHARGING SYSTEM
12-4 A 12-4 B
Hot at Hot at

SDC02

SDC04
all times all times

RD
1 C03670B 1 C03670A

HIGH CURRENT
BATTERY
JUNCTION
BOX (BJB)
F1 11-19
470A
13-64

1 C03670C

SBF01

RD
1 C01035B

BATTERY
JUNCTION
BOX (BJB)
11-15

1 C01035C
SBF01

POWERTRAIN
1 C0197A CONTROL
MODULE (PCM)
STARTER
SBF01

24-23
MOTOR MODULE
RD

20-4 COMMUNICATIONS
NETWORK

VDB04 WH-BU C0175B

1 C0102A HS1 CAN +
60
GENERATOR 14-12
VDB05 WH
B+ 151-65 151-73 HS1 CAN -
61
REGULATOR

C0102B
RC
Not used
2
LI VDC46 BU-BN C0175E
GENMON
1 66
POWER
DISTRIBUTION
POWER
DISTRIBUTION
2.2L
A B
13-2 13-2

BODY
CONTROL
MODULE (BCM)
11-5 151-30
151-34
SDC02

SDC04
RD

RD
1 C3365A BMS LIN 1 C3364A

3 C2280C

(+) BATTERY (+) AUXILIARY

151-28 151-29 BATTERY
151-28 151-29

CDC56
WH
(-) (-)

INLINE INLINE
FUSE 1 FUSE 2
F1 F2
3A 3A

S310
CDC56

CDC56

YE-RD
SDL01

SDL02
WH

WH
RD

2 1 C3666A 1 2 C3667A

BATTERY AUXILIARY
MONITORING BATTERY
SENSOR MONITORING
151-28 151-29 SENSOR
151-28 151-29

1 C3666C 1 C3667C 1 C3667D

GD108 BK

GD175
BK
G309
10-22
F1, F2, F3 HIGH CURRENT
BATTERY 2.2L
JUNCTION
BOX (BJB)
11-7 151-30
151-34
POWER
DISTRIBUTION
F1 POWER
SDC04 RD C3670A C3670C SBF01 RD DISTRIBUTION
13-1 B C 13-5
1 350A 1
Hot at
all times

F2 POWER
C3670D SBF02 YE-RD DISTRIBUTION
D 13-7
100A 1

F3
Not used
40A

BODY
CONTROL
MODULE (BCM)
AUXILIARY 11-5 151-30
BATTERY 151-34
RELAY

POWER C3670T CDC24 BU-GN C2280C AUX

DISTRIBUTION BATT
3 13 OFF
SDC02 RD C3670B
13-1 A
1
CDC27 BN-WH AUX
Hot at BATT
all times
2 30 ON

SBP03 BU-RD
4

C210 - 20 POWER
SBP03 BU-RD DISTRIBUTION
T 13-10 13-11
1 S311
AA Hot at
all times
POWER
DISTRIBUTION
13-3
F4, F5, F6, F7, F8, F9, 10, F11 2.2L
HIGH CURRENT
BATTERY
POWER JUNCTION
DISTRIBUTION BOX (BJB)
13-2 11-7 151-30
151-34
AA
F4 POWER
C3670F SBF04 GN-RD DISTRIBUTION
F
1 13-22
200A

F5 POWER
C3670G SBF05 GY-RD DISTRIBUTION
G
1 13-25
100A
auxiliary heater

C210 - 39 ELECTRIC
F6 C3670H SBF06 BN-RD SBF06 BN-RD C2603A BOOSTER
HEATER
80A 1 1 54-8

heated windshield

F7 POWER
C3670J SBF07 WH-RD DISTRIBUTION
J
1 13-26
80A

F8 POWER
C3670K SBF08 VT-RD DISTRIBUTION
K
1 13-4
100A

F9 POWER
C3670L SBF09 RD DISTRIBUTION
L
1 13-14
100A

F10 POWER
C3670M SBF10 YE-RD DISTRIBUTION
M
1 13-27
60A

F11 POWER
C3670N SBF11 BU-RD DISTRIBUTION
N
1 13-32 13-37
60A

POWER
DISTRIBUTION
13-59
F9, F10, F30, F32 BATTERY
2.2L
JUNCTION
BOX (BJB)
11-3 151-1 BATTERY
JUNCTION
POWER BOX (BJB)
DISTRIBUTION 11-3 151-1
LOW SPEED
SBF08 VT-RD C1035A F30 SBB30 BN-RD S110 COOLING FAN
13-3 K 3 RELAY
1 60A 33-1
Hot at
all times

BN-RD
SBB30
F32
HIGH SPEED
COOLING FAN
60A 3 RELAY
33-1

IGNITION
RELAY
13-6
S117 C139 - 5 S274
GD241 BK-BU GD241 BK-BU
2
G308
without: 10-21
Econetic

BK-BU
GD241
WINDSHIELD
WIPER
VT-RD
SBB32

MOTOR
RELAY
81-2
POWER
DISTRIBUTION
CDC32 BN-YE GD241 BK-BU
13-13 BC
1 2
Hot in Start Econetic
or Run

5
3

CRW03 VT-WH

C139 WINDSHIELD
CRW03 VT-WH F9 CBB09 VT-GY CBB09 VT-GY C1655 WIPER
S113 MOTOR
30A 8 1 81-3

AUXILIARY
CRW03 VT-WH F10 CBB10 YE-OG CBB10 YE-OG C1656 WINDSHIELD
WIPER
30A 9 1 MOTOR
81-3
F18, F19, F20, F21, F23, F24, F26 2.2L
GENERATOR
C102A 12-3 20-1
BATTERY 1
JUNCTION

SBF01
BOX (BJB)

RD
11-3 151-1
STARTER
C197A MOTOR
12-3 20-1
POWER 1
DISTRIBUTION
SBF01 RD C1035B C1035C SBF01 RD
13-2 C
1 1
Hot at
all times
C1010 ANTI-LOCK
F18 SBB18 YE-RD SBB18 YE-RD C135 BRAKE SYSTEM
(ABS) MODULE
40A 6 1 42-1

F23 SBB23 WH-RD SBB23 WH-RD

25A 1 25

GLOW PLUG
F20 SBB20 GN-RD C1273A MODULE
23-1
60A 5

F21 SBB21 GY-RD POWER

BB DISTRIBUTION
60A 13-6

BATTERY
JUNCTION
ECONETIC BOX (BJB)
F26 SBB26 YE-RD COOLANT
3 11-3 151-1
VALVE
3A RELAY
23-16

STARTER
F19 SBB19 BU-RD RELAY
3 20-1
30A

FUEL PUMP
F24 SBB24 VT-RD RELAY
3 23-6
7.5A
VT-RD
SBB24

1
F11, F12 BATTERY
JUNCTION 2.2L
BOX (BJB)
11-3 151-1

IGNITION
RELAY
POWER Econetic
DISTRIBUTION
CDC32 BN-YE GD241 BK-BU S117 C139 - 5 GD241 BK-BU S274 GD241 BK-BU
13-13 CC
1 2 G308
Hot in Start 10-21
or Run

POWER
DISTRIBUTION
5
SBB21 GY-RD 3
13-5 BB
Hot at
all times

air conditioning
BN-BU
CDC23

BATTERY
JUNCTION
BOX (BJB)
F11 AIR 11-3 151-1
CBB11 BN CONDITIONING
3 (A/C) CLUTCH
10A RELAY
54-9

F12 CBB12 GN-WH POWER

BD DISTRIBUTION
20A 13-8
F14, F15, F16, F35, F36, F37 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
11-1 151-30
151-34
POWER
C283B SBF02 YE-RD DISTRIBUTION
D 13-2
1
Hot at all times

BATTERY
JUNCTION
POWERTRAIN BOX (BJB)
CONTROL 11-3 151-1 POWERTRAIN
MODULE (PCM) CONTROL
RELAY MODULE (PCM)
23-2 33-2

F14 C139 C175B

SB114 BN-RD SB114 BN-RD CE302 YE-BU
5A 24 1 2 48

5
F15 SB115 WH-RD SB115 WH-RD 3
40A 6
5

F35 CBB35 YE-GY

GY-VT
CE612
29
15A S103

MASS AIR
FLOW (MAF)
SENSOR
23-5
F36 CBB36 BU-BN C128
S112
7.5A 3

F37 CBB37 WH
GY-VT
CE612

7.5A
3 C134
FUEL METERING
F16 POWER VALVE
SB116 VT-RD 23-3
DD DISTRIBUTION
40A 13-10 13-11 POWER
EE DISTRIBUTION CBB74 VT-BN C1138
13-9 1
F5 BATTERY
JUNCTION 2.2L
BOX (BJB)
11-3 151-1

POWER GLOW
DISTRIBUTION PLUG
RELAY
CBB39 VT-WH 23-4
13-9 BE
Hot in Start POWERTRAIN
or Run CE156 WH-VT C175T CONTROL
MODULE (PCM)
1 2 28 23-4

POWER
DISTRIBUTION
5
CBB12 GN-WH 3
13-6 BD

WH-VT
CE156
Hot in Start
or Run

emission requirements: stage V emissions

early production
FUEL
C134 - 16 C133 - 1 CE156 WH-VT C1263 VAPORIZER
S114 SYSTEM
2 GLOW PLUG
23-4
WH-VT
CE156

WH-VT
CE156

late production

POWERTRAIN
F5 CE156 WH-VT C175T CONTROL
MODULE (PCM)
3A 26 23-4
F38, F39 2.2L
BATTERY
JUNCTION
BOX (BJB)
11-3 151-1

CE612 GY-VT POWER

DISTRIBUTION
EE 13-7
Hot in Start or Run

BATTERY
air conditioning JUNCTION
BOX (BJB)
AIR 11-3 151-1
F38 CBB38 GY-BU CONDITIONING
1 (A/C) CLUTCH
7.5A RELAY
54-9

LOW SPEED
CBB39 VT-WH COOLING FAN
1 RELAY
33-1

HIGH SPEED
F39 CBB39 VT-WH CBB39 VT-WH COOLING FAN
1 RELAY
15A S109 33-1

ECONETIC
CBB39 VT-WH COOLANT
1 VALVE
RELAY
23-16

CBB39 VT-WH POWER

BE DISTRIBUTION
13-8

C144 - 9 FUEL
CBB39 VT-WH CBB39 VT-WH C4141 VAPORIZER
SYSTEM FUEL
1 PUMP
23-3

C134 - 17 HEATED
CBB39 VT-WH CBB72 GN-VT C171 OXYGEN
SENSOR (HO2S)
4 23-3
F3, F29 WITHOUT: CUSTOMER ACCESS
BODY CDC32 BN-YE POWER 2.2L
FF DISTRIBUTION
CONTROL 13-12
MODULE (BCM)
11-5 151-14 65 C210
151-18 151-30 Hot at DATA LINK
151-34 all times CONNECTOR
POWER (DLC)
C2280B SB116 VT-RD DISTRIBUTION 14-1
DD 13-7
28 C251
CDC32 BN-YE

CDC32
BN-YE
9
IGNITION
SWITCH
151-22
OFF

F3 C2280D SBP03 C250 ACC

C250 CDC32 BN-YE
65 BU-RD 4 BG 13-52
15A RUN 1 S224
POWER
BF START DISTRIBUTION

13-48 BODY
OFF CONTROL
CDC33 VT-GN MODULE (BCM)
BH 13-52 11-5 151-14
ACC 6 151-18
RUN S223 CDC35 BU-WH C2280D
START
START 7 71
BU-RD
SBP03

POWER

BU-WH
CDC35
T DISTRIBUTION without:
13-2 multi-function
emission requirements: stage IV display

CME05 GN-BN AUDIO

FRONT
51 C210

BU-WH
CDC35
CONTROL
11 C139 MODULE (ACM)
130-1

BU-WH
CDC35
C240A
16 C210
BATTERY 5
JUNCTION 16 C139
F29 BOX (BJB)
CME05
GN-BU

without: 3A 11-3 151-1 POWERTRAIN

multi-function CONTROL

BU-WH
early production

CDC35
display or MODULE (PCM)
3 C240A late production 20-2 20-3
emission requirements: stage V 23-17
AUDIO
FRONT CDC35 BU-WH S106 CDC35 BU-WH C175B
CONTROL START
MODULE (ACM)
20-2 20-3 47
130-1

CDC35 BU-WH
late production
emission requirements: stage IV
Emergency Services
F3, F29 CUSTOMER ACCESS BODY 2.2L
C212 C2237 CONTROL
IGNITION Not used
SWITCH MODULE (BCM)
151-22 1 40 11-5 151-14
BODY 151-18
CONTROL
MODULE (BCM) C250 CDC30 BU-GY C2280D
11-5 151-14 KEY IN
151-18 151-30 KEY IN 5 62
151-34 S228
IGNITION

CDC32 BN-YE POWER

C2280B SB116 FF DISTRIBUTION
DD 13-7 13-12
VT-RD 65 C210 DATA LINK
28 CONNECTOR
Hot at (DLC)
all times 14-1
POWER

CDC32
BN-YE
DISTRIBUTION OFF CDC32 BN-YE C251

F3 C2280D C250 ACC 9

SBP03
CDC32 BN-YE
15A 65 BU-RD 4 BG 13-52
RUN 1 S224

BF START POWER
DISTRIBUTION
13-48 OFF
CDC33 VT-GN
BH 13-52
ACC 6
Emergency Services
RUN C212 C2237
CDC35 BU-WH CDC31 ZA012 BK
BU-RD
SBP03

START 7 3 GN-OG 36

S223 CDC33 ZA112 OG-GN

POWER
T DISTRIBUTION
4 VT-GN 39
13-2

BU-WH
CDC35
BODY
CONTROL

BU-WH
CDC35
MODULE (BCM)
51 C210 11-5 151-14
emission requirements: stage IV 151-18

CME05 GN-BN C2280D

11 C139 16 C139 START
BATTERY 71
JUNCTION
16 C210 F29 BOX (BJB) POWERTRAIN

BU-WH
early production

CDC35
3A 11-3 151-1 CONTROL
or MODULE (PCM)
Not used late production 20-2 20-3
emission requirements: stage V 23-17
Emergency Services
12 C263
CDC35 BU-WH CDC35 BU-WH C175B
CME05 GN-BU C212 C2237
START
Not used S106 47
6 19

CDC35 BU-WH
late production
emission requirements: stage IV
F1 2.2L
CDC32 BN-YE POWER
JJ DISTRIBUTION
13-13
36 C139

CDC32
BN-YE
CDC32 BN-YE
GG 13-14
POWER POWER
DISTRIBUTION DISTRIBUTION
13-10 S276 CDC32 BN-YE
13-11 FF HH 13-14
Hot in Start
or Run
AUXILIARY
auxiliary climate control JUNCTION
BOX (AJB)
AUXILIARY 11-1 151-30
CDC32 BN-YE BLOWER 151-34
1 MOTOR
RELAY
52-1

CDC32 BN-YE F1

10A

RESTRAINTS
CB101 BU C310A CONTROL
MODULE (RCM)
19 46-1
F6, F7
2.2L

Hot in Start
or Run
POWER
DISTRIBUTION
13-12
JJ
CDC32
BN-YE

BATTERY
JUNCTION
BOX (BJB)
11-3 151-1

C1010 - 5 ANTI-LOCK
CDC32 BN-YE F6 CBB06 WH-BU CBB06 WH-BU C135 BRAKE SYSTEM
S115 (ABS) MODULE
3A 28 42-1

GLOW PLUG
F7 CBB07 GN-BU S102 CBB07 GN-BU C1273A MODULE
23-1
7.5A 4

early production

POWERTRAIN
CBB07 GN-BU C175B CONTROL
MODULE (PCM)
39 23-1 93-4

late production

CDC32 BN-YE POWER POWERTRAIN

BC DISTRIBUTION CBB07 GN-BU C175B CONTROL
13-4 MODULE (PCM)
39 23-1 93-4

CDC32 BN-YE POWER

CC DISTRIBUTION
13-6
F50, F51 AUXILIARY
JUNCTION 2.2L
BOX (AJB)
11-1 151-30
151-34

AUXILIARY IGNITION
RELAY 1
POWER
DISTRIBUTION
CDC32 BN-YE GD241 BK-BU S274 GD241 BK-BU
13-12 GG
1 2 G308
Hot in Start 10-21
or Run

5 CDC21 GY-BN S273 CDC21 GY-BN

3 KK 13-15

CDC21 GY-BN
LL 13-16
POWER
DISTRIBUTION
YE-RD
SB150

CDC21 GY-BN
MM 13-18

CDC21 GY-BN
PP 13-20
F50

POWER 60A
DISTRIBUTION
SBF09 RD
13-3 L
Hot at
all times F51

60A
BU-RD
SB151

AUXILIARY IGNITION CDC22 VT-OG

OO 13-19
RELAY 2
POWER
DISTRIBUTION
CDC22 VT-OG CDC22 VT-OG
3 RP 13-21
5 S279

POWER
DISTRIBUTION
CDC32 BN-YE 1 2 GD241 BK-BU S274 GD241 BK-BU
13-12 HH
G308
Hot in Start 10-21
or Run
AUXILIARY
JUNCTION
F19, F20, F21 2.2L
BOX (AJB)
11-1 151-30
151-34
POWER
CDC21 GY-BN DISTRIBUTION
KK 13-14
Hot in Start or Run
tachograph

TACHOGRAPH
F19 CB119 BN-WH C300 - 23 CB119 BN-WH C9027 - 1 CB119 BN-WH C9068A 60-7

5A 3

heated windshield heated mirror

F20 CB120 YE-VT S288 CB120 YE-VT POWER
BJ DISTRIBUTION
5A 13-17

AUXILIARY
heated windshield JUNCTION
BOX (AJB)
11-1 151-30
HEATED 151-34
CB120 YE-VT WINDSHIELD
1 ELEMENT
RH
RELAY
56-2

HEATED
CB120 YE-VT WINDSHIELD
1 ELEMENT
LH
YE-VT
CB120

RELAY
56-2

Direct Current/Alternating Current (DC/AC) inverter

DIRECT CURRENT/
2 C3664 CB120 YE-VT C3501 ALTERNATING CURRENT
(DC/AC) INVERTER
3 44-5

Camper Conversions

CB121 BU-GY C213

Not used
13

Emergency Services

F21 CB121 BU-GY POWER

BK DISTRIBUTION
10A 13-61
AUXILIARY
JUNCTION
F22, F23 2.2L
BOX (AJB)
11-1 151-30
151-34
POWER
CDC21 GY-BN DISTRIBUTION
LL 13-14
Hot in Start or Run

F22 CB122 GN-OG POWER

BL DISTRIBUTION
15A 13-52

fuel fired AUXILIARY

booster heater JUNCTION
BOX (AJB)
FUEL FIRED 11-1 151-30
F23 CB123 BN-YE S271 CB123 BN-YE BOOSTER 151-34
2 HEATER RELAY
7.5A 54-3

auxiliary climate control

late production: high roof
AUXILIARY
C300 - 59 C9028 - 17
BN-YE
CB123

CB123 BN-YE CB123 BN-YE C938 C937 BLOWER

MOTOR
17 10 SWITCH
SS 52-2

17 C210
POWER
DISTRIBUTION
13-18 electric booster heater

ELECTRIC
S227 CB123 BN-YE C2603C BOOSTER
HEATER
1 54-8

passenger airbag

MESSAGE
CB123 BN-YE C253 CENTER
SWITCH
2 46-6 60-6

BLOWER MOTOR SWITCH

CB123 BN-YE C271B 54-5
15
F3 AUXILIARY
JUNCTION
HEATED MIRROR 2.2L
BOX (AJB)
HEATED 11-1 151-30
REAR 151-34
WINDOW
RELAY
56-4 56-5
POWER
DISTRIBUTION
BODY
CB120 YE-VT CRD02 BN-BU C2280C CONTROL
13-15 BJ MODULE (BCM)
1 2 14 11-5 151-30
Hot in Start 151-34
or Run

heated rear window

liftgate
POWER
DISTRIBUTION HEATED REAR
5 S282 C300 - 30 CRD06 C935 - 9 CRD06 C406 - 9 C402A WINDOW
SB142 YE-RD 3 ELEMENT
13-24 BM BN-YE BK 1 56-4
Hot at
all times
rear doors

HEATED REAR
CRD06 C422 - 9 C4425A WINDOW
ELEMENT LH
BN-YE 1 56-5

HEATED REAR
C311 - 30 CRD06 C991 - 9 CRD06 C411 - 9 C4426A WINDOW
ELEMENT RH
BN-YE BK 1 56-5
CRD06
BN-YE

right hand drive

C340 - A1 right hand drive
EXTERIOR
F3 CB103 GY C339 - A1 CB103 BK C663 C521 MIRROR
LH
10A 1 1 56-6
124-1 124-3
right hand drive
C339 - A1 right hand drive
EXTERIOR
CB103 GY C340 - A1 CB103 BK C596 C626 MIRROR
RH
1 1 56-6
124-1 124-3
AUXILIARY
JUNCTION
F24, F46 2.2L
BOX (AJB)
11-1 151-30
151-34

Hot in Start
or Run
POWER
DISTRIBUTION
13-16
SS
HEADLAMP
F24 CB124 VT-GN C1021 ASSEMBLY LH
85-5
5A 10

HEADLAMP
CB124 VT-GN C1041 ASSEMBLY RH
85-5
10

POWER
CDC21 GY-BN DISTRIBUTION
MM 13-14
Hot in Start
or Run

DRIVER DOOR
F46 CB146 WH-BU S290 CB146 WH-BU C339 - A11 CB146 BK C535A WINDOW
CONTROL SWITCH
30A 7 100-1

PASSENGER DOOR
CB146 WH-BU C340 - A11 CB146 BK C604 WINDOW
CONTROL SWITCH
2 100-2
AUXILIARY
JUNCTION
F27, F28 2.2L
BOX (AJB)
11-1 151-30
151-34
POWER
CDC22 VT-OG DISTRIBUTION
OO 13-14
Hot in Start or Run

heated seats

S303 right hand drive

HEATED
F27 CB127 GN-BN S294 CB127 GN-BN C341F - 1 1 BU C320 FRONT
SEAT SWITCH
20A 1 119-2

HEATED
CB127 GN-BN C3660C - 1 1 BU C321 FRONT
SEAT SWITCH
1 119-1

cornering lamps

ADAPTIVE
F28 CB128 GY-VT C210 - 21 CB128 GY-VT C2800 FRONT
LIGHTING
20A 24 MODULE
85-6
AUXILIARY
JUNCTION
F29, F30 2.2L
BOX (AJB)
11-1 151-30
151-34
POWER
CDC21 GY-BN DISTRIBUTION
PP 13-14
Hot in Start or Run

parking aid camera,

without: lane departure warning

C300 - 28 IMAGE
F29 CB129 WH-VT CB129 WH-VT C9058 PROCESSING
MODULE B (IPMB)
10A 4 131-6

C311 - 28 C913 - 6 AUTO-DIMMING

CB129 WH-VT CB129 WH-VT CB129 WH-VT C911 INTERIOR
MIRROR
1 124-5 131-7

lane departure warning

parking aid camera

C300 - 28 IMAGE
F29 CB129 WH-VT S272 CB129 WH-VT CB129 WH-VT C9058 PROCESSING
MODULE B (IPMB)
10A 4 131-6
WH-VT
CB129

C210 - 22 STEERING COLUMN

CB129 WH-VT CB129 WH-VT C2414 CONTROL
MODULE (SCCM)
28 C311 9 31-14 81-10
85-9 90-12
136-1
WH-VT

F30
CB129

5A C913 - 6 IMAGE
CB129 WH-VT S910 C919 - 12 C9039 PROCESSING
MODULE A (IPMA)
1 136-2

parking aid camera

AUTO-DIMMING
CB129 WH-VT C911 INTERIOR
MIRROR
1 124-5 131-7
AUXILIARY
JUNCTION F34 2.2L
BOX (AJB)
11-1 151-30
151-34

POWER
CDC22 VT-OG DISTRIBUTION
RP 13-14
Hot in Start or Run

rear window wipers

liftgate

C300 - 24 C934 - 1 C405 - 1 REAR

F34 CB134 VT-BN CB134 BK CB134 BK C4218 WINDOW
WIPER MOTOR
20A S275 2 81-6

rear doors

C421 - 1 REAR
CB134 VT-BN CB134 VT-BN C476 WINDOW
WIPER MOTOR
VT-BN
CB134

2 LH
81-7

rear doors

C311 - 24 C983 - 1 C410 - 1 REAR

CB134 VT-BN CB134 BK CB134 BK C4171 WINDOW
WIPER MOTOR
2 RH
81-8

BATTERY
JUNCTION
C139 - 1 REAR BOX (BJB)
CB134 VT-BN CB134 VT-BN WINDOW 11-3 151-1
5 WIPER RELAY
81-5
AUXILIARY
JUNCTION
F35, F36, F37 2.2L
BOX (AJB)
11-1 151-30
151-34

POWER
C283C SBF04 GN-RD DISTRIBUTION
F 13-3
1
Hot at all times

DRIVER DOOR
F35 SB135 BU-RD C339 - A6 SB135 BK S508 SB135 BK C535A WINDOW
CONTROL SWITCH
5A 8 100-1

power mirrors

EXTERIOR
SB135 BK C527 MIRROR
CONTROL
6 SWITCH
124-1 124-3

AUXILIARY
JUNCTION
HORN BOX (AJB)
F36 SB136 GN-RD RELAY
3 11-1 151-30
44-1 151-34
20A

SYNC

SYNC
C210 - 70 C263 - 6 S200 MODULE [APIM]
F37 SB137 GY-RD SB137 GY-RD SB137 GY-RD C2383
130-7
7.5A 1

GLOBAL POSITIONING
UU SB137 GY-RD C2398 SYSTEM MODULE (GPSM)
130-7
1
13-23
Hot at
AUXILIARY
JUNCTION
F38, F39 2.2L
all times BOX (AJB)
13-22 11-1 151-30
151-34
UU
BATTERY
JUNCTION
C139 - 25 REAR BOX (BJB)
F38 SB138 BN-RD S283 SB138 BN-RD SB138 BN-RD WINDOW 11-3 151-1
1 WIPER RELAY
5A 81-5

AUXILIARY
JUNCTION
HORN BOX (AJB)
SB138 BN-RD RELAY 11-1 151-30
1 44-1 151-34

BLOWER
SB138 BN-RD MOTOR
1 RELAY
54-1

fuel fired booster heater

FUEL FIRED
SB139 WH-RD C2806 BOOSTER HEATER
CONTROL MODULE
2 54-4

auxiliary climate control

late production: high roof

S2005 C300 C9028 - 18 AUXILIARY
F39 SB139 SB139 WH-RD SB139 WH-RD C938 C937 BLOWER
WH-RD MOTOR
7.5A 39 18 11 SWITCH
52-2
SB139
WH-RD

RADIO
C311 C900 - 5 S908 FREQUENCY
SB139 SB139 WH-RD C9026
(RF) RECEIVER
WH-RD 39 3 117-12 118-1

13-23
AUXILIARY
VV JUNCTION
BLOWER BOX (AJB)
F40 SB140 VT-RD MOTOR 11-1 151-30
3 RELAY 151-34
40A 54-1

auxiliary climate control

AUXILIARY
F41 SB141 RD BLOWER
3 MOTOR
40A RELAY
52-1

heated rear window

F42 SB142 YE-RD POWER

BM DISTRIBUTION
30A 13-17

trailer tow

TRAILER
F43 SB143 BU-RD C3548B MODULE
95-1
30A 2

C145 - 21 C438 - 9 TRAILER

SB143 BU-RD SB143 BU-RD SB143 BU-RD C439 SOCKET
95-2
9

F44 SB144 GN-RD POWER

BN DISTRIBUTION
60A 13-33 13-38
AUXILIARY
JUNCTION
F5, F6, F8, F10 2.2L
BOX (AJB)
11-1 151-30
151-34

POWER
C283A SBF05 GY-RD DISTRIBUTION
G 13-3
1
Hot at all times

fuel fired booster heater

AUXILIARY HEATER
F5 SB105 GY-RD C145 - 14 SB105 GY-RD C4429 CONTROL
MODULE (AHCM)
20A 1 54-4

tachograph

TACHOGRAPH
F6 SB106 BN-RD C300 - 41 C9027 - 9 SB106 BN-RD C9068A 60-7

5A 1

Direct Current/Alternating Current (DC/AC) inverter

DIRECT CURRENT/
F8 SB108 VT-RD C3664 - 1 SB108 VT-RD C3501 ALTERNATING CURRENT
(DC/AC) INVERTER
40A 1 44-5

power seats

FRONT SEAT
F10 SB110 YE-RD C341E - 1 8 RD C369 CONTROL
SWITCH
30A 5 120-1 120-2
AUXILIARY
JUNCTION
F52, F53 2.2L
BOX (AJB)
11-1 151-30
151-34

heated windshield

POWER
SBF07 WH-RD DISTRIBUTION
J 13-3
Hot at
all times

heated windshield

AUXILIARY
JUNCTION
HEATED BOX (AJB)
F52 SB152 GN-RD WINDSHIELD 11-1 151-30
3 ELEMENT 151-34
40A LH
RELAY
56-2

HEATED
F53 SB153 GY-RD WINDSHIELD
3 ELEMENT
40A RH
RELAY
56-2
BODY
CONTROL
F6 2.2L
MODULE (BCM)
11-5 151-30
151-34
Hot at
all times
C2280A SBF10 YE-RD POWER
M DISTRIBUTION
1 13-3

F6
FRONT WASHER PUMP RELAY
15A (Non-serviceable)

C2280B CRW14 BU-WH

34
BO

13-28 13-29
1 C137

WINDSHIELD
WASHER
PUMP
M 81-9

REAR WASHER PUMP RELAY 2 C137

(Non-serviceable)

CRW34 BU-BN
32

GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137 BK-WH

GD137
31

G303
10-14
F7 LEFT HAND DRIVE POWER FOLDING MIRRORS 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at 11-5 151-30
all times 151-34
13-27
BO

F7
POWER MIRROR FOLD RELAY
7.5A (Non-serviceable)

EXTERIOR
C2280B CPM02 BU C339 - A13 CPM02 BK C521 MIRROR
LH
33 3 124-2

EXTERIOR
BP CPM02 BU C340 - A13 CPM02 BK C626 MIRROR
RH
3 124-2
13-30

POWER MIRROR UNFOLD RELAY

(Non-serviceable)

EXTERIOR
CPM01 YE-GN C339 - A12 CPM01 BK C521 MIRROR
LH
6 4 124-2

EXTERIOR
CPM01 YE-GN C340 - A12 CPM01 BK C626 MIRROR
RH
4 124-2

GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137 BK-WH

GD137
31

G303
10-14
F7 RIGHT HAND DRIVE POWER FOLDING MIRRORS 2.2L
BODY
CONTROL
MODULE (BCM)
11-5 151-30
Hot at all times 151-34
13-27
BO

F7
POWER MIRROR FOLD RELAY
7.5A (Non-serviceable)

EXTERIOR
C2280B CPM02 BU C339 - A13 CPM02 BK C596 MIRROR
RH
33 3 124-4

EXTERIOR
BP CPM02 BU C340 - A13 CPM02 BK C663 MIRROR
LH
3 124-4
13-30

POWER MIRROR UNFOLD RELAY

(Non-serviceable)

EXTERIOR
CPM01 YE-GN C339 - A12 CPM01 BK C596 MIRROR
RH
6 4 124-4

EXTERIOR
CPM01 YE-GN C340 - A12 CPM01 BK C663 MIRROR
LH
4 124-4

GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137 BK-WH

GD137
31

G303
10-14
F8, F9, F10 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at all times 11-5 151-30
151-34
13-28 13-29
BP Emergency Services

HIGH BEAM F10 C2237 - 33

RELAY C2280B CLF02 GY-BN
Not used
(Non-serviceable)
10A 5

HEADLAMP
CLF02 GY-BN C1021 ASSEMBLY LH
85-3
1

HEADLAMP
F9 CLF03 VT-OG C1041 ASSEMBLY RH
85-4
10A 17 1

front fog lamps

Emergency Services

CLF34 YE-OG C2237 - 35

Not used
FRONT FOG LAMP
RELAY
(Non-serviceable)

FRONT
CLF34 YE-OG CLF34 YE-OG C152 FOG LAMP LH
F8 86-2
16 S262 1
15A

FRONT
CLF34 YE-OG C162 FOG LAMP RH
86-2
1

13-31
F11 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at 11-5 151-30
all times 151-34
13-30
BQ
HEADLAMP
F11 C2280B CLF05 BU-GN C1041 ASSEMBLY RH
85-4 92-2
25A 12 8

C2280C CLS07 BN-YE

66 2

REAR LAMP
C311 - 15 C415 ASSEMBLY RH
CLS09 WH-OG CLS09 WH-OG
90-7 92-4
67 4

customer access

Camper Conversions
CLS10 GN-BN C213 C2237
MICRO

Not used
15 32

REAR LAMP
C2280B C300 - 13 C412 ASSEMBLY LH
CLS10 GN-BN
92-3 93-1
11 S299 5
GN-BN
CLS10

REAR LAMP
C311 - 13 S919 C415 ASSEMBLY RH
CLS10 GN-BN
92-4 93-1
2

5 C913 parking aid camera

AUTO-DIMMING
CLS10 GN-BN C911 INTERIOR
MIRROR
2 93-1 124-5
131-7

REAR LAMP
C311 - 17 C415 ASSEMBLY RH
CLS53 GY-VT CLS53 GY-VT
90-7 92-4
20 5
BODY
CONTROL
F12, F13 EARLY PRODUCTION 2.2L
MODULE (BCM)
11-5 151-14
151-18 151-30
151-34 Hot at all times
POWER
C2280A SBF11 BU-RD DISTRIBUTION
N 13-3
2

DATA LINK
F13 C2280D SBP13 GY-RD C251 CONNECTOR
(DLC)
15A 73 16 14-1

POWER
DISTRIBUTION
CLN01 GN-VT 13-35
BS
13-36
CLN01 GN-VT
BT 13-34
BATTERY CLN01 GN-VT
SAVER BU 13-33
RELAY
(Non-serviceable)
Camper Conversions
C2280B CLN01 GN-VT CLN01 GN-VT C213
Not used
9 S260 7

9 C210

GLOVE COMPARTMENT
S235 CLN01 GN-VT C254 LAMP
89-2
1

Thatcham category 1 alarm

ANTI-THEFT
F12 SBP12 GN-RD C154 ALARM HORN
WITH INTEGRAL
20A 29 3 BATTERY
117-14
BV

13-43 anti-theft alarm system

S305 ANTI-THEFT
CRT02 GY-VT CRT02 GY-VT C3549
MICRO

ALARM HORN
LH
21 1 117-13

ANTI-THEFT
CRT02 GY-VT C3550 ALARM HORN
RH
1 117-13
F47, F48, F49 AUXILIARY
JUNCTION
EARLY PRODUCTION 2.2L
BOX (AJB)
11-1 151-30
AUXILIARY 151-34
POWER
POINT
RELAY
44-2
POWER
DISTRIBUTION
CLN01 GN-VT GD137 BK-WH
13-32 BU
1 2 G303
Hot at all times 10-14
with battery saver
relay engaged

5
3

POWER
DISTRIBUTION
SB144 GN-RD
13-24 BN
Hot at
all times
GY-YE
CDC17

C210 - 35 AUXILIARY
F47 CB147 GN-BU CB147 GN-BU C2031 POWER
POINT
20A 2 44-4

rear passenger power outlet socket

C311 - 31 REAR PASSENGER

F48 CB148 GY-YE CB148 GY-YE C979 POWER
OUTLET
20A 2 SOCKET
44-4

C210 - 27 FRONT POWER

F49 CB149 VT-GY CB149 VT-GY C2033 OUTLET
SOCKET
20A 2 44-4
EARLY PRODUCTION 2.2L
Van - left-hand drive (short wheelbase)
Van (long wheelbase)

C925 - 1 LUGGAGE
CLN01 GN-VT CLN01 GN-VT C9056A COMPARTMENT
LAMP
1 89-4

C936 - 1 LUGGAGE
CLN01 GN-VT CLN01 GN-VT C9057A COMPARTMENT
LAMP
1 89-4

POWER
DISTRIBUTION C311 - 26
CLN01 GN-VT
13-32 BT S924

Hot at all times

GN-VT
CLN01
with battery saver
relay engaged

11 C900

FRONT INTERIOR
CLN01 GN-VT C929A LAMP
GN-VT
CLN01

89-2
1

without: Base

FRONT INTERIOR
CLN01 GN-VT C931A LAMP
S907 89-3
1

illuminated vanity mirrors

VANITY
CLN01 GN-VT C906 MIRROR
LAMP RH
1 89-3

VANITY
CLN01 GN-VT C907 MIRROR
LAMP LH
1 89-3
EARLY PRODUCTION Van - right-hand drive (short wheelbase)
2.2L
Van (long wheelbase)
VAN
DOUBLE CAB IN VAN CLN01 GN-VT
C9076 - 1
CLN01 GN-VT C9078A
LUGGAGE
COMPARTMENT
LAMP
1 89-5

POWER
DISTRIBUTION C300 - 26 C9077 - 1 LUGGAGE
CLN01 GN-VT CLN01 GN-VT CLN01 GN-VT C9079A COMPARTMENT
13-32 BS LAMP
S915 1 89-5
Hot at all times
with battery saver
relay engaged

GN-VT
CLN01

GN-VT
CLN01
1 C9076 1 C9077
Not used
GN-VT
CLN01

1 C922
GN-VT
CLN01

Double Cab in Van

THIRD ROW
CLN01 GN-VT C9054A INTERIOR LAMP
S901 89-6
1

FOOTWELL
CLN01 GN-VT C2056A LAMP
LH
1 89-6

FOOTWELL
CLN01 GN-VT C2057A LAMP
RH
1 89-6
EARLY PRODUCTION 2.2L
BUS
KOMBI

POWER
DISTRIBUTION C300 - 26 S915
CLN01 GN-VT CLN01 GN-VT CLN01 GN-VT C9077
13-32 BS Not used
1
Hot at all times

GN-VT
CLN01
with battery saver
relay engaged

1 C9076

GN-VT
CLN01
low roof

1 C922

LUGGAGE
CLN01 GN-VT C9075A COMPARTMENT
LAMP
1 89-7

GN-VT
CLN01

THIRD ROW
CLN01 GN-VT C9054A INTERIOR LAMP
89-8
1

FOURTH ROW
CLN01 GN-VT C9055A INTERIOR LAMP
S901 89-8
1

FOOTWELL
CLN01 GN-VT C2056A LAMP
LH
1 89-7

high roof
FOOTWELL
CLN01 GN-VT C2057C C2057A LAMP
RH
1 1 89-7
BODY
CONTROL
F12, F13 LATE PRODUCTION 2.2L
MODULE (BCM)
11-5 151-14
151-18 151-30
151-34 Hot at all times
POWER
C2280A SBF11 BU-RD DISTRIBUTION
N 13-3
2

DATA LINK
F13 C2280D SBP13 GY-RD C251 CONNECTOR
(DLC)
15A 73 16 14-1

BATTERY
SAVER
RELAY
(Non-serviceable)

POWER
C2280B CLN01 GN-VT DISTRIBUTION
NQ 13-39
9

Thatcham category 1 alarm

ANTI-THEFT
F12 SBP12 GN-RD C154 ALARM HORN
WITH INTEGRAL
20A 29 3 BATTERY
117-14
BV

13-43 anti-theft alarm system

S305 ANTI-THEFT
CRT02 GY-VT CRT02 GY-VT C3549
MICRO

ALARM HORN
LH
21 1 117-13

ANTI-THEFT
CRT02 GY-VT C3550 ALARM HORN
RH
1 117-13
F47, F48, F49 AUXILIARY
JUNCTION
LATE PRODUCTION 2.2L
BOX (AJB)
11-1 151-30
151-34
AUXILIARY POWER
POINT
RELAY
44-3
POWER
DISTRIBUTION
CB125 WH-OG GD137 BK-WH
13-39 BW
1 2 G303
Hot at all times 10-14
with battery saver
relay engaged

5
3

POWER
DISTRIBUTION
SB144 GN-RD
13-24 BN
Hot at
all times
GY-YE
CDC17

C210 - 35 AUXILIARY
F47 CB147 GN-BU CB147 GN-BU C2031 POWER
POINT
20A 2 44-4

rear passenger power outlet socket

C311 - 31 REAR PASSENGER

F48 CB148 GY-YE CB148 GY-YE C979 POWER
OUTLET
20A 2 SOCKET
44-4

C210 - 27 FRONT POWER

F49 CB149 VT-GY CB149 VT-GY C2033 OUTLET
SOCKET
20A 2 44-4
F25 LATE PRODUCTION 2.2L
POWER
CLN01 GN-VT DISTRIBUTION
BX
13-40 13-41
13-42

LUGGAGE
CB132 GN-VT C9075A COMPARTMENT
LAMP
1 89-14

GN-VT
CB132
THIRD ROW
CB132 GN-VT C9054A INTERIOR LAMP
89-15
1

FOURTH ROW
CB132 GN-VT C9055A INTERIOR LAMP
S901 89-15
1

FOOTWELL
CB132 GN-VT C2056A LAMP
LH
1 89-14

high roof
FOOTWELL
CB132 GN-VT C2057C C2057A LAMP
RH
1 1 89-14
F14 right hand drive
EXTERIOR 2.2L
BODY CLS21 BK C663 C521 MIRROR
CONTROL LH
MODULE (BCM) 8 8 90-3 124-1
Hot at 11-5 151-30 124-3
151-34 B1 C339
all times
13-37 B1 C340 right hand drive
BV C2280C CLS21 BU-GN
HEADLAMP
F14 61 CLS21 BU-GN C1021 ASSEMBLY LH
85-3 90-3
25A 6
daytime running lamps
CLF61 GY-BU
73 3

daytime running lamps

HEADLAMP
BY CLF62 VT-WH C1041 ASSEMBLY RH
85-4 90-4
13-44 74 3
CLS25 YE-VT

63 6
CLS25 YE-VT
right hand drive
B1 C339
right hand drive
B1 C340
EXTERIOR
MICRO

CLS25 BK C596 C626 MIRROR

RH
Emergency Services 8 8 90-4 124-1
124-3
CUSTOMER
ACCESS
140-8
REAR LAMP
CLS23 GY-OG S255 C300 CLS23 GY-OG C412 ASSEMBLY LH
86-3 90-5
60 16 1 92-3
CLS45 BN-GN CLS45 BN-GN
75 12 4
rear fog lamps
Emergency Services
CUSTOMER
ACCESS
140-9
REAR LAMP
CLS27 GN-OG S284 C311 CLS27 GN-OG C415 ASSEMBLY RH
86-3 90-5
62 16 6 92-4

CLS37 WH-BU CLS37 WH-BU

76 12 3
rear fog lamps
F15 2.2L
BODY
CONTROL
MODULE (BCM)
11-5 151-14 Emergency Services
151-18 151-30 C2237 - 34
Hot at 151-34 CLF04 BN-BU
all times Not used
13-43
BY C2280C
C1021 HEADLAMP
CLF04 BN-BU ASSEMBLY LH
F15 85-3 92-2
69 8
25A C2280B S263
CLS06 GN-OG CLS06 GN-OG
14 2
Emergency Services
C2237 - 26
CLS06 GN-OG
Not used

BZ
C300 C412 REAR LAMP
CLS08 VT-GN CLS08 VT-GN ASSEMBLY LH
13-47 2 90-7 92-3
15 15
C2280C CLS51 WH-GN CLS51 WH-GN

68 17 3
trailer tow

TRAILER
C3548C
MICRO

CLS51 WH-GN MODULE

95-1
3

C2280D CLN17 BN POWER

CA DISTRIBUTION
48 13-45

S281 C311 - 14
C2280B CLS04 YE-VT
Not used
13
Emergency Services
YE-VT
CLS04

CLS04 YE-VT CUSTOMER ACCESS

140-11
LICENSE
14 C300 C452 PLATE
LAMP LH
1 92-5 92-6
YE-VT
CLS04

rear doors rear doors

YE-VT
CLS04
C421 - 2 C495 - 1
2 C934
C405 - 2 C494 - 1 LICENSE
CLS04 CLS04 CLS04 YE-VT C462 PLATE
LAMP RH
BK YE-VT BK YE-VT S415 1 92-5 92-6
rear doors rear doors
heated windshield
2.2L
HEATED
CLN17 BN C2025 WINDSHIELD
SWITCH
3 56-1 71-4

front parking aid

PARKING
CLN17 BN C2035 AID
SWITCH
3 71-4 131-3

HAZARD
CLN17 BN C2039 FLASHER
SWITCH
3 71-2 90-2

POWER
DISTRIBUTION C210 - 45
CLN17 BN CLN17 BN CLN17 BN POWER
13-44 CA CB DISTRIBUTION
13-46
S225
START
CLN17 BN C2195 CONTROL
UNIT
3 40-1 71-2

heated rear window

HEATED
CLN17 BN C241 REAR
WINDOW
3 SWITCH
56-3 71-4

BLOWER MOTOR SWITCH

54-5 71-2 BK
CLN17 BN C271B or STEERING WHEEL
RD-WH C2998 SWITCH, LH UPPER
1
60-2 71-3
1
CLN17

STEERING WHEEL
BN

BK C2366 SWITCH, LH LOWER

STEERING COLUMN
CLN17

31-5 31-6
CONTROL 1
BN

71-3
MODULE (SCCM)
71-3
STEERING WHEEL
C2414 C218B BK C2367 SWITCH, RH LOWER
without: 71-3 130-12
multi-function 12 7 S2011 1
display BK
CLOCKSPRING or
AUDIO 71-3 RD-WH
C240A FRONT or STEERING WHEEL
CONTROL GY C2999 SWITCH, RH UPPER
14 MODULE (ACM) 71-3 130-10
71-2 130-1 2 130-11
tachograph
2.2L
TACHOGRAPH
C9027 - 2 CLN17 BN C9068A 60-7 71-6
2

auxiliary climate control

CLN17
late production: high roof

BN
AUXILIARY
C300 - 58 C9028 - 16 C938 C937 BLOWER
CLN17 BN CLN17 BN
MOTOR
S914 16 24 SWITCH
52-2 71-6

DRIVER
C339 - A2 C505 DOOR
CLN17 BN CLN17 BK
LOCK CONTROL
4 SWITCH
71-5 117-1
1
right hand drive
POWER
DISTRIBUTION PASSENGER
C340 - A2 C605 DOOR
CLN17 BN CLN17 BN CLN17 BK
13-45 CB LOCK CONTROL
S2002 1 SWITCH
Camper Conversions 71-5 117-1
4
CLN17 BN C214 right hand drive
Not used
6

Emergency Services

auxiliary heater
WATER
CLN17 BN C9435 HEATER
SWITCH
8 71-7 140-5

if equipped
BEACON
CLN17 BN C3665 - 2 C2239 - 3 S9005 CLN17 BN C9434 SWITCH
71-7 140-4
8

utility package
CLN17 BN C2237
AUXILIARY
Not used C9436 SWITCH 1
20 CLN17 BN
71-7 140-6
8

AUXILIARY
CLN17 BN C9437 SWITCH 2
71-7 140-7
8
F16, F17, F18, F19 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at 11-5 151-14
all times 151-18 151-30
151-34 multi-function
13-44
display
BZ
FRONT CONTROL/
F19 C2280D SBP19 BU-RD S229 SBP19 BU-RD C2123 DISPLAY INTERFACE
MODULE (FCDIM)
5A 44 1 130-3

MESSAGE
SBP19 BU-RD C253 CENTER
SWITCH
1 60-6

BRAKE PEDAL
F18 C2280B SBP18 YE-RD C278 POSITION (BPP)
SWITCH
10A 3 1 23-12 31-1
90-6

HEADLAMP
C2280D SBP18 YE-RD C205 SWITCH
71-1 85-1
69 1 86-1 89-1
92-1

STEERING COLUMN
SBP18 YE-RD C2414 CONTROL
MODULE (SCCM)
1 31-4 81-1
85-2 90-1
136-1

INSTRUMENT
F17 SBP17 RD C220 PANEL
CLUSTER (IPC)
7.5A 70 3 60-1

BLOWER MOTOR SWITCH

SBP17 RD C271B 54-5

multi-function
display
AUDIO
F16 C265 - 7 C240A FRONT
SBP16 VT-RD SBP16 VT-RD
CONTROL
20A 64 1 MODULE (ACM)
130-1 130-4
F2 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at 11-5 151-30
all times 151-34
13-10 13-11
BF
F2

15A DRIVER
CY UNLOCK
RELAY
(Non-serviceable)
13-50
DRIVER
C2280B CPL51 BU-GN C339 - A17 CPL51 BK C525 DOOR
LATCH
39 8 117-2 117-4
1
right hand drive

PASSENGER
UNLOCK
RELAY
(Non-serviceable)

PASSENGER
CPL66 BU-BN C340 - A17 CPL66 BK C609 DOOR
LATCH
45 1 117-5
8
right hand drive

13-49
GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137 BK-WH

GD137
31

G303
10-14
BODY
Hot at
CONTROL
MODULE (BCM)
2.2L
all times 11-5 151-30
13-48 151-34
CD DRIVER
LOCK
RELAY
(Non-serviceable)

C2280B REMOTE
CPL02 VT-GN
117-4 KEYLESS ENTRY
AND ALARM
18 27

DRIVER
DEADLOCK
RELAY
(Non-serviceable)

CPL06 GY-YE REMOTE

117-4 KEYLESS ENTRY
40 42 AND ALARM

LIFTGATE
UNLOCK
RELAY LIFTGATE
(Non-serviceable) LATCH
117-11

C300 - 36 C934 - 6 C405 - 6 C4339

C2280B CPL79 BN-VT CPL79 BK
41 1

GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137
GD137 BK-WH
31
G303
10-14
F1 2.2L
BODY
CONTROL
MODULE (BCM)
Hot at 11-5 151-30
all times 151-34
13-48
CY
F1

15A LEFT REAR

UNLOCK
RELAY
(Non-serviceable)
right hand drive

C2280B CPL53 WH-OG CPL54 GY-BU REMOTE

117-7 KEYLESS ENTRY
117-8 AND ALARM
19

RIGHT REAR
UNLOCK
RELAY
(Non-serviceable)
right hand drive

CPL54 GY-BU CPL53 WH-OG REMOTE

117-7 KEYLESS ENTRY
38 117-8 AND ALARM

13-51
GD137 BK-WH
23

GD137 BK-WH S256

BK-WH
GD137 BK-WH

GD137
31

G303
10-14
BODY
Hot at
CONTROL
MODULE (BCM)
2.2L
all times 11-5 151-30
13-50 151-34
CE REAR DOOR
UNLOCK
RELAY
(Non-serviceable)

REMOTE
C2280B CPL17 YE-VT KEYLESS ENTRY
117-9
117-10 AND ALARM
44

PASSENGER
LOCK
RELAY
(Non-serviceable)

CPL65 BN-GN REMOTE

117-5 KEYLESS ENTRY
AND ALARM
27 18

right hand drive

PASSENGER
DEADLOCK
RELAY
(Non-serviceable)

REMOTE
CPL07 VT-GY KEYLESS ENTRY
117-5
AND ALARM
42 40

right hand drive

GD137 BK-WH
23

GD137 BK-WH S256

24
BK-WH
GD137

GD137 BK-WH
31
G303
10-14
BODY
CONTROL
F4, F5, F20, F21 2.2L
MODULE (BCM)
11-5 151-14
151-18 151-30
151-34

POWER
C2280B CB122 GN-OG DISTRIBUTION
BL 13-16
36
Hot in Start
or Run

rear parking aid

C210 - 69 C311 - 23 PARKING

F4 C2280D CBP04 VT CBP04 VT CBP04 VT C9071A ASSIST
CONTROL
5A 66 1 MODULE (PAM)
131-1

rain sensor

lane departure warning

AUTOLAMP
F5 C311 - 41 C913 - 12 C919 - 6 AND
C2280B CBP05 YE CBP05 YE CBP05 YE C914
RAIN SENSOR
5A 25 1 81-4 85-7

POWER
C2280D CDC32 BN-YE DISTRIBUTION
BG 13-10 13-11
76
Hot in Start
or Run
PASSIVE
F20 CBP20 YE-VT C252 ANTI-THEFT
SYSTEM (PATS)
5A 43 1 TRANSCEIVER
112-1

POWER
CDC33 VT-GN DISTRIBUTION
BH 13-10 13-11 without:
75 Hot in Run multi-function
or Acc display

AUDIO
F21 CBP21 BU-GY C240A FRONT
CONTROL
3A 42 4 MODULE (ACM)
130-1
BODY
CONTROL
MODULE (BCM)
2.2L
late production
11-5 151-14
151-18 151-30
151-34 RME24 BU-WH
RADIO ANTI- C2280D CME03 YE-GY AUDIO SYSTEM/
THEFT SWITCH NAVIGATION
12 130-12

VRT23 VT-GY
PATS RX PASSIVE
1
ANTI-THEFT
VRT24 YE-OG SYSTEM
PATS TX 112-1
2

power mirrors

POWER FOLD C2280C CPM22 GY-BN POWER

MIRROR SWITCH MIRRORS
39 124-2 124-4

heated windshield

SWITCH LOW WASHER CMC20 VT INSTRUMENT

FLUID LEVEL CLUSTER
10 60-3

FRONT WIPER LIMP C2280D CRW36 GN-OG WIPERS

HOME SWITCH AND WASHERS
34 81-1

rear window wipers

C2280C CRW02 GY-BU WIPERS

CFEAC AND WASHERS
27 81-5

AJAR LEFT SIDE CPL36 GN CPL39 YE

DOOR SWITCH
35

AJAR RIGHT SIDE CPL39 YE CPL36 GN

DOOR SWITCH REMOTE
51 KEYLESS ENTRY
AND ALARM
AJAR LEFT FRONT CPL26 GN-VT CPL31 WH 117-2
DOOR SWITCH 117-3
44 117-6
117-9
AJAR RIGHT FRONT CPL31 WH CPL26 GN-VT 117-10
DOOR SWITCH 117-11
34
right hand drive
AJAR CPL81 BN-VT
SWITCH
50
BODY
CONTROL 2.2L
MODULE (BCM)
11-5 151-30
151-34

C2280C CPL30 BU-BN

CABIN UNLOCK
SWITCH 22

CABIN SET CPL29 YE-GY

SWITCH
20

CABIN RESET CPL28 VT-BN REMOTE

SWITCH KEYLESS ENTRY
36 AND ALARM
117-1
117-2

INT CENTRAL LOCK CPL42 GY-YE

UNLOCK SWITCH
25

CPL43 VT-GY
CABIN LOCK
SWITCH 56
BODY
CONTROL
MODULE (BCM)
2.2L
11-5 151-14
151-18 151-30
151-34

C2280D VDB04 WH-BU

HS CAN + MODULE
52 COMMUNICATIONS
NETWORK
VDB05 WH 14-3
HS CAN -
51

VDB07 VT-OG
MS CAN - MODULE
54
COMMUNICATIONS
NETWORK
VDB06 GY-OG 14-7
MS CAN +
53

REMOTE
C2280C VPL56 BU-GY KEYLESS ENTRY
LIN 0 RFR AND ALARM
1 117-12

VRW26 BN-YE WIPERS

LIN 8 RSM AND WASHERS
2 81-3

C2280D VDN05 YE-GY VEHICLE EMERGENCY MESSAGING SYSTEM

LIN 1 SWM 136-1
35

VLF25 GN-VT HEADLAMPS/ AUTOLAMPS

LIN 1 LSM
36 85-1

HORN RELAY C2280C CRH04 VT-GN

CTRL
43
HORN/CIGAR LIGHTER
HORN C2280D CRH02 BU-WH 44-1
SWITCH
17

DEMAND LIGHT C2280C RLN29 WH-OG INTERIOR

LAMPS
REAR SWITCH 72 89-2 89-9
BODY
CONTROL
MODULE (BCM)
2.2L
11-5 151-14
151-18 151-30
151-34

HAZARD C2280D CLS32 BN-YE

SWITCH
13

STOP LIGHT C2280C CCB08 VT-WH

TURN SIGNAL/ STOP/
SWITCH 58 HAZARD LAMPS
90-2 90-6
CLS17 YE-GY 90-8 90-9
90-10 90-11

CLS17 YE-GY
CHMSL
55

anti-theft alarm system

REMOTE
AJAR HOOD CRT17 WH-BN KEYLESS ENTRY
SWITCH AND ALARM
40 117-13

heated windshield
WINDSHIELD HEATER C2280D CRD03 BU-GN
INDICATION LED
41
WINDSHIELD HEATER CRD08 GN-OG HEATED WINDOW
SWITCH 37 56-1
56-2
C2280C CRD01 VT-OG
WINDSHIELD
HEATER CTRL 64

heated rear window

REAR WINDOW DEFROSTER C2280D CRD04 BN-GN

INDICATION LED
9 HEATED WINDOW
REAR WINDOW CRD09 BU-GY 56-3
DEFROST SWITCH
40

Camper Conversions

CE607 BN-YE C213

Not used
2

Emergency Services
C2280C CE607 BN-YE S292
ENGINE RUN STATUS CUSTOMER ACCESS
11 140-5 140-7

CE436 VT-OG
PCM WAKE ELECTRONIC ENGINE CONTROLS
70 23-2
BODY
CONTROL
MODULE (BCM)
2.2L
11-5 151-14
151-18 151-30
151-34

C2280C CR113 BN-YE

ENS SUPPLEMENTAL RESTRAINT SYSTEM
31 46-1

CE608 VT-GN
FUEL PUMP
RELAY CTRL 12 ELECTRONIC ENGINE CONTROLS
23-6
CR167 YE-VT
FUEL
PUMP ON 71

VMC11 YE-VT
FUEL PUMP
LEVEL SENSOR 29 INSTRUMENT CLUSTER
60-3
FUEL RMC32 GN-BU
LEVEL GND 46

C2280D CYT10 GN-BU

START/STOP SWITCH
STATUS LED 16 AUTO-START-STOP SYSTEM
40-1
CYT30 GY-VT
START/STOP
ENABLE SWITCH 38

FAN RELAY C2280C CH123 VT-GN MANUAL CLIMATE CONTROL SYSTEM

CTRL 54-1
9

electric booster heater

PTC HEATER C2280D CHP03 GN-BN

SWITCH 10 MANUAL CLIMATE CONTROL SYSTEM
54-8
PTC HEATER CHP01 BU-GN
CTRL 15

CH422 VT
AC ON
SWITCH 39
VH406 VT-BN
EVAPORATOR SENSOR MANUAL CLIMATE CONTROL SYSTEM
3
54-5
54-7
RH119 YE-VT
EVAPORATOR SENSOR
GND 4

CLUTCH BOT C2280C CE903 BU-OG ELECTRONIC ENGINE CONTROLS

SWITCH 52 23-13
BODY
CONTROL
MODULE (BCM)
2.2L
11-5 151-14
151-18 151-30
151-34

REMOTE
C2280D CPL77 BU-GN KEYLESS ENTRY
EPB WARNING LAMP
SWITCH SUPPLY AND ALARM
50 117-6

C2280C CMC07 BU-GN

BRAKE PAD WEAR
OUT SWITCH 21

BRAKE FLUID CMC19 GY-VT INSTRUMENT CLUSTER

LEVEL SWITCH 60-4
23 60-5
CMC25 WH-VT
PARK BRAKE
SWITCH 54

trailer tow

TRAILER TOW CAT13 GN-OG TRAILER/CAMPER ADAPTER

DETECTION 95-1
19

C2280B CLN43 WH-BU

INT.LIGHT 2
DIMMING 1 INTERIOR
LAMPS
89-2 89-4
CLN03 YE-GY
INT.LIGHT 1 89-7 89-9
DIMMING 2 89-11 89-14

C2280C CPL45 BN REMOTE

LIFTGATE RELEASE KEYLESS ENTRY
SWITCH 53 AND ALARM
117-11
F1, F2, F3, F4, F5, F6, F7, F8, F12, F13, F14 2.2L
HIGH CURRENT
Hot at BATTERY
all times JUNCTION
BOX (BJB)
POWER
DISTRIBUTION 11-7 151-55
151-56 151-57
13-3 151-60
BA
Camper Conversions

F12 C215
C3670P SBF12 GN-RD
Not used
60A A
1

Emergency Services

SUPPLEMENTARY
FUSE BOX
11-10 151-57
151-60

F8 C2237
SBF12 GN-RD SBS08 VT-RD
Not used
7.5A 14

SBF12 GN-RD F7 SBS07 WH-RD

Not used
10A 13

SBF12 GN-RD S246 SBF12 GN-RD F6 SBS06 BN-RD

Not used
7.5A 12

SBF12 GN-RD F2 SBS02 YE-RD

F13 Not used
Not used 8
5A
60A
SBF12 GN-RD F1 SBS01 RD
Not used
10A 7

SBF13 GY-RD F5 SBS05 GY-RD

Not used
7.5A 11

F14 C3670S SBF13 GY-RD S247 SBF13 GY-RD F4 SBS04 GN-RD

Not used
60A 1 10
7.5A
CF

SBF13 GY-RD F3 SBS03 BU-RD

POWER
DISTRIBUTION Not used
13-60 10A 9
F1, F2, F3 EMERGENCY SERVICES 2.2L
SVO
Hot at AUXILIARY
all times FUSE
PANEL
POWER 11-9 151-58
DISTRIBUTION 151-59
13-59
CF if equipped
BEACON
F1 SBF01 RD C2239 - 9 SBF01 RD S9004 SBF01 RD C9434 SWITCH
140-4
3A 2

auxiliary heater

WATER
SBF01 RD C9435 HEATER
SWITCH
2 140-5

utility package

AUXILIARY
SBF01 RD C9436 SWITCH 1
140-6
2

AUXILIARY
SBF01 RD C9437 SWITCH 2
140-7
2

F2 C2238
SBF02 YE-RD
Not used
20A K

SVO
AUXILIARY
BEACON FUSE
F3 SBF03 BU-RD RELAY PANEL
3 140-4 11-9 151-58
20A 151-59

POWER
DISTRIBUTION
13-61
F4, F9, F10, F11, F12 EMERGENCY SERVICES 2.2L
SVO
AUXILIARY
FUSE
PANEL
IGNITION 11-9 151-58
RELAY 151-59
POWER
DISTRIBUTION
CB121 BU-GY C3665 C2238 C2238 GD285 BK-WH S3012 GD285 BK-WH S3011 GD285 BK-WH
13-15 BK
4 M N 1 2 G310
Hot in Start 10-24
or Run
C2239 CAP19 GY-VT
Not used
8

SVO
AUXILIARY
FUSE
Hot at PANEL
all times 11-9 151-58
151-59 151-61
POWER 151-62 151-63
DISTRIBUTION
13-60
CG
5
F4 SBF04 GN-RD 3

20A

CDC21
BU
SUPPLEMENTARY
FUSE BOX
F10 C2238 11-10 151-57
CRB10 YE-OG 151-60
Not used
A

CH CRB11 BN F12 CBS12 GN-WH C2237

Not used
POWER 5A 18
DISTRIBUTION
13-62
F11 CRB11 BN S245 CRB11 BN F11 CBS11 BN
Not used
15A J 10A 17

CRB11 BN F10 CBS10 YE-OG

Not used
5A 16

F12 CRB11 BN F9 CBS09 VT-GY

Not used
5A 15
F5, F6, F7, F8, F9 EMERGENCY SERVICES
2.2L
SVO
AUXILIARY SVO
Hot at AUXILIARY
all times FUSE auxiliary heater
PANEL FUSE
POWER PANEL
DISTRIBUTION 11-9 151-58
151-59 WATER 11-9 151-58
13-61 HEATER 151-59
3 RELAY
CH
140-5
F5 SBF05 GY-RD

15A utility package

AUXILIARY
RELAY 2
3 140-7

WORK LAMP
F6 SBF06 BN-RD RELAY
3 140-10
15A

utility package

AUXILIARY
RELAY 1
3 140-6

F7 SBF07 WH-RD S3013 SBF07 WH-RD

15A roof mounted turn signals

TURN
SIGNAL
3 RELAY LH
140-8

TURN
SBF07 WH-RD SIGNAL
3 RELAY RH
140-9

F8 INTERIOR
SBF08 VT-RD LAMP RELAY
3 140-11
10A

2 WAY
F9 SBF09 RD C3438 RADIO
140-2
20A 1
A POWER DISTRIBUTION
13-64
2.0L

SDC02

BODY
RD
CONTROL
MODULE (BCM)
BMS 11-17 151-93
1 C03365A LIN 151-97

4 C02280F

(+) BATTERY
151-91 151-92

VDN03
GY-VT
(-) dual battery

INLINE
FUSE 1 POWER DISTRIBUTION
151-91 151-92 B
13-64
3A

SDC04
RD
SDL01

1 C03364A
RD

2 1 C03666A

BATTERY (+) AUXILIARY

MONITORING BATTERY
SENSOR 151-91 151-92
151-91 151-92 (-)

1 C03666B 1 C03666C 1 C03364B

GD108 BK-VT
GD175
BK

right hand drive

GD375
BK

G0309
10-55
F1, F2, F3, F71 HIGH CURRENT
BATTERY 2.0L
JUNCTION
BOX (BJB)
dual battery 11-19 151-93
151-97
POWER Hot at
DISTRIBUTION all times
F1 POWER
SDC04 RD C03670A C03670C SBF01 RD DISTRIBUTION
13-63 B C 13-67
1 470A 1
Hot at
all times

BODY
CONTROL
MODULE (BCM)
11-17 151-93
151-97

F2 C03670D SBF02 YE C02280H

100A 1 1

13-72

POWER AUXILIARY
DISTRIBUTION JUNCTION
BOX (AJB)
SDC02 RD C03670B 11-11 151-93
13-63 A 151-97
1
Hot at
all times F3 F71
C03670E SBF03 BU SB171 VT-RD

40A 1 40A

1 C03664

DIRECT CURRENT/
ALTERNATING CURRENT

VT-RD
SB108
(DC/AC) INVERTER
44-9
AA
C03501
13-65
1
F4, F5, F6, F7, F8, F36, F37 2.0L
HIGH CURRENT
BATTERY
Hot at JUNCTION
all times BOX (BJB)
13-64 11-19 151-93
151-97
AA

F4 POWER
C03670F SBF04 GN DISTRIBUTION
F
1 13-84
200A

F5 POWER
C03670G SBF05 GY DISTRIBUTION
G
1 13-86
100A
auxiliary heater

C0210 - 39 ELECTRIC
F6 C03670H SBF06 BN SBF06 BN-RD C02603A BOOSTER
HEATER
100A 1 1 54-18

heated windshield

F7 POWER
C03670J SBF07 WH DISTRIBUTION
J
1 13-88
80A

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
BODY
CONTROL
MODULE (BCM)
F8 C03670K SBF08 VT F36 SB136 GN-RD C02280G 11-17 151-93
GA 13-104 151-97
100A 1 50A 22

13-66
F37 SB137 GY-RD C02280G
HA 13-110
50A 21
F9, F10, F11, F15, F29, F32, F33 2.0L

HIGH CURRENT
BATTERY
Hot at JUNCTION
all times BOX (BJB)
11-19 151-93
13-65 151-97
AB

F9 POWER
C03670L SBF09 RD DISTRIBUTION
L
1 13-80
100A

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93 POWER
151-97 MF DISTRIBUTION
13-73

F10 C03670M F32 POWER

SBF10 BK SB132 VT-RD DISTRIBUTION
M
1 13-73
100A 60A S2025

F33 POWER
SB133 RD DISTRIBUTION
DM
13-71
60A

F11 POWER
C03670N SBF11 BU DISTRIBUTION
N
1 13-68
100A

auxiliary climate control

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
AUXILIARY
JUNCTION
AUXILIARY BOX (AJB)
F15 C03670T SBF15 WH F29 SB129 GY-RD BLOWER 11-11 151-93
3 MOTOR 151-97
60A 1 40A RELAY
52-4
F18, F19, F20, F21, F22, F23 C0102A
GENERATOR
12-5 20-4 2.0L
BATTERY 1

SBF01
JUNCTION

RD
BOX (BJB)
11-15 151-65 STARTER
POWER C0197A
DISTRIBUTION MOTOR
12-5 20-4
C01035C 1
SBF01 RD C01035B SBF01 RD
13-64 C
1 1
Hot at
all times twin fans BATTERY
JUNCTION
COOLING BOX (BJB)
F18 SBB18 YE-RD FAN
5 11-15 151-65
RELAY
40A 33-3

LOW SPEED
F19 SBB19 BU-RD S122 COOLING
3 FAN
40A RELAY
33-2 33-3
60A
single fan

BU-RD
single fan

SBB19
HIGH SPEED
COOLING
3 FAN
RELAY
33-2

REDUCTANT
F20 SBB20 GN-RD HEATER
3 RELAY
40A 24-9

GLOW PLUG
F21 SBB21 GY-RD C01273B MODULE
24-2
40A 2

F22 SBB22 BN-RD

40A 4

BATTERY
JUNCTION
AIR BOX (BJB)
F23 SBB23 WH-RD CONDITIONING 11-15 151-65
3 (A/C) CLUTCH
10A RELAY
54-19
F30, F32, F35, F36, F37 2.0L
BATTERY
JUNCTION
BOX (BJB)
11-15 151-65 fuel fired booster heater
POWER
DISTRIBUTION
AUXILIARY HEATER
F32 C0144 - 19 C04429 CONTROL
SBF11 BU C01035A SBB32 VT-RD SBB32 VT-RD
13-66 N MODULE (AHCM)
1 20A 1 54-13
Hot at
all times
F30

60A

POWERTRAIN
CONTROL
MODULE (PCM)
BN-RD
SBB30

POWER POWERTRAIN
RELAY CONTROL
24-1 MODULE (PCM)
POWER 24-1
DISTRIBUTION
SB117 RD CE302 YE-BU C0175B
13-86 BC
1 2 18
Hot at
all times

5
3

100

102

F35 CBB35 YE-GY

GY-VT
CE612

103
20A S103

F36 CBB36 BU-BN POWER

S112 KA DISTRIBUTION
20A 13-69

F37 CBB37 WH POWER

LA DISTRIBUTION
15A 13-69
GY-VT
CE612

POWER
EE DISTRIBUTION
13-70
F28, F29 2.0L

BATTERY
JUNCTION
BOX (BJB)
11-15 151-65

POWER
DISTRIBUTION C0134 POSITIVE CRANKCASE
S105 F28
CBB36 BU-BN CBB28 GY-VT CBB28 GN-RD C01833 VENTILATION (PCV)
13-68 KA VALVE HEATER ELEMENT
5 12 2 24-5
Hot in Start or Run

COOLANT
F29 CBB29 WH-VT CBB29 GY-RD C01812 WATER PUMP
24-5
15A 19 2

POWER
DISTRIBUTION C0144 - 18 REDUCTANT
CBB37 WH S106 CBB37 WH C04470 TANK
13-68 LA 24-7
18
Hot in Start or Run

C0134 - 17 S151 C01631 UNIVERSAL

CBB37 WH CBB37 WH CBB37 WH HEATED OXYGEN
SENSOR (HO2S) #11
1 24-6

EXHAUST GAS
CBB37 WH C01793 RECIRCULATION (EGR)
COOLER BYPASS
1 VALVE SOLENOID
24-6
F38, F39 2.0L
BATTERY
JUNCTION
BOX (BJB)
11-15 151-65

CE612 GY-VT POWER

DISTRIBUTION
EE 13-68
Hot in Start or Run
BATTERY
JUNCTION
BOX (BJB)
HIGH SPEED 11-15 151-65
F38 CBB38 GY-BU S110 CBB38 GY-BU COOLING
1 FAN
10A RELAY
33-2 33-3
twin fans

COOLING
CBB38 GY-BU FAN
1 RELAY
33-3

AIR
CBB38 GY-BU CONDITIONING
1 (A/C) CLUTCH
RELAY
54-19

LOW SPEED
CBB38 GY-BU COOLING
1 FAN
GY-BU

RELAY
CBB38

33-2 33-3

C0134 - 16 AIR CONDITIONING (A/C)

CBB38 GY-BU S153 CBB38 GY-BU C01110 COMPRESSOR
CONTROL SOLENOID
1 54-19

ELECTRIC HEATED
CBB38 GY-BU C01162 THERMOSTAT
24-2
1

GLOW PLUG
F39 CBB39 VT-WH S109 CBB39 VT-WH C01273C MODULE
24-2
10A 8

C0144 - 15 NOx
CBB39 VT-WH CBB39 VT-WH C04373A SENSOR
MODULE
1 24-3
F65, F66 2.0L

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
FUEL PUMP POWERTRAIN
RELAY CONTROL
24-11 MODULE (PCM)
POWER 24-11
DISTRIBUTION
SB117 RD CE226 YE-VT C0139 - 32 C0134 - 9 CE226 YE-VT C0175E
13-86 DJ
1 2 32
Hot at
all times

POWER
DISTRIBUTION 5
SB133 RD 3
13-66 DM

Hot at
all times

CE608 VT-GN

FUEL PUMP
CONTROL
MODULE
24-12

F65 CB165 WH-OG C0145 - 18 C04000 - 1 CB165 WH-OG C0433

20A 1

FUEL FILTER
HEATER/
WATER-IN-FUEL
SENSOR
24-11
F66 CB166 BU-WH C0145 - 17 CB166 BU-WH C04350

40A 4
F18 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-77
151-81
Hot at
all times
BODY
13-64 CONTROL
MODULE (BCM)
DD 11-17 151-77
IGNITION
SWITCH 151-81 151-93
151-85 151-97
OFF

F18 C02280A SBP18 C0250 ACC

C0250 CDC32 BN-YE C02280B
5A 12 YE-RD 4 RUN/START
RUN 1 37

BF START

13-90
OFF
CDC33 VT-GN
RUN/ACC
ACC 6 50

RUN S221
CDC35 BU-WH CDC35 BU-WH C02280A
START
START 7 14

C02280G
KEY IN START

BU-WH
CDC35
1
5

INHIBIT
automatic transmission 51 C0210
16 C0139
3 Not used POWERTRAIN
CONTROL

BU-WH
SELECTOR LEVER

CDC35
ASSEMBLY MODULE (PCM)
37-1 20-5 24-23

C0175B
C02810 CDC41 WH-BN
PARK BRAKE START

BU-GY
CDC30
without: 6
10 multi-function
display

BODY AUDIO
CONTROL FRONT

BU-WH
CDC35
MODULE (BCM) CONTROL
11-17 151-77 MODULE (ACM)
151-81 20-5 130-13

C0240A
C02280B
KEY IN 5
38
F39, F40 2.0L

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
RUN/START
RELAY
POWER
DISTRIBUTION BODY
SB132 VT-RD CDC55 BN-VT C02280F CONTROL
13-66 MODULE (BCM)
MF
1 2 25 11-17 151-93
151-97
Hot at
all times

POWER
DISTRIBUTION 5
SB132 VT-RD 3
13-66 M

Hot at
all times
HEATED
CB139 VT-WH C03660C - 1 1 BU C0321 FRONT
SEAT SWITCH
1 119-2
CDC55
BN-VT

Hot in Start
or Run
HEATED
F39 CB139 VT-WH CB139 VT-WH C0341F - 1 1 BU C0320 FRONT
SEAT SWITCH
20A S253 1 119-2

GLOW PLUG
F40 CB140 YE-GN C0139 - 10 S102 CB140 YE-GN C01273C MODULE
24-4
5A 10

13-74 POWERTRAIN
CB140 YE-GN C0175B CONTROL
MODULE (PCM)
58 24-4
F41, F42, F43 2.0L

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
Hot in Start 151-97
or Run
13-73 fuel fired booster heater
JA
AUXILIARY
JUNCTION
BOX (AJB)
FUEL FIRED 11-11 151-93
F41 CB141 BU BOOSTER 151-97
1 HEATER RELAY
5A 54-12

HEADLAMP
F42 CB142 GN S254 CB142 GN C01021 ASSEMBLY LH
85-12
5A 10

HEADLAMP
CB142 GN C01041 ASSEMBLY RH
85-12
CB142

10
GN

HEADLAMP
C0210 - 18 CB142 GN C0205 SWITCH
71-8 85-8
9 86-4 89-16
92-7

TRANSMISSION
F43 CB143 GY C0139 - 9 CB143 GY S104 CB143 GY C01822 CONTROL
MODULE (TCM)
5A 33 29-1
CB143

JB
GY

13-75 TRANSMISSION
C0134 - 1 CB143 GY C01792 AUXILIARY
OIL PUMP
2 29-4
F44, F45 2.0L
AUXILIARY
JUNCTION
Hot in Start BOX (AJB)
or Run 11-11 151-93
151-97 stop and start
13-74 LOW VOLTAGE
DIRECT CURRENT/
JB DIRECT CURRENT
(DC/DC) CONVERTER
31-14 40-3
40-6 52-6
145-6 146-4
POWER
F44 CB144 VT CB144 VT C02513 C02513 CDC78 VT-BN DISTRIBUTION
BJ 13-76
10A 7 5

without stop and start

POWER
CB144 VT C02513 BK C02513 CDC78 VT-BN DISTRIBUTION
BJ 13-76
7 5
CB144
VT

VEHICLE
C0145 - 29 CB144 VT C0408 - 12 CB144 VT C04396 DYNAMICS
MODULE (VDM)
16 41-1

ADAPTIVE
F45 CB145 YE C0210 - 21 CB145 YE C02800 FRONT
LIGHTING
20A 24 MODULE
85-13

13-77
2.0L

POWER
DISTRIBUTION PROXIMITY WARNING
CDC78 VT-BN S263 CDC78 VT-BN C0192 - 1 C01582
CDC78 BK RADAR UNIT
13-75 BJ 31-13 31-14
10 40-6 146-3
Hot in Start 146-4
or Run

CDC78 VT-BN C0311 - 28

Not used

CDC78
VT-BN

AUXILIARY
C0300 - 59 CDC78 VT-BN C09028 - 17 CDC78 VT-BN C0937 BLOWER
CDC78
VT-BN

MOTOR
10 SWITCH
40-6 52-5
52-6

liftgate
28 C0300
REAR
CDC78 BK C0406 - 8 CDC78 BK C0494 - 5 SMP22 YE-VT C04357 PARKING AID
CAMERA
1 40-6 145-5
145-6
CDC78
VT-BN

rear doors

REAR
C0935 - 8 CDC78 BK C0422 - 8 CDC78 BK C0495 - 5 SMP22 YE-VT C04357 PARKING AID
CAMERA
1 40-6 145-5
145-6
F46, F47, F48 2.0L
AUXILIARY
JUNCTION
Hot in Start BOX (AJB)
or Run 11-11 151-93
151-97
13-75

POWER
F46 CB146 WH-BU DISTRIBUTION
BJ 13-78
5A

POWER
DISTRIBUTION
BZ 13-78

Hot in Start
or Run

AUXILIARY
JUNCTION
AUXILIARY BOX (AJB)
CB146 WH-BU BLOWER 11-11 151-93
1 MOTOR 151-97
RELAY
52-4

HEATED
CB146 WH-BU WINDSHIELD
1 ELEMENT
LH
RELAY
56-8

HEATED
CB146 WH-BU WINDSHIELD
1 ELEMENT
RH
RELAY
56-8

ANTI-LOCK
F47 CB147 GN-BU C01010 - 5 CB147 GN-BU C0135 BRAKE SYSTEM
(ABS) MODULE
5A 28 42-4

F48 C03665 - 6
CB148 GY-YE
Not used
10A
F24 AUXILIARY 2.0L
JUNCTION
BOX (AJB)
HEATED 11-11 151-93 HEATING,
REAR 151-97 VENTILATION AND
WINDOW AIR CONDITIONING (HVAC)
RELAY CONTROL MODULE
56-10 56-11 54-16 56-10
56-11
POWER
DISTRIBUTION
CB146 WH-BU CRD02 BN-BU C0210 - 60 CRD02 BN-BU C02357A
13-77 BJ
1 2 16
Hot in Start
or Run
POWER
DISTRIBUTION
13-77 BZ

POWER
DISTRIBUTION 5
SB104 GN-RD 3
13-80 BM

Hot at
all times

CRD06 BN-YE

EXTERIOR
MIRROR
right hand drive LH
56-12 124-6
C0340 - A1 124-8
right hand drive

F24 CB124 VT-GN C0339 - A1 CB124 BK C0517 C0521

CRD06 BN-YE
S285
10A 1 1

EXTERIOR
MIRROR
right hand drive RH
56-12 124-6
C0339 - A1 124-8
right hand drive

CB124 VT-GN C0340 - A1 CB124 BK C0622 C0626

1 1
rear heated window

CRD06 BN-YE POWER

MM DISTRIBUTION
13-79
F31 2.0L
REAR HEATED WINDOW

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97

POWER
DISTRIBUTION
CRD06 BN-YE
MM 13-78

F31

30A
BU-OG
CB131

S252
BU-OG

BU-OG
CB131

CB131

liftgate

HEATED REAR
CB131 BK C0406 - 9 CB131 BK C0402A WINDOW
ELEMENT
1 56-10
30 C0311 30 C0300
BU-OG

BU-OG
CB131

CB131

rear doors

HEATED REAR
C0935 - 9 CB131 BK C0422 - 9 CB123 BK C04425A WINDOW
ELEMENT LH
1 56-11

HEATED REAR
C0991 - 9 CB131 BK C0411 - 9 CB131 BK C04426A WINDOW
ELEMENT RH
1 56-11
AUXILIARY
JUNCTION
F1, F2, F4, F5, F6, F7, F72 2.0L
BOX (AJB)
11-11 151-93
151-97

POWER
C0283A SBF09 RD DISTRIBUTION
L 13-66
1
Hot at all times

POWER
DISTRIBUTION
F1 SB101 RD
CB 13-82
60A
AUXILIARY
JUNCTION
BOX (AJB)
BLOWER 11-11 151-93
F2 SB102 YE-RD MOTOR
3 151-97
RELAY
40A 54-10

POWER
DISTRIBUTION
F4 SB104 GN-RD
BM 13-78
40A

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93 TRAILER
151-97 SOCKET
95-4

F72 SB172 VT-RD C0145 - 21 SB172 VT-RD C0438 - 9 SB143 BU-RD C0439

30A 9
GY-RD
SB105

TRAILER
F5 SB105 GY-RD SB105 GY-RD C03548B MODULE
95-3
40A S291 1

POWER
F6 SB106 BN-RD DISTRIBUTION
NB 13-89
40A
POWER
F7 SB107 WH-RD DISTRIBUTION
NC 13-89
40A
JD

13-81
F8, F9, F10, F69 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
Hot at all times 11-11 151-93
151-97
13-80
JD
AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
HORN 151-97
F8 SB108 VT-RD RELAY
3 44-6
20A

REAR WASHER
F9 SB109 RD RELAY
5 81-18
15A

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97 TACHOGRAPH
60-16

F10 S292 F69 SB169 GY-RD C0300 - 41 C09027 - 9 SB169 GY-RD C09068A
SB110 YE-RD

10A 7.5A 1

POWER
SB110 YE-RD DISTRIBUTION
NE 13-89

POWER
SB110 YE-RD DISTRIBUTION
CA 13-82

AUXILIARY
JUNCTION
HORN BOX (AJB)
SB110 YE-RD RELAY 11-11 151-93
1 44-6 151-97

BLOWER
SB110 YE-RD MOTOR
1 RELAY
54-10
AUXILIARY
F49 JUNCTION 2.0L
BOX (AJB)
FRONT WIPER 11-11 151-93
RELAY 151-97
81-11
POWER
DISTRIBUTION BODY
SB110 YE-RD CDC64 WH-BU C02280F CONTROL
13-81 CA MODULE (BCM)
1 2 24 11-17 151-93
Hot at 151-97
all times

POWER
DISTRIBUTION 5 CRW03 VT-WH
SB101 RD 3
13-80 CB

Hot at
all times

F49

20A

13-83

liftgate

REAR WINDOW
C0405 - 1 C04218 WIPER
VT-GY

CB149 BK CB149 BK
CB149

MOTOR
1 81-15

rear doors

REAR
S257 C0300 - 24 CB149 VT-GY C0934 - 1 CB149 BK C0421 - 1 CB149 BK C0476 WINDOW
WIPER
3 MOTOR LH
81-16
VT-GY
CB149

REAR
C0311 - 24 CB149 VT-GY C0983 - 1 CB149 BK C0410 - 1 CB149 BK C04171 WINDOW
WIPER
3 MOTOR RH
81-17
F50, F51, F52 2.0L
AUXILIARY
JUNCTION
13-82 BOX (AJB)
11-11 151-93
JE 151-97
AUXILIARY
JUNCTION
BOX (AJB)
REAR WASHER 11-11 151-93
F50 CB150 YE-OG RELAY 151-97
1 81-18
5A

rain sensor

AUTOLAMP
CB150 YE-OG C0311 - 41 C0913 - 12 CB150 YE-OG C0914 AND
RAIN SENSOR
1 81-13 85-14

left hand drive

WINDSHIELD
F51 CB151 BN C01655 WIPER
MOTOR
25A 8 81-12

right hand drive

AUXILIARY
CB151 BN C01656 WINDSHIELD
WIPER
1 MOTOR
81-12

WINDSHIELD
F52 CB152 GN-WH C01655 WIPER
MOTOR
25A 8 81-12

left hand drive

AUXILIARY
CB152 GN-WH C01656 WINDSHIELD
WIPER
1 MOTOR
81-12
AUXILIARY
JUNCTION
F53, F54, F55, F57 2.0L
BOX (AJB)
11-11 151-93
151-97

POWER
C0283C SBF04 GN DISTRIBUTION
F 13-65
1
Hot at all times

BATTERY
JUNCTION
REAR AIR BOX (BJB)
F53 SB153 GY-RD C0145 - 19 SB153 GY-RD C0144 - 21 SB153 GY-RD 11-15 151-65
SUSPENSION
5 RELAY
40A 41-2

C0145 - 24 C0408 - 13 VEHICLE

F54 SB154 GY-RD SB154 BN-RD SB154 BN-RD C04396 DYNAMICS
MODULE (VDM)
15A 18 41-1

C01010 - 6 ANTI-LOCK
F55 SB155 WH-RD SB155 WH-RD C0135 BRAKE SYSTEM
(ABS) MODULE
40A 1 42-4

FRONT SEAT
F57 SB157 RD C0341E - 1 8 RD C0369 CONTROL
SWITCH
30A 5 120-3 120-4

13-85
AUXILIARY
JUNCTION
F1, F59, F60 2.0L
BOX (AJB)
11-11 151-93
151-97
Hot at all times
BATTERY
13-84 JUNCTION
BOX (BJB)
HH STARTER 11-15 151-65
RELAY
20-4 STARTER
MOTOR
20-4
F59 SB159 BU-RD C0139 - 12 C0134 - 14 C01019 - 1
CDC26 GY-OG CDC26 GY-OG C0197B
30A 3
5 1

POWERTRAIN
1 2 S127 C0175B CONTROL
CDC12 YE
MODULE (PCM)
36 20-4 24-23

CDC25 BN-GN S130

without:
multi-function
display

BATTERY AUDIO
JUNCTION FRONT
BOX (BJB) CONTROL
BN-GN
CDC25

11-15 151-65 MODULE (ACM)

20-5 130-13
F1 CME05 GN-BU C0139 - 44 C0268 - 20 CME05 GN-BU C0240A

5A 3

TRAILER
F60 SB160 GN-RD C03548B MODULE
95-3
15A 2
AUXILIARY
JUNCTION
F15, F16, F17, F18 2.0L
BOX (AJB)
11-11 151-93
151-97

POWER
C0283B SBF05 GY DISTRIBUTION
G 13-65
1
Hot at all times

stop and start

BODY
LOW VOLTAGE CONTROL
DIRECT CURRENT/ MODULE (BCM)
DIRECT CURRENT 11-17 151-93
(DC/DC) CONVERTER 151-97
40-3 40-4

F15 SB115 WH-RD C02513 C02513 CDC77 GY-YE C02280G

FI 13-102
50A 8 3 17

without stop and start

SB115 WH-RD C02513 BK C02513 CDC77 GY-YE

8 3

C01010 - 1 ANTI-LOCK
F16 SB116 VT-RD SB116 VT-RD C0135 BRAKE SYSTEM
(ABS) MODULE
25A 25 42-4

POWER
DISTRIBUTION
F17 SB117 RD
DJ 13-71
5A
POWER
C0139 - 31 DISTRIBUTION
SB117 RD SB117 RD
BC 13-68

BRAKE PEDAL
F18 SB118 YE-RD C0278 POSITION
(BPP) SWITCH
10A 1 24-20 31-7
JF 90-17

13-87
AUXILIARY
JUNCTION
F19, F20, F21, F22 2.0L
BOX (AJB)
11-11 151-93
151-97
Hot at all times
13-86
JF

AUXILIARY
JUNCTION
EXTERNAL BOX (AJB)
F19 SB119 BU-RD LOCKING 11-11 151-93
5 RELAY 151-97
15A 117-30

FUEL FIRED
F20 SB120 GN-RD C02806 BOOSTER HEATER
CONTROL MODULE
5A 2 54-13

TRANSMISSION
F21 C0139 S121 CONTROL
SB121 GY-RD SB121 GY-RD C01822
MODULE (TCM)
15A 1 29-1
8
SB121 GY-RD
31

C0134 - 18 TRANSMISSION
F22 SB122 BN-RD SB122 BN-RD C01792 AUXILIARY
OIL PUMP
25A 1 29-4
3
AUXILIARY
JUNCTION
F34, F35 2.0L
BOX (AJB)
11-11 151-93
151-97

heated windshield

POWER
SBF07 WH DISTRIBUTION
J 13-65
Hot at
all times

heated windshield

AUXILIARY
JUNCTION
HEATED BOX (AJB)
F34 SB134 YE-RD WINDSHIELD 11-11 151-93
3 ELEMENT 151-97
40A LH
RELAY
56-8

HEATED
F35 SB135 BU-RD WINDSHIELD
3 ELEMENT
40A RH
RELAY
56-8
F13, F14, F30 REAR PASSENGER
2.0L
F30 C0311 - 31 C0979
CDC80 VT-WH CB130 YE-BU CB130 YE-BU POWER
OUTLET
20A 2 SOCKET
AUXILIARY 44-8
JUNCTION
BOX (AJB)
11-11 151-93
AUXILIARY POWER 151-97
POINT
RELAY
44-7
POWER
DISTRIBUTION
SB106 BN-RD
13-80 NB
3
Hot at 5
all times

BN-WH

YE-GY
YE-RD

CDC72

CDC71
SB110

POWER POINT
RELAY
44-7
Hot at
all times
BODY
POWER 2 CDC72 BN-WH C02280F CONTROL
DISTRIBUTION MODULE (BCM)
SB110 YE-RD 4 33
11-17 151-93
13-81 NE 151-97
CDC71 YE-GY
1 23
POWER
DISTRIBUTION 5
SB107 WH-RD 3
13-80 NC
Hot at
all times
CDC17 GY-YE

C0210 AUXILIARY
F13 CB113 GY-BN CB113 GY-BN C02031 POWER
POINT
20A 35 2 44-8

FRONT POWER
F14 CB114 VT-OG CB114 VT-OG C02033 OUTLET
SOCKET
20A 27 2 44-8
F2 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-93
Hot at 151-97
all times
13-72
BF

AUXILIARY
JUNCTION
BOX (AJB)
FOLD 11-11 151-93
F2 C02280C SBP02 YE-RD S295 SBP02 YE-RD MIRROR 151-97
4 MODULE
7.5A 29 RELAY
124-7 124-9

YE-RD
SBP02
DRIVER DOOR
right hand drive WINDOW
CONTROL SWITCH
S615 right hand drive 100-3 100-5

C0339 - A6 SBP02 BK S508 SBP02 BK C0648A C0535A

8 8

EXTERIOR
MIRROR
CONTROL
SWITCH
124-6 124-8
right hand drive

SBP02 BK C0618 C0527

6 6

13-91
F8, F38 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-93
Hot at 151-97
all times
13-90
BG ANTI-THEFT
F8 C02280C CRT02 GY-VT S305 CRT02 GY-VT C03549 ALARM
HORN LH
34 1 117-34
10A

ANTI-THEFT
CRT02 GY-VT C03550 ALARM
HORN RH
1 117-34

ACCESSORY DRIVER DOOR

DELAYED WINDOW
RELAY CONTROL SWITCH
(Non-serviceable) 100-3 100-5
right hand drive

F38 S259 C0339 - A11 C0648A C0535A

CBP38 GY-BU CBP38 BK

30A 36 7 7

PASSENGER DOOR
WINDOW
GY-BU
CBP38

CONTROL SWITCH
100-4 100-6
right hand drive
FA C0340 - A11
CBP38 BK C0592 C0604
13-92 2 2
F11, F15, F17 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-77
Hot at 151-81 151-93 AUXILIARY
all times 151-97 BLOWER
MOTOR
13-91 SWITCH
52-5 52-6
FA

F11 C02280C S297 C0300 - 39 C09028 - 18 C0937

SBP11 BU-RD SBP11 BU-RD

5A 15 11

BU-RD
SBP11
INTRUSION
SENSOR
117-35

C0311 - 27 C0913 - 11 C09800

SBP11 BU-RD
1

ANTI-THEFT
F17 C02280A C0268 - 8 C0154 ALARM HORN
SBP17 RD SBP17 RD
WITH INTEGRAL
11 3 BATTERY
5A 117-35

POWERTRAIN
C02280F C0139 - 30 C0175B CONTROL
CE261 GY-OG CE261 GY-OG MODULE (PCM)
29 41 24-12

GATEWAY
F15 C02431 MODULE A
C02280A SBP15 WH-RD (GWM)
14-8
10A 19 13

13-93
F24 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-93
Hot at 151-97
all times
13-92
FB

F24

30A

CENTRAL LOCK
RELAY
(Non-serviceable)

C02280C POWER
CPL11 GY-BN DISTRIBUTION
FC
13-94 13-96
35

DOUBLE LOCK
RELAY
(Non-serviceable)

POWER
CPL12 VT-OG DISTRIBUTION
FD
13-95 13-97
32

FE
GD233 BK
13-98 10
G0303
10-47
F63, F64 2.0L
LEFT HAND DRIVE

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
POWER
CPL11 GY-BN DISTRIBUTION
FC 13-93

DRIVER
F63 CPL11 GY-BN S2020 CPL11 GY-BN C0339 - A16 CPL11 BK C0525 DOOR
LATCH
15A 7 117-23

SLIDING
CPL11 GY-BN C0706A DOOR
CONTACT
2 PLATE LH
117-28

REAR
DOOR
rear doors LATCH
117-31

F64 CPL11 GY-BN S275 CPL11 GY-BN C0311 - 37 CPL11 GY-BN C0983 - 5 CPL11 BK C0410 - 5 CPL11 BK C0486

15A 2

PASSENGER
CPL11 GY-BN C0340 - A16 CPL11 BK C0609 DOOR
LATCH
2 117-25

SLIDING
CPL11 GY-BN C0806A DOOR
CONTACT
2 PLATE RH
117-28
F61, F62 2.0L
LEFT HAND DRIVE

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
POWER
CPL12 VT-OG DISTRIBUTION
FD 13-93

DRIVER
F61 CPL12 VT-OG S2021 CPL12 VT-OG C0339 - B17 CPL12 BK C0525 DOOR
LATCH
15A 6 117-23

SLIDING
CPL12 VT-OG C0706A DOOR
CONTACT
3 PLATE LH
117-28

REAR
DOOR
rear doors LATCH
117-31

F62 CPL12 VT-OG S276 CPL12 VT-OG C0311 - 38 CPL12 VT-OG C0983 - 2 CPL12 BK C0410 - 2 CPL12 BK C0486

15A 3

PASSENGER
CPL12 VT-OG C0340 - B17 CPL12 BK C0609 DOOR
LATCH
3 117-25

SLIDING
CPL12 VT-OG C0806A DOOR
CONTACT
3 PLATE RH
117-28
F63, F64 2.0L
RIGHT HAND DRIVE

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
POWER
CPL11 GY-BN DISTRIBUTION
FC 13-93

PASSENGER
F63 CPL11 GY-BN S2020 CPL11 GY-BN C0340 - A16 CPL65 BK C0502 DOOR
LATCH
15A 7 117-26

SLIDING
CPL11 GY-BN C0706A DOOR
CONTACT
2 PLATE LH
117-29

REAR
DOOR
rear doors LATCH
117-31

F64 CPL11 GY-BN S275 CPL11 GY-BN C0311 - 37 CPL11 GY-BN C0983 - 5 CPL11 BK C0410 - 5 CPL11 BK C0486

15A 2

DRIVER
CPL11 GY-BN C0339 - A16 CPL11 BK C0603 DOOR
LATCH
2 117-24

SLIDING
CPL11 GY-BN C0806A DOOR
CONTACT
2 PLATE RH
117-29
F61, F62 2.0L
RIGHT HAND DRIVE

AUXILIARY
JUNCTION
BOX (AJB)
11-11 151-93
151-97
POWER
CPL12 VT-OG DISTRIBUTION
FD 13-93

PASSENGER
F61 CPL12 VT-OG S2021 CPL12 VT-OG C0340 - B17 CPL07 BK C0502 DOOR
LATCH
15A 6 117-26

SLIDING
CPL12 VT-OG C0706A DOOR
CONTACT
3 PLATE LH
117-29

REAR
DOOR
rear doors LATCH
117-31

F62 CPL12 VT-OG S276 CPL12 VT-OG C0311 - 38 CPL12 VT-OG C0983 - 2 CPL12 BK C0410 - 2 CPL12 BK C0486

15A 3

DRIVER
CPL12 VT-OG C0339 - B17 CPL12 BK C0603 DOOR
LATCH
3 117-24

SLIDING
CPL12 VT-OG C0806A DOOR
CONTACT
3 PLATE RH
117-29
F3, F25, F26 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-93
Hot at 151-97
all times
13-93

FE
F3

20A

AUXILIARY
JUNCTION
UNLOCK BOX (AJB)
DRIVER DRIVER
11-11 151-93 DOOR
RELAY 151-97
(Non-serviceable) LATCH
right hand drive 117-23 117-24

C02280C CPL51 BU-GN F25 CPL51 BU-GN C0339 - A17 CPL51 BK C0603 C0525

27 7.5A 1 8

UNLOCK
PASSENGER PASSENGER
RELAY DOOR
(Non-serviceable) LATCH
right hand drive 117-25 117-26

F26 CPL66 BU-BN C0340 - A17 CPL66 BK C0502 C0609

CPL66 BU-BN
5 7.5A 8 1

FF
GD233 BK
13-99
10
G0303
10-47
F16 2.0L
BODY
CONTROL
Hot at MODULE (BCM)
all times 11-17 151-93
151-97
13-98
FF
F16

15A

UNLOCK
DRIVER
SLIDING
RELAY left hand drive
(Non-serviceable)
SLIDING DOOR
C02280C C0706A CONTACT
CPL53 WH-OG PLATE LH
117-28
33 1

right hand drive

SLIDING DOOR
C0806A CONTACT
CPL53 WH-OG PLATE RH
117-29
1

UNLOCK
PASSENGER
SLIDING
RELAY left hand drive
(Non-serviceable)
SLIDING DOOR
C0806A CONTACT
CPL54 GY-BU PLATE RH
117-28
24 1

right hand drive

SLIDING DOOR
FG C0706A CONTACT
CPL53 WH-OG PLATE LH
13-100 117-29
1

GD233 BK
10
G0303
10-47
F20, F34 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-77
Hot at 151-81
all times
13-99
FG

F34

30A

RUN/START
RELAY
(Non-serviceable)

TACHOGRAPH
Hot in Start or Run 60-16

F20 C02280A CBP20 YE-VT C0210 - 23 C0300 - 23 C09027 - 1 CBP20 YE-VT C09068A

5A 5 3

13-101
F19, F21, F23, F35, F36 2.0L
BODY
CONTROL
MODULE (BCM)
Hot in Start or Run 11-17 151-77
151-81 151-93
13-100 151-97 multi-function
display
FH
MESSAGE
F19 C02280A CBP19 BN-WH C0264 - 12 CBP19 BN-WH C0253 CENTER
SWITCH
5A 7 2 46-12 60-15
auxiliary heater
ELECTRIC
F21 CBP21 BU-GY C02603C BOOSTER
HEATER
5A 6 1 54-18

without
multi-function
display
AUDIO
F23 CBP23 BN-YE C0240A FRONT
CONTROL
10A 2 4 MODULE (ACM)
130-13

DIRECT CURRENT/
C02280C CBP23 BN-YE C03664 - 2 CB120 YE-VT C03501 ALTERNATING CURRENT
(DC/AC) INVERTER
30 3 44-9

RESTRAINTS
F35 C02280A CBP35 YE-GY C0268 - 11 CBP35 YE-GY C0310A CONTROL
MODULE (RCM)
5A 4 19 46-8

STEERING COLUMN
F36 CBP36 BU-BN C02414 CONTROL
MODULE (SCCM)
15A 15 9 31-10 81-10
85-9 90-12
146-1

C09012 AUTO-DIMMING
C02280C CBP36 BU-BN C0311 - 23 S930 C0913 - 6 CBP36 BU-BN INTERIOR
MIRROR
8 1 124-10

rear parking aid

PARKING ASSIST
CBP36 BU-BN C09071A CONTROL
MODULE (PAM)
1 145-1
F12, F13 2.0L
BODY
CONTROL
MODULE (BCM)
Start/Stop Bus 11-17 151-77
151-81
13-86
FI
HEATING,
F12 C02280A SBP12 GN-RD S230 SBP12 GN-RD C02357A VENTILATION AND
AIR CONDITIONING (HVAC)
7.5A 10 32 CONTROL MODULE
40-4 54-14
multi-function
display

SBP12 GN-RD C0263 - 6

Not used

INSTRUMENT
F13 SBP13 GY-RD S244 SBP13 GY-RD C0220 PANEL
CLUSTER (IPC)
7.5A 8 3 40-4 60-9

STEERING COLUMN
FJ SBP13 GY-RD C02414 CONTROL
MODULE (SCCM)
1 31-10 40-4
13-103 81-10 85-9
90-12 146-1

GATEWAY
SBP13 GY-RD C02431 MODULE A
(GWM)
24 14-8 40-4
F32, F33 2.0L
BODY
CONTROL
MODULE (BCM)
11-17 151-77
Start/Stop Bus 151-81 151-93
151-97
13-102
FJ

RADIO
F32 C02280C SBP32 VT-RD C0311 - 39 C0900 - 7 SBP32 VT-RD C09026 FREQUENCY (RF)
RECEIVER
10A 22 6 40-5 117-33
118-2

multi-function
display

FRONT CONTROL/
C02280A SBP32 VT-RD C0264 - 6 S207 SBP32 VT-RD C02123A DISPLAY INTERFACE
MODULE (FCDIM)
9 1 40-5 130-18
145-7

SYNC
SBP32 VT-RD C02383 MODULE [APIM]
40-5 130-24
1

SYNC without navigation

GLOBAL POSITIONING
SBP32 VT-RD C02398 SYSTEM MODULE (GPSM)
40-5 130-24
1

MESSAGE
SBP32 VT-RD C0253 CENTER
SWITCH
1 40-5 60-15

multi-function
display
AUDIO
F33 SBP33 RD C0265 - 7 SBP33 RD C0240A FRONT
CONTROL
20A 22 1 MODULE (ACM)
40-5 130-13
130-19
BODY
Hot at
CONTROL 2.0L
MODULE (BCM)
all times
11-17 151-93
13-65 151-97
GA
FRONT
C02280G CLF29 BN C0110 - 5 CLF29 BN C0152 FOG LAMP LH
86-5
12 2

HEADLAMP
C02280F CLS21 BU-GN S271 CLS21 BU-GN C01021 ASSEMBLY LH
85-10 90-14
39 6
right hand drive

C0340 - B1 right hand drive

EXTERIOR
C0339 - B1 CLS21 BK C0517 C0521 MIRROR LH
85-10 90-14
8 8 124-6 124-8

HEADLAMP
C02280E CLS06 GN-OG C01021 ASSEMBLY LH
85-10 92-8
24 2

C02280G CLF04 BN-BU

4 8

CLF02 GY-BN

11 1

C02280F CLF61 GY-BU

40 3
daytime
running
lamps
GB

13-105
BODY
Hot at
CONTROL 2.0L
all times MODULE (BCM)
11-17 151-93
13-104 151-97
GB

C0311 - 17 REAR LAMP

CLS53 GY-VT CLS53 GY-VT C0415 ASSEMBLY RH
90-18 92-10
5

REAR LAMP
ASSEMBLY LH
90-16 90-18
C0300 C0412 92-9 93-3
C02280F CLS08 VT-GN CLS08 VT-GN

30 15 2

C02280C CLS53 GY-VT CLS53 GY-VT CLS51 WH-GN

12 S2017 17 3

CLS10 GN-BN S299 CLS10 GN-BN CLS10 GN-BN

11 13 5

C02280E CLS23 GY-OG CLS23 GY-OG

26 16 1

REAR LAMP
CLS10 GN-BN C0311 - 13 C0415 ASSEMBLY RH
CLS10 GN-BN
92-10 93-3
2

13-106
VAN 2.0L

Van - RHD (SWB without LED)

BODY Van - LOW ROOF (LWB, SWB with LED)
Hot at CONTROL
all times MODULE (BCM)
11-17 151-93 LUGGAGE
C09077 - 3 COMPARTMENT
13-105 151-97 CLN43 WH-BU C09079B
LAMP
GC 1 89-20 89-21

Van - RHD (SWB without LED)

WH-BU
CLN43
Van - LOW ROOF (LWB, SWB with LED)
Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
S269 C0300 - 5 C09076 - 5 COMPARTMENT
C02280C CLN43 WH-BU C09078B
LAMP
26 1 89-20 89-21
S916 89-22

Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
CLN43 WH-BU C09448B COMPARTMENT
LAMP
1 89-22

Van - LHD (SWB without LED)

Van - LOW ROOF (LWB, SWB with LED)

LUGGAGE
WH-BU
CLN43

C0936 - 3 CLN43 WH-BU C09057B COMPARTMENT

LAMP
1 89-19 89-21
WH-BU
CLN43

Van - LHD (SWB without LED)

Van - LOW ROOF (LWB, SWB with LED)
Van - HIGH ROOF (LWB, SWB with LED)

LUGGAGE
C0311 - 1 C0925 - 5 C09056B COMPARTMENT
CLN43 WH-BU
LAMP
1 89-19 89-21
S920 89-22

Van - HIGH ROOF (LWB, SWB with LED)

GD
LUGGAGE
CLN43 WH-BU C09447B COMPARTMENT
13-107 LAMP
1 89-22
DOUBLE CAB IN VAN 2.0L

BODY
Hot at CONTROL
all times MODULE (BCM)
11-17 151-93
13-106 151-97
GD LUGGAGE
C09077 - 3
CLN43 WH-BU C09079B COMPARTMENT
LAMP
1 89-23

WH-BU
CLN43
S269 C0300 - 5 C09076 - 5
C02280C CLN43 WH-BU
Not used
26 WH-BU S916
CLN43

C0311 - 1 S920 C0925 - 5

CLN43 WH-BU
Not used
WH-BU
CLN43

LUGGAGE
GE C0936 - 3 COMPARTMENT
CLN43 WH-BU C09057B
LAMP
13-108 1 89-23
BUS, KOMBI 2.0L

BODY
CONTROL
Hot at MODULE (BCM)
all times
11-17 151-93
13-107 151-97
GE
C09077 - 3
Not used

WH-BU
CLN43
THIRD ROW
S269 C0300 - 5 C09076 - 5 C0922 - 5 S925 INTERIOR LAMP
C02280C CLN43 WH-BU C09054B
89-27
26 2
S916

FOURTH ROW
CLN43 WH-BU C09055B INTERIOR LAMP
89-27
2

LUGGAGE
CLN43 WH-BU C09075A COMPARTMENT
LAMP
1 89-26
WH-BU
CLN43

13-109

C0311 - 1 S920 C0925 - 5

CLN43 WH-BU
Not used
WH-BU
CLN43

C0936 - 3
Not used
BODY
CONTROL 2.0L
Hot at MODULE (BCM)
all times
11-17 151-93
13-108 151-97
GF

liftgate

HIGH
CLS17 BK C0405 - 5 CLS17 BK C0475 MOUNTED
STOPLAMP
1 90-20

rear doors

high roof

C0300 - 18 C0934 - 5 HIGH

C02280E S270 C0421 - 5 C04001 - 1 CLS17 C04431 MOUNTED
CLS17
STOPLAMP LH
13 BK BK 1 90-19
or
YE-GY
YE-GY
CLS17

HIGH
C0311 - 18 CLS17 YE-GY C0991 - 10 CLS17 BK C0411 - 10 C04430 MOUNTED
STOPLAMP RH
1 90-19

multi-function
display

HAZARD
C02280E CPL77 BU-GN C0268 - 3 C0264 - 9 CPL77 BU-GN C02039 FLASHER
SWITCH
39 2 90-13 117-27
BODY
Hot at CONTROL 2.0L
all times MODULE (BCM)
11-17 151-93
13-65 151-97
HA
FRONT
C02280G CLF34 YE-OG C0110 - 6 CLF34 YE-OG C0162 FOG LAMP RH
86-5
5 2

HEADLAMP
C02280F CLS25 YE-VT S129 CLS25 YE-VT C01041 ASSEMBLY RH
85-11 90-15
38 6

right hand drive

C0339 - B1

YE-VT
right hand drive

CLS25
EXTERIOR
C0340 - B1 CLS25 BK C0622 C0626 MIRROR RH
85-11 90-15
8 8 124-6 124-8

HEADLAMP
ASSEMBLY RH
C02280E CLS07 BN-YE C01041 85-11 92-8
23 2

C02280G CLF05 BU-GN

2 8

CLF03 VT-OG

6 1

C02280F CLF62 VT-WH

36 3
daytime
running
lamps
HB

13-111
BODY
CONTROL 2.0L
Hot at MODULE (BCM)
all times 11-17 151-93
151-97
13-110
HB

POWERTRAIN
C02280F CE436 VT-OG C0139 - 23 CE436 VT-OG C0175B CONTROL
MODULE (PCM)
18 59 24-1

C02280G

3
YE-VT
CLS04

LICENSE
14 C0300 C0452 PLATE
LAMP LH
2 92-11 92-12
YE-VT
CLS04

rear doors rear doors

YE-VT
CLS04
C0421 - 2 C0495 - 1
2 C0934
C0405 - 2 C0494 - 1 LICENSE
CLS04 CLS04 CLS04 YE-VT C0462 PLATE
LAMP RH
HC BK BK 2 92-11 92-12
S425
13-112
BODY
Hot at
CONTROL 2.0L
MODULE (BCM)
all times
11-17 151-93
13-111 151-97
HC

REAR LAMP
ASSEMBLY RH
C02280E C0311 C0415 86-6 90-16
CLS27 GN-OG CLS27 GN-OG
90-18 92-10
52 16 6

C02280F CLS09 WH-OG CLS09 WH-OG

37 15 4

C02280C CLS37 WH-BU S272 CLS37 WH-BU CLS37 WH-BU

25 12 3

REAR LAMP
CLS37 WH-BU C0300 - 12 C0412 ASSEMBLY LH
CLS37 WH-BU
86-6 92-9
4

13-113
BODY HEATED
Hot at
CONTROL CLN17 BN C02025 WINDSHIELD 2.0L
all times MODULE (BCM) SWITCH
11-17 151-77 3 56-7 71-11
13-112 151-81
HD
PARKING
CLN17 BN C02035 AID
SWITCH
3 71-11 145-3

HEATED
CLN17 BN C0241 REAR
WINDOW
3 SWITCH
without: 56-9 71-11
multi-function
display

AUDIO
CLN17 BN C0240A FRONT
CONTROL
14 MODULE (ACM)
71-9 130-13

POWER
C02280B CLN17 BN S225 CLN17 BN DISTRIBUTION
HE
13-114
45
START
CLN17 BN C02195 CONTROL
UNIT
3 40-2 71-9

SELECTOR LEVER
CLN17 BN C02810 ASSEMBLY
37-1 71-9
7
POWER
CLN17 BN DISTRIBUTION BK
HF 13-114 or STEERING WHEEL
RD-WH C02998 SWITCH, LH UPPER
CLN17

60-10
1
BN

STEERING WHEEL
STEERING BK C02366 SWITCH, LH LOWER
COLUMN 31-11 31-12
CONTROL 1
MODULE (SCCM)
71-10
STEERING WHEEL
C02414 C0218B BK C02367 SWITCH, RH LOWER
130-28
12 7 S2011 1
BK
HG CLOCKSPRING or
71-10 RD-WH
or STEERING WHEEL
13-115 GY C02999 SWITCH, RH UPPER
130-17 130-27
2
2.0L
tachograph

TACHOGRAPH
C09027 - 2 CLN17 BN C09068A 60-16 71-13
2

auxiliary climate control

CLN17
BN
AUXILIARY
C0300 - 58 C09028 - 16 C0937 BLOWER
CLN17 BN CLN17 BN
MOTOR
S914 24 SWITCH
52-5 52-6
71-13

C0340 - A2 right hand drive

right hand drive
FRONT DOOR
C0339 - A2 C0541 C0505 LOCK
CLN17 BN CLN17 BK
SWITCH LH
4 4 71-12 117-15
117-16

C0339 - A2 right hand drive

right hand drive
POWER
DISTRIBUTION FRONT DOOR
C0268 - 15 C0340 - A2 LOCK
CLN17 BN CLN17 BN CLN17 BK C0632 C0605
13-113 HE SWITCH RH
S268 1 1 71-12 117-15
117-16

C03665 - 2
CLN17 BN
Not used

HEADLAMP
CLN17 BN C0205 SWITCH
71-8 85-8
15 86-4 89-16
92-7

multi-function
display
POWER
DISTRIBUTION HAZARD
C0263 - 12 FLASHER
CLN17 BN CLN17 BN CLN17 BN C02039
13-113 HF SWITCH
S224 3 71-9 90-13
BODY
Hot at CONTROL F1 2.0L
all times MODULE (BCM)
11-17 151-77
13-113 151-81 151-93
HG 151-97
PASSIVE
C02280B CPK43 GY-VT C0252 ANTI-THEFT
SYSTEM (PATS)
47 1 TRANSCEIVER
112-1

SELECTOR LEVER
C02280E CET53 BU-OG C0210 - 16 CET53 BU-OG C02810 ASSEMBLY
37-1
12 12

Double Cab in Van

THIRD ROW
C02280C S266 C0300 - 56 C09076 - 6 C0922 - 6 S901 CLN01 GN-VT C0963B C09054B INTERIOR LAMP
89-24 89-27
14 2 2

Bus, Kombi

FOURTH ROW
F1 CLN01 GN-VT C09055B INTERIOR LAMP
89-27
C0311 C0925 - 6 2
10A
Not used
20

FRONT INTERIOR
C0900 - 1 S907 CLN01 GN-VT C0929B LAMP
89-17
4 2

dome lamp 2

FRONT INTERIOR
CLN01 GN-VT C0931B LAMP
89-18
2

illuminated vanity mirrors

VANITY
CLN01 GN-VT C0906 MIRROR
LAMP RH
HI 1 89-18

13-116
VANITY
CLN01 GN-VT C0907 MIRROR
LAMP LH
1 89-18
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-93
Hot at 151-97
all times
13-115
HI

Double Cab in Van

Double Cab in Van
S903
THIRD ROW
C02280C S267 C0300 - 21 C09076 - 4 C0922 - 4 S940 CLN03 YE-GY C0963B INTERIOR LAMP
89-24
13 1

FOOTWELL
CLN03 YE-GY C02056A LAMP
LH
1 89-24 89-25

Kombi (high roof)

FOOTWELL
CLN03 YE-GY C02057C C02057A LAMP
RH
1 1 89-24 89-25

C0311 CLN03 YE-GY C0925 - 4

Not used
19

FRONT
CLN03 YE-GY C0900 - 2 CLN03 YE-GY C0929B INTERIOR LAMP
89-17
3 1

YE-GY
CLN03
dome lamp 2

FRONT
C0931B INTERIOR LAMP
89-18
1
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-77
151-81 151-93
151-97

C02280E CPL30 BU-BN

CABIN UNLOCK SWITCH
16

CPL28 VT-BN
CABIN RESET SWITCH
43
CPL29 YE-GY
CABIN SET SWITCH
30
REMOTE
CPL26 GN-VT KEYLESS ENTRY
AJAR DRIVER SWITCH AND ALARM
33 117-15 117-16
117-17 117-18
117-19 117-20
CPL31 WH
AJAR PASSENGER SWITCH
21

CPL43 VT-GY
UNLOCK SWITCH
4

CPL42 GY-YE
LOCK SWITCH
17

C02280F VDN03 GY-VT CHARGING SYSTEM

LIN 3 SPL1 12-4
4

C02280B VPL56 BU-GY

K-LINE
26
right hand drive
REMOTE
C02280E CPL39 YE CPL36 GN KEYLESS ENTRY
AJAR RIGHT SIDE DOOR SWITCH AND ALARM
19 46 117-27 117-33

CPL36 GN CPL39 YE
AJAR LEFT SIDE DOOR SWITCH
46 19
right hand drive

C02280A CCB08 VT-WH

BOO FEED TURN SIGNAL/STOP/HAZARD LAMPS
1 90-17
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-77
151-81 151-93
151-97

C02280G CDC35 BU-WH STARTING

START SYSTEM
1 20-5

REMOTE
C02280E VRT26 VT KEYLESS ENTRY
LIN 3 SPL2 AND ALARM
36 117-35

PASSIVE
C02280B VDN01 BU-WH ANTI-THEFT
LIN 1 SYSTEM
52
112-1

C02280E CR167 YE-VT SUPPLEMENTAL

ENS RESTRAINT SYSTEM
49 46-8

C02280F CRT17 WH-BN

AJAR HOOD SWITCH REMOTE
14
KEYLESS ENTRY
AND ALARM
117-31 117-32
117-34
C02280E CPL81 BN-VT
AJAR LIFTGATE / REAR
CARGO DOOR SWITCH 34
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-77
151-81 151-93
151-97

C02280G VDB04 WH-BU

HS1 CAN + MODULE
10 COMMUNICATIONS
NETWORK
VDB05 WH 14-11
HS1 CAN -
9

C02280B CLF19 VT-GN

AUTOLAMP
21

CLF24 YE-BU
HEADLAMP ON
15
HEADLAMPS/ AUTOLAMPS
85-8
CLF23 WH-VT
HEADLAMP OFF
16

CLS34 GY
PARK
2

CLF21 GY-VT
FRONT FOG
20
FOG LAMPS
86-4
CLF57 BN-YE
REAR FOG
8

CLN56 BN-VT
DIM -
3 CLUSTER AND
PANEL ILLUMINATION
71-8
CLN55 YE-VT
DIM +
7
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-77
151-81 151-93
151-97

C02280B CRH02 BU-WH

HORN SWITCH HORN/CIGAR LIGHTER
18 44-6

CLS32 BN-YE TURN SIGNAL/STOP/HAZARD LAMPS

HAZARD 90-13
19

TRAILER TOW C02280E CAT13 GN-OG TRAILER/CAMPER ADAPTER

DETECTION 40 95-3

CMC25 WH-VT INSTRUMENT CLUSTER

PARK BRAKE 60-13
47

C02280F RLN29 WH-OG INTERIOR

FRONT DOME LIGHT LAMPS
6 89-17

GD240 BK-GN right hand drive

C02280C GD235 BK-GY

LOGIC GND
6

GD240 BK-GN right hand drive

GD235 BK-GY
LOGIC GND
7

GD233 BK
PWR GND
10
right hand drive right hand drive

G0303 G0304 G0307 G0304 G0307

10-47 10-48 10-53 10-48 10-53
BODY
CONTROL 2.0L
MODULE (BCM)
11-17 151-93
151-97

C02280C CPL84 GN-BN

UNLOCK CARGO/LIFTGATE REMOTE
31
KEYLESS ENTRY
AND ALARM
117-30
C02280E CPL45 BN 117-32
LIFTGATE RELEASE SWITCH
1

C02280F CMC19 GY-VT

BRAKE FLUID SWITCH
28
INSTRUMENT CLUSTER
60-13
RMC19 YE-GY
BRAKE FLUID RETURN
35

C03665 - 5
CE607 BN-YE
ENGINE RUN Not used
34

CRH04 VT-GN HORN/CIGAR LIGHTER

HORN RELAY CONTROL 44-6
20
ANTI-THEFT
C02280E VDN04 VT-WH S137 VDN04 VT-WH C0154 ALARM HORN
LIN 4 WITH INTEGRAL
37 2 BATTERY
117-35

VDN04 VT-WH

53 C0300 liftgate

C0935 - 6 REAR
VDN04 VT-WH VDN04 BK C0406 - 6 VDN04 BK C0494 - 6 VMP24 WH C04357 PARKING AID
CAMERA
2 145-5 145-6

rear doors

REAR
VDN04 BK C0422 - 6 VDN04 BK C0495 - 6 VMP24 WH C04357 PARKING AID
CAMERA
2 145-5 145-6
Hot at
all times
Hot in Start
or Run
2.2L
BODY IGNITION
CONTROL SWITCH
F13 MODULE (BCM) 13-10 13-11
15A 11-5
13-32

1 C250

73 C2280D

VDB06 GY-OG MODULE

J 14-6 COMMUNICATIONS
NETWORK
VDB07 VT-OG
K 14-6

CDC32
BN-YE
multi-function
display

MODULE
COMMUNICATIONS
S224 NETWORK
VDB13 BU-GY
A 14-2

VDB14 VT-GY
B 14-2
GY-RD

CDC32
BN-YE
SBP13

16 9 3 11 1 8 C251
DATA LINK
CONNECTOR
(DLC)
151-14 151-18
VBATT VPWR MS CAN + MS CAN - I CAN + I CAN -

GND GND HS CAN - HS CAN +

MODULE
4 5 14 6 C251 COMMUNICATIONS
NETWORK
VDB04 WH-BU
BK-BU

BK-VT
GD167

GD116

C 14-3

VDB05 WH
D 14-3

G202 G201
10-6 10-6
MULTI-FUNCTION DISPLAY 2.2L
INSTRUMENT
MODULE PANEL
COMMUNICATIONS CLUSTER (IPC)
NETWORK 60-1

VDB13 BU-GY S212 VDB13 BU-GY S233 VDB13 BU-GY C220

14-1 A I CAN +
5

VDB14 VT-GY S213 VDB14 VT-GY S234 VDB14 VT-GY

14-1 B I CAN -
4

BU-GY
VDB14
VT-GY

VDB13
FRONT CONTROL/
DISPLAY INTERFACE
MODULE (FCDIM)
130-3

VDB13 BU-GY C2123

I CAN +
4
6 13 C265
VDB14 VT-GY
I CAN -
5

AUDIO
FRONT
CONTROL
SYNC MODULE (ACM)
130-4

VDB13 BU-GY S207 VDB13 BU-GY C240A

I CAN +
14

VDB14 VT-GY S206 VDB14 VT-GY

I CAN -
15

SYNC
MODULE [APIM]
130-7

VDB13 BU-GY C2383

I CAN +
16

14-3 E HS CAN +
53

VDB05 WH S203 VDB05 WH

14-3 F HS CAN -
54

WH-BU
VDB04

VDB05
WH
2 8 C264

68 67 C210

44 45 C311

MODULE
COMMUNICATIONS
C900 C900 NETWORK
S922 VDB04 WH-BU S904 VDB04 WH-BU
G 14-5
4 12

VDB05 WH S905 VDB05 WH

H 14-5
S921 10 6
3 9 C919
WH-BU
VDB04

SYNC

GLOBAL POSITIONING
S205 VDB06 GY-OG C2398 SYSTEM MODULE (GPSM)
MS CAN + 130-7
2

S204 VDB07 VT-OG

MS CAN -
3

11 5 C264

14 15 C210
MODULE
COMMUNICATIONS
C300 NETWORK
S300 VDB06 GY-OG S918 VDB06 GY-OG
L 14-7
48

S301 VDB07 VT-OG S917 VDB07 VT-OG

M 14-7
49

GY-OG
GY-OG

VDB06

VDB07
VT-OG
VDB06

VDB07
VT-OG

parking aid
trailer tow camera

1 2 C3548C 2 3 C9058

TRAILER IMAGE
MODULE PROCESSING
MS CAN + MS CAN - 95-1 MS CAN + MS CAN - MODULE B (IPMB)
131-6
MODULE tachograph
COMMUNICATIONS
NETWORK
2.2L
TACHOGRAPH
VDB06 GY-OG C9027 S912 VDB06 GY-OG C9068C 60-7
14-6 L MS CAN +
7 5

VDB07 VT-OG S913 VDB07 VT-OG

14-6 M MS CAN -
15 7

6 14 C9027

46 47 C300

4 5 C145

fuel fired booster heater

AUXILIARY HEATER
S408 VDB06 GY-OG C4429 CONTROL
MS CAN + MODULE (AHCM)
4 54-4

S409 VDB07 VT-OG

MS CAN -
5

2 3 C145

12 13 C210
GY-OG
VDB06

VDB07
VT-OG

53 54 C2280D

BODY
CONTROL
MS CAN + MS CAN - MODULE (BCM)
11-5
Hot at
all times Start/Stop Bus 2.0L
BODY
CONTROL
F15 F13 MODULE (BCM)
10A 7.5A 11-17 VDB06 GY-OG MODULE
13-92 13-102 J 14-15 14-17 COMMUNICATIONS
NETWORK
VDB07 VT-OG
K 14-15 14-17
19 8 C02280A

GY-RD
SBP13
MODULE
COMMUNICATIONS
S244 NETWORK
VDB29 GN-BU
A 14-9 14-10

VDB30 WH-GN
B
WH-RD

14-9 14-10
GY-RD
SBP15

SBP13

13 24 23 22 16 15 C02431
GATEWAY
MODULE A
(GWM)
151-77 151-81
VBATT VPWR MS CAN + MS CAN - HS3 CAN + HS3 CAN -

GND GND HS2 CAN - HS2 CAN + HS1 CAN - HS1 CAN +

MODULE
1 14 17 18 19 20 C02431 COMMUNICATIONS
NETWORK
VDB04 WH-BU
C 14-11

VDB05 WH
D 14-11
BK-WH

MODULE
BK-VT
GD266

GD216

COMMUNICATIONS
NETWORK
VDB25 GN-OG
G 14-13

VDB26 GY-BU
G0202 G0201 H 14-13
10-38 10-39 10-38 10-39
WITHOUT MULTI-FUNCTION DISPLAY 2.0L

Not used Not used

2 1 C02122

WH-GN

GN-BU
VDB30

VDB29
INSTRUMENT
MODULE PANEL
COMMUNICATIONS CLUSTER (IPC)
NETWORK 60-9

VDB29 GN-BU S236 VDB29 GN-BU C0220

14-8 A HS3 CAN +
5

VDB30 WH-GN S237 VDB30 WH-GN

14-8 B HS3 CAN -
4
MULTI-FUNCTION DISPLAY 2.0L

INSTRUMENT
PANEL
CLUSTER (IPC)
Not used Not used 60-9

VDB29 GN-BU C0220

2 1 C02122 HS3 CAN +
5

VDB30 WH-GN
HS3 CAN -
4

WH-GN

GN-BU
VDB30

VDB29
MODULE
COMMUNICATIONS
NETWORK 6 13 C0265
VDB29 GN-BU
14-8 A S236

SYNC
VDB30 WH-GN
14-8 B S237

WH-GN

GN-BU
VDB30

VDB29
SYNC
MODULE [APIM]
130-24

10 4 C0263 S212 VDB29 GN-BU C02383

HS3 CAN +
16

S213 VDB30 WH-GN

HS3 CAN -
17
WH-GN

WH-GN
GN-BU

GN-BU
VDB30

VDB29

VDB30

VDB29
AUDIO
FRONT FRONT CONTROL/
CONTROL DISPLAY INTERFACE
MODULE (ACM) MODULE (FCDIM)
130-19 130-18 145-7

C0240A VDB29 GN-BU S208 S210 VDB29 GN-BU C02123A

HS3 CAN + HS3 CAN +
14 4

VDB30 WH-GN S209 S211 VDB30 WH-GN

HS3 CAN - HS3 CAN -
15 5
cornering lamps
2.0L
ADAPTIVE
FRONT
MODULE LIGHTING
COMMUNICATIONS MODULE
NETWORK 85-13

VDB04 WH-BU S232 VDB04 WH-BU C02800

14-8 C HS1 CAN +
19

VDB05 WH S233 VDB05 WH

14-8 D HS1 CAN -
7

multi-function
2 8 C0263 display

SYNC

WH-BU
VDB04

VDB05
SYNC
MODULE [APIM]

WH
130-24

S202 VDB04 WH-BU C02383

HS1 CAN +
53

S203 VDB05 WH
HS1 CAN -
54

multi-function
2 8 C0264 display

2 1 C0268
BODY
CONTROL
MODULE (BCM) MODULE
11-17 COMMUNICATIONS
NETWORK
C02280G VDB04 WH-BU S240 VDB04 WH-BU
HS1 CAN + CC 14-12
10

VDB05 WH S241 VDB05 WH

HS1 CAN - CD 14-12
9
2.0L

MODULE
COMMUNICATIONS
NETWORK
LOW VOLTAGE
VDB04 WH-BU S2015 VDB04 WH-BU C02513 DIRECT CURRENT/
14-11 CC HS1 CAN + DIRECT CURRENT (DC/DC)
1 CONVERTER
40-3
VDB05 WH S2016 VDB05 WH
14-11 CD HS1 CAN -
4

1 2 C0312
rear parking aid

PARKING ASSIST
S922 VDB04 WH-BU C09071A CONTROL
HS1 CAN + MODULE (PAM)
6 145-1

S921 VDB05 WH
HS1 CAN -
15

3 4 C0312

47 48 C0139
automatic transmission

TRANSMISSION
S107 VDB04 WH-BU C01822 CONTROL
HS1 CAN + MODULE (TCM)
47 29-1

S108 VDB05 WH
HS1 CAN -
48

POWERTRAIN
VDB04 WH-BU C0175B CONTROL
HS1 CAN + MODULE (PCM)
60 24-23

VDB05 WH
HS1 CAN -
61
2.0L
MODULE adaptive cruise
COMMUNICATIONS
NETWORK
PROXIMITY WARNING
C0210 C0192 C01582 RADAR UNIT
VDB25 GN-OG S135 VDB25 BK
14-8 G HS2 CAN + 31-13 31-14
70 4 8 146-3 146-4

VDB26 GY-BU S136 VDB26 BK

14-8 H HS2 CAN -
69 3 7

RESTRAINTS
S2022 VDB25 GN-OG C0310B CONTROL
HS2 CAN + MODULE (RCM)
48 46-8

S2023 VDB26 GY-BU

HS2 CAN -
47

33 34 C0145 vehicle dynamic suspension

C0408 VEHICLE
S416 VDB25 GN-OG C04396 DYNAMICS
HS2 CAN + MODULE (VDM)
14 54 41-1
S417 VDB26 GY-BU
HS2 CAN -
15 53

6 7 C0145

VDB25 GN-OG
DG 14-14
MODULE
COMMUNICATIONS
VDB26 GY-BU NETWORK
DH 14-14
MODULE
COMMUNICATIONS
2.0L
NETWORK
C01010 ANTI-LOCK
VDB25 GN-OG S244 VDB25 GN-OG VDB25 GN-OG C0135 BRAKE SYSTEM
14-13 DG HS2 CAN + (ABS) MODULE
3 26 42-4

VDB26 GY-BU S245 VDB26 GY-BU VDB26 GY-BU

14-13 DH HS2 CAN -
4 14

46 47 C0311

10 12 C0900

lane departure warning

AUTO-DIMMING
S905 VDB25 GN-OG C09012 INTERIOR
HS2 CAN + MIRROR
12 124-10

S904 VDB26 GY-BU

HS2 CAN -
13

6 4 C0900

52 53 C0311

STEERING COLUMN
C0268 C02414 CONTROL
VDB25 GN-OG VDB25 GN-OG
HS2 CAN + MODULE (SCCM)
5 4 31-10 81-10
85-9 90-12
VDB26 GY-BU VDB26 GY-BU 146-1
HS2 CAN -
6 5
MODULE LEFT HAND DRIVE 2.0L
COMMUNICATIONS
NETWORK
C02122
VDB06 GY-OG S234 VDB06 GY-OG
14-8 J Not used
3

VDB07 VT-OG S235 VDB07 VT-OG

14-8 K Not used
4

multi-function
11 5 C0263 display

SYNC without navigation

GLOBAL POSITIONING
VDB06 GY-OG C02398 SYSTEM
MS CAN + MODULE (GPSM)
S205 2 130-24

S204 VDB07 VT-OG

MS CAN -
3

11 5 C0264
multi-function
display

12 13 C0268

fuel fired booster heater MODULE

COMMUNICATIONS
C0145 C0145 C0300 NETWORK
S408 VDB06 GY-OG
AL 14-16
4 2 48

S409 VDB07 VT-OG

AM 14-16
5 3 49
GY-OG
VDB06

VDB07
VT-OG

4 5 C04429

AUXILIARY HEATER
CONTROL
MS CAN + MS CAN - MODULE (AHCM)
54-13
LEFT HAND DRIVE 2.0L
MODULE tachograph
COMMUNICATIONS
NETWORK
TACHOGRAPH
VDB06 GY-OG C09027 VDB06 GY-OG C09068C 60-16
14-15 AL MS CAN +
6 5

VDB07 VT-OG VDB07 VT-OG

14-15 AM MS CAN -
14 7

46 47 C0300

48 49 C0311

RADIO
S932 C0913 VDB06 GY-OG C09026 FREQUENCY (RF)
MS CAN + RECEIVER
8 4 117-33 118-2

S933 VDB07 VT-OG

MS CAN -
7 3

7 8 C0311

trailer tow
C0268 C02357A
S300 VDB06 GY-OG
MS CAN +
9 23

S301 VDB07 VT-OG

MS CAN -
10 24
GY-OG
VDB06

VDB07
VT-OG

HEATING,
VENTILATION AND
AIR CONDITIONING (HVAC)
CONTROL MODULE
3 2 C03548C 54-14

TRAILER
MODULE
MS CAN + MS CAN - 95-3
MODULE RIGHT HAND DRIVE 2.0L
COMMUNICATIONS
NETWORK
C02122
VDB06 GY-OG S234 VDB06 GY-OG
14-8 J Not used
3

VDB07 VT-OG S235 VDB07 VT-OG

14-8 K Not used
4

multi-function
11 5 C0263 display

SYNC without navigation

GLOBAL
VDB06 GY-OG C02398 POSITIONING
MS CAN + SYSTEM
S205 2 MODULE (GPSM)
130-24
S204 VDB07 VT-OG
MS CAN -
3

11 5 C0264
multi-function
display

12 13 C0268

trailer tow MODULE

COMMUNICATIONS
C0300 NETWORK
S300 VDB06 GY-OG
BL 14-18
46
S301 VDB07 VT-OG
BM 14-18
47
GY-OG
VDB06

VDB07
VT-OG

3 2 C03548C

TRAILER
MODULE
MS CAN + MS CAN - 95-3
RIGHT HAND DRIVE 2.0L

MODULE tachograph
COMMUNICATIONS
NETWORK
TACHOGRAPH
VDB06 GY-OG C09027 VDB06 GY-OG C09068C 60-16
14-17 BL MS CAN +
6 5

VDB07 VT-OG VDB07 VT-OG

14-17 BM MS CAN -
14 7

48 49 C0300

7 8 C0311

RADIO
S932 C0913 VDB06 GY-OG C09026 FREQUENCY (RF)
MS CAN + RECEIVER
8 4 117-33 118-2

S933 VDB07 VT-OG

MS CAN -
7 3

48 49 C0311

C0268 C02357A
VDB06 GY-OG VDB06 GY-OG
MS CAN +
9 23

VDB07 VT-OG VDB07 VT-OG

MS CAN -
10 24

HEATING,
VENTILATION AND
AIR CONDITIONING (HVAC)
CONTROL MODULE
54-14
Hot at all times
HIGH CURRENT 2.2L
BATTERY
F1 JUNCTION
350A BOX (BJB)
13-2 11-7

1 C3670C

SBF01

RD
SBB19 BU-RD
1 C1035B
BATTERY
JUNCTION
BOX (BJB)
11-3
STARTER
F19 3 2 RELAY
30A
13-5

5 1

1 C1035C

GY-OG
CDC26
SBF01

14 C134
RD

GY-OG

BN-GN
CDC26

CDC25

CDC12

YE
1 C1019
CDC26 GY-OG

C197A 1 1 C197B
SBF01

STARTER
RD

MOTOR
151-1
37 25 C175B
1 C102A POWERTRAIN
SMC SMCS CONTROL
GENERATOR MODULE (PCM)
12-3 23-17
Hot at EMISSION REQUIREMENTS:
all times 2.2L
BODY STAGE IV
CONTROL
F3 MODULE (BCM)
15A 11-5
13-10 13-11
START

71 C2280D 65 C2280D

BU-RD
SBP03
BU-WH

POWER
CDC35

SBP03 BU-RD DISTRIBUTION

13-10 13-11

4 C250
IGNITION
SWITCH
13-10 13-11

BATTERY
JUNCTION
F29 BOX (BJB)
3A 11-3
START

RUN

ACC

13-10 13-11
OFF

BU-WH
CDC35
7 C250

BU-WH
CDC35
BU-WH
CDC35

CME05
GN-BN
S223

51 C210 11 C139

16 C139

CME05
GN-BU
early production
S106
16 C210
BU-WH
CDC35

late production
without:

CME05
GN-BU
multi-function
display

47 C175B 3 C240A
POWERTRAIN AUDIO
CONTROL FRONT
START MODULE (PCM) CONTROL
23-17 MODULE (ACM)
130-1
Hot at EMISSION REQUIREMENTS: STAGE V
all times 2.2L
BODY
CONTROL
F3 MODULE (BCM)
15A 11-5
13-10 13-11
START

71 C2280D 65 C2280D
BU-WH

BU-RD
CDC35

SBP03
POWER
SBP03 BU-RD DISTRIBUTION
13-10 13-11

4 C250
IGNITION
SWITCH
13-10 13-11
START

RUN

ACC

OFF

7 C250
BU-WH
CDC35

11 C139
CME05
GN-BN

S223

CME05
GN-BU
51 C210

16 C210
16 C139
BU-WH
CDC35

without:

CME05
GN-BU
multi-function
display
47 C175B 4 C175T
3 C240A
POWERTRAIN
CONTROL AUDIO
START START MODULE (PCM) FRONT
23-17 CONTROL
MODULE (ACM)
130-1
Hot at all times Hot at all times
HIGH CURRENT AUXILIARY 2.0L
BATTERY JUNCTION
F1 JUNCTION F59 BOX (AJB)
470A BOX (BJB) 30A 11-11
13-64 11-19 13-85

1 C03670C

BU-RD
SB159
SBF01

RD
12 C0139
1 C01035B
BATTERY
JUNCTION
BOX (BJB)
11-15
STARTER
3 1 RELAY

5 2

1 C01035C

GY-OG

BN-GN
CDC26

CDC12

CDC25
YE
STARTING SYSTEM
SBF01

14 C0134
S130
RD

S127 A 20-5

GY-OG
CDC26
1 C01019
CDC26 GY-OG

BN-GN
CDC12

CDC25
C0197A 1 1 C0197B

YE
SBF01

STARTER
RD

MOTOR
151-65
36 53 C0175B
1 C0102A POWERTRAIN
SMC SMCS CONTROL
GENERATOR MODULE (PCM)
12-5 24-23
Hot at
all times 2.0L
BODY
CONTROL
F18 MODULE (BCM)
5A 11-17 STARTING SYSTEM
13-72
START START 20-4 A

1 C02280G 14 12 C02280A

BN-GN
CDC25
BU-WH

BU-WH
CDC35

CDC35

YE-RD
SBP18
BATTERY
JUNCTION
F1 BOX (BJB)
4 C0250 5A 11-15
13-85
IGNITION
SWITCH
13-72

CME05
GN-BU
START

RUN 44 C0139

ACC

OFF
16 C0139

7 C0250

CME05
GN-BU
BU-WH
CDC35

S221
20 C0268

51 C0210
Not used
BU-WH

BU-WH

CME05
GN-BU
CDC35

CDC35
without:
multi-function
display

5 3 C0240A
6 C0175B
AUDIO
POWERTRAIN FRONT
CONTROL START SMCS CONTROL
START MODULE (PCM) MODULE (ACM)
24-23 130-13
Hot at Hot in Start
all times or Run 2.2L
BATTERY
JUNCTION
BOX (BJB)
F20 F7 11-3
60A 7.5A
13-5 13-13

late production

CBB07 GN-BU

GN-BU
CBB07 early production

S102 CBB07 GN-BU

GN-RD

GN-BU
CBB07
SBB20

5 4 C1273A 39 C175B
GLOW PLUG POWERTRAIN
MODULE CONTROL
VBATT VPWR 151-2 151-10 VPWR MODULE (PCM)
151-2

C1273A CE151 BN-VT C175B

GPFB GPFB
1 45
CE609 WH-OG
GPC GPC
2 40

C1273B C1681
CE243 GY-VT CE243 GY-VT
GP1
3 1
CE244 BU-BN CE244 BU-BN
GP2
1 2
CE245 VT-WH CE245 VT-WH
GP3
4 3
CE246 YE-BU CE246 YE-BU
GP4
GND 6 4

3 C1273A 1 C1904 1 C1903 1 C1902 1 C1901

BK-GN
GD120

GLOW GLOW GLOW GLOW

PLUG 4 PLUG 3 PLUG 2 PLUG 1
151-10 151-10 151-10 151-10
GD120 BK-GN
G105
S101 10-1
Hot at
all times 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
11-1
F15 F14
40A 5A
13-7 13-7

6 24 C139

WH-RD

BN-RD
SB115

SB114
CE612 GY-VT S112 CE612 GY-VT

BATTERY
JUNCTION
A POWERTRAIN BOX (BJB)
3 1 CONTROL 11-3
MODULE (PCM)
ELECTRONIC RELAY
ENGINE F35
CONTROLS B C 15A 5 2
23-3 13-7
23-3 23-5

YE-GY

YE-BU
CBB35

CE302
CE436 VT-OG S103

28 29 17 5 48 C175B

23 C139 POWERTRAIN
CONTROL
PCM VPWR VPWR VPWR PCMRC MODULE (PCM)
WAKE 151-2
VT-OG
CE436

GND GND GND GND GND

7 2 3 42 53 C175B

70 C2280C
BK-GN

BK-GN

BK-GN
BK-YE
GD121

GD120

BODY GD120
CONTROL
PCM MODULE (BCM)
WAKE 11-5 S118
GD120 BK-GN
G104 G105
10-1 S101 10-1
23-2 Hot in Start
or Run 2.2L
A ELECTRONIC
ENGINE
CONTROLS

GY-VT
CE612
BATTERY
Hot in Start JUNCTION
or Run BOX (BJB)
11-3
23-2
B
F39
15A
F37 13-9
7.5A
13-7
POWERTRAIN
CONTROL
MODULE (PCM)
151-2 151-10

VT-WH
CBB39
CBB37
FUEL

WH
METERING
VALVE
151-9 3 C134
C175E CE256 BU-OG C1138 C1138 CBB74 VT-BN
FVCV
25 2 1
FUEL
VAPORIZER
SYSTEM FUEL
PUMP
151-3
C144 - 1 C4141 C4141 C144 - 9 S109
C175T CE523 BN-GN CBB39 VT-WH
FVP M
2 2 1

VT-WH
CBB39

VT-WH

VT-WH
CBB39

CBB39
HEATED OXYGEN
SENSOR (HO2S) 17 C134
151-11
C134 - 21 C171 C171
CE233 WH-OG CBB72 GN-VT
UO2SHTR
3 3 4 D E

C175E ZA214 BK S151

SHIELD
37 SHIELD 23-4 23-16

C175T C134
LE449 VT-GN ELECTRONIC
UO2SGREF21 ENGINE
16 22 2
VE827 WH-GN CONTROLS
UO2S21
27 23 6

VE826 BN-VT
UO2S11
13 25 5
LE448 GY-BU
UO2SGREF11
14 24 1
Hot in Start Hot in Start
or Run or Run 2.2L
BATTERY ELECTRONIC
JUNCTION ENGINE
BOX (BJB) CONTROLS
F12 11-3
20A 23-3
13-6
D

GN-WH

VT-WH
CBB12

CBB39
BATTERY
JUNCTION
GLOW BOX (BJB)
3 1 PLUG 11-3
RELAY
F5
3A
13-8 5 2

CE156 WH-VT S114

early production
CE156 WH-VT

16 C134
late production
WH-VT

WH-VT
CE156

CE156
1 C133
WH-VT
CE156

emission requirements:
stage V
2 C1263

FUEL
VAPORIZER
SYSTEM
GLOW PLUG
151-13
1 C1263

26 C175T 28 C175T
BK-YE
GD109

POWERTRAIN POWERTRAIN
CONTROL CONTROL
FVGPRM MODULE (PCM) FVGPR MODULE (PCM)
151-2 G111 151-2
10-4
BATTERY
Hot in Start
JUNCTION 2.2L POWERTRAIN
CONTROL
BOX (BJB)
or Run 11-3 MODULE (PCM)
23-2 151-2
C

F36
7.5A
13-7
BU-BN
CBB36

RE320 BU C175T
SIGRTN
15
3 4 C128
MASS AIR
FLOW (MAF)
VREF 5V SENSOR
151-2
DIGITAL

5 2 C128
VE740 VT-GY
IAT
9
VE807 YE-VT
MAF
24

FUEL SUPPLY
LINE PRESSURE
SENSOR
151-3
C144 - 2
GD135 BK-GY C4432 C4432 VE830 GN-WH VE830 GN-WH
FVCV
2 1 23
12 C145
BK-GY
GD135

S270
BK-GY
GD135

G304
10-16
Hot at
all times
2.2L
BATTERY
JUNCTION
BOX (BJB)
F24 11-3
7.5A
13-5

VT-RD
SBB24
SBB24 VT-RD

BATTERY
JUNCTION
FUEL BOX (BJB)
3 1 PUMP 11-3
RELAY

5 2

BODY
CONTROL

YE-GY
MODULE (BCM)

CE515
11-5 POWERTRAIN
CONTROL
MODULE (PCM)
8 C144 151-2

YE-GY

VT-GN
CE515

CE608
FUEL C145
PUMP LEVEL C2280C VMC11 YE-VT FUEL
SENSOR PUMP ON
29 1 2 4 C463
RMC32 GN-BU 9 C175B
FUEL
LEVEL GND 46 13 FUEL PUMP AND
SENDER UNIT
C463 M 151-39
18 30 C139
1

VT-GN

YE-VT
CR167
CE608
3 C463
BK-VT
12 71 C2280C
GD132

fuel fired FUEL PUMP FUEL

S410 booster RELAY CTRL PUMP ON
heater
BK-VT
GD132

BODY
CONTROL
MODULE (BCM)
G400 11-5
10-25
POWERTRAIN
CONTROL
2.2L
MODULE (PCM)
151-2 151-10

CRANKSHAFT
POSITION (CKP)
SENSOR
151-10

C175E VE711 YE-VT C101

CKP
32 3
C134
C175T LE135 GY-VT LE135 GY-VT
VREF
38 9 1
RE135 GN-BN RE135 GN-BN
SIGRTN
44 32 2

FUEL INJECTOR 1
151-9
C175E CE205 GN-BU C181 C181
INJ1
48 2 1
RE205 YE-BU
INJ1RTN
35

FUEL INJECTOR 2
151-9
CE206 GY-YE C182 C182
INJ2
12 2 1
S150
RE206 BU-OG
INJ2RTN
11

FUEL INJECTOR 3
151-9
CE207 VT-GY C183 C183
INJ3
36 2 1
RE206 BU-OG

FUEL INJECTOR 4
151-9
CE208 YE-OG C184 C184
INJ4
24 2 1
RE208 BU
INJ4RTN
23
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
151-2 151-10
DIESEL PARTICULATE
C139 C1471 FILTER (DPF) DIFFERENTIAL
C175T LE147 BN-BU LE147 BN-BU
VREF PRESSURE SENSOR
37 35 3 151-5

VE713 GN-OG VE713 GN-OG

DPF
8 33 1
RE147 WH-BU RE147 WH-BU
SIGRTN
30 32 2

FUEL RAIL
C175E ZA203 OG-BU C106 PRESSURE (FRP)
SIGRTN SENSOR
29 1 151-9

VE727 BU-BN
FRP
7 2
LE230 BN-BU
VREF
1 3

INTAKE
C180 CAMSHAFT
ZA204 OG-GN POSITION (CMP)
VREF
15 1 SENSOR
151-9
ZA215 OG-BK
SIGRTN
34 2
VE706 BN-BU
CMP
4 3

CMC24 GY
OPS
5
1 C103

ENGINE
OIL PRESSURE
(EOP) SWITCH
ENGINE OIL 1) Low pressure
1 2 2) Normal level
ZA213 OG-GY C104 QUALITY,
SIGRTN TEMPERATURE 151-10
21 3 AND LEVEL
SENSOR
LE423 GN-VT 151-11
OLS
40 1
CMC14 BN-YE
OTS
19 2
POWERTRAIN
CONTROL
MODULE (PCM)
ENGINE COOLANT
TEMPERATURE
2.2L
151-2 151-10 (ECT) SENSOR
151-9
C175E VE716 YE C1061 C1061
ECT
18 1 2
RE141 BN-GN
SIGRTN
22

INTAKE AIR
TEMPERATURE (IAT)
SENSOR
151-10
C175T C134 C1140 C1140
VE755 YE-VT VE755 YE-VT
IAT
11 10 1 2
RE332 YE-BU RE332 YE-BU
SIGRTN
6 31
AMBIENT AIR
TEMPERATURE
SENSOR
151-6
C139 C132 C132
VE750 GN-BU VE750 GN-BU
AAT
21 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
18 27
EXHAUST GAS
emission requirements: TEMPERATURE
stage V SENSOR 1
151-13
C134 C133 C3601 C3601
VE722 BN VE722 BN
EGT1
22 27 7 1 2
RE146 VT-OG S190 RE146 VT-OG
SIGRTN
33 13 15
EXHAUST GAS
TEMPERATURE
SENSOR 3
151-13
C175B VE771 BN-VT VE771 BN-VT C3603 C3603
EGT3
8 2 4 1 2
RE146 VT-OG

EXHAUST GAS
TEMPERATURE
SENSOR 2
151-13
C175T VE726 YE-GY VE726 YE-GY C3602 C3602
EGT2
47 26 6 1 2
RE145 GY-VT RE145 GY-VT
SIGRTN
34 12 14
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
151-2 151-10

THROTTLE
BODY
C175E LE428 BU-WH C1449 151-10
ETCREF
2 3
VE820 GY
TP1
16 6
RE427 YE-VT
ETCRTN
8 2

LE134 YE
TACM+ M
43 4
RE134 BU-OG
TACM-
44 1

C175B RE136 VT-GN C139 RE136 VT-GN

APPRTN1
13 45
LE136 GN-OG LE136 GN-OG
APPVREF1
38 19 1 3 C2040

ACCELERATOR
PEDAL
C2040 POSITION (APP)
VE701 YE-OG VE701 YE-OG SENSOR
APP1 151-30 151-34
20 43 2

VE702 BU-WH VE702 BU-WH

APP2
19 42 5

4 6 C2040
RE137 YE-GN RE137 YE-GN
APPRTN2
22 46
LE137 BU-GY LE137 BU-GY
APPVREF2
44 20
POWERTRAIN
CONTROL
MODULE (PCM)
2.2L
151-10
TURBOCHARGER
C175E VE814 WH-OG C1718 VARIABLE VANE
VNTREF ACTUATOR
13 5 151-9
VE825 VT-BN
VNT
17 4
RE405 GN-WH
VNTRTN
10 3

CE432 BU
VNT- M
42 2
CE431 WH
VNT+
41 1

MANIFOLD
RE454 OG-BK C1087 ABSOLUTE
SIGRTN PRESSURE (MAP)
20 2 SENSOR
151-9
VE803 BU-GN
MAP
28 1
LE423 GN-VT
VREF
14 3

COOLED EXHAUST
VE921 GY-BU C1068 GAS RECIRCULATION
EVPREF (EGR) VALVE
3 6 151-9
RE405 GY-WH
EVP
26 2
LE423 GN-VT
EVPRTN
9 4

CE101 WH-VT
EVA+ M
45 1
CE102 YE-BU
EVA-
46 5

FUEL RAIL
TEMPERATURE
SENSOR
151-9
RE405 GN-WH C1257 C1257
SIGRTN
6 2 1
VE728 GN
FRT
31
Hot at
all times 2.2L
BODY
CONTROL
F18 MODULE (BCM)
10A 11-5
13-47

3 C2280B

POWERTRAIN
CONTROL
MODULE (PCM)

YE-RD
SBP18
151-2

CCB15 BN-GN C139 - 37 CCB15 BN-GN C175B

BPS
12

1 3 C278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-30 151-34

4 2 C278

VT-WH

BK-GY
CCB08

GD135
S270

BK-GY
GD135

G304
BODY 10-16
CONTROL
MODULE (BCM)
11-5

C139 - 41
C2280C CCB08 VT-WH S286 CCB08 VT-WH CCB08 VT-WH
STOP LIGHT
SWITCH BPP
58 46
BODY POWERTRAIN
CONTROL 2.2L CONTROL
MODULE (BCM) MODULE (PCM)
11-5 151-2

CLUTCH S268 C139

C2280C CE903 BU-OG CE903 BU-OG C175B
BOT CPP-BT
SWITCH 40 36
52

CE904 GN-VT
CPP-TT
31 21

BU-OG

GN-VT
CE903

CE904
3 5 C260

BU-OG

GN-VT
CE903

CE904
auto-start-stop
1 C257 2 C2354

CLUTCH PEDAL CLUTCH PEDAL

POSITION (CPP) POSITION (CPP)
BOTTOM OF TOP OF
TRAVEL SWITCH TRAVEL SWITCH
151-30 151-34 151-30 151-34

2 C257 3 C2354

BK-GY
GD135
BK-GY
GD135

early production
BK-GY

S208
GD135

late production

6 C260

S270
BK-GY
GD135

G304
10-16
POWERTRAIN
CONTROL
MODULE (PCM)
2.2L
151-2

auto-start-stop

C139 C260 CLUTCH

C175T RE403 WH-VT RE403 WH-VT C277 PEDAL
SIGRTN POSITION (CPP)
45 39 4 4 SENSOR
151-30 151-34
VE757 WH VE757 WH
CPP2
19 34 1 3
LE403 GN LE403 GN
VREF
39 38 2 2

auto-start-stop

NEUTRAL
POSITION
SENSOR
C134 C133 151-12
C175B VET72 GY-BU VET72 GY-BU C1306
GEAR NEUTRAL #2
16 6 11 1
RET71 GY-BN RET71 GY-BN
SIGRTN
24 33 13 4
VET71 GN-VT VET71 GN-VT
GEAR NEUTRAL #1
34 8 10 3
LET71 YE-GN LET71 YE-GN
VREF
51 7 12 2

C175T C139
VE925 GN-WH
PTO_RPM
20 28
VE925 GN-WH VE925 GN-WH
GND SENSE
46 29
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
151-2

WATER-IN-FUEL
SENSOR
151-3
C175B C144 C4350 C4350
VE823 BU-BN VE823 BU-BN
WIF
31 7 1 2
RE823 GY-YE RE823 GY-YE
SIGRTN
35 6

air conditioning

RH108 BN
SIGRTN
23
1 C1260

AIR CONDITIONING
VH433 VT-OG C1260 (A/C) PRESSURE
ACPT TRANSDUCER
32 2 151-3

3 C1260
LH108 GY-BN
VREF
50
ECONETIC
Hot in Start 2.2L
Hot at or Run
all times
ELECTRONIC
BATTERY ENGINE
JUNCTION CONTROLS
BOX (BJB) 23-3
F26 11-3
3A
13-5 E

VT-WH
YE-RD

CBB39
SBB26
BATTERY
JUNCTION
ECONETIC BOX (BJB)
3 1 COOLANT 11-3
VALVE
RELAY
5
YE-GY 2
CE148

4 C1912
YE-GY
CE148

YE-GY
CE148
2 C1913

COOLANT BYPASS
VALVE
151-2

1 C1913
BK-YE
GD129

1 C1912
S117 GD241 BK-BU
14 C175B
5 C139
POWERTRAIN
CONTROL
S274 CBVR MODULE (PCM)
151-2
G308
10-21
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
151-2 151-10

C175B VDB04 WH-BU MODULE

HS CAN +
COMMUNICATIONS
10 NETWORK
VDB05 WH
HS CAN - 14-5
11

CDC25 BN-GN
SMC
37
CDC12 YE
SMCS
STARTING
25 SYSTEM
CDC35 BU-WH 20-1
START 20-2 20-3
47
C175T CME05 GN-BN
START
4
emission requirements: stage V

C175B CDC54 WH-GN AUTO-START-STOP SYSTEM

SMCS 40-1
41

C175E VDC42 GN CHARGING

GENMON SYSTEM
30 12-3

C175B CH302 WH-BN MANUAL CLIMATE CONTROL SYSTEM

ACCR 54-9
49

C175T CET47 BU REVERSING LAMPS

REVERSE 93-2
52

C175B CEC02 GN-BU

LFC
52 COOLING FAN
33-1
CEC01 WH-BU
HFC
27
Hot at Hot at
Hot in Start
or Run all times all times 2.0L
AUXILIARY BATTERY AUXILIARY
JUNCTION F30 JUNCTION F17 JUNCTION
F40 BOX (BJB) BOX (AJB)
5A BOX (AJB) 60A 5A
11-11 13-68 11-15 13-86 11-11
13-73
CE612 GY-VT S112

ELECTRONIC
ENGINE
YE-GN
CB140

GY-VT
CONTROLS

BN-RD
A

SBB30
CE612

SB117
RD
BA 24-11
ELECTRONIC
ENGINE
CONTROLS 31 C0139
10 C0139 24-2
YE-GN

BATTERY
CB140

JUNCTION
POWERTRAIN BOX (BJB)
3 1 CONTROL 11-15
S102 CB140 YE-GN MODULE (PCM)
POWER
F35 RELAY
B C 20A 5 2
G 13-68
24-5 24-6
ELECTRONIC
ENGINE
CONTROLS
24-4

YE-GY

YE-BU
CBB35

CE302
YE-GN
CB140

CE436 VT-OG S103

59 58 100 102 103 18 C0175B

23 C0139 POWERTRAIN
CONTROL
WAKE UP VPWR VPWR VPWR VPWR PCMRC MODULE (PCM)
151-66
VT-OG
CE436

CASEGND PWRGND PWRGND PWRGND PWRGND

1 96 97 98 99 C0175B

18 C02280F
BK-GN

BK-GN

BK-GN
BK-YE
GD121

GD120

GD120
BODY
CONTROL
PCM MODULE (BCM)
WAKE 11-17 S118
GD120 BK-GN
G0104 G0105
10-32 S101 10-32
24-1 Hot in Start
or Run 2.0L
A
ELECTRONIC
ENGINE
CONTROLS

GY-VT
CE612
Hot at Hot at
all times all times
BATTERY
JUNCTION
BOX (BJB)
11-15
F21 F22 F39 F38
40A 40A 10A 10A
13-67 13-67 13-70 13-70

GY-BU
CBB38
VT-WH
CBB39

S110

ELECTRONIC 16 C0134
ENGINE
CONTROLS
S109
AA 24-3 S153
VT-WH
GY-RD

GY-BU
BN-RD

CBB39

CBB38
SBB21

SBB22

2 4 C01273B 8 C01273C 1 C01162

GLOW PLUG ELECTRIC HEATED
MODULE THERMOSTAT
VBATT VBATT VPWR 151-66 151-73

2 C01162

GND

9 C01273C
GN-VT
CE131
BK-GN
GD120

POWERTRAIN
C0175E CONTROL
GD120 BK-GN ELT MODULE (PCM)
G0105 64 151-72
S101 10-32
NOx
SENSOR 2.0L
MODULE
151-102

ELECTRONIC
ENGINE
CONTROLS C0144 - 15
CBB39 VT-WH CBB39 VT-WH C04373A
24-2 AA VPWR
GLOW PLUG 1
MODULE Hot in Start
151-66 or Run

C0144 S418
C01273C VE253 YE-GY VE253 YE-GY
CAN + CAN +
2 4 2
S419
VE254 BN-WH VE254 BN-WH
CAN - CAN -
3 3 3

BN-WH
YE-GY
NOx

VE253

VE254
POWERTRAIN
CONTROL SENSOR
MODULE (PCM) 151-102
151-66 GY C04373B
VS + VS +
1
BK
C0175B VE253 YE-GY COM COM
CAN + 2
62 2 WH
IP1 IP1
VE254 BN-WH 3
CAN - GN
63 1 IP2 IP2
5
BU
HEATER +
8
YE
HEATER -
4

PK
MEMORY +
TRIMMING 6
RESISTOR BK
MEMORY -
7

GD481 BK-GN C04373A

GND
4
G0410
10-66
2.0L

24-1 Hot in Start

or Run
G
ELECTRONIC
ENGINE
CONTROLS
YE-GN
CB140

10 C01273C
GLOW PLUG
MODULE
VPWR 151-66 151-72

C01273A C01681
CE243 GY-VT CE243 GY-VT
GP1
4 2

CE244 BU-BN CE244 BU-BN

GP2
3 1

CE245 VT-WH CE245 VT-WH

GP3
1 4

CE246 YE-BU CE246 YE-BU

GP4
2 3

1 C01904 1 C01903 1 C01902 1 C01901

GLOW GLOW GLOW GLOW

PLUG 4 PLUG 3 PLUG 2 PLUG 1
151-72 151-72 151-72 151-72
BATTERY
JUNCTION 2.0L
BOX (BJB)
Hot in Start 11-15
or Run
24-1
B

F36
20A
13-68

S105

BU-BN

BU-BN
CBB36

CBB36
BATTERY
JUNCTION
BOX (BJB)
F28 F29 11-15
5A 15A
13-69 13-69

WH-VT
CBB29
GY-VT
CBB28
POSITIVE CRANKCASE
VENTILATION (PCV)
VALVE HEATER ELEMENT 12 19 C0134
151-73

C01833 C01833 CBB28 GN-RD

1 2
GD121

GY-RD
CBB29
BK

COOLANT WATER
PUMP
151-73

S150 GD121 BK C01812 C01812

1 2
POWERTRAIN G0111
CONTROL 10-36
MODULE (PCM)
151-66

C0175B C0134 - 22
VE380 BN-VT VE380 BN-VT
CPC
38 3
BATTERY
Hot in Start JUNCTION 2.0L
or Run BOX (BJB)
24-1 11-15
C

F37
15A
13-68
POWERTRAIN
CONTROL
MODULE (PCM)
151-72

CBB37
WH
S106

CBB37
WH
17 C0134

EXHAUST GAS
RECIRCULATION (EGR) E

CBB37
COOLER BYPASS

WH
VALVE SOLENOID 24-7
151-74
ELECTRONIC
C0175E CE465 YE-GN C01793 C01793 CBB37 WH ENGINE
EGRCBV S151 CONTROLS
62 2 1

UNIVERSAL
HEATED OXYGEN
SENSOR (HO2S) #11
151-74
C01631 C01631
CE233 WH-OG CBB37 WH
UO2SHTR11
61 2 1

LE449 VT-GN
UO2SPC11
73 6

LE448 GY-BU
UO2SGREF11
72 5
VE826 BN-VT
UO2S11
71 4
REDUCTANT
TANK 2.0L
151-102

REDUCTANT
PUMP
ASSEMBLY

RDPBP GND
RDPAP RDPCP

7 8 16 15
SHIELD

BK
6 2 7 8

ELECTRONIC RDPAP RDPCP

ENGINE RDPBP GND
CONTROLS
C0144
CBB37 WH CBB37 WH C04470 RD
24-6 E VPWR
18 18 5
Hot in Start or Run

POWERTRAIN REDUCTANT
CONTROL PUMP
MODULE (PCM) CONTROL
151-66 MODULE

C0175B VE354 GN-BU VE354 GN-BU RD

RDPC RDPC
37 24 4 4

RE354 WH-BU RE354 WH-BU WH

RDPM RDPM
24 28 14 3
S410 GD411 BK-BU BK GND
8 1
GLOW PLUG G0411
MODULE 10-66
151-66

REDUCTANT
C01273C VE352 BN VE352 BN RD PRESSURE LINE
RDHTRC2 HEATING ASSEMBLY
12 17 10 1

S410 GD411 BK-BU BK

1 2
G0411
10-66
REDUCTANT
POWERTRAIN
TANK 2.0L
151-102
CONTROL
MODULE (PCM)
151-66
REDUCTANT
PUMP
ASSEMBLY

C0175B C0144 C04470

CE379 GY-BN CE379 GY-BN RD
VREF
15 5 15 13

VE839 YE-GY VE839 YE-GY WH

RDL
68 6 5 14

RE839 GN-VT RE839 GN-VT BK

SIGRTN
34 31 16 6

CE353 YE-OG CE353 YE-OG RD

VREF
13 8 19 5

VE833 BU-WH VE833 BU-WH WH

RDP
70 7 2 4

RE353 GN-VT RE353 GN-VT BK

SIGRTN
32 29 6 3

VE838 VT-GY VE838 VT-GY RD

RDT
69 9 3 1

RE838 BU-OG RE838 BU-OG BK

SIGRTN
16 30 13 2

GLOW PLUG
MODULE
151-66

C01273C VE356 GY-VT VE356 GY-VT RD

RDHTRC1
6 16 9 9
S410 GD411 BK-BU BK
11 11
G0411
10-66
GLOW PLUG Hot at all times
MODULE BATTERY 2.0L
151-66 JUNCTION
F20 BOX (BJB)
RDHTRCTRL 40A 11-15
13-67

5 C01273C

GN-BN

GN-RD
SBB20
CE611

BATTERY
JUNCTION
REDUCTANT BOX (BJB)
2 3 HEATER 11-15
RELAY

1 5
BK-YE
GD121

GN-BN
CE375

S118
BK-YE
GD121

G0104 3 C01273B
151-66
GLOW PLUG
MODULE
RDHTRPWR 151-66
POWERTRAIN
CONTROL
MODULE (PCM)
2.0L
151-66 151-72

REDUCTANT
INJECTOR
151-74
C0175B C0134 C01618 C01618
VE351 VT-OG VE351 VT-OG
RI
72 23 1 2
VE350 GY VE350 GY
SIGRTN
73 24

EXHAUST GAS
TEMPERATURE
SENSOR 1
151-74
C0175E VE722 BN C01711 C01711
EGT1
41 1 2
RE722 BU-OG
SIGRTN
1

early production

EXHAUST GAS
TEMPERATURE
manual transmission SENSOR 3
manual transmission 151-74 manual transmission
C0133
VE771 BN-VT VE771 BN-VT C01931 C01713 C01713 C01931
EGT3
42 4 1 1 2 2

manual transmission manual transmission

GY-OG GY-OG

RE771 GY-WH RE771 GY-WH

SIGRTN
17 16

EXHAUST GAS
TEMPERATURE
SENSOR 2
151-74
VE723 GN-VT C01756 C01756
EGT2
56 1 2
RE723 WH-BU
SIGRTN
2
Hot at Hot at
all times all times 2.0L
AUXILIARY
ELECTRONIC JUNCTION
ENGINE BOX (AJB)
CONTROLS F33
60A 11-11
24-1 13-66

SB133
SB117

RD
RD

AUXILIARY
JUNCTION
FUEL BOX (AJB)
1 3 PUMP 11-11
RELAY

2 5 F66 F65
40A 20A
13-71 13-71
YE-VT
CE226

WH-OG
BU-WH
CE608 VT-GN

CB166

CB165
32 C0139

9 C0134 17 18 C0145

WH-OG
BU-WH

CB165
CB166
YE-VT
CE226

32 C0175E 4 C04350
1 C04000
FUEL FILTER
C0175B C0144 C04350 HEATER/
FUEL PUMP VE823 BU-BN VE823 BU-BN
RELAY CTRL WIF WATER-IN-FUEL

WH-OG
66 12 2 SENSOR

CB165
151-102
RE823 GY-YE RE823 GY-YE
SIGRTN
42 33 1

3 C04350 X
POWERTRAIN
CONTROL 24-12
MODULE (PCM) S413 fuel fired booster heater
151-66 151-72 ELECTRONIC
ENGINE
BK-VT
GD412

CONTROLS

G0408
10-65
BODY
ELECTRONIC
CONTROL
MODULE (BCM) ENGINE 2.0L
FUEL CONTROLS
PUMP 11-17
ON 24-11

29 C02280F X
C0139 - 30
CE261 GY-OG
GY-OG
CE261

WH-OG
CB165
41 C0175B

POWERTRAIN
IES CONTROL
MODULE (PCM) 1 C0433
151-66
FUEL PUMP
VPWR FUEL CONTROL
C0175B VE518 C0144 C04000 C0433 MODULE
FPM FPM 151-103
25 BN-WH 10 2 7

VE225
FPC FPC
54 YE-OG 11 3 3
FP FP
GND PWR RTN

4 5 8 C0433

BK-YE
GD413
SHIELD

INSTRUMENT
7 8 C04000 PANEL
CLUSTER (IPC)
60-11
BK-YE
GD413

C04000 - 5 C0145 - 1 C0210 - 11 C0220

VMC11 FUEL
SENDER 1
YE-VT 1

WH-BN
YE-GY
BK-YE
GD413

RE515
CE515

1 4 2 C0463
FUEL PUMP AND
SENDER UNIT
M 151-103

3 C0463
C04000 - 4 C0145 - 13 C0210 - 10 FUEL
RMC32 SENDER 1
G0412 RETURN
10-66 GN-BU 7
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-72

FUEL RAIL
C0175E RE238 BU-BN C0106 PRESSURE (FRP)
SIGRTN SENSOR
28 2 151-73

VE727 BU
FRP
38 1
LE238 GY
VREF
13 3

FUEL
VE773 WH-BN C01475 PRESSURE
LPFST AND TEMPERATURE
54 4 SENSOR
151-74
LE423 GN
VREF
9 3
VE761 BN-BU
LPFSP
51 1
RE232 VT-WH
SIGRTN
24 2

FUEL RAIL
PRESSURE (FRPS)
SOLENOID
151-73

VE377 BN C01794 C01794

FRP2
31 1 2
RE377 WH-VT
SIGRTN
16

FUEL
INJECTION
PUMP
151-74

CE226 YE-VT C01589 C01589

FIP M
76 1 2

RE226 GN-VT
SIGRTN
77
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-72

CRANKSHAFT
POSITION (CKP)
SENSOR
151-74

C0175E VE711 YE-VT C01930

CKP
45 1

LE135 GY-VT
VREF
7 3
RE135 GN-BN
SIGRTN
22 2

FUEL INJECTOR 1
151-72
CE205 GN-BU C01561 C01561
INJ1
93 1 2
RE205 YE-BU
INJ1RTN
94

FUEL INJECTOR 2
151-72
CE206 GY-YE C01562 C01562
INJ2
83 1 2
RE206 BU-OG
INJ2RTN
84

FUEL INJECTOR 3
151-72
CE207 VT-GY C01563 C01563
INJ3
78 1 2
RE207 GN-VT
INJ3RTN
79

FUEL INJECTOR 4
151-72
CE208 YE-OG C01564 C01564
INJ4
88 1 2
RE208 BU
INJ4RTN
89
2.0L POWERTRAIN
CONTROL
MODULE (PCM)
151-66 151-72

CE378 GN-VT C0175B

VREF
14

RE320 BU
SIGRTN
33
2 3 C0128
MASS AIRFLOW/
INTAKE AIR TEMPERATURE
VREF 5V (MAF/IAT) SENSOR
151-66
DIGITAL

1 4 C0128
VE740 VT-GY
IAT
71
VE807 YE-VT
MAF
44

MANIFOLD
ABSOLUTE
PRESSURE
AND TEMPERATURE
(MAPT) SENSOR
151-73

C01935 LE329 BU C0175E

VREF
2 5

VE803 BU-GN
MAP
1 57
VE740 VT-GY
IAT2
3 55
RE329 WH-BN
SIGRTN
4 20
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-72

DIESEL PARTICULATE
C01472 FILTER
C0175E RE749 GY-BU PRESSURE SENSOR
SIGRTN
2 151-73
26

VE749 VT
VREF
11 3
VE758 BU-BN
DPF
43 1

CAMSHAFT
C01275 POSITION (CMP)
LE143 GN-BN SENSOR
VREF 151-73
12 1

RE143 VT
SIGRTN
27 2
VE706 BN-BU
CMP
59 3

VE774 YE-BU
OPS
49
1 C0103

ENGINE
OIL PRESSURE
(EOP) SWITCH
ENGINE OIL 151-74
1 2 1) Low pressure
CE908 BU-BN C01149 QUALITY,
OLS TEMPERATURE 2) Normal level
35 3 AND LEVEL
SENSOR
RE908 BN-BU 151-74
SIGRTN
34 1
VE717 BU-OG
OTS
50 2
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-66 151-72
ENGINE
COOLANT TEMPERATURE
(ECT) SENSOR
151-73
C0175E VE716 YE C01064 C01064
ECT
39 1 2
RE141 BN-GN
SIGRTN
30

CYLINDER HEAD
TEMPERATURE
(CHT) SENSOR
151-74
VE712 BU-GY C0107 C0107
CHT
40 1 2
RE138 BU-GN
SIGRTN
15

AMBIENT AIR
TEMPERATURE
(AAT) SENSOR
151-69
C0175B C0139 C0132 C0132
VE750 GN-BU VE750 GN-BU
AAT
52 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
35 27
POWERTRAIN
CONTROL
MODULE (PCM)
2.0L
151-66 151-72

TURBOCHARGER
ACTUATOR
C0175E LE437 YE C01718 151-73
VREF
8 5
VE825 VT-BN
TCA
36 4
RE437 GY
SIGRTN
23 3

CE431 WH
TCA+ M
92 1
CE432 BU
TCA-
87 2

EXHAUST GAS
RECIRCULATION
LE180 YE-BU C01389 (EGR) VALVE
VREF 151-73
4 3
VE721 WH-OG
EGRV
37 5
RE180 GY-BU
SIGRTN
19 4

LE139 BN-YE
EGRV+ M
91 1
RE139 GY
EGRV-
86 2

C0175B C0139
VE925 GN-WH
PTO_RPM
67 29
VE925 GN-WH VE925 GN-WH
GND SENSE
43 28
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-66 151-72

THROTTLE
BODY
C0175E LE428 BU-WH C01368 151-73
ETCREF
10 1
VE802 GY
TP1
52 5
RE427 YE-VT
ETCRTN
25 3

LE134 YE
TACM+ M
82 6
RE134 BU-OG
TACM-
81 4

C0175B RE136 VT-GN C0139 RE136 VT-GN

APPRTN1
31 45
LE136 GN-OG LE136 GN-OG
APPVREF1
12 46 1 3 C02040

ACCELERATOR
PEDAL
C02040 POSITION (APP)
VE701 YE-OG VE701 YE-OG SENSOR
APP1 151-93 151-97
50 43 2

VE702 BU-WH VE702 BU-WH

APP2
49 42 5

4 6 C02040
RE137 YE-GN RE137 YE-GN
APPRTN2
30 19
LE137 BU-GY LE137 BU-GY
APPVREF2
11 20
Hot at
all times 2.0L
AUXILIARY
JUNCTION
F18 BOX (AJB)
10A 11-11
13-86

POWERTRAIN
CONTROL
MODULE (PCM)

YE-RD
SB118
151-66

CCB15 BN-GN C0139 - 37 CCB15 BN-GN C0175B

BPS
3

1 2 C0278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-93 151-97

4 3 C0278

BK-GN

BK-GY
GD240

GD235
S288 S286
VT-WH
CCB08

BK-GN

BK-GY
GD240

GD235
G0307 G0304
BODY 10-52 10-49
CONTROL
MODULE (BCM)
11-17 left hand drive right hand drive

C0268 - 14 C0139 - 41
C02280A CCB08 VT-WH S260 CCB08 VT-WH CCB08 VT-WH
BOO FEED BPP
1 22
MANUAL TRANSMISSION 2.0L

POWERTRAIN
CONTROL
MODULE (PCM)
151-66

CLUTCH
C0139 C0260
C0277 PEDAL
C0175B LE403 GN LE403 GN
VREF POSITION
7 38 2 2 (CPP) SENSOR
151-93 151-97
VE772 YE-BU VE772 YE-BU
CPP1
64 14 3 3
VE757 WH VE757 WH
CPP2
45 34 1 1
RE403 WH-VT RE403 WH-VT
SIGRTN
26 39 4 4

NEUTRAL
POSITION
SENSOR
C0134 C0133 151-75
VET72 GY-BU VET72 GY-BU C01306
GEAR NEUTRAL #2
46 6 11 1
RET71 GY-BN RET71 GY-BN
SIGRTN
27 33 13 4
VET71 GN-VT VET71 GN-VT
GEAR NEUTRAL #1
65 8 10 3
LET71 YE-GN LET71 YE-GN
VREF
8 7 12 2
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-66

air conditioning

C0175B RH433 BU-GY

SIGRTN
29
1 C01260

AIR CONDITIONING
VH433 VT-OG C01260 (A/C) PRESSURE
ACPT TRANSDUCER
10 3 151-66

2 C01260
LH315 WH-GN
VREF
48
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
151-66 151-72

C0175B VDB04 WH-BU MODULE

HS1 CAN +
COMMUNICATIONS
60 NETWORK
HS1 CAN - VDB05 WH
14-12
61

CDC25 BN-GN
SMCS
53
CDC12 YE STARTING
SMC SYSTEM
36 20-4 20-5
CDC35 BU-WH
START
6

CE170 WH-BU AUTO-START-STOP SYSTEM

SME 40-3
74

C0175E VDC46 BU-BN CHARGING

GENMON SYSTEM
66 12-5

C0175B CH302 WH-BN

ACCR
20 MANUAL CLIMATE CONTROL SYSTEM
54-19
VE462 WH-BN
VACC
57

automatic transmission

CET40 GN-OG TRANSMISSION CONTROLS

TRSW-PN 29-1
5

manual transmission

CET47 BU REVERSING LAMPS

REVERSE 93-4
39

CEC02 GN-BU
HFC
56 COOLING FAN
33-2 33-3
CEC01 WH-BU
LFC
17
Hot at all times Hot in Start or Run
AUXILIARY
2.0L
JUNCTION
BOX (AJB)
F21 F43 11-11
15A 5A
13-87 13-74

GY-RD

CB143
SB121

GY
8 9 C0139

S121
S104
GY-RD

GY-RD

CB143
SB121

SB121

GY
1 31 33 C01822

TRANSMISSION
VBATT VBATT VPWR CONTROL
MODULE (TCM)
151-66

C01822 VDB04 WH-BU MODULE

HS1 CAN + COMMUNICATIONS
47 NETWORK
VDB05 WH 14-12
HS1 CAN -
48

POWERTRAIN
C0175B CONTROL
CET40 GN-OG MODULE (PCM)
PARK-NEUTRAL TRSW-PN
16 5 24-23

PWR GND PWR GND CASE GND

9 39 41 C01822
BK-YE
GD409

GD409

GD121
BK

S117 S118
BK-YE
GD409

GD121
BK

G0106 G0104
10-32 10-32
6F55 TRANSMISSION
TRANSMISSION CONTROL
MODULE (TCM)
2.0L
151-76
151-66

C0168 C0134 C01822

TSS VET33 WH-OG VET33 WH-OG
TSS
19 13 50

TSS / OSS VPWR LE111 VT-GN LE111 VT-GN

VREF
20 2 20

OSS VET26 BN-GN VET26 BN-GN

OSS
10 26 51
TSS / OSS GND RET24 BN-BU
9

TR GND RET24 BN-BU S152 RET24 BN-BU

TSS / OSS / TR GND
8 33 49
TRS C0140
TR-1 VET29 VT-WH VET29 VT-WH
TR-1
4 10 34
TR-2 VET30 YE VET30 YE
TR-2
5 11 35
TR-3 VET28 GY-VT VET28 GY-VT
TR-3
6 9 36
TR-4 VET31 BU-OG VET31 BU-OG
TR-4
7 12 37

TFT VET27 BN-YE VET27 BN-YE

TFT
2 8 54

TFT SIG RTN C0134 - 32 S119

RET42 WH-BN RET42 WH-BN
SIGRTN
3 46

WH-BN
SELECTOR LEVER

RET42
ASSEMBLY
37-1

C02810 C0210 C0139

CET34 BN-GN CET34 BN-GN CET34 BN-GN
TCS GND
TCS GND
3 17 15 53

SST GND RET42 WH-BN RET42 WH-BN

4 20 21
CET43 GY CET43 GY CET43 GY
SST + SST +
5 22 18 58
CET42 GN-VT CET42 GN-VT CET42 GN-VT
SST - SST -
6 48 17 59
2.0L

TRANSMISSION
CONTROL
MODULE (TCM)
151-66
6F55
TRANSMISSION
151-76

C0140
C0168 CET25 BU-GN CET25 BU-GN C01822
TSPC
15 7 2

SSA CET05 BU-WH CET05 BU-WH

SSA
13 1 42

SSB CET06 GN-BN CET06 GN-BN

SSB
16 2 7

SSC CET07 GY-OG CET07 GY-OG

SSC
17 3 6

SSD CET08 BN-WH CET08 BN-WH

SSD
12 4 43
C0134 - 20 S114
SSE CET18 GY-YE CET18 GY-YE
SSE
1 11
C0140
LPC CET09 YE-VT CET09 YE-VT
LPC
18 5 4

TCC CET10 BU-GY CET10 BU-GY

TCC
14 6 3
Hot at all times Hot in Start or Run
AUXILIARY
2.0L
JUNCTION
BOX (AJB)
F22 F43 11-11
25A 5A
13-87
BN-RD 13-74

CB143
SB122

GY
3 9 C0139
BN-RD
SB122

S104

18 1 C0134
BN-RD

CB143
SB122

TRANSMISSION
CONTROL
1 2 C01792 MODULE (TCM)
151-66
TRANSMISSION
VBATT VPWR AUXILIARY
OIL PUMP
151-76

C01792 C0134 C01822

VYT11 VT-GY VYT11 VT-GY
AUX TRANS FLUID AUX TRANS FLUID
PRESS CONTROL 4 10 17 PRESS CONTROL

VYT12 YE-GN VYT12 YE-GN

AUX TRANS FLUID AUX TRANS FLUID
PRESS MONITOR 5 11 52 PRESS MONITOR

GND

6 C01792
GD121
BK

S150
GD121
BK

G0111
10-36
Hot at
all times 2.2L
BODY
CONTROL
F18 MODULE (BCM)
10A 11-5
13-47

3 C2280B

POWERTRAIN
CONTROL
MODULE (PCM)

YE-RD
SBP18
23-12

CCB15 BN-GN C139 - 37 CCB15 BN-GN C175B

BPS
12

1 3 C278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-30 151-34

4 2 C278

VT-WH

BK-GY
CCB08

GD135
S270

BK-GY
GD135

G304
BODY 10-16
CONTROL
MODULE (BCM)
11-5

C139 - 41
C2280C CCB08 VT-WH S286 CCB08 VT-WH CCB08 VT-WH
STOP LIGHT
SWITCH BPP
58 46
BODY POWERTRAIN
CONTROL
MODULE (BCM)
CONTROL 2.2L
MODULE (PCM)
11-5 23-13

CLUTCH S268 C139

C2280C CE903 BU-OG CE903 BU-OG C175B
BOT CPP-BT
SWITCH 52 40 36

CE904 GN-VT
CPP-TT
31 21

BU-OG

GN-VT
CE903

CE904
3 5 C260

BU-OG

GN-VT
CE903

CE904
auto-start-stop
1 C257 2 C2354

CLUTCH PEDAL CLUTCH PEDAL

POSITION (CPP) POSITION (CPP)
BOTTOM OF TOP OF
TRAVEL SWITCH TRAVEL SWITCH
151-30 151-34 151-30 151-34

2 C257 3 C2354

BK-GY
GD135
BK-GY
GD135

early production
BK-GY

S208
GD135

late production

6 C260

S270
BK-GY
GD135

G304
10-16
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
23-10

THROTTLE
BODY
C175E LE428 BU-WH C1449 151-10
ETCREF
2 3
VE820 GY
TP1
16 6
RE427 YE-VT
ETCRTN
8 2

LE134 YE
TACM+ M
43 4
RE134 BU-OG
TACM-
44 1

C175B RE136 VT-GN C139 RE136 VT-GN

APPRTN1
13 45
LE136 GN-OG LE136 GN-OG
APPVREF1
38 19 1 3 C2040

ACCELERATOR
PEDAL
C2040 POSITION (APP)
VE701 YE-OG VE701 YE-OG SENSOR
APP1 151-30 151-34
20 43 2

VE702 BU-WH VE702 BU-WH

APP2
19 42 5

4 6 C2040
RE137 YE-GN RE137 YE-GN
APPRTN2
22 46
LE137 BU-GY LE137 BU-GY
APPVREF2
44 20
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 SWM HS CAN - HS CAN +

69 35 51 52 C2280D
SBP18 YE-RD POWER
DISTRIBUTION
13-47

WH-BU
VDB05

VDB04
YE-RD
SBP18

WH
VDN05
YE-GY
1 C2414

STEERING COLUMN
CONTROL
VBATT MODULE (SCCM)
151-22

MODULE
COMMUNICATIONS
MULTIFUNCTION SWITCH NETWORK
14-3
lane departure warning
C2414 VDN05 YE-GY
LIN 1 SWM S216
11
VDN05 YE-GY
LIN 1 SWM
2

VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
4 NETWORK
VDB05 WH 14-3
HS CAN -
GND 5

14 C2414
GD165
BK

S219
GD165
BK

G205
10-8
WITHOUT:
ADAPTIVE CRUISE CONTROL 2.2L
CLUSTER AND
PANEL ILLUMINATION
BK
71-3
1 C2366

STEERING WHEEL
SWITCH
LH LOWER
1) On/Off
2) Reset/Cancel
340 732 3) Set +
4) Set -
5) Asld On/Off
151-23
5 3 215

2 4
147

362 1

2 4 3 5 C2366

BN
RD-BU
S2010
WH
RD

BN
8 15 16 10 C218B
CLOCKSPRING
151-22 151-23

5 C218A

BK-GY
GD184
STEERING COLUMN
CONTROL
CRUISE CRUISE CRUISE MODULE (SCCM)
SIG 1 GND SIG 2 151-22
S226

BK-GY
GD184
G206
10-9
ADAPTIVE CRUISE CONTROL
2.2L
CLUSTER AND
PANEL ILLUMINATION
BK
71-3
1 C2366

STEERING WHEEL
SWITCH
LH LOWER
1) On/Off
1540 732 2) Reset/Cancel
3) Set +
4) Set -
5 3 5) Asld On/Off
158 215 6) Distance -
7) Distance +
151-23
6 4
113 147

7
143

1 2

2 4 3 5 C2366

BN
RD-BU
S2010
WH
RD

BN
8 15 16 10 C218B
CLOCKSPRING
151-22 151-23

5 C218A

BK-GY
GD184
STEERING COLUMN
CONTROL
CRUISE CRUISE CRUISE MODULE (SCCM)
SIG 1 GND SIG 2 151-22
S226

BK-GY
GD184
G206
10-9
Hot at
all times 2.0L
AUXILIARY
JUNCTION
F18 BOX (AJB)
10A 11-11
13-86

POWERTRAIN
CONTROL
MODULE (PCM)

YE-RD
SB118
24-20

CCB15 BN-GN C0139 - 37 CCB15 BN-GN C0175B

BPS
3

1 2 C0278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-93 151-97

4 3 C0278

BK-GN

BK-GY
GD240

GD235
S288 S286
VT-WH
CCB08

BK-GN

BK-GY
GD240

GD235
G0307 G0304
BODY 10-52 10-49
CONTROL
MODULE (BCM)
11-17 left hand drive right hand drive

C0268 - 14 C0139 - 41
C02280A CCB08 VT-WH S260 CCB08 VT-WH CCB08 VT-WH
BOO FEED BPP
1 22
MANUAL TRANSMISSION 2.0L

POWERTRAIN
CONTROL
MODULE (PCM)
24-21

CLUTCH
C0139 C0260 C0277 PEDAL
C0175B LE403 GN LE403 GN
VREF POSITION
7 38 2 2 (CPP) SENSOR
151-93 151-97
VE772 YE-BU VE772 YE-BU
CPP1
64 14 3 3
VE757 WH VE757 WH
CPP2
45 34 1 1
RE403 WH-VT RE403 WH-VT
SIGRTN
26 39 4 4

THROTTLE
BODY
C0175E LE428 BU-WH C01368 151-73
ETCREF
10 1
VE802 GY
TP1
52 5
RE427 YE-VT
ETCRTN
25 3

LE134 YE
TACM+ M
82 6
RE134 BU-OG
TACM-
81 4

C0175B RE136 VT-GN C0139 RE136 VT-GN

APPRTN1
31 45
LE136 GN-OG LE136 GN-OG
APPVREF1
12 46 1 3 C02040

ACCELERATOR
PEDAL
C02040 POSITION (APP)
VE701 YE-OG VE701 YE-OG SENSOR
APP1 151-93 151-97
50 43 2

VE702 BU-WH VE702 BU-WH

APP2
49 42 5

4 6 C02040
RE137 YE-GN RE137 YE-GN
APPRTN2
30 19
LE137 BU-GY LE137 BU-GY
APPVREF2
11 20
Hot in Start or Run Start/Stop Bus 2.0L
BODY
CONTROL
MODULE (BCM)
F36 F13 11-17
15A 7.5A
13-101 13-102
HS1 CAN - HS1 CAN +

15 8 C02280A 9 10 C02280G

WH-BU
VDB05

VDB04
GY-RD
SBP13

WH
S244

GY-RD
BU-BN
CBP36

SBP13

9 1 C02414
MODULE
STEERING COLUMN COMMUNICATIONS
CONTROL NETWORK
VPWR VBATT MODULE (SCCM) 14-11
151-85

MULTIFUNCTION SWITCH

C02414 VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
4 NETWORK
VDB26 GY-BU 14-14
HS2 CAN -
5

GND GND

10 14 C02414
GD265

GD265
BK

S219
GD265
BK

G0205
10-41
WITHOUT:
ADAPTIVE CRUISE CONTROL 2.0L
CLUSTER AND
PANEL ILLUMINATION
BK
71-10
1 C02366

STEERING WHEEL
SWITCH
LH LOWER
1) On/Off
2) Reset/Cancel
340 732 3) Set +
4) Set -
5) Asld On/Off
151-86
5 3 215

4
147

2
362 1

2 4 3 5 C02366

BN
RD-BU
S2010
WH
RD

BN
8 15 16 10 C0218B
CLOCKSPRING
151-85 151-86

5 C0218A

BK-GY
GD284
STEERING COLUMN
CONTROL
CRUISE CRUISE CRUISE MODULE (SCCM)
SIG 1 GND SIG 2 151-85
S226

BK-GY
GD284
G0206
10-42
ADAPTIVE CRUISE CONTROL 2.0L
CLUSTER AND
PANEL ILLUMINATION
BK
71-10
1 C02366

STEERING WHEEL
SWITCH
LH LOWER
1) On/Off
1540 732 2) Reset/Cancel
3) Set +
4) Set -
5 3 5) Asld On/Off
158 215 6) Distance -
7) Distance +
151-86
6 4
113 147

7
143

1 2

2 4 3 5 C02366

BN
RD-BU
S2010
WH
RD

BN
8 15 16 10 C0218B
CLOCKSPRING
151-85 151-86

5 C0218A

BK-GY
GD284
STEERING COLUMN
CONTROL
CRUISE CRUISE CRUISE MODULE (SCCM)
SIG 1 GND SIG 2 151-85
S226

BK-GY
GD284
G0206
10-42
ADAPTIVE CRUISE 2.0L
Hot in Start or Run
WITHOUT STOP AND START AUXILIARY
JUNCTION
F44 BOX (AJB)
10A 11-11
13-75

CB144
VT
C0192 - 1 S253 C02513 BK C02513
CDC78 BK CDC78 VT-BN
5 7
10 C01582

PROXIMITY WARNING
RADAR UNIT
VPWR 151-68

C01582 VDB25 BK
HS2 CAN + 14-13 MODULE
8 COMMUNICATIONS
VDB26 BK NETWORK
HS2 CAN - 14-13
7
AUTO-DIMMING
INTERIOR
MIRROR
124-10

C0192 C0311 C0913 C09012

VMF04 BK VMF04 BN-BU VMF04 BN-BU VMF04 BN-BU
CAN + CAN +
9 9 44 1 3
VMF05 BK VMF05 GY-BU VMF05 GY-BU VMF05 GY-BU
CAN - CAN -
18 10 45 2 4

GND

4 C01582
anti-theft alarm system

GD124 BK S185 GD124 BK GD124 BK-VT S131 GD124 BK-VT

6 G0109
10-35
ADAPTIVE CRUISE 2.0L
Hot in Start or Run
STOP AND START AUXILIARY
JUNCTION
F44 BOX (AJB)
10A 11-11
13-75

LOW VOLTAGE
DIRECT CURRENT/

CB144
DIRECT CURRENT

VT
(DC/DC) CONVERTER
40-3 40-6

C0192 - 1 S253 C02513 C02513

CDC78 BK CDC78 VT-BN
5 7
10 C01582

PROXIMITY WARNING
RADAR UNIT
VPWR 151-68

C01582 VDB25 BK
HS2 CAN + 14-13 MODULE
8 COMMUNICATIONS
VDB26 BK NETWORK
HS2 CAN - 14-13
7
AUTO-DIMMING
INTERIOR
MIRROR
124-10

C0192 C0311 C0913 C09012

VMF04 BK VMF04 BN-BU VMF04 BN-BU VMF04 BN-BU
CAN + CAN +
9 9 44 1 3
VMF05 BK VMF05 GY-BU VMF05 GY-BU VMF05 GY-BU
CAN - CAN -
18 10 45 2 4

GND

4 C01582
anti-theft alarm system

GD124 BK S185 GD124 BK GD124 BK-VT S131 GD124 BK-VT

6 G0109
10-35
Hot in Start Hot at
or Run all times 2.2L
BATTERY
JUNCTION
F39 F30 BOX (BJB)
15A 60A 11-3
13-9 13-4

VT-WH

BN-RD
CBB39

SBB30
S110

S109
VT-WH

VT-WH
BN-RD

BN-RD
CBB39

CBB39
SBB30

SBB30
BATTERY
JUNCTION
BOX (BJB)
LOW SPEED HIGH SPEED 11-3
1 3 COOLING FAN 3 1 COOLING FAN
RELAY RELAY

2 5 5 2
GN-BU
CEC09

CEC07
BN
C1027 C1027
S116
1 2

WH-BU
GN-BU
CEC02

CEC01
COOLING 2 C1074
FAN
RESISTOR COOLING
151-2 FAN
MOTOR
M 151-2

52 C175B 1 C1074 27 C175B

POWERTRAIN POWERTRAIN
BK-BU
GD119

LFC CONTROL HFC CONTROL

MODULE (PCM) MODULE (PCM)
23-17 23-17
G103
10-1 10-32
Hot in Start Hot at
or Run all times
SINGLE FAN 2.0L
BATTERY
JUNCTION
F38 F19 BOX (BJB)
10A 60A 11-15
13-70 13-67
GY-BU

BU-RD
CBB38

SBB19
S122

S110
GY-BU

GY-BU
BU-RD

BU-RD
CBB38

CBB38
SBB19

SBB19
BATTERY
JUNCTION
BOX (BJB)
LOW SPEED HIGH SPEED 11-15
1 3 COOLING FAN 3 1 COOLING FAN
RELAY RELAY

2 5 5 2
WH-BU

GN-BU

GN-BU
CEC01

CEC09

CEC07

CEC02
BN
C01027 C01027
S128 S116 S111
1 2

COOLING 2 C01074
FAN
RESISTOR COOLING
151-66 FAN
MOTOR
151-66
WH-BU

GN-BU
CEC01

CEC02
17 C0175B 1 C01074 56 C0175B

POWERTRAIN POWERTRAIN
BK-BU
GD119

LFC CONTROL HFC CONTROL

MODULE (PCM) MODULE (PCM)
24-23 24-23
G0103
10-31
TWIN FANS 2.0L
Hot at Hot in Start Hot at
all times or Run all times
BATTERY
JUNCTION
F18 F38 F19 BOX (BJB)
40A 10A 40A 11-15
13-67 13-70 13-67

S110

GY-BU

BU-RD
YE-RD

CBB38

CBB38
SBB18

SBB19
BATTERY
JUNCTION
BOX (BJB)
11-15
COOLING HIGH SPEED LOW SPEED
4 5 1 FAN 1 3 COOLING FAN 1 3 COOLING FAN
RELAY RELAY RELAY

3 2 2 5 2 5
F8
20A

CEC07 BN

GN-WH
WH-BU
GN-BU

GN-BU
YE-OG

BK-BU

VT-GY

VT-GY
CEC06

CEC02

CEC01

CEC08
GD119

CEC05

CEC05
S138 S128
S115
1 C01078
1 C01048
COOLING
BK-BU
GD119

FAN COOLING
MOTOR 2 S113 FAN
M 151-66 G0103 MOTOR 1
10-31 151-66
M

WH-BU
GN-BU

VT-GY
CEC02

CEC05

CEC01
2 C01078
2 C01048
BK-BU
GD119

56 17 C0175B
S115
POWERTRAIN
CONTROL
BK-BU
GD119

HFC LFC MODULE (PCM)

24-23
G0103
10-31
TRANSMISSION
Hot at all times Hot at all times CONTROL 2.0L
BODY MODULE (TCM)
CONTROL 29-2
MODULE (BCM)
11-17 TCS GND SIGRTN SST + SST -

53 46 58 59 C01822

S119
12 C02280E 45 C02280B

WH-BN
BN-GN

GN-VT
CET34

RET42

CET43

CET42
GY
BU-OG

CLN17
CET53

INSTRUMENT

BN
PANEL CLUSTER 15 21 18 17 C0139
(IPC)
PARK 60-9
DETECT
16 C0210

WH-BN
BN-GN

GN-VT
CET34

RET42

CET43

CET42
S225 9 C0220

GY
17 20 22 48 C0210

WH-BN
BU-OG

BN-GN

GN-VT
CLN17
CET53

CET52

CET34

RET42

CET43

CET42
GN

GY
BN

12 7 9 3 4 5 6 C02810

SELECTOR LEVER
ASSEMBLY
SOL CTRL ILLUMINATION PDS NO TCS GND SST GND SST + SST - 151-77 151-81

SOL GND PDS GND PARK BRAKE

11 8 10 C02810

WH-BN
CDC41
BK-GY

BK-GY
GD284

GD284

3 C0250
S227
IGNITION
INHIBIT SWITCH
13-72
BK-GY
GD284

G0206
10-42
BODY
CONTROL 2.2L
MODULE (BCM)
START/STOP 11-5
START/STOP SWITCH
ENABLE STATUS
HS CAN - HS CAN + SWITCH LED

51 52 38 16 C2280D

WH-BU
VDB05

VDB04
WH
CLUSTER AND
PANEL ILLUMINATION
INSTRUMENT 71-2
PANEL

GN-BU
GY-VT
MODULE

CYT30

CYT10
CLUSTER (IPC)
60-1 COMMUNICATIONS
NETWORK
14-3

CLN17
SMCS

BN
12 C220 6 1 3 C2195

START
WH-GN
CDC54

CONTROL
UNIT
151-15 151-19

MODULE
49 C210 COMMUNICATIONS
NETWORK
14-5
WH-GN
CDC54

5 2 C2195

BK-GY

BK-GY
22 C139
GD184

GD184
WH-BU
WH-GN

VDB05

VDB04
CDC54

S226
WH

41 11 10 C175B
BK-GY
GD184

POWERTRAIN
SMCS HS CAN - HS CAN + CONTROL
MODULE (PCM)
23-17
G206
10-9
HEATING,
VENTILATION AND
AIR CONDITIONING (HVAC)
2.0L
START/STOP CONTROL MODULE
START/STOP START/STOP SWITCH 54-14 54-16
DISABLE ENABLE STATUS
MS CAN - MS CAN + SWITCH SWITCH LED

24 23 29 6 22 C02357A

GY-OG
VDB07
VT-OG

VDB06

VT-GY
CE937
14 C0210

VT-GY
CE937
CLUSTER AND
PANEL ILLUMINATION
71-9

GN-BU
GY-VT
MODULE

CYT30

CYT10
COMMUNICATIONS 4 C03665
NETWORK
14-16 14-18 Not used

CLN17
BN
6 1 3 C02195

START
CONTROL
UNIT
151-78 151-82

5 2 C02195

GD284 BK-GY

BK-GY
GD284
S226

BK-GY
GD284
G0206
10-42
Hot at all times Hot in Start or Run
AUXILIARY 2.0L
JUNCTION
RUN/START BOX (AJB)
F15 F44 RELAY 11-11
50A 10A 13-73
13-86 13-75 2

POWERTRAIN

CDC55
BN-VT
CONTROL
MODULE (PCM)
SME 24-23
WH-RD
SB115

74 C0175B
WH-BU
CE170

CB144
25 C02280F

VT
26 C0139 BODY
CONTROL
RUN/START MODULE (BCM)
(FET) 11-17
8 2 7 C02513
LOW VOLTAGE
DIRECT CURRENT/
VBATT ENGINE START SIGNAL VPWR DIRECT CURRENT (DC/DC)
CONVERTER
151-93 151-95

GND HS1 CAN - HS1 CAN +

6 4 1 C02513
HS1 HS1
CAN - CAN +
WH-BU
VDB05

VDB04
WH

9 10 C02280G

WH-BU
VDB04
VDB05
WH
GD233
BK

14-12 14-12

MODULE 14-11 14-11

COMMUNICATIONS
NETWORK
MODULE
G0303 COMMUNICATIONS
10-47 NETWORK
LOW VOLTAGE
DIRECT CURRENT/ 2.0L
DIRECT CURRENT (DC/DC)
CONVERTER
151-93 151-95

Hot at all times

C02513 CDC77 GY-YE
PWR OUT 1
3

BODY
CONTROL
MODULE (BCM)
11-17

Start/Stop Bus
C02280G

HEATING,
F12 C02280A SBP12 GN-RD S230 SBP12 GN-RD C02357A VENTILATION AND
AIR CONDITIONING (HVAC)
7.5A 10 32 CONTROL MODULE
54-14
multi-function
display

SBP12 GN-RD C0263 - 6

Not used

INSTRUMENT
F13 SBP13 GY-RD S244 SBP13 GY-RD C0220 PANEL
CLUSTER (IPC)
7.5A 8 3 60-9

STEERING COLUMN
FJ SBP13 GY-RD C02414 CONTROL
MODULE (SCCM)
1 31-10 81-10
40-5 85-9 90-12
146-1

GATEWAY
SBP13 GY-RD C02431 MODULE A
(GWM)
24 14-8
BODY
CONTROL 2.0L
MODULE (BCM)
11-17
Start/Stop Bus

40-4
FJ

RADIO
F32 C02280C SBP32 VT-RD C0311 - 39 C0900 - 7 SBP32 VT-RD C09026 FREQUENCY (RF)
RECEIVER
10A 22 6 117-33 118-2

multi-function
display

FRONT CONTROL/
C02280A SBP32 VT-RD C0264 - 6 S207 SBP32 VT-RD C02123A DISPLAY INTERFACE
MODULE (FCDIM)
9 1 130-18 145-7

SYNC
SBP32 VT-RD C02383 MODULE [APIM]
130-24
1

SYNC without navigation

GLOBAL POSITIONING
SBP32 VT-RD C02398 SYSTEM MODULE (GPSM)
130-24
1

MESSAGE
SBP32 VT-RD C0253 CENTER
SWITCH
1 60-15

multi-function
display
AUDIO
F33 SBP33 RD C0265 - 7 SBP33 RD C0240A FRONT
CONTROL
20A 22 1 MODULE (ACM)
130-13 130-19
LOW VOLTAGE
DIRECT CURRENT/ 2.0L
DIRECT CURRENT (DC/DC)
CONVERTER
151-93 151-95
Hot in Start
or Run PROXIMITY WARNING
C02513 CDC78 VT-BN S263 CDC78 VT-BN C0192 - 1 C01582
CDC78 BK RADAR UNIT
PWR OUT 2 31-14 146-4
5 10

CDC78 VT-BN C0311 - 28

Not used

CDC78
VT-BN

AUXILIARY
C0300 - 59 CDC78 VT-BN C09028 - 17 CDC78 VT-BN C0937 BLOWER
CDC78
VT-BN

MOTOR
10 SWITCH
52-6

liftgate
28 C0300
REAR
CDC78 BK C0406 - 8 CDC78 BK C0494 - 5 SMP22 YE-VT C04357 PARKING AID
CAMERA
1 145-6
CDC78
VT-BN

rear doors

REAR
C0935 - 8 CDC78 BK C0422 - 8 CDC78 BK C0495 - 5 SMP22 YE-VT C04357 PARKING AID
CAMERA
1 145-6
Hot at all times Hot in Start or Run
AUXILIARY 2.0L
JUNCTION
BOX (AJB)
F54 F44 11-11
15A 10A
13-84 13-75

GY-RD

CB144
SB154

VT
24 29 C0145

13 12 C0408
BN-RD

CB144
SB154

VT
18 C04396 16 C04396

VEHICLE
DYNAMICS
VBATT VPWR MODULE
(VDM)
151-100

C04396 VDB25 GN-OG

HS2 CAN + 14-13
MODULE
54 COMMUNICATIONS
NETWORK
VDB26 GY-BU 14-13
HS2 CAN -
53

ECU GND CASE GND

1 37 C04396
BK-YE

BK-YE
GD406

GD406

GD406 BK-YE C0408 - 20 GD406 BK-YE

S425 G0406
10-64
Hot at all times
AUXILIARY 2.0L
JUNCTION
F53 BOX (AJB)
40A 11-11
13-84

C0144 - 21 C0145 - 19
SB153 GY-RD

BATTERY
JUNCTION
BOX (BJB)
11-15
REAR AIR
1 5 SUSPENSION
RELAY

2 3
WH-VT

BU-BN
YE-VT
CCL01

RCL01

CCL08
26 22 14 C0144

S420

1 4 C04620

AIR
SUSPENSION
WH-VT

BN-VT
YE-VT
CCL01

RCL01

CCL14

COMPRESSOR
M 151-102

2 3 C04620

BK-GN
GD410
1 8 5 6 C0408
G0407
WH-VT

GY-OG

10-64
BN-VT
YE-VT
CCL01

RCL01

CCL14

RCL14

47 46 11 10 C04396
VEHICLE
DYNAMICS
RELAY POWER RELAY CONTROL EXHAUST EXHAUST MODULE (VDM)
VALVE POWER VALVE CONTROL 151-100
2.0L
VEHICLE
DYNAMICS
MODULE
(VDM)
151-100 AIR
SUSPENSION
VALVE ASSEMBLY
151-104

C04396 C0408 C04292

CCL05 WH-BN CCL05 WH-BN
BLOCKER VALVE RL POWER LR VALVE
13 19 1
RCL05 VT-GY RCL05 VT-GY
BLOCKER VALVE RL CONTROL LR VALVE GND
14 18 5

RCL18 VT-WH RCL18 VT-WH

PRESSURE SENSOR GND PRESSURE SENSE GND
25 10 8

LCL19 GN LCL19 GN
PRESSURE SENSOR SIG PRESSURE SENSE SIG
44 7 3

LCL18 BU-GN LCL18 BU-GN

PRESSURE SENSOR SIG PRESSURE SENSE SIG
43 9 7

CCL07 YE-GY CCL07 YE-GY

BLOCKER VALVE RR POWER RR VALVE
29 17 6
RLC07 WH-BU RLC07 WH-BU
BLOCKER VALVE RR CONTROL RR VALVE GND
30 16 2
2.0L
VEHICLE
DYNAMICS
MODULE
(VDM)
151-100

REAR HEIGHT
SENSOR
RH
151-104
C04396 LCL12 VT-OG C0408 LCL12 VT-OG C04093
HEIGHT SIGNAL RR
20 2 1
C04093 RCL12 GN-WH
2
VCL12 WH-VT
3

REAR HEIGHT
SENSOR
LH
151-104

VCL12 WH-VT VCL12 WH-VT VCL12 WH-VT C04092

HEIGHT SIGNAL POWER
39 4 S415 3
C04092 RCL12 GN-WH
2 S414
LCL13 GN-BU LCL13 GN-BU
HEIGHT SIGNAL LR
40 11 1

RCL12 GN-WH RCL12 GN-WH

HEIGHT SIGNAL GND
21 3
Hot at Hot in Start
all times or Run 2.2L
BATTERY
JUNCTION
BOX (BJB)
F18 F23 F6 11-3
40A 25A 3A
13-5 13-5 13-13

WH-RD

WH-BU
YE-RD

CBB06
SBB18

6
SBB23
1 5 C1010
WH-RD

WH-BU
YE-RD

CBB06
SBB18

SBB23

1 25 28 C135
ANTI-LOCK
BRAKE SYSTEM
MTR B+ VALVE B+ VPWR (ABS) MODULE
151-5

C135 VDB04 WH-BU

HS CAN + MODULE
26 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-5
14

C1603 BRAKE
VACUUM LCA37 YE-OG VACUUM
PWR SWITCH
5 3
RCA37 WH-BU 151-7 151-8
VACUUM
RETURN
32 2
VCA38 BN-VT
VACUUM
SIGNAL 37 1

RESTRAINTS
CONTROL
VCA23 BU-WH C310B MODULE (RCM)
HS CAN YAW + HS CAN YAW + 46-1
33 60
VCA24 GN-OG
HS CAN YAW - HS CAN YAW -
GND GND 20 59

13 38 C135
BK-GN

BK-GN
GD187

GD187

GD187 BK-GN
G107
S120 10-2
ANTI-LOCK 2.2L
BRAKE SYSTEM
(ABS) MODULE
151-5

FRONT WHEEL
SPEED SENSOR
LH
151-5
C150 RCA17 BU S122 RCA17 YE C135
LF SENSOR LO
2 S121 8
VCA03 BK VCA03 VT-WH
LF SENSOR HI
1 19

FRONT WHEEL
SPEED SENSOR
RH
151-5
C160 RCA19 BU S133 RCA19 VT
RF SENSOR LO
2 S134 4
VCA05 BK VCA05 GY-VT
RF SENSOR HI
1 16

REAR WHEEL
SPEED SENSOR
LH
151-40
C440 RCA18 BU C423 RCA18 BN-GN C145 RCA18 BN-GN
LR SENSOR LO
2 6 10 18
VCA04 BK VCA04 BU-OG VCA04 BU-OG
LR SENSOR HI
1 5 11 31

REAR WHEEL
SPEED SENSOR
RH
151-40
C426 RCA20 BU RCA20 BN RCA20 BN
RR SENSOR LO
2 8 8 29
VCA06 BK VCA06 WH-OG VCA06 WH-OG
RR SENSOR HI
1 7 9 17
CUSTOMER ACCESS 2.2L

ANTI-LOCK
BRAKE SYSTEM
(ABS) MODULE
151-5

Camper Conversions

C135 C213
VMC05 VT-OG
VSO Not used
2 3

Emergency Services

C3665 - 1 C2238 - S C2237

VMC05 VT-OG VMC05 VT-OG VMC05 VT-OG
Not used
31
Hot at Hot in Start
all times or Run 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F55 F16 F47 11-11
40A 25A 5A
13-84 13-86 13-77
WH-RD

GN-BU
VT-RD

CB147
SB155

6 SB116
1 5 C01010
WH-RD

GN-BU
VT-RD

CB147
SB155

SB116

1 25 28 C0135
ANTI-LOCK
BRAKE SYSTEM
MTR B+ VALVE B+ VPWR (ABS) MODULE
151-68

C0135 VDB26 GY-BU

HS2 CAN + MODULE
26 COMMUNICATIONS
VDB25 GN-OG NETWORK
HS2 CAN - 14-14
14

C01603 BRAKE
VACUUM LCA37 YE-OG VACUUM
PWR SWITCH
5 3
RCA37 WH-BU 151-70 151-71
VACUUM
RETURN
32 2
VCA38 BN-VT
VACUUM
SIGNAL 37 1

GND GND

13 38 C0135
BK-GN

BK-GN
GD187

GD187

GD187 BK-GN
G0107
S120 10-33
ANTI-LOCK 2.0L
BRAKE SYSTEM
(ABS) MODULE
151-68

FRONT WHEEL
SPEED SENSOR
LH
151-68
C0150 RCA17 BU S1122 RCA17 YE C0135
LF SENSOR LO
2 S1121 8
VCA03 BK VCA03 VT-WH
LF SENSOR HI
1 19

FRONT WHEEL
SPEED SENSOR
RH
151-68
C0160 RCA19 BU S133 RCA19 VT
RF SENSOR LO
2 S134 4
VCA05 BK VCA05 GY-VT
RF SENSOR HI
1 16

REAR WHEEL
SPEED SENSOR
LH
151-104
C0440 RCA18 BU C0423 RCA18 BN-GN C0145 RCA18 BN-GN
LR SENSOR LO
2 6 10 18
VCA04 BK VCA04 BU-OG VCA04 BU-OG
LR SENSOR HI
1 5 11 31

REAR WHEEL
SPEED SENSOR
RH
151-104
C0426 RCA20 BU RCA20 BN RCA20 BN
RR SENSOR LO
2 8 8 29
VCA06 BK VCA06 WH-OG VCA06 WH-OG
RR SENSOR HI
1 7 9 17
ANTI-LOCK
BRAKE SYSTEM 2.0L
(ABS) MODULE
151-68

C03665 - 1
C0135 VMC05 VT-OG
VSO Not used
2

BRAKE PAD
WEAR OUT
SWITCH 21

CMC07
BU-GN

CMC06
BN-BU
23 22 C0145

CMC07

CMC06
BU-GN

BN-BU
S123

S131

1 2 C0423

BK-VT
GD124
CMC07

CMC09

CMC06

GD124
WH

WH
G0109
YE

YE
10-35

1 2 C04427 1 2 C01687

REAR BRAKE FRONT BRAKE

PAD WEAR PAD WEAR
SENSOR LH SENSOR LH
151-104 151-68
SB138 BN-RD SB136 GN-RD
2.2L
Hot at S283 Hot at
all times all times
AUXILIARY
JUNCTION
F38 HORN F36 BOX (AJB)
5A 1 3 RELAY 20A 11-1
13-23 13-22

2 5

S264 Emergency Services

VT-GN

VT-GN
CRH04

CRH04

CRH01
YE-RD
30 C2237 43 C2280C
BODY
Not used CONTROL
HORN RELAY MODULE (BCM)
CTRL 11-5
HORN SWITCH

HORN
17 C2280D 151-6
BU-WH
CRH02

5 4 C218A
C131
CLOCKSPRING 2
BK-GY
GD184

151-22 151-23

10 9 C218B

BK-YE
GD129
WH-YE
BN

S226
1 C217A S125

S2010 HORN
SWITCH
BK-GY
GD184

BK-YE
GD129
2 1 1) Normally open
BN

2) Horn activated
151-23

G206 1 C217B G110

10-9 10-4
EARLY PRODUCTION 2.2L
Hot at
all times
BODY
CONTROL
F13 MODULE (BCM)
15A 11-5
13-32 13-37

BATTERY
SAVER
RELAY
(Non-serviceable)

9 C2280B

GN-VT
CLN01
S260

GN-VT
CLN01
SB144 GN-RD
Hot at
all times
AUXILIARY
JUNCTION
F44 BOX (AJB)
60A 11-1
13-24
AUXILIARY
3 1 POWER
POINT
RELAY
5 2
GY-YE
CDC17

BK-WH
GD137

HORN/CIGAR LIGHTER
44-4 G303
10-14
LATE PRODUCTION 2.2L
Hot at all times
with battery saver
relay engaged
AUXILIARY
JUNCTION
F25 BOX (AJB)
7.5A 11-1
13-39

WH-OG
CB125
S2101

WH-OG
CB125
SB144 GN-RD
Hot at
all times
AUXILIARY
JUNCTION
F44 BOX (AJB)
60A 11-1
13-24
AUXILIARY
3 1 POWER
POINT
RELAY
5 2
GY-YE
CDC17

BK-WH
GD137

HORN/CIGAR LIGHTER
44-4

G303
10-14
HORN/CIGAR LIGHTER
44-2 44-3 2.2L
Hot at all times
A with battery saver
GY-YE relay engaged
CDC17

AUXILIARY
JUNCTION
BOX (AJB)
11-1

F47 F49 F48

20A 20A 20A
13-33 13-38 13-33 13-38 13-33 13-38
GN-BU

VT-GY

GY-YE
CB147

CB149

CB148
35 27 C210
31 C311
GN-BU

VT-GY

GY-YE
CB147

CB149

CB148
rear passenger power
outlet socket

2 C2031 2 C2033 2 C979

FRONT POWER REAR PASSENGER
AUXILIARY POWER
POWER OUTLET
SOCKET OUTLET
POINT SOCKET
1) Normally open 1) Normally open 1 2
1 2 1 2 2) Power socket activated 1) Normally open
2) Power point activated 2) Power socket activated
151-16 151-20 151-16 151-20
151-37

1 C2031 1 C2033 1 C979

BK-BU

BK-BU
GD114

GD114

BK-GN
GD351
multi-function
display
1 8 C265
BK-BU

BK-BU
GD114

GD114

G404
10-29
G200
10-5
DIRECT CURRENT/ALTERNATING CURRENT (DC/AC) INVERTER 2.2L
Hot at Hot in Start
all times or Run
AUXILIARY
JUNCTION
F8 F20 BOX (AJB)
40A 5A 11-1
13-25 13-15

YE-VT
CB120
VT-RD
SB108
S288

YE-VT
CB120
1 2 C3664

VT-RD

YE-VT
CB120
SB108
1 3 C3501

DIRECT CURRENT/
VBATT VPWR ALTERNATING CURRENT
(DC/AC) INVERTER
151-31 151-35

GND

2 C3501
BK-GY
GD182

4 C3664
BK-GY
GD182

G305
10-18
SB110 YE-RD SB108 VT-RD
Hot at S292 Hot at
2.0L
all times all times
AUXILIARY
JUNCTION
F10 HORN F8 BOX (AJB)
10A 1 3 RELAY 20A 11-11
13-81 13-81

2 5

VT-GN
CRH04

CRH01
YE-RD
20 C02280F
BODY
CONTROL
HORN RELAY MODULE (BCM)
CONTROL 11-17
HORN SWITCH

HORN
18 C02280B 151-69

BU-WH
CRH02

5 4 C0218A
C0131
CLOCKSPRING 2
BK-GY
GD284

151-85 151-86

10 9 C0218B

BK-YE
GD129
WH-YE
BN

S226
1 C0217A S125

S2010 HORN
SWITCH
BK-GY
GD284

BK-YE
GD129
2 1 1) Normally open
BN

2) Horn activated
151-86

G0206 1 C0217B G0110

10-42 10-36
Hot at Hot at Hot at
all times all times all times 2.0L
AUXILIARY
JUNCTION
F7 F10 F6 BOX (AJB)
40A 10A 40A 11-11
13-80
WH-RD 13-81 13-80

BN-RD
YE-RD
SB107

SB110

SB106
SB110 YE-RD

AUXILIARY
JUNCTION
BOX (AJB)
11-11
POWER AUXILIARY
3 4 POINT 4 3 POWER
RELAY POINT
RELAY
5 1 2 2 1 5

CDC72 BN-WH

CDC71 YE-GY

VT-WH
GY-YE

BN-WH
CDC17

CDC80
YE-GY
CDC71

CDC72

A B

44-8 23 33 C02280F 44-8

HORN/CIGAR LIGHTER BODY HORN/CIGAR LIGHTER
CONTROL
SET RESET MODULE (BCM)
11-17
HORN/CIGAR LIGHTER HORN/CIGAR LIGHTER
44-7 44-7 2.0L
Hot at all times Hot at all times
A with power point B with auxiliary power point
relay engaged relay engaged

VT-WH
GY-YE
CDC17

CDC80
AUXILIARY
JUNCTION
BOX (AJB)
11-11

F13 F14 F30

20A 20A 20A
13-89 13-89 13-89
GY-BN

VT-OG

YE-BU
CB113

CB114

CB130
35 27 C0210
31 C0311
GY-BN

VT-OG

YE-BU
CB113

CB114

CB130
rear passenger power
outlet socket

2 C02031 2 C02033 2 C0979

1 C02031 1 C02033 1 C0979

BK-BU

BK-BU
GD214

GD214

BK-GN
GD351
multi-function
display
1 8 C0265
BK-BU

BK-BU
GD214

GD214

G0404
10-62
G0200
10-37
DIRECT CURRENT/ALTERNATING CURRENT (DC/AC) INVERTER 2.0L
Hot at Hot in Start
all times or Run
AUXILIARY BODY
JUNCTION CONTROL
F71 BOX (AJB) F23 MODULE (BCM)
40A 11-11 10A 11-17
13-64 13-101

30 C02280C

VT-RD

BN-YE
CBP23
SB171
1 2 C03664

VT-RD

YE-VT
CB120
SB108

1 3 C03501

DIRECT CURRENT/
VBATT VPWR ALTERNATING CURRENT
(DC/AC) INVERTER
151-94 151-98

GND

2 C03501
BK-GY
GD182

4 C03664
BK-GY
GD382

G0305
10-50
Warning
Hot in Start
or Run ! Do not attempt to diagnose or troubleshoot 2.2L
Supplemental Restraint System circuitry without
AUXILIARY consulting the Workshop Manual. Improper
JUNCTION troubleshooting could cause the supplemental
F1 BOX (AJB) restraints to deploy inadvertently,
10A 11-1 causing injury.
CB101 13-12

19 C310A

RESTRAINTS
CONTROL
RUN/START MODULE (RCM)
151-30 151-34

C310B VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
48 NETWORK
VDB05 WH 14-5
HS CAN - BODY
47 CONTROL
MODULE (BCM)
11-5

CR113 BN-YE C2280C

ENS ENS
42 31

ANTI-LOCK
BRAKE SYSTEM
(ABS) MODULE
42-1

VCA23 BU-WH C135

HS CAN YAW + HS CAN YAW +
60 33
VCA24 GN-OG
HS CAN YAW - HS CAN YAW -
59 20

CASE GROUNDED
Warning
! Do not attempt to diagnose or troubleshoot 2.2L
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently,
causing injury.

RESTRAINTS
CONTROL
MODULE (RCM)
151-30 151-34

DRIVER
SAFETY BELT
PRETENSIONER
151-26

C323 CR120 BU-OG C310B

DRIV_PRETENSIONER_FEED
2 52
RR120 BN-GN
DRIV_PRETENSIONER_RTN
1 51

DRIVER
SAFETY BELT
BUCKLE
SWITCH
151-46
C341D
CR201 GN-BU
DRIV_BUCKLE_SW
1 54

RR155 GY
GND
2 53

PASSENGER
SAFETY BELT
PRETENSIONER
151-27

C303 CR122 WH-OG

PASS_PRETENSIONER_FEED
2 49
RR122 BN
PASS_PRETENSIONER_RTN
1 50
DUAL PRETENSIONER Warning
2.2L
! Do not attempt to diagnose or troubleshoot
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently,
causing injury.

RESTRAINTS
CONTROL
MODULE (RCM)
151-30 151-34

DRIVER
SAFETY BELT
PRETENSIONER
151-30 151-34
151-46

C341B CR170 GN C310B

DRIV_PRETENSIONER_FEED
1 16
RR170 BN-BU
DRIV_PRETENSIONER_RTN
2 15

PASSENGER
SAFETY BELT
PRETENSIONER
151-32 151-33
151-48

C3660A CR171 VT-GN

PASS_PRETENSIONER_FEED
1 13
RR171 GY
PASS_PRETENSIONER_RTN
2 14
Warning
! Do not attempt to diagnose or troubleshoot 2.2L
Supplemental Restraint System circuitry without RESTRAINTS
consulting the Workshop Manual. Improper CONTROL
troubleshooting could cause the supplemental MODULE (RCM)
restraints to deploy inadvertently, 151-30 151-34
causing injury.

side airbags

VR217 GY-YE C310B DRVR_SIDE_

IM_SN_FEED
44
RR131 VT-GY
DRVR_SIDE_
1 2 C3248 43 IM_SN_RTN

DRIVER SIDE
IMPACT
SENSOR
151-26

VR218 YE-OG PASS_SIDE_

IM_SN_FEED
45
RR132 BU-WH
PASS_SIDE_
1 2 C3249 46 IM_SN_RTN

PASSENGER SIDE
IMPACT
SENSOR
151-27

C192 C310A FRT_CR_

VR213 VT-GN VR213 VT-GN
SN_FEED
11 17
RR129 YE-GY RR129 YE-GY
FRT_CR_
5 18 SN_RTN
1 2 C1465

FRONT
IMPACT SEVERITY
SENSOR
151-5
!
Warning
Do not attempt to diagnose or troubleshoot
2.2L
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
RESTRAINTS troubleshooting could cause the supplemental
CONTROL restraints to deploy inadvertently,
MODULE (RCM) causing injury.
151-30 151-34

CLOCKSPRING
151-22

DRIVER
C210 AIRBAG
C310A CR101 VT-BN CR101 VT-BN C218A VT C216 151-23
DRVR_AIRBAG_1_FEED
29 57 1 1

RR101 YE-GN RR101 YE-GN GN

DRVR_AIRBAG_1_RTN
30 58 2 2

passenger airbag

C210 PASSENGER
C310A CR103 GY-BU CR103 GY-BU C256 AIRBAG
PASS_AIRBAG_1_FEED 151-14 151-18
28 25 1
RR103 VT-GN RR103 GN-VT
PASS_AIRBAG_1_RTN
27 26 2
PASSENGER AIRBAG Hot in Start
or Run 2.2L
AUXILIARY
JUNCTION
F23 BOX (AJB)
Warning 7.5A 11-1
! Do not attempt to diagnose or troubleshoot 13-16
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently, POWER
causing injury. DISTRIBUTION
13-16

BN-YE
CB123
17 C210

RESTRAINTS S227
CONTROL

BN-YE
MODULE (RCM)

CB123
151-30 151-34

2 C253

MESSAGE
VPWR CENTER
SWITCH
60-6
C310A C210 C253
CR114 YE-OG CR114 YE-OG
PAD ON IND +
INDICATOR 13 8 3

CR116 GN-WH CR116 GN-WH

PAD OFF INDICATOR IND -
20 2 4
GND

PASSENGER 6 C253
AIRBAG
DEACTIVATION
(PAD) SWITCH
151-14 151-18

BK-VT
GD116
PASS ROW 1 CR225 YE CR225 YE C2099
AIRBAG CONTROL
SWITCH OFF 26 6 4
S222
RR224 GY-BU RR224 GY-BU
ACS RETURN
14 3 5

PASS ROW 1

BK-VT
GD116
CR224 GN CR224 GN
AIRBAG CONTROL
SWITCH ON 25 1 6

G201
10-6
SIDE AIRBAGS Warning
2.2L
! Do not attempt to diagnose or troubleshoot
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently,
causing injury.

RESTRAINTS
CONTROL
MODULE (RCM)
151-30 151-34

C310B C341A
CR105 GN-BU DRIVER
DRVR_SIDE_AIR_FEED SIDE
40 1 AIRBAG
RR105 GY-YE 151-30 151-34
DRVR_SIDE_AIR_RTN
39 2 151-46

C3660B
CR106 VT-GY PASSENGER
PASS_SIDE_AIR_FEED SIDE AIRBAG
37 1 151-32 151-33
RR106 YE-OG
PASS_SIDE_AIR_RTN 151-48
38 2

right hand drive right hand drive

C310A C300 C311

CR109 BN-BU CR109 BN-BU CR111 BN-WH C9018 DRIVER SIDE
DRVR SIDE_CANOPY_FEED AIR CURTAIN
22 10 10 1 151-24 151-25
RR109 BU-GN RR109 BU-GN RR111 YE-VT
DRVR SIDE_CANOPY_RTN
21 11 11 2

right hand drive right hand drive

C311 C300
CR111 BN-WH CR111 BN-WH CR109 BN-BU C9019 PASSENGER SIDE
PASS SIDE_CANOPY_FEED AIR CURTAIN
23 10 10 1 151-24 151-25
RR111 YE-VT RR111 YE-VT RR109 BU-GN
PASS SIDE_CABOPY_RTN
24 11 11 2
Hot in Start Warning
or Run ! Do not attempt to diagnose or troubleshoot 2.0L
BODY Supplemental Restraint System circuitry without
CONTROL consulting the Workshop Manual. Improper
F35 MODULE (BCM) troubleshooting could cause the supplemental
5A 11-17 restraints to deploy inadvertently,
13-101 causing injury.

4 C02280A
YE-GY
CBP35

11 C0268
YE-GY
CBP35

19 C0310A

RESTRAINTS
CONTROL
RUN/START MODULE (RCM)
151-93 151-95

C0310B VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
48 NETWORK
VDB26 GY-BU 14-13
HS2 CAN -
47

BODY
CONTROL
MODULE (BCM)
11-17

CR167 YE-VT C02280E

ENS ENS
42 49

CASE GROUNDED
Warning
! Do not attempt to diagnose or troubleshoot 2.0L
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently,
causing injury.

RESTRAINTS
CONTROL
MODULE (RCM)
151-93 151-95

DRIVER
SAFETY BELT
PRETENSIONER
151-89 151-90 right hand drive

C0323 C03338 CR120 BU-OG C0310B

DRIV_PRETENSIONER_FEED
2 2 52
RR120 BN-GN
DRIV_PRETENSIONER_RTN
1 1 51

DRIVER
SAFETY BELT
BUCKLE
SWITCH
151-112
C0341D
CR201 GN-BU
DRIV_BUCKLE_SW
1 54

RR155 GY
GND
2 53

PASSENGER
SAFETY BELT
PRETENSIONER
151-89 151-90 right hand drive

C0303 C03066 CR122 WH-OG

PASS_PRETENSIONER_FEED
2 2 49
RR122 BN
PASS_PRETENSIONER_RTN
1 1 50
Warning
! Do not attempt to diagnose or troubleshoot 2.0L
Supplemental Restraint System circuitry without RESTRAINTS
consulting the Workshop Manual. Improper CONTROL
troubleshooting could cause the supplemental MODULE (RCM)
restraints to deploy inadvertently, 151-93 151-95
causing injury.

side airbags

VR217 GY-YE C0310B DRVR_SIDE_

IM_SN_FEED
44
RR131 VT-GY
DRVR_SIDE_
1 2 C03248 43 IM_SN_RTN

DRIVER SIDE
IMPACT
SENSOR
151-89 151-90

VR218 YE-OG PASS_SIDE_

IM_SN_FEED
45
RR132 BU-WH
PASS_SIDE_
1 2 C03249 46 IM_SN_RTN

PASSENGER SIDE
IMPACT
SENSOR
151-89 151-90

C0192 C0310A FRT_CR_

VR213 BK VR213 VT-GN
SN_FEED
11 17
RR129 BK RR129 YE-GY
FRT_CR_
5 18 SN_RTN
1 2 C01465

FRONT
IMPACT SEVERITY
SENSOR
151-68
!
Warning
Do not attempt to diagnose or troubleshoot
2.0L
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
RESTRAINTS troubleshooting could cause the supplemental
CONTROL restraints to deploy inadvertently,
MODULE (RCM) causing injury.
151-93 151-95

CLOCKSPRING
151-85

DRIVER
C0210 AIRBAG
C0310A CR101 VT-BN CR101 VT-BN C0218A VT C0216 151-86
DRVR_AIRBAG_1_FEED
29 57 1 1

RR101 YE-GN RR101 YE-GN GN

DRVR_AIRBAG_1_RTN
30 58 2 2

passenger airbag

C0210 PASSENGER
C0310A CR103 GY-BU CR103 GY-BU C0256 AIRBAG
PASS_AIRBAG_1_FEED 151-77 151-81
28 25 1
RR103 VT-GN RR103 VT-GN
PASS_AIRBAG_1_RTN
27 26 2
PASSENGER AIRBAG Hot in Start
or Run 2.0L
BODY
CONTROL
F19 MODULE (BCM)
5A 11-17
Warning 13-101
! Do not attempt to diagnose or troubleshoot
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental 7 C02280A
restraints to deploy inadvertently,
causing injury.

BN-WH
CBP19
multi-function
display
12 C0264

RESTRAINTS

BN-WH
CONTROL

CBP19
MODULE (RCM)
151-93 151-95
2 C0253
multi-function
display MESSAGE
VPWR CENTER
SWITCH
C0310A C0210 C0264 C0253 60-15
CR114 YE-OG CR114 YE-OG
PAD ON IND +
INDICATOR 13 8 3 3

CR116 GN-WH CR116 GN-WH

PAD OFF INDICATOR IND -
20 2 7 4
GND

PASSENGER 6 C0253
AIRBAG
DEACTIVATION
(PAD) SWITCH
151-77 151-81

BK-VT
GD216
PASS ROW 1 CR225 YE CR225 YE C02099
AIRBAG CONTROL
SWITCH OFF 26 6 4 multi-function
S206 display
RR224 GY-BU RR224 GY-BU
ACS RETURN
14 3 5
1 C0263

PASS ROW 1 CR224 GN CR224 GN

AIRBAG CONTROL S222
SWITCH ON 25 1 6

BK-VT
GD216
G0201
10-38 10-39
SIDE AIRBAGS Warning
2.0L
! Do not attempt to diagnose or troubleshoot
Supplemental Restraint System circuitry without
consulting the Workshop Manual. Improper
troubleshooting could cause the supplemental
restraints to deploy inadvertently,
causing injury.

RESTRAINTS
CONTROL
MODULE (RCM)
151-93 151-95

C0310B C0341A
CR105 GN-BU DRIVER
DRVR_SIDE_AIR_FEED SIDE
40 1 AIRBAG
RR105 GY-YE 151-112
DRVR_SIDE_AIR_RTN
39 2

C03660B
CR106 VT-GY PASSENGER
PASS_SIDE_AIR_FEED SIDE AIRBAG
37 1 151-114
RR106 YE-OG
PASS_SIDE_AIR_RTN
38 2

right hand drive right hand drive

C0310A C0300 C0311

CR109 BN-BU CR109 BN-BU CR111 BN-WH C09018 DRIVER SIDE
DRVR SIDE_CANOPY_FEED AIR CURTAIN
22 10 10 1 151-87 151-88
RR109 BU-GN RR109 BU-GN RR111 YE-VT
DRVR SIDE_CANOPY_RTN
21 11 11 2

right hand drive right hand drive

C0311 C0300
CR111 BN-WH CR111 BN-WH CR109 BN-BU C09019 PASSENGER SIDE
PASS SIDE_CANOPY_FEED AIR CURTAIN
23 10 10 1 151-87 151-88
RR111 YE-VT RR111 YE-VT RR109 BU-GN
PASS SIDE_CABOPY_RTN
24 11 11 2
Hot in Start Hot at
or Run all times 2.2L
IGNITION AUXILIARY
SWITCH JUNCTION
13-10 13-11 F41 BOX (AJB)
40A 11-1
13-24

1 C250
S224

65 C210

SB141
RD
S276
CDC32
BN-YE

AUXILIARY
JUNCTION
BOX (AJB) AUXILIARY
AUXILIARY 11-1 BLOWER
1 3 BLOWER MOTOR
MOTOR SWITCH
RELAY 151-52
2 5

VHA25 BN-VT C938 C937 PWM SIGNAL

BLOWER 1
20 1
20 C9028
BN-GN
CHA02

late production: high roof

VHA25
BN-VT
31 C300
BK-BU
GD241

1 C9060 20 C9059
BN-GN

VHA25
CHA02

BN-VT
S274 4 3 C940A

AUXILIARY
VPWR CONTROL BLOWER MOTOR
CONTROL
BK-BU
GD241

MODULE
GND + - 151-38

2 C940A 1 2 C940B

6 C9060
YE-GN

AUXILIARY
VH309

BN-VT
RH309
BLOWER
MOTOR
BK-VT
GD147

151-38
C939 C939
G308 G402 M
1 2
10-21 10-28
Hot at Hot in Start
all times or Run
2.2L
AUXILIARY
JUNCTION
F39 BOX (AJB)
7.5A F23 11-1
13-23 7.5A
13-16

POWER POWER
DISTRIBUTION DISTRIBUTION
13-23 13-16

BN-YE
CB123
S271
WH-RD
SB139

BN-YE
CB123
39 59 C300

18 17 C9028
WH-RD

BN-YE
CB123
SB139

18 17 C938 late production: high roof

11 10 C937

AUXILIARY
VBATT VPWR BLOWER
MOTOR
SWITCH
151-52

C937 C938 CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
GND 24 16 71-6

late production: high roof

8 C937

15 C938 late production: high roof

GD133
BK

15 C9028
GD133
BK

G300
10-11
AUXILIARY
BLOWER 2.2L
MOTOR
SWITCH
151-52 AUXILIARY
TEMPERATURE
DOOR
ACTUATOR
151-38
late production: high roof
C9028 C9059
C937 C938 CHA20 BU-GN CHA20 BU-GN CHA20 BU-GN C9062
AIR BYPASS COIL 1
5 2 2 2 1
CHA24 WH-GN CHA24 WH-GN CHA24 WH-GN
AIR BYPASS COMMON
9 1 1 1 2
CHA21 GY CHA21 GY CHA21 GY
AIR BYPASS COIL 2
18 3 3 3 3
M
CHA22 VT CHA22 VT CHA22 VT
AIR BYPASS COIL 3
4 4 4 4 4

CHA23 YE CHA23 YE CHA23 YE

AIR BYPASS COIL 4
17 5 5 5 6

AUXILIARY AIR
DISTRIBUTION
DOOR
ACTUATOR
151-38

CHA41 GY-YE CHA41 GY-YE CHA41 GY-YE C9061

TEMP COIL 1
3 7 7 7 1
CHA40 VT-WH CHA40 VT-WH CHA40 VT-WH
TEMP COMMON
23 6 6 6 2
CHA42 GN CHA42 GN CHA42 GN
TEMP COIL 2
16 8 8 8 3
M
CHA43 BN-BU CHA43 BN-BU CHA43 BN-BU
TEMP COIL 3
2 9 9 9 4

CHA44 WH-BU CHA44 WH-BU CHA44 WH-BU

TEMP COIL 4
15 10 10 10 6
Hot in Start Hot at
or Run all times 2.0L
AUXILIARY
JUNCTION
F46 F29 BOX (AJB)
5A 40A 11-11
13-77 13-66
WH-BU

GY-RD
CB146

SB129
CB146 WH-BU

AUXILIARY
JUNCTION
BOX (AJB) AUXILIARY
HEATED AUXILIARY 11-11 BLOWER
1 REAR 1 3 BLOWER MOTOR
WINDOW MOTOR SWITCH
RELAY RELAY 151-116
56-10 56-11 2 5

VHA25 BN-VT C0937 PWM SIGNAL

BLOWER 1
1
20 C09028

BN-GN
CHA02

VHA25
BN-VT
31 C0300
BK-WH
GD238

1 C09060 20 C09059
BN-GN

VHA25
CHA02

BN-VT
S287 4 3 C0940A

AUXILIARY
VPWR CONTROL BLOWER MOTOR
CONTROL
BK-WH
GD238

MODULE
GND + - 151-101

2 C0940A 1 2 C0940B
BK-GN
GD307

YE-GN

AUXILIARY
VH309

BN-VT
RH309
BLOWER
6 C09060 MOTOR
151-101
BK-WH
GD307

C0939 C0939
M
1 2
G0308 G0402
10-54 10-58
WITHOUT STOP AND START 2.0L
Hot in Start
or Run
AUXILIARY
Hot at JUNCTION
all times BOX (AJB)
F44 11-11
BODY 10A
CONTROL 13-75
F11 MODULE (BCM)
5A 11-17
13-92

15 C02280C

CB144
VT
BU-RD
SBP11

S263 C02513 BK C02513

S297
5 7
BU-RD

CDC78
VT-BN
SBP11

39 59 C0300

18 17 C09028

CDC78
VT-BN
BU-RD
SBP11

11 10 C0937

AUXILIARY
VBATT VPWR BLOWER
MOTOR
SWITCH
151-116

C0937 CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
24 71-13
GND

8 C0937
BK-WH
GD307

C09028 - 15
GD236 BK-GN

G0300
10-43
STOP AND START 2.0L
Hot in Start
or Run
AUXILIARY
Hot at JUNCTION
all times BOX (AJB)
F44 11-11
BODY 10A
CONTROL 13-75
F11 MODULE (BCM)
5A 11-17
13-92

LOW VOLTAGE
15 C02280C DIRECT CURRENT/

CB144
DIRECT CURRENT

VT
BU-RD

(DC/DC) CONVERTER
SBP11

40-3 40-6

S263 C02513 C02513

S297
5 7
BU-RD

CDC78
VT-BN
SBP11

39 59 C0300

18 17 C09028

CDC78
VT-BN
BU-RD
SBP11

11 10 C0937

AUXILIARY
VBATT VPWR BLOWER
MOTOR
SWITCH
151-116

C0937 CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
24 71-13
GND

8 C0937
BK-WH
GD307

C09028 - 15 GD236 BK-GN

G0300
10-43
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Hot at
all times 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
F40 F38 11-1
40A 5A
13-24 13-23

S283

BN-RD
VT-RD
SB140

SB138
AUXILIARY
JUNCTION
BOX (AJB)
BLOWER 11-1
3 1 MOTOR
RELAY

5
YE-GN 2
CH402

VT-GN
CH123
32 C210
YE-GN
CH402

9 C2280C
1 C2004 BODY
FAN RELAY CONTROL
BLOWER MODULE (BCM)
MOTOR CTRL
11-5
M 151-15 151-19

2 C2004
VT-OG
CH430

54-2 54-3
MANUAL CLIMATE
CONTROL SYSTEM
WITHOUT:
FUEL FIRED BOOSTER HEATER 2.2L

MANUAL CLIMATE
CONTROL SYSTEM
54-1

A
VT-OG
CH430

BLOWER MOTOR SWITCH

151-16 151-20
S237 CH430 VT-OG C271A
POSITION 4 (HIGH)
4
CH429 GY-BN
POSITION 3 (MEDIUM HIGH)
3
VT-OG
CH430

CH428 GN-WH
POSITION 2 (MEDIUM LOW)
2
CH427 BN
POSITION 1 (LOW)
1
4 3 1 2 C293 GND

5 C271A

BK-WH
GD185
BLOWER
MOTOR
RESISTOR
151-15 151-19

38 C210

BK-WH
GD185
33 C210

BK-WH
GD185
G203
10-7
Hot in Start
or Run
FUEL FIRED BOOSTER HEATER 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
F23 11-1
7.5A
13-16

POWER
DISTRIBUTION MANUAL CLIMATE
13-16 CONTROL SYSTEM
54-1
BN-YE
CB123

A
BLOWER MOTOR SWITCH
151-16 151-20

VT-OG
CH430
auxiliary
climate control CH430 VT-OG C271A
POSITION 4 (HIGH)
S237 4
S271 CH429 GY-BN
POSITION 3 (MEDIUM HIGH)
3

VT-OG
CH430
CH428 GN-WH
POSITION 2 (MEDIUM LOW)
2
CH427 BN CH427 BN
POSITION 1 (LOW)
S231 1
4 3 1 2 C293 GND

CH427
BN
BN-YE

5 C271A
CB123

BLOWER
MOTOR 34 38 C210
RESISTOR
151-15 151-19

CH427
BN
GD185 BK-WH

AUXILIARY
JUNCTION
BOX (AJB)
FUEL FIRED 11-1
2 5 4 BOOSTER
HEATER
RELAY
1 3
BK-BU
GD241

33 C210

BK-WH
GD185

S274

G308 G203
10-21 10-7
FUEL FIRED BOOSTER HEATER 2.2L
Hot at
all times
AUXILIARY
JUNCTION
F5 Hot at
BOX (AJB) all times
20A 11-1
13-25 AUXILIARY
JUNCTION
F39 BOX (AJB)
7.5A 11-1
13-23
GY-RD
SB105

WH-RD
SB139
14 C145
GY-RD

S2005
SB105

WH-RD
SB139
1 C4429

2 C2806
AUXILIARY HEATER
CONTROL FUEL FIRED
VBATT MODULE (AHCM) BOOSTER HEATER
VBATT CONTROL MODULE
151-39
151-33
C4429
VDB06 GY-OG
MS CAN + MODULE
4 COMMUNICATIONS
NETWORK
VDB07 VT-OG 14-7
MS CAN -
5

VHF04 BN-BU C145 VHF04 BN-VT C2806

SIG SIG
3 24 5
GND GND

6 C2806

2 C4429
BK-VT
GD132

BK-GN
GD140
S410
BK-VT
GD132

G400 G306
10-25 10-19
Hot at Hot in Start
all times or Run 2.2L
BODY AUXILIARY
CONTROL JUNCTION
F17 MODULE (BCM) BOX (AJB)
7.5A F23 11-1
11-5 7.5A
13-47
13-16

70 C2280D POWER
DISTRIBUTION
13-16
POWER

BN-YE
DISTRIBUTION

CB123
13-47

17 C210
SBP17
RD

S227 electric booster heater

BN-YE
CB123
14 15 C271B

BLOWER MOTOR SWITCH

151-16 151-20
VBATT VPWR

C271B CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
1 71-2

BODY
CONTROL
MODULE (BCM)
11-5
customer access

CH422 VT S236 CH422 VT C2280D

AC ON AC ON
SWITCH SWITCH
5 39
GND GND

CH422
VT
4 17 C271B 5 C212
BK-GY

BK-GY
GD184

GD184

CH422
VT
S226

12 C213 Camper Conversions

BK-GY
GD184

21 C2237

G206 Not used

10-9
BLOWER MOTOR SWITCH
151-16 151-20 2.2L

FOOTWELL
VENT
C271B CH202 BU-GN C236 DOOR
PANEL COIL 1 ACTUATOR
7 1 151-15 151-19
CH201 BN-BU
PANEL COMMON
3 2
CH203 GN-BN
PANEL COIL 2
8 3
M
CH204 GY-OG
PANEL COIL 3
9 4

CH205 BN-WH
PANEL COIL 4
10 6

TEMPERATURE
DOOR
CH233 VT-BN C2092 ACTUATOR
TEMP COIL 4 151-15 151-19
20 1
CH232 WH-BN
TEMP COMMON
2 2
CH234 YE-GN
TEMP COIL 3
21 3
M
CH235 BU
TEMP COIL 2
22 4

CH236 WH
TEMP COIL 1
23 6

AIR INLET
CH208 GN-OG C289 DOOR
RECIRCULATION OUT 2 ACTUATOR
19 6 5 151-15 151-19
M
CH207 BU-GY
RECIRCULATION OUT 1
18 5 6

right hand
drive
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
23-9 23-15

AMBIENT AIR
TEMPERATURE
SENSOR
151-6
C175T C139 C132 C132
VE750 GN-BU VE750 GN-BU
AAT
21 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
18 27

C175B RH108 BN
SIGRTN
23
1 C1260

AIR CONDITIONING
VH433 VT-OG C1260 (A/C) PRESSURE
ACPT TRANSDUCER
32 2 151-3

3 C1260
LH108 GY-BN
VREF
50

BODY
CONTROL
MODULE (BCM)
11-5
EVAPORATOR
TEMPERATURE
SENSOR
151-15 151-19

C2280D VH406 VT-BN C296 C296

EVAPORATOR
SENSOR 3 1 2

EVAPORATOR RH119 YE-VT

SENSOR GND
4
ELECTRIC BOOSTER HEATER 2.2L
Hot at Hot in Start
all times or Run
HIGH CURRENT AUXILIARY
BATTERY JUNCTION
F6 JUNCTION BOX (AJB)
80A BOX (BJB) F23 11-1
13-3 11-7 7.5A
13-16

1 C3670H POWER
DISTRIBUTION
13-16
BN-RD

BN-YE
CB123
SBF06

BLOWER MOTOR SWITCH

151-16 151-20
39 17 C210

C271B
S227 PTC HEATER SWITCH
6
BN-RD

BN-YE
CB123
SBF06

GN-BN
CHP03
BODY
CONTROL
1 C2603A 1 C2603C MODULE (BCM)
11-5
ELECTRIC
VBATT VPWR BOOSTER
HEATER C2280D
151-14 151-18 PTC HEATER SWITCH
10

C2603C CHP01 BU-GN

PTC HEATER CTRL PTC HEATER CTRL
2 15

GND

1 C2603B
BK-WH
GD285

G204
10-7
Hot in Start Hot in Start
or Run or Run 2.2L
BATTERY
JUNCTION
F38 F11 BOX (BJB)
7.5A 10A 11-3
13-9 13-6

GY-BU
CBB38

CBB11
BN
BATTERY
JUNCTION
BOX (BJB)
AIR 11-3
1 3 CONDITIONING
(A/C) CLUTCH
RELAY

2 5

VT-WH
CH401
MODULE 15 C134
COMMUNICATIONS
NETWORK
14-5

VT-WH
CH401
1 C100
AIR CONDITIONING (A/C)
CLUTCH AND
AIR CONDITIONING (A/C)
WH-BU

WH-BN

CLUTCH
VDB04

VDB05

CH302

FIELD COIL
WH

151-11

2 C100

10 11 49 C175B

GD122
BK
POWERTRAIN
CONTROL
HS CAN HS CAN ACCR MODULE (PCM)
+ - 23-17
G106
10-2
Hot at
all times 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F2 F10 11-11
40A 10A
13-80 13-81

S292

YE-RD

YE-RD
SB102

SB110
AUXILIARY
JUNCTION
BOX (AJB)
BLOWER 11-11
3 1 MOTOR
RELAY

5
YE-GN 2

VT-GN
CH402

CH123
32 36 C0210
YE-GN
CH402

1 C02004

BLOWER

VT-GN
CH123
MOTOR
M 151-78 151-82

2 C02004
31 C02357A
VT-OG
CH430

HEATING,
VENTILATION AND
FAN RELAY AIR CONDITIONING (HVAC)
CTRL CONTROL MODULE
151-78 151-82
A

54-11 54-12
MANUAL CLIMATE
CONTROL SYSTEM
WITHOUT: 2.0L
FUEL FIRED BOOSTER HEATER

MANUAL CLIMATE
CONTROL SYSTEM
54-10

A
VT-OG
CH430

HEATING,
VENTILATION AND
S239 CH430 VT-OG C02357B AIR CONDITIONING (HVAC)
POSITION 4 (HIGH) CONTROL MODULE
4 151-78 151-82

CH429 GY-BN
POSITION 3 (MEDIUM HIGH)
3
VT-OG
CH430

CH428 GN-WH
POSITION 2 (MEDIUM LOW)
2
CH427 BN
POSITION 1 (LOW)
1
4 3 1 2 C0293 GND

5 C02357B

BK-GY
GD215
BLOWER
MOTOR
RESISTOR
151-78 151-82

38 C0210

BK-GY
GD215
33 C0210

BK-GY
GD215
G0203
10-40
FUEL FIRED BOOSTER HEATER
Hot in Start 2.0L
or Run
AUXILIARY
JUNCTION
BOX (AJB)
F41 11-11
5A
13-74

MANUAL CLIMATE
CONTROL SYSTEM
54-10 HEATING,
VENTILATION AND
A AIR CONDITIONING (HVAC)
CONTROL MODULE
151-78

VT-OG
CH430
CH430 VT-OG C02357B
POSITION 4 (HIGH)
S239 4
CH429 GY-BN
POSITION 3 (MEDIUM HIGH)
3

VT-OG
CH430
CH428 GN-WH
POSITION 2 (MEDIUM LOW)
2
CH427 BN CH427 BN
POSITION 1 (LOW)
S231 1
4 3 1 2 C0293 GND

CH427
BN
5 C02357B
CB141
BU

BLOWER
MOTOR 34 38 C0210
RESISTOR
151-78

CH427
BN
GD215 BK-GY

AUXILIARY
JUNCTION
BOX (AJB)
FUEL FIRED 11-11
1 5 4 BOOSTER
HEATER
RELAY
2 3
BK-WH
GD238

33 C0210

BK-GY
GD215
S287

G0308 G0203
10-54 10-40
FUEL FIRED BOOSTER HEATER
2.0L
Hot at Hot at
all times all times
BATTERY AUXILIARY
JUNCTION JUNCTION
F32 BOX (BJB) F20 BOX (AJB)
20A 11-15 5A 11-11
13-68 13-87
VT-RD
SBB32

19 C0144

GN-RD
SB120
VT-RD
SBB32

1 C04429

2 C02806

AUXILIARY HEATER FUEL FIRED

CONTROL BOOSTER HEATER
VBATT MODULE (AHCM) VBATT CONTROL MODULE
151-102 151-96

C04429
VDB06 GY-OG
MS CAN + MODULE
4 COMMUNICATIONS
NETWORK
VDB07 VT-OG 14-15
MS CAN -
5

C0145 - 26 C02806
VHF04 BN-VT VHF04 BN-VT
SIG SIG
3 5
GND GND

GND

2 6 C04429 6 C02806
BK-VT

BK-VT
GD412

GD412

BK-GN
GD240
GD412 BK-VT

S413 G0408 G0307

10-65 10-52
Start/Stop Bus 2.0L
BODY
CONTROL
F12 MODULE (BCM)
7.5A 11-17
13-102

10 C02280A

GN-RD
SBP12
multi-function
S230 display

GN-RD
SBP12
32 C02357A

HEATING,
VBATT VENTILATION AND
AIR CONDITIONING (HVAC)
CONTROL MODULE
151-78 151-82

C02357A VDB06 GY-OG

MS CAN + MODULE
23 COMMUNICATIONS
NETWORK
VDB07 VT-OG 14-16 14-18
MS CAN -
24

GND GND GND

5 10 26 C02357A
BK-GY

BK-GY

BK-GY
GD284

GD284

S226
BK-GY
GD284

G0206
10-42
HEATING,
VENTILATION AND 2.0L
AIR CONDITIONING (HVAC)
CONTROL MODULE
151-78 151-82
FOOTWELL
VENT
C02357A CH202 BU-GN C0236 DOOR
PANEL COIL 1 ACTUATOR
17 1 151-78 151-82
CH201 BN-BU S223
PANEL COMMON
14 2
CH203 GN-BN
PANEL COIL 2
4 3
M
CH204 GY-OG
PANEL COIL 3
18 4

CH205 BN-WH
PANEL COIL 4
3 6

BN-BU
CH201
TEMPERATURE
DOOR
CH233 VT-BN C02092 ACTUATOR
TEMP COIL 4 151-78 151-82
19 6

2
CH234 YE-GN
TEMP COIL 3
1 4
M
CH235 BU
TEMP COIL 2
20 3

CH236 WH
TEMP COIL 1
2 1

AIR INLET
CH208 GN-OG C0289 DOOR
RECIRCULATION OUT 2 ACTUATOR
8 6 5 151-78 151-82
M
CH207 BU-GY
RECIRCULATION OUT 1
7 5 6

right hand
drive
HEATING,
VENTILATION AND 2.0L
AIR CONDITIONING (HVAC)
CONTROL MODULE
151-78 151-82
EVAPORATOR
TEMPERATURE
SENSOR
151-78 151-82

C02357A VH406 VT-BN C0296 C0296

EVAPORATOR
SENSOR 9 1 2

EVAPORATOR RH119 YE-VT

SENSOR GND
25

START/STOP
ENABLE CYT30 GY-VT
SWITCH 6
AUTO-START-STOP SYSTEM
40-2
START/STOP CYT10 GN-BU
SWITCH
STATUS 22
LED
C0210 - 14 C03665 - 4
START/STOP CE937 VT-GY CE937 VT-GY
DISABLE Not used
SWITCH 29

CRD08 GN-OG
WINDSHIELD HEATER SWITCH
11
CRD03 BU-GN
WINDSHIELD HEATER INDICATION LED
12
CRD01 VT-OG
WINDSHIELD HEATER CTRL
15 HEATED WINDOW
56-7 56-8
56-9 56-10
CRD02 BN-BU
REAR WINDOW DEFROST CTRL
16

CRD09 BU-GY
REAR WINDOW DEFROST SWITCH
27

CRD04 BN-GN
REAR WINDOW DEFROST INDICATION LED
28
POWERTRAIN
CONTROL 2.0L
MODULE (PCM)
24-17 24-22

AMBIENT AIR
TEMPERATURE
(AAT) SENSOR
151-69
C0175B C0139 C0132 C0132
VE750 GN-BU VE750 GN-BU
AAT
52 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
35 27

RH433 BU-GY
SIGRTN
29
1 C01260

AIR CONDITIONING
VH433 VT-OG C01260 (A/C) PRESSURE
ACPT TRANSDUCER
10 3 151-66

2 C01260
LH315 WH-GN
VREF
48
AUXILIARY HEATER 2.0L
Hot at Hot in Start
all times or Run
HIGH CURRENT BODY
BATTERY CONTROL
F6 JUNCTION F21 MODULE (BCM)
100A BOX (BJB) 5A 11-17
13-65 11-19 13-101

1 C03670H 6 C02280A
SBF06
BN

39 C0210

BU-GY
BN-RD

CBP21
SBF06

1 C02603A 1 C02603C

ELECTRIC
BOOSTER HEATING,
VBATT VPWR VENTILATION AND
HEATER
151-77 151-81 AIR CONDITIONING (HVAC)
CONTROL MODULE
151-78 151-82

C02603C VHP01 BU-GN C02357A

PTC SIGNAL PTC PWM
2 30

GND

1 C02603B
BK-WH
GD285

G0204
10-40
Hot in Start Hot at
or Run all times 2.0L
BATTERY
JUNCTION
F38 F23 BOX (BJB)
10A 10A 11-15
13-70 13-67

S110

WH-RD
GY-BU
CBB38

SBB23
GY-BU
CBB38
BATTERY
JUNCTION
BOX (BJB)
16 C0134 AIR 11-15
1 3 CONDITIONING
(A/C) CLUTCH
RELAY
GY-BU
CBB38

2 5

S153

1 C01110

VT-WH
CH401
AIR CONDITIONING (A/C)
COMPRESSOR
MODULE CONTROL
COMMUNICATIONS SOLENOID
151-74 21 C0134
NETWORK
14-12
2 C01110

VT-WH
CH401
WH-BN
VE462

1 C0100

AIR CONDITIONING (A/C)

15 C0134 CLUTCH AND
AIR CONDITIONING (A/C)
WH-BU

WH-BN

COMPRESSOR
VDB04

VDB05

CH302

S124 151-74
WH

WH-BN
VE462

2 C0100

60 61 57 20 C0175B S150

POWERTRAIN

GD121
CONTROL
HS1 CAN HS1 CAN VACC ACCR MODULE (PCM)

BK
+ - 24-23
G0111
10-36
HEATED WINDSHIELD 2.2L
BODY
CONTROL
MODULE (BCM)
WINDSHIELD 11-5
HEATER WINDSHIELD
INDICATION HEATER
LED SWITCH

41 37 C2280D

CLUSTER AND
PANEL ILLUMINATION
71-4

GN-OG
BU-GN
CRD03

CRD08

CLN17
BN
1 6 3 C2025

HEATED
WINDSHIELD
SWITCH
151-15 151-19

5 2 C2025
BK-GY

BK-GY
GD184

GD184 S226

BK-GY
GD184

G206
10-9
HEATED WINDSHIELD 2.2L
Hot at Hot in Start Hot at
all times or Run all times
AUXILIARY
JUNCTION
BOX (AJB)
F52 F20 F53 11-1
40A 5A 40A
13-26 13-15 13-26

YE-VT
CB120
CB120 YE-VT
GN-RD

GY-RD
SB152

SB153
S288

YE-VT
CB120
AUXILIARY
JUNCTION
BOX (AJB)
11-1
HEATED HEATED
3 1 WINDSHIELD 1 3 WINDSHIELD
ELEMENT ELEMENT
LH RH
RELAY RELAY
5 2 2 5
BN-WH

CRD01 VT-OG
CRD10

CRD11
YE-VT
VT-OG
CRD01

29 C300 29 C311
BN-WH
CRD10

CRD11
YE-VT
1 C9069 1 C9070
64 C2280C
HEATED HEATED
WINDSHIELD BODY WINDSHIELD
ELEMENT WINDSHIELD CONTROL ELEMENT
LH HEATER MODULE (BCM) RH
151-24 CTRL 11-5 151-25
HEATED MIRROR 2.2L
BODY
CONTROL
MODULE (BCM)
11-5
REAR WINDOW
REAR WINDOW DEFROSTER DEFROST
INDICATION LED SWITCH

9 40 C2280D

CLUSTER AND
PANEL ILLUMINATION
71-4

BN-GN

BU-GY
CRD04

CRD09

CLN17
BN
1 6 3 C241

HEATED
REAR
WINDOW
SWITCH
151-15 151-19

5 2 C241
BK-GY

BK-GY
GD184

GD184 S226
BK-GY
GD184

G206
10-9
heated windshield
HEATED MIRROR 2.2L
S288
LIFTGATE

YE-VT

YE-VT
CB120

CB120
SB142 YE-RD
Hot at Hot in Start
all times or Run
AUXILIARY
JUNCTION
F42 F20 BOX (AJB)
30A 5A 11-1
13-24 HEATED 13-15
3 1 REAR
WINDOW
RELAY

5 2

CRD06
BN-YE
HEATED
CRD06 BN-YE WINDOW
A 56-6
heated rear window

S282
CRD06

CRD06
BN-YE

BN-YE
30 C300 30 C311
CRD06
BN-YE

2 9 C935
9 C991
CRD06
GD149

Not used
BK

BN-BU
CRD02
2 9 C406

S401
BK-GY
GD149

1 C402B 1 C402A

HEATED REAR 14 C2280C

WINDOW
ELEMENT BODY
G401 151-45 CONTROL
10-26 MODULE (BCM)
11-5
heated windshield
HEATED MIRROR 2.2L
S288
REAR DOORS

YE-VT

YE-VT
CB120

CB120
SB142 YE-RD
Hot at Hot in Start
all times or Run
AUXILIARY
JUNCTION
F42 F20 BOX (AJB)
30A 5A 11-1
13-24 HEATED 13-15
3 1 REAR
WINDOW
RELAY

5 2

CRD06 BN-YE HEATED

A WINDOW
56-6
heated rear window

S282
CRD06

CRD06
BN-YE

BN-YE
30 C300 30 C311

2 9 C935 9 2 C991
BK-GY

CRD06

CRD06
BN-YE
GD149

GD351
BK

BK
2 9 C422 9 2 C411

BN-BU
CRD02
S402 S404
BK-GY

BK-GN
GD149

GD351
1 C4425B 1 C4425A 1 C4426A 1 C4426B

G401 G404
10-27 10-29 14 C2280C
HEATED REAR HEATED REAR
WINDOW WINDOW BODY
ELEMENT LH ELEMENT RH CONTROL
151-44 151-44 MODULE (BCM)
11-5
HEATED MIRROR 2.2L
HEATED
WINDOW
56-4 CRD06 BN-YE
A
56-5

Hot in Start or Run

with Heated Rear AUXILIARY
Window Relay engaged JUNCTION
BOX (AJB)
F3 11-1
10A
13-17

G302 G307

BK-GN
BK-VT

GD240
GD134

10-13 10-20
CB103

CB103
GY

GY
B11 A1 C340 right hand drive A1 B11 C339 right hand drive

B11 A1 C339 A1 B11 C340

GD240
GD134

CB103

CB103
BK

BK
BK

S603 right hand drive S504 right hand drive

S504 S603

S505 left hand drive S505 right hand drive

2 1 C521 1 2 C626

2 1 C663 right hand drive 1 2 C596 right hand drive

EXTERIOR EXTERIOR
MIRROR MIRROR
LH RH
124-1 124-3 124-1 124-3
HEATED WINDSHIELD 2.0L
HEATING,
VENTILATION AND
AIR CONDITIONING (HVAC)
WINDSHIELD CONTROL MODULE
HEATER WINDSHIELD 54-16
INDICATION HEATER
LED SWITCH

12 11 C02357A

CLUSTER AND
PANEL ILLUMINATION
71-11

GN-OG
BU-GN
CRD03

CRD08

CLN17
BN
1 6 3 C02025

HEATED
WINDSHIELD
SWITCH
151-78 151-82

5 2 C02025

GD284 BK-GY

BK-GY
GD284
S226
BK-GY
GD284

G0206
10-42
HEATED WINDSHIELD 2.0L
Hot at Hot in Start Hot at
all times or Run all times
AUXILIARY
JUNCTION
BOX (AJB)
F34 F46 F35 11-11
40A 5A 40A
13-88 13-77 13-88

WH-BU
CB146

BU-RD
YE-RD
SB134

SB135
CB146 WH-BU

AUXILIARY
JUNCTION
BOX (AJB)
11-11
HEATED HEATED
3 1 WINDSHIELD 1 3 WINDSHIELD
ELEMENT ELEMENT
LH RH
RELAY RELAY
5 2 2 5
BN-WH

CRD01 VT-OG
CRD10

CRD11
YE-VT
VT-OG
CRD01
13 C0210

29 C0300 29 C0311
VT-OG
CRD01
BN-WH
CRD10

CRD11
YE-VT
15 C02357A

WINDSHIELD
1 C09069 HEATER 1 C09070
CTRL
HEATED HEATED
WINDSHIELD WINDSHIELD
ELEMENT HEATING, ELEMENT
LH VENTILATION AND RH
151-87 AIR CONDITIONING (HVAC) 151-88
CONTROL MODULE
54-16
HEATED DEFROST 2.0L
HEATING,
VENTILATION AND
AIR CONDITIONING (HVAC)
REAR CONTROL MODULE
WINDOW REAR WINDOW 54-16
DEFROST DEFROST
INDICATION LED SWITCH

28 27 C02357A

CLUSTER AND
PANEL ILLUMINATION
71-11

BN-GN

BU-GY
CRD04

CRD09

CLN17
BN
1 6 3 C0241

HEATED
REAR
WINDOW
SWITCH
151-78 151-82

5 2 C0241

GD284 BK-GY

BK-GY
GD284 S226

BK-GY
GD284

G0206
10-42
HEATED DEFROST 2.0L
LIFTGATE

WH-BU
CB146
SB104 GN-RD
Hot at Hot in Start
all times or Run
AUXILIARY
JUNCTION
F4 F46 BOX (AJB)
40A 5A 11-11
13-80 HEATED 13-77
3 1 REAR
WINDOW
RELAY

5 2
F31
30A
13-79
CRD06

CRD06
BN-YE

BN-YE
BU-OG
CB131

HEATED
CRD06 BN-YE WINDOW
S252 A 56-12
S285
BU-OG
CB131

BN-BU
CRD02
30 C0300

heated rear window

BU-OG

60 C0210
CB131

9 2 C0935

BN-BU
CRD02
GD350
CB131
BK

9 2 C0406 16 C02357A

S401 REAR WINDOW

BK-WH
GD350

DEFROST
1 C0402A 1 C0402B CTRL
HEATED REAR
WINDOW
ELEMENT HEATING,
151-111 G0401 VENTILATION AND
10-56 AIR CONDITIONING (HVAC)
CONTROL MODULE
54-16
HEATED DEFROST 2.0L
REAR DOORS

WH-BU
CB146
SB104 GN-RD
Hot at Hot in Start
all times or Run
AUXILIARY
JUNCTION
F4 F46 BOX (AJB)
40A 5A 11-11
13-80 HEATED 13-77
3 1 REAR
WINDOW
RELAY

5 2
F31
30A
13-79

CRD06
BN-YE
CRD06
BN-YE
BU-OG
CB131

HEATED
CRD06 BN-YE WINDOW
A 56-12
S285

heated rear window

BN-BU
CRD02
CB131 BU-OG
S252

30 C0300 30 C0311
60 C0210
9 2 C0935 9 2 C0991
GD350

GD351
CB131

CB131
BK

BN-BU
CRD02
9 2 C0422 9 2 C0411
CB123

S402 S404
BK

16 C02357A
BK-WH

BK-GN
GD350

GD351
1 C04425A 1 C04425B 1 C04426A 1 C04426B

REAR WINDOW
DEFROST
G0401 G0404 CTRL
10-57 10-62
HEATED REAR HEATED REAR HEATING,
WINDOW WINDOW VENTILATION AND
ELEMENT LH ELEMENT RH AIR CONDITIONING (HVAC)
151-110 151-110 CONTROL MODULE
54-16
HEATED MIRROR 2.0L
HEATED
WINDOW
CRD06 BN-YE
56-10 56-11 A

Hot in Start or Run

with Heated Rear AUXILIARY
Window Relay engaged JUNCTION
BOX (AJB)
F24 11-11
10A
13-78

G0306
10-51
G0302

VT-GN

BK-YE
BK-VT

GD239
GD234

10-45 10-46

CB124

CB124
B11 A1 C0340 right hand drive A1 B11 C0339 right hand drive

B11 A1 C0339 A1 B11 C0340

GD239
GD234

CB124

CB124
BK

BK
BK

S513 right hand drive

S613 right hand drive
S504

GD239
GD234

BK
BK

2 1 C0521 1 2 C0626

2 1 C0517 right hand drive 1 2 C0622 right hand drive

EXTERIOR EXTERIOR
MIRROR MIRROR
LH RH
124-6 124-8 124-6 124-8
Hot at
all times 2.2L
BODY
CONTROL
F17 MODULE (BCM)
7.5A 11-5
13-47

70 C2280D

SBP17 RD POWER
DISTRIBUTION
SBP17

13-47
RD

3 C220

INSTRUMENT
VBATT PANEL
CLUSTER (IPC)
151-15 151-19
multi-function
display

C220 VDB13 BU-GY

I CAN + MODULE
5 14-2 COMMUNICATIONS
VDB14 VT-GY NETWORK
I CAN -
4

VDB06 GY-OG
MS CAN + MODULE
2 VDB07 VT-OG 14-6 COMMUNICATIONS
MS CAN - NETWORK
1

DISPLAY CMC29 GN-VT

SIGNAL 130-11 AUDIO SYSTEM/ NAVIGATION
8

POWERTRAIN
C210 - 49 C139 - 22 C175B CONTROL
CDC54 WH-GN CDC54 WH-GN
SMCS SMCS MODULE (PCM)
GND 12 41 23-17

10 C220
BK-VT
GD116

S222
BK-VT
GD116

G201
10-6
RD-WH
or 2.2L
BK
71-3
CLUSTER AND PANEL ILLUMINATION 1 C2998
STEERING WHEEL
SWITCH
LH UPPER
1) Right
2) Left
1 3) Down
511 4) Up
5) OK
2 151-23
301

3
182

4
multi-function 121
display
5
STEERING WHEEL 68
SWITCH,
RH UPPER
130-11
3 2 4 C2998

1 C2999

BN
BU-WH
S2012
S2010
BU-WH

BN
3 1 10 C218B
CLOCKSPRING
151-22 151-23

INSTRUMENT 5 C218A
PANEL
CLUSTER (IPC)
151-15 151-19 STEERING COLUMN
CONTROL

BK-GY
GD184
MODULE (SCCM)
151-22
DISPLAY/ C220 RMC27 WH-BN C2414
TRIP GND
6 8 S226
TRIP VMC29 YE
SIGNAL

BK-GY
GD184
7 6

G206
10-9
BODY
CONTROL 2.2L
MODULE (BCM)
11-5

C2280D VDB04 WH-BU

HS CAN + MODULE
52 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-3
51

VDB07 VT-OG
MS CAN - MODULE
54 COMMUNICATIONS
VDB06 GY-OG NETWORK
MS CAN + 14-7
53

CE515 YE-GY ELECTRONIC

FUEL C145 ENGINE
PUMP LEVEL C2280C VMC11 YE-VT VMC11 YE-VT CONTROLS
SENSOR 23-6
29 1 2 4 C463
RMC32 GN-BU RMC32 GN-BU
FUEL
LEVEL GND 46 13 FUEL PUMP AND
SENDER UNIT
C463 M 151-39

SWITCH CMC20 VT
LOW WASHER
FLUID LEVEL 10 3 C463
heated windshield
2 C138

BK-VT
LOW WASHER

GD132
FLUID WARNING
INDICATOR
SWITCH
1) Low fluid level
1 2 2) Normal level
151-6
S410 fuel fired
booster heater
1 C138
GD125
BK

BK-VT
GD132
GD125 BK

S131
G109
10-3 G400
10-25
POWERTRAIN
CONTROL 2.2L
MODULE (PCM) AMBIENT AIR
23-8 23-9 TEMPERATURE
SENSOR
151-6
C175T C139 C132 C132
VE750 GN-BU VE750 GN-BU
AAT
21 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
18 27

C175E CMC24 GY
OPS
5
1 C103

ENGINE
OIL PRESSURE
(EOP) SWITCH
BODY 1) Low pressure
CONTROL 1 2 2) Normal level
MODULE (BCM) 151-10
11-5

BRAKE FLUID C2280C CMC19 GY-VT

LEVEL SWITCH
23

Emergency Services

S293 C3663 - 2
PARK BRAKE CMC25 WH-VT
SWITCH
54 2 C124
1 C306
WH-VT
CMC25

LOW BRAKE
PARKING BRAKE FLUID WARNING
WARNING INDICATOR SWITCH
INDICATOR SWITCH 1) Low fluid level
37 C2237 1) Brake applied 2) Normal level
2) Brake released 1 2
1 2 151-7 151-8
151-31 151-35
Not used

1 C124
2 C306
BK-GY

BK-GY
GD135

GD135
3 C3663

S270
BK-GY
GD135

G304
10-16
BODY
CONTROL 2.2L
MODULE (BCM)
11-5

BRAKE PAD C2280C

WEAR OUT
SWITCH 21

CMC07
BU-GN

CMC06
BN-BU
23 22 C145
CMC07

CMC06
BU-GN

BN-BU
CMC09 GY-OG

S123

1 2 3 4 C423 CMC08 GN-BN

early production
S124 S130
CMC07

CMC09

CMC08
CMC09

CMC06

CMC08

GD125
WH

WH
WH

WH
YE

YE
YE

YE
S131

1 2 C4427 1 2 C4428 1 2 C1687 1 2 C1688

REAR BRAKE REAR BRAKE PAD FRONT BRAKE FRONT BRAKE

GD125
PAD WEAR WEAR SENSOR RH PAD WEAR PAD WEAR

BK
SENSOR LH 151-40 SENSOR LH SENSOR RH
151-40 151-5 151-5

G109
10-3 10-36
multi-function 2.2L
display passenger airbag

Hot at Hot in Start

all times or Run
BODY AUXILIARY
CONTROL JUNCTION
F19 MODULE (BCM) F23 BOX (AJB)
5A 11-5 7.5A 11-1
13-47 13-16

44 C2280D POWER
DISTRIBUTION
13-16
BU-RD
SBP19

BN-YE
CB123
S229 S227 CB123 BN-YE C210 - 17
BU-RD

BN-YE
CB123
SBP19

1 2 C253

MESSAGE
CENTER
VBATT VPWR
SWITCH
151-14 151-18 passenger airbag

RESTRAINTS
C210 C310A CONTROL
C253 CR114 YE-OG CR114 YE-OG PAD ON
IND + INDICATOR MODULE (RCM)
3 8 13 46-6

CR116 GN-WH CR116 GN-WH PAD OFF

IND -
4 2 20 INDICATOR

multi-function
display

FRONT CONTROL/
MFD VMC49 VT-GY C2123 DISPLAY INTERFACE
SELECT MFD MODULE (FCDIM)
GND SELECT 130-3
5 8

6 C253
BK-VT
GD116

S222 GD116 BK-VT

G201
10-6
Hot in Start Hot at TACHOGRAPH 2.2L
or Run all times
AUXILIARY
JUNCTION
F19 F6 BOX (AJB)
5A 5A 11-1
13-15 13-25

BN-WH

BN-RD
CB119

SB106
23 41 C300

1 9 C9027
BN-WH

BN-RD
CB119

3 SB106
1 C9068A

TACHOGRAPH
VPWR VBATT 151-50

C9068A CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
2 71-6

C9068C VDB06 GY-OG MODULE

MS CAN +
5 COMMUNICATIONS
VDB07 VT-OG NETWORK
MS CAN - 14-7
7
GND GND

5 6 C9068A
GD133

GD133
BK

S911

16 C9027
GD133
BK

G300
10-11
TACHOGRAPH 2.2L

TACHOGRAPH
151-50
INSTRUMENT
PANEL
CLUSTER (IPC)
151-15 151-19

C9027 C300 C210 - 7 C220

C9068B VMC36 GY-BU VMC36 GY-BU
PULSE PULSE
7 5 50 11

TACHOGRAPH
VEHICLE
SPEED
SENSOR (VSS)
151-33 151-34

C275 C2477
VMC38 GY-YE VMC38 GY-YE DATA
DATA
4 RMC35 GN 3 43 4 RMC35 GN 4
SENSOR -
2 11 42 3 2 SENSOR -

VMC39 BU VMC39 BU SPEED

SPEED
3 LMC35 WH-BU 4 44 2 LMC35 WH-BU 3
SENSOR +
1 12 45 1 1 SENSOR +
Start/Stop Bus 2.0L
BODY
CONTROL
F13 MODULE (BCM)
7.5A 11-17
13-102

8 C02280A
GY-RD
SBP13

S244
GY-RD
SBP13

3 C0220

INSTRUMENT
VBATT PANEL
CLUSTER (IPC)
151-78 151-82

C0220 VDB29 GN-BU

HS3 CAN + MODULE
5 14-9 14-10 COMMUNICATIONS
VDB30 WH-GN NETWORK
HS3 CAN -
4

automatic transmission

SELECTOR LEVER
CET52 GN C02810 ASSEMBLY
PARK PDS NO 37-1
DETECT 9 9

GND

12 C0220
BK-VT
GD216

S222
BK-VT
GD216

G0201
10-38 10-39
RD-WH
or
BK
2.0L
71-10
CLUSTER AND PANEL ILLUMINATION 1 C02998
STEERING WHEEL
SWITCH
LH UPPER
1) Right
2) Left
1 3) Down
511 4) Up
5) OK
151-86
2
301

3
182

4
multi-function 121
display
5
STEERING WHEEL 68
SWITCH,
RH UPPER
130-27
3 2 4 C02998

1 C02999

BN
BU-WH
S2012
S2010

BU-WH

BN
3 1 10 C0218B
CLOCKSPRING
151-85 151-86

5 C0218A

STEERING COLUMN

BK-GY
CONTROL

GD284
MODULE (SCCM)
151-85

S226

BK-GY
GD284
G0206
10-42
INSTRUMENT
PANEL 2.0L
CLUSTER (IPC)
151-78 151-82 FUEL PUMP
CONTROL
MODULE
24-12

CE515 YE-GY C0433 FP

C0210 C0145 C04000 PWR
C0220 VMC11 YE-VT 5
FUEL VMC11 YE-VT
SENDER 1
1 11 1 5
2 1 C0463

FUEL PUMP AND

SENDER UNIT
M 151-103

3 4 C0463
FUEL RMC32 GN-BU RMC32 GN-BU
SENDER 1
RETURN 7 10 13 4 RE515 WH-BN FP
RTN
8

heated windshield

SWITCH C0210 - 9
CMC20 VT CMC20 VT
LOW WASHER
FLUID LEVEL 2

2 C0138

LOW WASHER
FLUID WARNING
INDICATOR
SWITCH
1) Low fluid level
1 2 2) Normal level
151-69

1 C0138

S131 GD124 BK-VT

G0109
10-35
POWERTRAIN
CONTROL
MODULE (PCM)
2.0L
24-16 24-17

AMBIENT AIR
TEMPERATURE
(AAT) SENSOR
151-69
C0175B C0139 C0132 C0132
VE750 GN-BU VE750 GN-BU
AAT
52 13 1 2
RE335 BN-VT RE335 BN-VT
SIGRTN
35 27

C0175E VE774 YE-BU

OPS
49
1 C0103

ENGINE
OIL PRESSURE
(EOP) SWITCH
1) Low pressure
1 2 2) Normal level
151-74
BODY
CONTROL
MODULE (BCM)
2.0L
11-17

BRAKE FLUID C02280F CMC19 GY-VT

SWITCH 28
2 C0124

LOW BRAKE
FLUID WARNING
INDICATOR SWITCH
1) Low fluid level
1 2 2) Normal level
151-70 151-71

1 C0124
BRAKE FLUID RMC19 YE-GY
RETURN
35

right hand drive

C02280E S293 C03663 - 2

CMC25 WH-VT CMC25 WH-VT
PARK BRAKE
47
1 C0306

WH-VT
CMC25
PARKING BRAKE
WARNING
INDICATOR SWITCH
7 C0210 1) Brake applied
1 2 2) Brake released
151-94 151-98
Not used

2 C0306

BK-GY
GD135
3 C03663

S288 S286

BK-GN

BK-GY
GD240

GD235
G0307 G0304
10-52 10-49

left hand drive right hand drive

ANTI-LOCK
BRAKE SYSTEM
(ABS) MODULE
2.0L
42-6

BRAKE PAD C0135

WEAR OUT
SWITCH 21

CMC07
BU-GN

CMC06
BN-BU
23 22 C0145
CMC07

CMC06
BU-GN

BN-BU
S123

S131

1 2 C0423

BK-VT
GD124
CMC07

CMC09

CMC06

GD124
WH

WH
G0109
YE

YE
10-35

1 2 C04427 1 2 C01687

REAR BRAKE FRONT BRAKE

PAD WEAR PAD WEAR
SENSOR LH SENSOR LH
151-104 151-68
Hot in Start
or Run Start/Stop Bus 2.0L
BODY
CONTROL
F19 F32 MODULE (BCM)
5A 10A 11-17
13-101 13-103

7 9 C02280A
BN-WH

VT-RD
CBP19

SBP32
multi-function
display
12 6 C0264

S207
BN-WH

VT-RD
CBP19

SBP32

2 1 C0253

MESSAGE
CENTER
VPWR VBATT
SWITCH multi-function
151-77 151-81 display
RESTRAINTS
CONTROL
C0264 C0210 C0310A MODULE (RCM)
C0253 CR114 YE-OG CR114 YE-OG PAD ON
IND + INDICATOR 46-12
3 3 8 13

CR116 GN-WH CR116 GN-WH PAD OFF

IND -
4 2 20 INDICATOR
7

multi-function
display

FRONT CONTROL/
MFD VMC49 VT-GY C02123A DISPLAY INTERFACE
SELECT MFD MODULE (FCDIM)
GND SELECT 130-18 145-7
5 8

6 C0253
BK-VT
GD216

multi-function
display

C0263 - 1 S222
GD216 BK-VT GD216 BK-VT
G0201
S206 10-38 10-39
Hot in Start
or Run
Hot at
all times
TACHOGRAPH 2.0L
BODY AUXILIARY
CONTROL JUNCTION
F20 MODULE (BCM) F69 BOX (AJB)
5A 11-17 7.5A 11-11
13-100 13-81

5 C02280A

23 C0210

GY-RD
YE-VT
CBP20

SB169
23 41 C0300

GY-RD
SB169
YE-VT
CBP20

1 9 C09027

GY-RD
YE-VT
CBP20

SB169

3 1 C09068A

TACHOGRAPH
VPWR VBATT 151-116

C09068A CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
2 71-13

C09068C VDB06 GY-OG MODULE

MS CAN +
5 COMMUNICATIONS
VDB07 VT-OG NETWORK
MS CAN - 14-16 14-18
7

GND GND

5 6 C09068A
BK-GN

BK-GN
GD236

GD236

GD236 BK-GN C09027 - 16 GD236 BK-GN

S911 G0300
10-43
TACHOGRAPH 2.0L

TACHOGRAPH
151-116

C09068B C09027 C0300

VMC36 GY-BU VMC36 GY-BU
PULSE ends in harness near AJB
7 5 50

TACHOGRAPH
VEHICLE
SPEED
SENSOR (VSS)
151-96 151-97

C0275 C02477
VMC38 GY-YE VMC38 GY-YE DATA
DATA
4 RMC35 GN 3 43 4 RMC35 GN 4
SENSOR -
2 11 42 3 2 SENSOR -

VMC39 BU VMC39 BU SPEED

SPEED
3 LMC35 WH-BU 4 44 2 LMC35 WH-BU 3
SENSOR +
1 12 45 1 1 SENSOR +
Hot at
all times
2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 LSM

69 36 C2280D
POWER
DISTRIBUTION
13-47

GN-VT
YE-RD

VLF25
SBP18

1 5 C205
HEADLAMP
SWITCH
VBATT LIN 1 LSM
151-14 151-18

GND HEADLAMP LEVELING OUT

7 6 C205

VT-GN
VLF22
GD165
BK

5 C210

VT-GN
VLF22
S219
GD165
BK

HEADLAMPS/
AUTOLAMPS
85-1
G205
10-8
Hot at
all times 2.2L
BODY
CONTROL
F15 MODULE (BCM)
25A 11-5
13-44

MICRO

48 C2280D
CLN17 BN
A 71-3

CLN17
BN
CLN17 BN
B 71-4
CLUSTER AND
CLN17 BN PANEL ILLUMINATION
C 71-4
S225 CLN17 BN
D 71-4
CLN17

C210 - 45
BN

CLN17 BN
E 71-5

1 C271B
CLN17

CLN17
without:
BN

BN
BLOWER MOTOR SWITCH multi-function
54-5 display

3 C2195 3 C2039

CLN17
START HAZARD
CONTROL FLASHER

BN
UNIT SWITCH
40-1 90-2
14 C240A

AUDIO
FRONT
CONTROL
5 C2039 MODULE (ACM)
130-1
2 C2195
BK-GY

BK-GY
GD184

GD184

S226
BK-GY
GD184

G206
10-9
CLUSTER AND
PANEL ILLUMINATION
CLN17 BN
2.2L
71-2 A

12 C2414

STEERING COLUMN
CONTROL
MODULE (SCCM)
151-22

CLOCKSPRING
151-22 151-23

7 C218B

BK
S2011 or
RD-WH
or
GY
BK BK BK
or
RD-WH

1 C2366 1 C2998 1 C2367 2 C2999

STEERING WHEEL STEERING WHEEL STEERING WHEEL STEERING WHEEL

SWITCH SWITCH SWITCH SWITCH
LH LOWER LH UPPER RH LOWER RH UPPER
31-5 31-6 60-2 130-12 130-10 130-11

5 C2366 4 C2998 4 C2367 3 C2999

S2010
BN BN

CLOCKSPRING
151-22 151-23
BN

C218B C218A GD184 BK-GY S226 GD184 BK-GY

10 5
G206
10-9
CLUSTER AND
PANEL ILLUMINATION
2.2L
71-2 D

heated windshield
CLUSTER AND front
PANEL ILLUMINATION parking aid

71-2 C

CLUSTER AND
PANEL ILLUMINATION
71-2 B
heated rear window
CLN17

CLN17

CLN17
BN

BN
3 C241 3 C2035 3 C2025

HEATED PARKING HEATED

REAR AID WINDSHIELD
WINDOW SWITCH SWITCH
SWITCH 131-3 56-1
56-3

2 C241 2 C2035 2 C2025

BK-GY
BK-GY

BK-GY
GD184

GD184
GD184

S226
BK-GY
GD184

G206
10-9
CLUSTER AND
PANEL ILLUMINATION 2.2L
CLN17 BN
71-2 E

S2002 CLN17 BN CLUSTER AND

F PANEL ILLUMINATION
71-6

Emergency Services
CLN17

CLN17
CLN17 BN C3665 - 2 CLUSTER AND
BN

BN
G PANEL ILLUMINATION
71-7

CLN17 BN C2237
Not used
20

A2 C339 A2 C340

CLN17
CLN17

BK
BK

right hand right hand

1 drive 4 drive

4 C505 1 C605

DRIVER PASSENGER
DOOR DOOR
LOCK CONTROL LOCK CONTROL
SWITCH SWITCH
117-1 117-16 117-1 117-16

2 C505 3 C605
right hand right hand
3 drive 2 drive

right hand
GD135

GD135

left hand
drive
drive
BK

C339 - B12 S270

GD135 BK-GY C340 - B12 S270 right hand
right hand GD135 BK-GY
drive drive
S502
S602
G304 G304 G304 G304
10-15 10-15 10-15 10-15
CLUSTER AND
PANEL ILLUMINATION
2.2L
71-5 F

CLN17
BN
58 C300

CLN17
BN

S914 CLN17 BN
CLN17
BN

16 C9028 2 C9027
CLN17

CLN17
BN

BN
auxiliary
climate control

16 C938 late production: high roof

tachograph
24 C937 2 C9068A

AUXILIARY TACHOGRAPH
BLOWER 60-7
MOTOR
SWITCH
52-2
EMERGENCY SERVICES 2.2L
CLUSTER AND
PANEL ILLUMINATION
CLN17 BN
71-5 G

3 C2239

CLN17
BN
utility package if equipped
auxiliary heater
S9005
CLN17

CLN17

CLN17
BN

BN
8 C9437 8 C9436 8 C9434 8 C9435

AUXILIARY AUXILIARY BEACON WATER

SWITCH 2 SWITCH 1 SWITCH HEATER
140-7 140-6 140-4 SWITCH
140-5

4 C9437 4 C9436 4 C9434 4 C9435

BK-WH

BK-WH
GD285

GD285

GD285
S9002

2 C2239

S3011
BK-WH
GD285

G310
10-23
Hot in Start or Run 2.0L
AUXILIARY
JUNCTION
F42 BOX (AJB)
5A 11-11
13-74
CB142
GN

S104 BODY
CONTROL
MODULE (BCM)
11-17
CB142

AUTO HEADLAMP HEADLAMP FRONT REAR

LAMP ON OFF PARK FOG FOG DIM - DIM +

CLUSTER AND PANEL

18 C0210 21 15 16 2 20 8 3 7 C02280B ILLUMINATION
G 71-9

WH-VT
VT-GN

GY-VT
YE-BU

BN-YE

BN-VT
CLN56

CLN55

CLN17
YE-VT
CB142

CLF19

CLF24

CLF23

CLS34

CLF21

CLF57
GN

BN
9 13 12 10 11 14 2 3 6 15 C0205
HEADLAMP
AUTOLAMP HEADLAMP HEADLAMP PARK FRONT REAR DIM - DIM + ILLUM SWITCH
VPWR 151-77 151-81
ON OFF FOG FOG

HEADLAMP ILLUM
LEVELING GND GND

1 4 5 C0205

GD265

GD265
5 C0210

BK
S242
S219
VT-GN

VT-GN
VLF22

VLF22

GD265
BK

85-8 85-8

HEADLAMPS/ G0205
AUTOLAMPS 10-41
Hot at all times
BODY 2.0L
CONTROL
MODULE (BCM)
11-17

45 C02280B

CLN17 BN

CLN17
A 71-10

BN
CLN17 BN CLN17 BN
71-8 G B 71-11
CLUSTER AND
CLN17 BN PANEL ILLUMINATION
C 71-11
CLN17 BN CLN17 BN S225 CLN17 BN
D 71-11
S224
multi-function
12 C0263 display C0268 - 15
CLN17 BN
E 71-12
CLN17
BN

CLN17
3 C02039 without:

CLN17
multi-function
HAZARD display

BN
FLASHER
SWITCH 3 C02195
90-13 7 C02810

CLN17
START
CONTROL

BN
UNIT
40-2
14 C0240A
5 C02039
SELECTOR LEVER
ASSEMBLY
37-1
BK-VT
GD216

2 C02195
without: AUDIO
BK-GY
multi-function FRONT
GD284

S206
display CONTROL
MODULE (ACM)
130-13
1 C0263 GD284 BK-GY
S226
S222
BK-GY
GD284
BK-VT
GD216

G0201 multi-function G0206

10-39 display 10-42
CLUSTER AND
PANEL ILLUMINATION
CLN17 BN
2.0L
71-9 A

12 C02414

STEERING COLUMN
CONTROL
MODULE (SCCM)
151-85

CLOCKSPRING
151-85 151-86

7 C0218B

BK
S2011 or
RD-WH
or
GY
BK BK BK
or
RD-WH

1 C02366 1 C02998 1 C02367 2 C02999

STEERING WHEEL STEERING WHEEL STEERING WHEEL STEERING WHEEL
SWITCH SWITCH SWITCH SWITCH
LH LOWER LH UPPER RH LOWER RH UPPER
31-11 31-12 60-10 130-28 130-17 130-27

5 C02366 4 C02998 4 C02367 3 C02999

S2010
BN BN

CLOCKSPRING
151-85 151-86
BN

C0218B C0218A GD284 BK-GY S226 GD284 BK-GY

10 5
G0206
10-42
CLUSTER AND
PANEL ILLUMINATION 2.0L
71-9 D

heated windshield
CLUSTER AND
PANEL ILLUMINATION front parking aid

71-9 C

CLUSTER AND
PANEL ILLUMINATION
71-9 B
heated defrost
CLN17

CLN17

CLN17
BN

BN
3 C0241 3 C02035 3 C02025

HEATED PARKING HEATED

REAR AID WINDSHIELD
WINDOW SWITCH SWITCH
SWITCH 145-3 56-7
56-9

2 C0241 2 C02035 2 C02025

BK-GY
BK-GY

BK-GY
GD284

GD284
GD284

S226
BK-GY
GD284

G0206
10-42
CLUSTER AND
PANEL ILLUMINATION 2.0L
CLN17 BN
71-9 E

S268 CLN17 BN CLUSTER AND

F PANEL ILLUMINATION
71-13
CLN17

CLN17
BN

CLN17
BN
A2 C0340 right hand drive A2 C0339 right hand drive

A2 C0339 A2 C0340 2 C03665

Not used

CLN17
CLN17

BK
BK

4 C0541 right hand drive 1 C0632 right hand drive

4 C0505 1 C0605

FRONT DOOR FRONT DOOR

LOCK LOCK
SWITCH LH SWITCH RH
117-15 117-16 117-15 117-16

2 C0505 3 C0605

2 C0541 right hand drive 3 C0632 right hand drive

GD235

GD235
BK

BK
GD240
GD240

BK
BK

S512 S612
S603
S502
B12 C0340 B12 C0339

B12 C0339 B12 C0340

S286
BK-GN
GD240
BK-GN

BK-GY

BK-GY
GD240

GD235

GD235
G0307
G0307 G0304 10-52 G0304
10-52 10-49 10-49
left hand drive
left hand drive right hand drive right hand drive
CLUSTER AND
PANEL ILLUMINATION
2.0L
71-12 F

CLN17
BN
58 C0300

CLN17
BN
S914 CLN17 BN
CLN17
BN

16 C09028 2 C09027
CLN17

CLN17
BN

BN
auxiliary
climate control

tachograph
24 C0937 2 C09068A

AUXILIARY TACHOGRAPH
BLOWER 60-16
MOTOR
SWITCH
52-5 52-6
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A FRONT WIPER
13-47 LIMP HOME
SWITCH LIN 1 SWM HS CAN - HS CAN +

69 34 35 51 52 C2280D
SBP18 YE-RD POWER
DISTRIBUTION
13-47

WH-BU
VDB05

VDB04
CRW36
GN-OG
YE-RD
SBP18

WH
VDN05
YE-GY
1 C2414

STEERING
COLUMN
VBATT CONTROL
MODULE (SCCM)
WIPER/WASHER 151-22
SWITCH MODULE
COMMUNICATIONS
NETWORK
C2414 14-3
FRONT WIPER
LIMP HOME SWITCH 3
lane departure warning
VDN05 YE-GY
LIN 1 SWM S216
11
VDN05 YE-GY
LIN 1 SWM
2

VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
4 NETWORK
VDB05 WH 14-3
HS CAN -
GND 5

14 C2414
GD165
BK

S219
GD165
BK

G205
10-8
Hot in Start
or Run 2.2L
IGNITION
SWITCH
13-10 13-11

1 C250

S224

65 C210

S276

36 C139

S115
SBB32 VT-RD

CDC32
BN-YE
Hot at
all times
BATTERY
JUNCTION
BOX (BJB)
WINDSHIELD 11-3
3 1 WIPER
F32 MOTOR
60A RELAY
13-4 IGNITION
5 2 RELAY
13-6
2

GD241
VT-WH
CRW03

BK-BU
without:

BK-BU
GD241
Econetic

BK-BU
A GD241

WIPERS AND
WASHERS
S117
81-3
Econetic
5 C139

GD241 BK-BU
S274 G308
10-21
WIPERS AND
WASHERS
81-2
2.2L
A

VT-WH
CRW03
BODY
CONTROL
S113 MODULE (BCM)
11-5
VT-WH

VT-WH
CRW03

CRW03
BATTERY LIN 8 RSM
JUNCTION
F10 F9 BOX (BJB)
30A 30A 11-3 2 C2280C
13-4 13-4

VRW26
VT-GY

BN-YE
CBB09
YE-OG
CBB10

9 8 C139
S265

VRW26
YE-OG

VT-GY

BN-YE
CBB10

CBB09
VRW28 WH-OG

1 3 C1656 3 1 4 C1655

VRW26
BN-YE
AUXILIARY WINDSHIELD
WINDSHIELD WIPER
WIPER MOTOR
VPWR LIN MOTOR LIN VPWR LIN 151-7 151-8
151-7 151-8
GND GND

M M
B

2 C1656 2 C1655 WIPERS AND

WASHERS
BK-YE

BK-YE
GD129

GD129

81-4

rain sensor
S126
BK-YE
GD129

G110
10-4
RAIN SENSOR Hot in Start 2.2L
or Run
BODY
CONTROL
MODULE (BCM)
F5 11-5
5A WIPERS AND
13-52 WASHERS
81-3

25 C2280B B

VRW26

BN-YE
CBP05
YE
22 41 50 C311

VRW26
BK-GN

BN-YE
GD140

CBP05
YE
7 12 10 C913

S909

VRW26

BN-YE
CBP05
YE
BK-GN
GD140

lane departure
1 6 4 C919 warning

VRW26
BK-GN

BK-BU

BN-YE
GD140

GD140

CBP05
YE

2 1 3 C914
AUTOLAMP
AND
GND VPWR LIN RAIN SENSOR
151-50

G306
10-19
REAR WINDOW WIPERS 2.2L
Hot in Start Hot at
or Run all times
AUXILIARY
JUNCTION
F34 F38 BOX (AJB)
20A 5A 11-1
13-21 13-23

BN-RD
VT-BN
CB134

SB138
S275 S283

1 25 C139

VT-BN
CB134

BN-RD
SB138
BATTERY
JUNCTION
BOX (BJB)
REAR 11-3
4 5 1 WINDOW
WIPER
RELAY
3 2
late production
BK-VT
GD134
BK-WH

CRW05

CRW02
GY-BU
GD137

4 2 15 C139

late production
CRW05

CRW02
GY-BU
BK-VT
GD134

C 27 C2280C
BK-WH
GD137

WIPERS AND BODY

late production WASHERS CONTROL
81-6 81-7 CFEAC MODULE (BCM)
G303 G302 11-5
10-14 10-13
REAR WINDOW WIPERS Hot in Start
2.2L
or Run
AUXILIARY
LIFTGATE JUNCTION
F34 BOX (AJB)
20A 11-1
13-21
WIPERS AND
WASHERS
81-5

CRW05

VT-BN
CB134
BU
S275
S277

CRW05

VT-BN

VT-BN
CB134

CB134
BU

BU
25 C311 25 24 C300 24 C311

CRW05

VT-BN

VT-BN
CB134

CB134
BU

BU
2 C935 4 C983 4 1 C934 1 C983
Not used Not used

CRW05
GD149

CB134
BK

BK
2 C406 4 1 C405

S401

CRW05

CB134
BK-GY
GD149

GD149

BK
BK

1 3 2 C4218

REAR
WINDOW
WIPER MOTOR
151-45

M
G401
10-26
REAR WINDOW WIPERS Hot in Start
2.2L
or Run
AUXILIARY
REAR DOORS JUNCTION
F34 BOX (AJB)
20A 11-1
13-21

WIPERS AND
WASHERS
81-5

CRW05

VT-BN
CB134
BU
S275
S277

CRW05

VT-BN

VT-BN
CB134

CB134
BU

BU
25 24 C300
D E

CRW05

VT-BN
CB134
WIPERS AND WIPERS AND
WASHERS

BU
WASHERS
81-8 81-8

2 C935 4 1 C934

CRW05
BK-GY

VT-BN
GD149

CB134
BU
2 C422 4 1 C421

S402
CRW05

VT-BN
CB134
BK-GY

BK-GY
GD149

GD149

1 3 2 C476

REAR
WINDOW
WIPER MOTOR
LH
151-44
M
G401
10-27
REAR WINDOW WIPERS 2.2L
REAR DOORS

WIPERS AND WIPERS AND

WASHERS WASHERS
81-7 81-7

D E

CRW05

VT-BN
CB134
BU
25 24 C311

CRW05

VT-BN
CB134
BU
2 C991 4 1 C983

CRW05
GD351

CB134
BK

BK
2 C411 4 1 C410

S404
CRW05

CB134
BK-GN
GD351

GD351

BK
BK

1 3 2 C4171

REAR
WINDOW
WIPER MOTOR
RH
151-44
M
G404
10-29
Hot at
all times 2.2L
BODY
CONTROL
F6 MODULE (BCM)
15A 11-5
13-27

REAR WASHER PUMP RELAY FRONT WASHER PUMP RELAY

(Non-serviceable) (Non-serviceable)

31 24 23 32 34 C2280B
BK-WH

BK-WH

BU-WH
CRW34

CRW14
BU-BN
GD137

GD137

S256

WINDSHIELD
WASHER
PUMP
BK-WH
GD137

151-6

C137 C137
M
2 1

G303
10-14
Hot in Start or Run Start/Stop Bus 2.0L
BODY
CONTROL
MODULE (BCM)
F36 F13 11-17
15A 7.5A
13-101 13-102
HS1 CAN - HS1 CAN +

15 8 C02280A 9 10 C02280G

WH-BU
VDB05

VDB04
GY-RD
SBP13

WH
S244

GY-RD
BU-BN
CBP36

SBP13

9 1 C02414
MODULE
STEERING COLUMN COMMUNICATIONS
CONTROL NETWORK
VPWR VBATT MODULE (SCCM) 14-11
151-85

WIPER/WASHER
SWITCH

C02414 VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
4 NETWORK
VDB26 GY-BU 14-14
HS2 CAN -
5

GND GND

10 14 C02414
GD265

GD265
BK

S219
GD265
BK

G0205
10-41
Hot at
all times
Hot at
all times
2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F1 F10 11-11
60A 10A
13-80 13-81

YE-RD
SB110
S292

YE-RD
SB101

SB110
RD AUXILIARY
JUNCTION
BOX (AJB)
FRONT 11-11
3 1 WIPER
RELAY

5 2
VT-WH
CRW03

WH-BU
CDC64
A

WIPERS AND
WASHERS
81-12

24 C02280F
BODY
CONTROL
FRONT MODULE (BCM)
WIPER RELAY 11-17
CONTROL
WIPERS AND
WASHERS 2.0L STEERING COLUMN
81-11 CONTROL
MODULE (SCCM)
A 151-85

VT-WH
CRW03
LIMP HOME LIN

AUXILIARY 3 2 C02414
JUNCTION
BOX (AJB)

CRW36

GN-OG

YE-GY
C 81-13

VX107
11-11
F52 F51 F51 F52
25A 25A 25A 25A
13-83 13-83 13-83 13-83
19 12 C0210

right hand drive right hand drive

YE-GY
VX107
GN-WH

right hand drive

CB152

CB151 BN CB152 GN-WH

right hand drive S249

CB151
BN

CRW36

GN-OG

YE-GY

YE-GY
VX107

VX107
VRW28 WH-OG

1 3 C01656 3 8 1 4 C01655

AUXILIARY WINDSHIELD
WINDSHIELD WIPER
WIPER MOTOR
MOTOR LIN VPWR LIMP HOME LIN 151-70 151-71
VPWR LIN
151-70 151-71
GND GND
B
M M

WIPERS AND
WASHERS
2 C01656 6 C01655 81-13
BK-YE

BK-YE
GD129

GD129

rain sensor

S126

G0110
10-36
AUXILIARY
JUNCTION 2.0L
BOX (AJB)
81-12 C D 81-15 81-16 11-11

F50
5A
13-83

WIPERS AND
WASHERS
WIPERS AND 81-12
WASHERS
CB150 YE-OG
G 81-18 B

YE-GY
VX107
YE-OG
CB150
rain sensor

41 50 C0311

YE-OG

YE-GY
VX107
CB150
11 C0900
BK-GN

BK-GN
GD308

GD308

S923 rear parking aid S909 12 10 C0913

BK-GN

YE-OG

YE-GY
GD308

VX107
CB150

3 1 2 C0914
BK-GN

AUTOLAMP
GD308

AND
GND VPWR LIN RAIN SENSOR
151-115

G0405
10-63
WITHOUT REAR WINDOW WIPERS 2.0L

WINDSHIELD
WIPER
MOTOR
151-70 151-71

WASHER

7 C01655

BU-WH
CRW14
1 C0137

WINDSHIELD
WASHER
PUMP
M 151-69

2 C0137

BK-GY
GD123

S132
BK-GY
GD123

G0108
10-34
REAR WINDOW WIPERS AUXILIARY
JUNCTION 2.0L
BOX (AJB)
81-13 D 11-11
LIFTGATE WINDSHIELD
WIPER
MOTOR F49
151-70 151-71 20A
13-82
REAR WIPER

11 C01655

CRW05

VT-GY
CB149
BU
S257
S277

CRW05

VT-GY

VT-GY
CB149

CB149
BU

BU
25 C0311 25 24 C0300 24 C0311
CRW05

CRW05

VT-GY

VT-GY
CB149

CB149
BU

BU
2 C0935 4 C0983 4 1 C0934 1 C0983
Not used Not used
CRW05
GD350

CB149
BK

BK
2 C0406 4 1 C0405

S401
CRW05

CB149
BK-WH
GD350

GD350

BK
BK

3 2 1 C04218

REAR
WINDOW
WIPER MOTOR
151-111

M
G0401
10-56
REAR WINDOW WIPERS 2.0L AUXILIARY
JUNCTION
BOX (AJB)
WINDSHIELD 81-13 D 11-11
REAR DOORS WIPER
MOTOR
151-70 151-71 F49
20A
13-82
REAR WIPER

11 C01655

CRW05

VT-GY
CB149
BU
S257
S277

CRW05

VT-GY

VT-GY
CB149

CB149
BU

BU
25 24 C0300
F E

CRW05

VT-GY
CB149
WIPERS AND WIPERS AND
WASHERS

BU
WASHERS
81-17 81-17

2 C0935 4 1 C0934

CRW05
GD350

CB149
BK

BK
2 C0422 4 1 C0421

S402
CRW05

CB149
BK-GY
GD350

GD350

BK
BK

1 2 3 C0476

REAR
WINDOW
WIPER MOTOR
LH
151-110
M
G0401
10-57
REAR WINDOW WIPERS 2.0L
REAR DOORS

WIPERS AND WIPERS AND

WASHERS WASHERS
81-16 81-16

F E

CRW05

VT-GY
CB149
BU
25 24 C0311

CRW05

VT-GY
CB149
BU
2 C0991 4 1 C0983

CRW05
GD351

CB149
BK

BK
2 C0411 4 1 C0410

S404
CRW05

CB149
BK-GN
GD351

GD351

BK
BK

1 2 3 C04171

REAR
WINDOW
WIPER MOTOR
RH
151-110
M
G0404
10-62
REAR WINDOW WIPERS 2.0L
Hot at all times
AUXILIARY
JUNCTION
BOX (AJB) WIPERS AND
F9 WASHERS
15A 11-11
81-13
13-81
G

YE-OG
CB150
SB109
RD
AUXILIARY
JUNCTION
BOX (AJB)
11-11
REAR
4 5 1 WASHER
RELAY

3 2

CRW23
VT-GN
BK-GY

2 C0137
BK-YE
GD129

GD123

WINDSHIELD
WASHER
PUMP
S126 S132 M 151-69
BK-GY
BK-YE
GD129

GD123

1 C0137
BU-WH
CRW14

CRW12
GY-OG
G0110 G0108
10-36 10-34

left hand drive right hand drive

7 12 C01655
WINDSHIELD
WIPER
MOTOR
WASHER REAR 151-70 151-71
WASHER
RELAY
CONTROL
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 LSM

69 36 C2280D
POWER
DISTRIBUTION
13-47

GN-VT
YE-RD

VLF25
SBP18

1 5 C205
HEADLAMP
SWITCH
VBATT LIN 1 LSM
151-14 151-18

GND HEADLAMP LEVELING OUT

7 6 C205

VT-GN
VLF22
GD165
BK 5 C210

S219
S242

VT-GN

VT-GN
GD165

VLF22

VLF22
BK

A B

85-5 85-5
G205
10-8 HEADLAMPS/
AUTOLAMPS
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 SWM HS CAN - HS CAN +

69 35 51 52 C2280D
SBP18 YE-RD POWER
DISTRIBUTION
13-47

WH-BU
VDB05

VDB04
YE-RD
SBP18

WH
VDN05
YE-GY
1 C2414

STEERING COLUMN
CONTROL
VBATT MODULE (SCCM)
151-22

MODULE
COMMUNICATIONS
NETWORK
MULTIFUNCTION SWITCH 14-3
lane departure
warning
C2414 VDN05 YE-GY
LIN 1 SWM S216
11
VDN05 YE-GY
LIN 1 SWM
2

VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
4 NETWORK
VDB05 WH 14-3
HS CAN -
GND 5

14 C2414
GD165
BK

S219
GD165
BK

G205
10-8
Hot at Hot at Hot at
all times all times all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15 F14 11-5
25A 25A
13-44 HIGH BEAM 13-43
RELAY
(Non-serviceable)

MICRO MICRO
F10
10A
13-30

TURN SIGNAL/
STOP/ 69 C2280C 5 C2280B 73 C2280C
HAZARD LAMPS
90-3
daytime
Emergency Services Emergency Services running
PARKING, lamps
REAR AND

GY-BN
BN-BU
LICENSE
CLF04

CLF02
LAMPS

GY-BU
92-2

CLF61
34 C2237 33 C2237

Not used Not used

GN-OG
BU-GN

GY-BN
BN-BU
CLS21

CLS06

CLF04

CLF02
6 2 8 1 3 C1021
HEADLAMP
ASSEMBLY LH
151-6
BEAM

BEAM
TURN

PARK

DTRL
HIGH
LOW

4 C1021

BK-YE
GD129
GD129 BK-YE

S125 G110
10-4
Hot at Hot at Hot at
all times all times all times 2.2L
BODY
CONTROL
MODULE (BCM)
F11 F14 11-5
25A 25A
13-31 HIGH BEAM 13-43
RELAY
(Non-serviceable)

MICRO MICRO
F9
10A
13-30
TURN SIGNAL/
STOP/
HAZARD LAMPS
90-4 12 17 C2280B 74 C2280C

PARKING, daytime
REAR AND running
LICENSE lamps
LAMPS

VT-WH
92-2

CLF62
BU-GN

VT-OG
BN-YE
YE-VT
CLS25

CLS07

CLF05

CLF03
6 2 8 1 3 C1041
HEADLAMP
ASSEMBLY RH
151-6
BEAM

BEAM
TURN

PARK

DTRL
HIGH
LOW

4 C1041

BK-GY
GD123
GD123 BK-GY

S132 G108
10-3
Hot in Start
or Run 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
F24 11-1
5A
13-18

VT-GN

VT-GN
CB124

CB124
HEADLAMPS/
HEADLAMPS/ AUTOLAMPS
AUTOLAMPS 85-1 85-8
85-1 85-12

A B
VT-GN

VT-GN
VLF22

VLF22
9 10 C1021 9 10 C1041

HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
DOWN UP 151-6 DOWN UP 151-6
LEVELING

LEVELING
M M

GND GND

7 C1021 7 C1041

BK-GY
BK-YE
GD129

GD123
S125 S132

BK-GY
BK-YE
GD129

GD123
G110 G108
10-4 10-3
Hot in Start
or Run CORNERING LAMPS 2.2L
AUXILIARY
JUNCTION
F28 BOX (AJB)
20A 11-1
13-19
GY-VT
CB128

21 C210
GY-VT
CB128

24 C2800

ADAPTIVE
FRONT
VBATT LIGHTING
MODULE
151-14 151-18

C2800 VDB04 WH-BU MODULE

HS CAN +
19 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-3
7

C210
CLF07 GY-OG CLF07 GY-OG
SBR
1 50
CLF06 BN-GN CLF06 BN-GN
SBL
13 44
5 C1021 5 C1041
HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
151-6 151-6

GND

BENDING
BENDING
4 C2800
GD165
BK

4 C1021 4 C1041
S219

BK-GY
GD123
BK-YE
GD129
GD165

GD129 BK-YE GD123 BK-GY

G205 S125 G110 S132 G108

10-8 10-4 10-3
AUTOLAMPS 2.2L
Hot in Start
or Run
BODY
CONTROL
MODULE (BCM)
F5
5A 11-5
13-52
LIN 8 RSM

25 C2280B 2 C2280C

VRW26
BN-YE
CBP05
S265

VRW26
22 41 50 C311

BN-YE
4 C1655

VRW26
BK-GN

BN-YE
GD140

CBP05
YE
LIN

7 12 10 C913
WINDSHIELD
WIPER
MOTOR
S909 81-3

VRW26
BN-YE
CBP05
YE
BK-GN
GD140

lane departure warning

1 6 4 C919

VRW26
BK-GN

BK-BU

BN-YE
GD140

GD140

CBP05
YE

2 1 3 C914

AUTOLAMP
AND
GND VPWR LIN RAIN SENSOR
151-50

G306
10-19
Hot in Start or Run 2.0L
AUXILIARY
JUNCTION
F42 BOX (AJB)
5A 11-11
13-74
CB142
GN

S104 BODY
CONTROL
MODULE (BCM)
11-17
CB142

HEADLAMP HEADLAMP FRONT REAR

AUTOLAMP ON OFF PARK FOG FOG DIM - DIM +

CLUSTER AND PANEL

18 C0210 21 15 16 2 20 8 3 7 C02280B ILLUMINATION
71-8

WH-VT
VT-GN

GY-VT
YE-BU

BN-YE

BN-VT
CLN56

CLN55

CLN17
YE-VT
CB142

CLF19

CLF24

CLF23

CLS34

CLF21

CLF57
GN

BN
9 13 12 10 11 14 2 3 6 15 C0205
HEADLAMP
AUTOLAMP HEADLAMP HEADLAMP PARK FRONT REAR DIM - DIM + ILLUM SWITCH
VPWR 151-77 151-81
ON OFF FOG FOG

HEADLAMP ILLUM
LEVELING GND GND

1 4 5 C0205

GD265

GD265
5 C0210

BK
S242
S219
VT-GN

VT-GN
VLF22

VLF22

GD265
BK

A B

85-12 85-12

HEADLAMPS/ G0205
AUTOLAMPS 10-41
Hot in Start or Run Start/Stop Bus 2.0L
BODY
CONTROL
MODULE (BCM)
F36 F13 11-17
15A 7.5A
13-101 13-102
HS1 CAN - HS1 CAN +

15 8 C02280A 9 10 C02280G

WH-BU
VDB05

VDB04
GY-RD
SBP13

WH
S244

GY-RD
BU-BN
CBP36

SBP13

9 1 C02414
MODULE
STEERING COLUMN COMMUNICATIONS
CONTROL NETWORK
VPWR VBATT MODULE (SCCM) 14-11
151-85

MULTIFUNCTION SWITCH

C02414 VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
4 NETWORK
VDB26 GY-BU 14-14
HS2 CAN -
5

GND GND

10 14 C02414
GD265

GD265
BK

S219
GD265
BK

G0205
10-41
Hot at all times 2.0L
BODY
CONTROL
MODULE (BCM)
11-17

39 C02280F 24 C02280E 4 11 C02280G 40 C02280F

BU-GN
CLS21 daytime
running
lamps

S271
BU-GN
CLS21

GN-OG
BU-GN

GY-BN

GY-BU
BN-BU
CLS21

CLS06

CLF04

CLF02

CLF61
B1 C0340 right hand drive

B1 C0339

6 2 8 1 3 C01021
HEADLAMP
ASSEMBLY LH
151-69
CLS21
BK

BEAM

BEAM
TURN

PARK

DTRL
HIGH
LOW

8 C0521
4 C01021
8 C0517 right hand drive

BK-YE
GD129
EXTERIOR
MIRROR GD129 BK-YE
LH
124-6 124-8 S125 G0110
10-36
Hot at all times 2.0L
BODY
CONTROL
MODULE (BCM)
11-17

38 C02280F 23 C02280E 2 6 C02280G 36 C02280F

YE-VT
CLS25
daytime
running
lamps

S129
YE-VT
CLS25

VT-WH
BU-GN

VT-OG
BN-YE
YE-VT
CLS25

CLS07

CLF05

CLF03

CLF62
B1 C0339 right hand drive

B1 C0340

6 2 8 1 3 C01041
HEADLAMP
ASSEMBLY RH
151-69
CLS25
BK

BEAM

BEAM
TURN

PARK

DTRL
HIGH
LOW

8 C0626
4 C01041
8 C0622 right hand drive

BK-GY
GD123
EXTERIOR
MIRROR GD123 BK-GY
RH
124-6 124-8 S132 G0108
10-34
Hot in Start
or Run 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F42 11-11
5A
13-74

S254

HEADLAMPS/ HEADLAMPS/
AUTOLAMPS AUTOLAMPS
85-8 85-8

A B
VT-GN

VT-GN
VLF22

VLF22
CB142

CB142
GN

GN
9 10 C01021 9 10 C01041

HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
DOWN UP 151-69 DOWN UP 151-69
LEVELING

LEVELING
M M

GND GND

7 C01021 7 C01041

BK-GY
BK-YE
GD129

GD123
S125 S132

BK-GY
BK-YE
GD129

GD123
G0110 G0108
10-36 10-34
Hot in Start
or Run CORNERING LAMPS 2.0L
AUXILIARY
JUNCTION
F45 BOX (AJB)
20A 11-11
13-75
CB145
YE

21 C0210
CB145
YE

24 C02800

ADAPTIVE
FRONT
VBATT LIGHTING
MODULE
151-77 151-81

C02800 VDB04 WH-BU MODULE

HS1 CAN +
19 COMMUNICATIONS
VDB05 WH NETWORK
HS1 CAN - 14-11
7

C0210
CLF07 GY-OG CLF07 GY-OG
SBR
1 50
CLF06 BN-GN CLF06 BN-GN
SBL
13 37
5 C01021 5 C01041
HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
151-69 151-69

GND

BENDING
BENDING
4 C02800
GD265
BK

4 C01021 4 C01041
S219

BK-GY
GD123
BK-YE
GD129
GD265

GD129 BK-YE GD123 BK-GY

G0205 S125 G0110 S132 G0108

10-41 10-36 10-34
AUTOLAMPS 2.0L
Hot at all times
with front wiper
relay engaged
AUXILIARY STEERING COLUMN
JUNCTION CONTROL
BOX (AJB) MODULE (SCCM)
F50 151-85
5A 11-11
13-83 LIN

2 C02414

YE-GY
VX107
YE-OG
CB150
12 C0210

S249

YE-GY
VX107
41 50 C0311
4 C01655

YE-OG

YE-GY
VX107
CB150
11 C0900 LIN
BK-GN

BK-GN
GD308

GD308

WINDSHIELD
WIPER
MOTOR
81-12

S923 rear parking aid S909 12 10 C0913

BK-GN

YE-OG

YE-GY
GD308

VX107
CB150

3 1 2 C0914
BK-GN

AUTOLAMP
GD308

AND
GND VPWR LIN RAIN SENSOR
151-115

G0405
10-63
Hot at
all times
2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 LSM

69 36 C2280D
POWER
DISTRIBUTION
13-47

GN-VT
YE-RD

VLF25
SBP18

1 5 C205
HEADLAMP
SWITCH
VBATT LIN 1 LSM
151-14 151-18

GND HEADLAMP LEVELING OUT

7 6 C205

VT-GN
VLF22
GD165
BK

5 C210

VT-GN
VLF22
S219
GD165
BK

HEADLAMPS/
AUTOLAMPS
85-1
G205
10-8
FRONT FOG LAMPS
2.2L
Hot at
all times
BODY
CONTROL
MODULE (BCM)
F8 11-5
15A
13-30

FRONT FOG LAMP

RELAY
(Non-serviceable)

16 C2280B
Emergency Services

CLF34 YE-OG C2237 - 35

YE-OG
CLF34

Not used

S262
YE-OG

YE-OG
CLF34

CLF34
1 C152 1 C162
FRONT FRONT
FOG LAMP LH FOG LAMP RH
151-6 151-6

2 C152 2 C162
BK-GY
BK-YE
GD129

GD123

GD129 BK-YE GD123 BK-GY

S125 G110 S132 G108

10-4 10-3
REAR FOG LAMPS
2.2L
Hot at
all times
BODY
CONTROL
MODULE (BCM)
F14 11-5
25A
13-43

MICRO

75 76 C2280C

WH-BU
BN-GN
CLS45

CLS37
12 C300 12 C311

WH-BU
BN-GN
CLS45

CLS37
4 C412 3 C415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
90-5 90-5
92-3 92-4
FOG

FOG
6 C412 1 C415
BK-GY

BK-GN
GD149

GD351

G401 G404
10-26 10-27 10-29
Hot in Start or Run 2.0L
AUXILIARY
JUNCTION
F42 BOX (AJB)
5A 11-11
13-74
CB142
GN

S104 BODY
CONTROL
MODULE (BCM)
11-17
CB142

AUTO HEADLAMP HEADLAMP FRONT REAR

LAMP ON OFF PARK FOG FOG DIM - DIM +

CLUSTER AND PANEL

18 C0210 21 15 16 2 20 8 3 7 C02280B ILLUMINATION
71-8

WH-VT
VT-GN

GY-VT
YE-BU

BN-YE

BN-VT
CLN56

CLN55

CLN17
YE-VT
CB142

CLF19

CLF24

CLF23

CLS34

CLF21

CLF57
GN

BN
9 13 12 10 11 14 2 3 6 15 C0205
HEADLAMP
AUTO HEADLAMP HEADLAMP PARK FRONT REAR DIM - DIM + ILLUM SWITCH
VPWR 151-77 151-81
LAMP ON OFF FOG FOG

HEADLAMP ILLUM
LEVELING GND GND

1 4 5 C0205

GD265

GD265
5 C0210

BK
S242
S219
VT-GN

VT-GN
VLF22

VLF22

GD265
BK

85-8 85-8

HEADLAMPS/ G0205
AUTOLAMPS 10-41
FRONT FOG LAMPS 2.0L
Hot at all times Hot at all times
BODY
CONTROL
MODULE (BCM)
11-17

12 5 C02280G

YE-OG
CLF29

CLF34
BN
5 6 C0110

YE-OG
CLF29

CLF34
BN
2 C0152 2 C0162
FRONT FRONT
FOG LAMP LH FOG LAMP RH
151-67 151-67

1 C0152 1 C0162
BK-GY

BK-GY
GD123

GD123
S197

12 C0110

S132

BK-GY
GD123 G0108
10-34
REAR FOG LAMPS
2.0L
Hot at all times
BODY
CONTROL
MODULE (BCM)
11-17

25 C02280C

WH-BU
CLS37
S272

WH-BU

WH-BU
CLS37

CLS37
12 C0300 12 C0311
WH-BU

WH-BU
CLS37

CLS37
4 C0412 3 C0415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
90-16 92-9 90-16 92-10
FOG

FOG
6 C0412 1 C0415
BK-WH

BK-GN
GD350

GD351
G0401 G0404
10-56 10-57 10-62
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 LSM

69 36 C2280D
POWER
DISTRIBUTION
13-47

GN-VT
YE-RD

VLF25
SBP18

1 5 C205
HEADLAMP
SWITCH
VBATT LIN 1 LSM
151-14 151-18

GND HEADLAMP LEVELING OUT

7 6 C205

VT-GN
VLF22
GD165
BK

5 C210

VT-GN
VLF22
S219
GD165
BK

HEADLAMPS/
AUTOLAMPS
85-1
G205
10-8
EARLY PRODUCTION Hot at
all times
2.2L
BODY
CONTROL
F13
15A MODULE (BCM)
13-32 13-37 11-5

BATTERY
SAVER
RELAY
(Non-serviceable)

INT.LIGHT DEMAND LIGHT

1 DIMMING REAR SWITCH

2 C2280B 72 C2280C 9 C2280B Camper Conversions

CLN01 GN-VT C213

Not used

WH-OG

GN-VT
RLN29

CLN01
YE-GY
CLN03

Camper 7
Conversions
CLN01 GN-VT
C213 S260
Not used S261
8 INTERIOR
A LAMPS 9 C210
89-5 89-6
3 5 26 C311 89-7
CLN03 YE-GY

GN-VT
CLN01
WH-OG
YE-GY

S924
CLN03

RLN29

B 89-4
INTERIOR
LAMPS
G C 89-4 S235
2 8 11 C900 without: Base

GN-VT
CLN01
INTERIOR
LAMPS S907
89-6 D 89-3
1 C254
E 89-3 INTERIOR
WH-OG

GN-VT LAMPS GLOVE COMPARTMENT

RLN29

CLN01
YE-GY
CLN03

without: Base LAMP

F 89-3 151-15 151-19

1 C929B 1 C929C 1 C929A

FRONT INTERIOR
LAMP
1) On
2) Off 2 C254
YE-GY
CLN03

3) Courtesy

BK-GY
151-37 151-49

GD184
3 1 2 1 2 1 151-50

2 S226
H

BK-GY
GD184
2 C929B
INTERIOR C900 - 1
LAMPS GD238 BK-WH GD238 BK-WH
89-3 G301 G206
S906 10-12 10-9
EARLY PRODUCTION 2.2L
WITHOUT: BASE
illuminated vanity mirrors

Hot at all times Hot at all times Hot at all times

with battery saver with battery saver with battery saver
relay engaged relay engaged relay engaged
INTERIOR INTERIOR INTERIOR
LAMPS LAMPS LAMPS
89-2 89-2 89-2

D E F
GN-VT

GN-VT

GN-VT
CLN01

CLN01

CLN01
1 C931A 1 C907 1 C906
FRONT INTERIOR VANITY VANITY
LAMP MIRROR MIRROR
1) On LAMP LH LAMP RH
2) Off 151-49 151-49
3) Courtesy
151-50
3 1

2
3 C907 3 C906

1 2 C931B
BK-WH

BK-WH

BK-WH
YE-GY
CLN03

GD238

GD238
S906

BK-WH
GD238
INTERIOR
LAMPS
89-2
1 C900
BK-WH
GD238

G301
10-12
EARLY PRODUCTION 2.2L
VAN

Hot at all times Hot at all times

with battery saver with battery saver
relay engaged relay engaged
INTERIOR INTERIOR
LAMPS LAMPS
89-2 89-2

B C
GN-VT

GN-VT
CLN01

CLN01
Van - left-hand drive
1 C925 1 C936 (short wheelbase)
Van (long wheelbase)

1 C9056A 1 C9057A
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-51 151-51

1 C9056B 1 C9057B

INTERIOR
WH-BU

WH-BU
CLN43

CLN43
LAMPS
89-5

J
5 C925 3 C936
WH-BU

WH-BU

WH-BU
CLN43

CLN43

CLN43
CLN43 WH-BU C311 - 1 CLN43 WH-BU

S920
1 C2280B

BODY
CONTROL
INT.LIGHT MODULE (BCM)
2 DIMMING
11-5
Hot at all times
with battery saver EARLY PRODUCTION 2.2L
relay engaged
INTERIOR VAN
LAMPS
89-2

A GN-VT
CLN01

26 C300

S915 CLN01 GN-VT

Van - right-hand drive

(short wheelbase)
1 C9076 1 C9077 Van (long wheelbase)
GN-VT

GN-VT
CLN01

CLN01
1 C9078A 1 C9079A
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-51 151-51

1 C9078B 1 C9079B
WH-BU

WH-BU
CLN43

CLN43
5 C9076 3 C9077

S916 CLN43 WH-BU

5 C300
WH-BU
CLN43

INTERIOR
LAMPS
89-4
Hot at all times
with battery saver EARLY PRODUCTION 2.2L
relay engaged
INTERIOR DOUBLE CAB IN VAN
LAMPS
89-2

A
GN-VT
CLN01

26 C300

S915 C9076 C922 S901

1 1

GN-VT
CLN01
1 C9077
Not used 1 C9054A

GN-VT

GN-VT
CLN01

CLN01
THIRD ROW
INTERIOR LAMP
1) On
1 C2056A 1 C2057A 2) Off
3) Courtesy
FOOTWELL FOOTWELL 151-52
LAMP LAMP 3 1
LH RH
151-52 151-52
2

1 C2056B 1 C2057B 1 2 C9054B

BK-WH
YE-GY

YE-GY

YE-GY
CLN03

CLN03

GD150
6 C922

3 3

BK-GY
S903

GD149
21 C300
YE-GY
CLN03

6 C9076

BK-WH
GD150
INTERIOR
LAMPS
89-2 G403
10-28
Hot at all times
with battery saver EARLY PRODUCTION 2.2L
relay engaged
INTERIOR BUS
LAMPS
89-2 KOMBI
A

GN-VT
CLN01
CLN01 GN-VT
K 89-8
INTERIOR
CLN01 GN-VT LAMPS
26 C300 low roof
L 89-8

S915 C9076 C922

S901
1 1

1 C9077

GN-VT
CLN01
Not used

GN-VT

GN-VT
CLN01

CLN01
1 C2057C Kombi (high roof)

1 C2056A 1 C2057A
Not used Not used 1 C9075A
5 C925 3 C936 FOOTWELL FOOTWELL
LAMP LAMP LUGGAGE
LH RH COMPARTMENT
WH-BU

WH-BU

151-52 151-52 LAMP

CLN43

151-52

1 C2056B 1 C2057B
S920 1 C9075B

WH-BU

WH-BU
CLN43

CLN43

CLN43
Not used
3 C9077
WH-BU
CLN43

S916 S925
5 5
1 C311 5 C300
CLN43 WH-BU
M 89-8
WH-BU

WH-BU
CLN43

CLN43

INTERIOR
CLN43 WH-BU LAMPS
N 89-8

1 C2280B
BODY
INT.LIGHT CONTROL
2 DIMMING MODULE (BCM)
11-5
EARLY PRODUCTION 2.2L
BUS
KOMBI
Hot at all times Hot at all times
with battery saver with battery saver
relay engaged relay engaged

INTERIOR INTERIOR
LAMPS LAMPS
89-7 K 89-7 L

GN-VT
CLN01

GN-VT
CLN01
1 C9055A
1 C9054A FOURTH ROW
INTERIOR LAMP
THIRD ROW 1) On
INTERIOR LAMP 2) Off
1) On 3) Courtesy
2) Off 151-52
3) Courtesy 3 1
151-52
3 1
2
2
1 2 C9055B
1 2 C9054B

WH-BU

BK-WH
CLN43

GD150
INTERIOR
LAMPS
WH-BU
CLN43

BK-WH

89-7 N
GD150

INTERIOR
LAMPS S902

89-7 M
6 C922 low roof

BK-GY
GD149
6 C9076

BK-WH
GD150
G403
10-28
LATE PRODUCTION Hot at all times
with battery saver
relay engaged
2.2L
AUXILIARY
BODY JUNCTION
CONTROL F25 BOX (AJB)
MODULE (BCM) 7.5A 11-1
11-5 13-39

INT.LIGHT DEMAND LIGHT

1 DIMMING REAR SWITCH

WH-OG
CB125
2 C2280B 72 C2280C

WH-OG
RLN29
YE-GY
CLN03

INTERIOR
NZ LAMPS
89-13
Camper
Conversions
CB125 WH-OG S2101 CB125 WH-OG
C213
Not used S261
8 9 C210

3 5 26 C311
CLN03 YE-GY
WH-OG

WH-OG

WH-OG
YE-GY
CLN03

RLN29

CB125

CB125
NG
2 8 11 C900 without: Base
INTERIOR
LAMPS S907
89-13 ND 89-10
INTERIOR 1 C254
NE 89-10
WH-OG

WH-OG
LAMPS GLOVE COMPARTMENT
RLN29

CB125
YE-GY
CLN03

without: Base LAMP

NF 89-10 151-15 151-19

1 C929B 1 C929C 1 C929A

FRONT INTERIOR
LAMP
1) On
2) Off 2 C254
YE-GY
CLN03

3) Courtesy

BK-GY
151-37 151-49

GD184
3 1 2 1 2 1 151-50

2 S226
NH

BK-GY
GD184
2 C929B
INTERIOR C900 - 1
LAMPS GD238 BK-WH GD238 BK-WH
89-10 G301 G206
S906 10-12 10-9
LATE PRODUCTION 2.2L
WITHOUT: BASE illuminated vanity mirrors

Hot at all times Hot at all times Hot at all times

with battery saver with battery saver with battery saver
relay engaged relay engaged relay engaged
INTERIOR INTERIOR INTERIOR
LAMPS LAMPS LAMPS
89-9 89-9 89-9

ND NE NF
WH-OG

WH-OG

WH-OG
CB125

CB125

CB125
1 C931A 1 C907 1 C906
FRONT VANITY VANITY
INTERIOR LAMP MIRROR MIRROR
1) On LAMP LH LAMP RH
2) Off 151-49 151-49
3) Courtesy
151-50
3 1

2
3 C907 3 C906

1 2 C931B
BK-WH

BK-WH

BK-WH
YE-GY
CLN03

GD238

GD238
S906

BK-WH
GD238
INTERIOR
LAMPS
89-9
1 C900
BK-WH
GD238

G301
10-12
Hot at all times
with battery saver LATE PRODUCTION 2.2L
relay engaged
AUXILIARY
F32
JUNCTION VAN
BOX (AJB)
10A 11-1
13-40

Camper Conversions

S2100 CB132 GN-VT C213

Not used
7

CB132 GN-VT INTERIOR

NA LAMPS
89-12
2 C311
GN-VT
CB132

CB132 GN-VT

Van - left-hand drive

1 C925 1 C936 (short wheelbase)
Van (long wheelbase)

1 C9056A 1 C9057A
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-51 151-51
INTERIOR
LAMPS
89-12
1 C9056B 1 C9057B
NJ
WH-BU

WH-BU
CLN43

CLN43

WH-BU
CLN43
5 C925 3 C936
WH-BU

WH-BU
CLN43

CLN43

C311 - 1
CLN43 WH-BU CLN43 WH-BU
S920
1 C2280B

BODY
CONTROL
INT.LIGHT MODULE (BCM)
2 DIMMING
11-5
Hot at all times
with battery saver LATE PRODUCTION 2.2L
relay engaged
INTERIOR VAN
LAMPS
89-11

NA GN-VT
CB132

26 C300

CB132 GN-VT

Van - right-hand drive

(short wheelbase)
1 C9076 1 C9077 Van (long wheelbase)
GN-VT

GN-VT
CB132

CB132
1 C9078A 1 C9079A
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-51 151-51

1 C9078B 1 C9079B
WH-BU

WH-BU
CLN43

CLN43
5 C9076 3 C9077

S916 CLN43 WH-BU

5 C300
WH-BU
CLN43

INTERIOR
LAMPS
89-11
Hot at all times Hot at all times
with battery saver LATE PRODUCTION with battery saver 2.2L
relay engaged relay engaged
AUXILIARY
F32
JUNCTION DOUBLE CAB IN VAN INTERIOR
LAMPS
BOX (AJB)
10A 11-1 89-9
13-41
NZ

Camper Conversions

WH-OG
S2100 CB132 GN-VT C213

CB125
Not used
7

C311 - 2 C925 - 1 56 C300

CB132 GN-VT CB132 GN-VT
GN-VT

Not used
CB132

2 C9076

26 C300 2 C922
C9076 C922

WH-OG
1 1

CB125
GN-VT
CB132
GN-VT
CB132

1 C9054A
THIRD ROW
INTERIOR LAMP
1) On
1 C2056A 1 C2057A 2) Off
FOOTWELL FOOTWELL 3) Courtesy
LAMP LAMP 151-52
LH RH 3 1
151-52 151-52
2

1 C2056B 1 C2057B
1 2 C9054B

BK-WH
YE-GY

YE-GY

YE-GY
CLN03

CLN03

GD150
6 C922

4 4 S903
21 C300

BK-WH
GD150
YE-GY
CLN03

6 C9076

BK-WH
GD150
INTERIOR
LAMPS G403
89-9 10-28
Hot at all times
with battery saver LATE PRODUCTION 2.2L
relay engaged
AUXILIARY
JUNCTION BUS
F32 BOX (AJB)
10A 11-1 KOMBI
13-42

Camper Conversions

S2100 CB132 GN-VT C213

Not used
7
GN-VT
CB132

CB132 GN-VT
NK 89-15
INTERIOR
low roof CB132 GN-VT LAMPS
NL 89-15
26 C300 C9076 C922
CB132 GN-VT S901
1 1

GN-VT
CB132
GN-VT

GN-VT
CB132

CB132
1 C2057C Kombi (high roof)
Not used Not used
1 C2056A 1 C2057A
5 C925 3 C936 1 C9075A
FOOTWELL FOOTWELL
LAMP LAMP LUGGAGE
WH-BU

WH-BU
CLN43

CLN43

LH RH COMPARTMENT
151-52 151-52 LAMP
151-52

S920 1 C2056B 1 C2057B

1 C9075B
WH-BU

WH-BU

WH-BU
CLN43

CLN43

CLN43
Not used
WH-BU

3 C9077
CLN43

S916 S925
5 5
1 C311 5 C300
CLN43 WH-BU
NM 89-15
WH-BU

WH-BU

INTERIOR
CLN43

CLN43

CLN43 WH-BU LAMPS

NN 89-15

1 C2280B
BODY
CONTROL
INT.LIGHT MODULE (BCM)
2 DIMMING
11-5
LATE PRODUCTION 2.2L
BUS
KOMBI
Hot at all times Hot at all times
with battery saver with battery saver
relay engaged relay engaged

INTERIOR INTERIOR
LAMPS LAMPS
89-14 NK 89-14 NL

GN-VT

GN-VT
CB132

CB132
1 C9055A
1 C9054A FOURTH ROW
INTERIOR LAMP
THIRD ROW 1) On
INTERIOR LAMP 2) Off
1) On 3) Courtesy
2) Off 151-52
3) Courtesy 3 1
151-52
3 1
2
2
1 2 C9055B
1 2 C9054B

WH-BU

BK-WH
CLN43

GD150
INTERIOR
LAMPS
WH-BU
CLN43

BK-WH

89-14 NN
GD150

INTERIOR
LAMPS S902

89-14 NM
6 C922 low roof

BK-GY
GD149
6 C9076

BK-WH
GD150
G403
10-28
Hot in Start or Run 2.0L
AUXILIARY
JUNCTION
F42 BOX (AJB)
5A 11-11
13-74
CB142
GN

S104 BODY
CONTROL
MODULE (BCM)
11-17
CB142

AUTO HEADLAMP HEADLAMP FRONT REAR

LAMP ON OFF PARK FOG FOG DIM - DIM +

CLUSTER AND PANEL

18 C0210 21 15 16 2 20 8 3 7 C02280B ILLUMINATION
71-8

WH-VT
VT-GN

GY-VT
YE-BU

BN-YE

BN-VT
CLN56

CLN55

CLN17
YE-VT
CB142

CLF19

CLF24

CLF23

CLS34

CLF21

CLF57
GN

BN
9 13 12 10 11 14 2 3 6 15 C0205
HEADLAMP
AUTO HEADLAMP HEADLAMP PARK FRONT REAR DIM - DIM + ILLUM SWITCH
VPWR 151-77 151-81
LAMP ON OFF FOG FOG

HEADLAMP ILLUM
LEVELING GND GND

1 4 5 C0205

GD265

GD265
5 C0210

BK
S242
S219
VT-GN

VT-GN
VLF22

VLF22

GD265
BK

85-8 85-8

HEADLAMPS/ G0205
AUTOLAMPS 10-41
Hot at Hot at
all times all times 2.0L
BODY
CONTROL
MODULE (BCM)
F1 11-17
10A
13-115

FRONT DOME
LIGHT

13 C02280C 6 C02280F 14 C02280C

WH-OG

GN-VT
RLN29

CLN01
YE-GY
CLN03

INTERIOR
S266 A LAMPS
S267
89-24 89-27
YE-GY
CLN03

3 5 4 C0311

WH-OG
YE-GY

GN-VT
CLN03

RLN29

CLN01
G

INTERIOR 2 3 1 C0900
LAMPS dome lamp 2
89-24 89-25
S907
D 89-18

E 89-18 INTERIOR
WH-OG

LAMPS

GN-VT
RLN29

CLN01
YE-GY
CLN03

dome lamp 2
F 89-18

1 C0929B 1 C0929C 2 C0929B

FRONT
INTERIOR LAMP
2 1) On
YE-GY

2) Off
CLN03

3 1 2 1 2 1 3) Courtesy
151-115

H
1 C0929A
INTERIOR
LAMPS C0900- 5 S931
89-18 GD241 BK GD241 BK-BU GD241 BK-BU

S906 G0301
dome lamp 2 10-44
DOME LAMP 2 2.0L

illuminated vanity mirrors

INTERIOR
LAMPS
INTERIOR INTERIOR
LAMPS LAMPS
89-17 89-17 89-17 89-17

D E F
H

GN-VT

GN-VT
CLN01

CLN01
YE-GY

GN-VT
CLN03

CLN01

1 2 C0931B 1 C0907 1 C0906

FRONT VANITY VANITY

INTERIOR LAMP MIRROR MIRROR
2 1) On LAMP LH LAMP RH
2) Off 151-115 151-115
3 1 2 1 2 1 3) Courtesy
151-115

3 C0907 3 C0906

1 C0931A

GD241

GD241
BK

BK
GD241
BK

S906

GD241
BK
5 C0900

BK-BU
GD241

S931
BK-BU
GD241

G0301
10-44
VAN - LHD 2.0L
Hot at all times
BODY
SWB WITHOUT LED CONTROL
MODULE (BCM)
11-17

26 C02280C

WH-BU
CLN43
CLN43 WH-BU CLN43 WH-BU

S269

5 C0300 1 C0311
Not used
S920

3 C0936

5 C0925

WH-BU

WH-BU
CLN43

CLN43
1 C09056B 1 C09057B

LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-117 151-117

1 C09056A 1 C09057A

GD306

GD306
BK

BK
1 C0925 1 C0936

S931

BK-BU
GD241
G0301
10-44
VAN - RHD 2.0L
Hot at all times
BODY
SWB WITHOUT LED CONTROL
MODULE (BCM)
11-17

26 C02280C

WH-BU
CLN43
CLN43 WH-BU CLN43 WH-BU

S269

5 C0300 1 C0311
Not used
S916

3 C09077

5 C09076
WH-BU

WH-BU
CLN43

CLN43

1 C09078B 1 C09079B
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-118 151-118

1 C09078A 1 C09079A
GD306

GD306
BK

1 C09076 1 C09077

S915
GD306
BK

G0403
10-59
VAN - LOW ROOF 2.0L
Hot at all times
BODY
LWB CONTROL
MODULE (BCM)
11-17
SWB WITH LED

26 C02280C

WH-BU
CLN43
CLN43 WH-BU CLN43 WH-BU

S269

5 C0300 1 C0311

S920
S916

5 C09076 3 C09077 5 C0925 3 C0936

WH-BU

WH-BU
WH-BU

WH-BU

CLN43

CLN43
CLN43

CLN43

1 C09078B 1 C09079B 1 C09056B 1 C09057B

LUGGAGE LUGGAGE LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT COMPARTMENT COMPARTMENT
LAMP LAMP LAMP LAMP
151-119 151-119 151-119 151-119

1 C09078A 1 C09079A 1 C09056A 1 C09057A

GD306

GD306
GD306

GD306

BK
BK

1 C09076 1 C09077 1 C0925 1 C0936

S915 S931

BK-BU
GD241
GD306
BK

G0403 G0301
10-59 10-44
VAN - HIGH ROOF 2.0L
Hot at all times
BODY
LWB CONTROL
MODULE (BCM)
11-17
SWB WITH LED

26 C02280C

WH-BU
CLN43
CLN43 WH-BU CLN43 WH-BU

S269

5 C0300 1 C0311
FRONT
CLN43 WH-BU S920 CLN43 WH-BU
S916

3 C09077 3 C0936
5 C09076 Not used 5 C0925 Not used

WH-BU

WH-BU
WH-BU

WH-BU

CLN43

CLN43
CLN43

CLN43

1 C09078B 1 C09448B 1 C09056B 1 C09447B

LUGGAGE LUGGAGE LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT COMPARTMENT COMPARTMENT
LAMP LAMP LAMP LAMP
151-120 151-120 151-120 151-120

1 C09078A 1 C09448A 1 C09056A 1 C09447A

GD306

GD306
GD306

GD306

BK
BK

1 C09076 1 C0925

S915 S931
BK-BU
GD306

GD241
BK

G0403 G0301
10-59 10-44
DOUBLE CAB IN VAN 2.0L
Hot at all times
BODY
CONTROL
MODULE (BCM)
11-17

26 C02280C

WH-BU
CLN43
S269 CLN43 WH-BU

5 C0300 1 C0311

S916 S920

3 C09077 3 C0936

WH-BU

WH-BU
CLN43

CLN43
1 C09079B 1 C09057B
LUGGAGE LUGGAGE
COMPARTMENT COMPARTMENT
LAMP LAMP
151-121 151-121

1 C09079A 1 C09057A
GD306

GD306
BK

BK
1 C09077 1 C0936

S915 S931

BK-BU
GD306

GD241
BK

G0403 G0301
10-60 10-44
DOUBLE CAB IN VAN 2.0L
LWB

SWB WITHOUT LED

INTERIOR
LAMPS
89-17 INTERIOR
LAMPS
C0300 - 56 C09076 - 6 C0922 - 6
89-17 A
G
YE-GY
CLN03

21 C0300
C09076 C0922
S903

YE-GY

GN-VT
CLN03

CLN01
4 4

1 2 C0963B
YE-GY

YE-GY
CLN03

CLN03
THIRD ROW
2 INTERIOR LAMP
1) On
1 C02056A 1 C02057A 2) Off
1 3 3) Courtesy
FOOTWELL FOOTWELL 151-121
LAMP LAMP
LH RH
151-121 151-121

1 C02056B 1 C02057B 1 C0963A

GD306

GD306
BK

BK
1 1 S943 2 C0922
GD306
BK

2 C09076
S915
GD306

S915
BK

G0403 G0403
10-60 10-60
BUS 2.0L
KOMBI
INTERIOR
LAMPS
89-17

YE-GY
CLN03

21 C0300
C09076 C0922 S940

4 4

YE-GY
CLN03
YE-GY
CLN03
1 C02057C Kombi (high roof)

1 C02056A 1 C02057A
FOOTWELL FOOTWELL
LAMP LAMP
LH RH
151-122 151-122

1 C02056B 1 C02057B

GD306

GD306
BK

BK
S941
1 1
GD306
BK

S915
GD306
BK

G0403
10-61
BUS Hot at all times
BODY 2.0L
KOMBI CONTROL
MODULE (BCM)
11-17

26 C02280C

WH-BU
CLN43
S269

5 C0300

S916

5 C09076

5 C0922
CLN43 WH-BU
S925 M 89-27
INTERIOR
LAMPS
CLN43 WH-BU
N 89-27

WH-BU
CLN43
1 C09075A
LUGGAGE
COMPARTMENT
LAMP
151-122

1 C09075B
GD306
BK

S941

1 C0922

1 C09076

S915
G0403
10-61
BUS INTERIOR 2.0L
KOMBI LAMPS
C0300 - 56 C09076 - 6 C0922 - 6
89-17 A

INTERIOR INTERIOR
LAMPS LAMPS
89-26 M 89-26 N

GN-VT
CLN01
S901
WH-BU

WH-BU
GN-VT

GN-VT
CLN43

CLN01

CLN43

CLN01
1 2 C09054B 1 2 C09055B
FOURTH ROW
THIRD ROW INTERIOR LAMP
INTERIOR LAMP 1) On
2 1) On 2
2) Off
2) Off 3) Courtesy
3 1 2 1 2 1 3) Courtesy 3 1 2 1 2 1
151-122
151-122

1 C09054A 1 C09055A
GD306

GD306
BK

BK
S942

2 C0922

2 C09076

S915
GD306
BK

G0403
10-61
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 SWM HS CAN - HS CAN +

69 35 51 52 C2280D
SBP18 YE-RD POWER
DISTRIBUTION
13-47

WH-BU
VDB05

VDB04
YE-RD
SBP18

WH
VDN05
YE-GY
1 C2414

STEERING COLUMN
CONTROL
VBATT MODULE (SCCM)
151-22

MODULE
COMMUNICATIONS
NETWORK
MULTIFUNCTION SWITCH 14-3
lane departure
warning
C2414 VDN05 YE-GY
LIN 1 SWM S216
11
VDN05 YE-GY
LIN 1 SWM
2

VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
4 NETWORK
VDB05 WH 14-3
HS CAN -
GND 5

14 C2414
GD165
BK

S219
GD165
BK

G205
10-8
BODY
CONTROL 2.2L
MODULE (BCM)
11-5
EPB WARNING HAZARD
LAMP SWITCH SUPPLY SWITCH

50 13 C2280D

CLUSTER AND
PANEL ILLUMINATION
71-2

BU-GN

BN-YE
CPL77

CLS32

CLN17
BN
2 1 3 C2039

HAZARD
DOOR FLASHER
LOCK SWITCH
STATUS 151-14 151-18

5 C2039
BK-GY
GD184

S226
BK-GY
GD184

G206
10-9
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F14 11-5
25A
13-43

MICRO

61 C2280C

CLS21 BU-GN

B1 C340 right hand drive

BU-GN
CLS21

B1 C339

CLS21
BK
6 C1021
HEADLAMP 8 C663 right hand drive
ASSEMBLY LH
85-3 85-6
8 C521

EXTERIOR
MIRROR
LH
TURN

124-1 124-3

4 C1021
2 C521

2 C663 right hand drive C340 - B11 right hand drive

BK-YE
GD129

GD134 BK C339 - B11 GD134 BK-VT

S504
GD129 BK-YE S505
S603
S125 G110 left hand drive G302
10-4 right hand drive 10-13
Hot at all times
BODY 2.2L
CONTROL
MODULE (BCM)
F14 11-5
25A
13-43

MICRO

63 C2280C

CLS25 YE-VT

B1 C339 right hand drive

YE-VT
CLS25

B1 C340

CLS25
BK
6 C1041
HEADLAMP 8 C596 right hand drive
ASSEMBLY RH
85-4 85-6
8 C626

EXTERIOR
MIRROR
RH
TURN

124-1 124-3

4 C1041
2 C626

2 C596 right hand drive C339 - B11 right hand drive

BK-GY
GD123

GD240 BK C340 - B11 GD240 BK-GN

S603
GD123 BK-GY S505
S504
S132 G108 right hand drive G307
10-3 right hand drive 10-20
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F14
11-5
25A
13-43

MICRO

60 62 C2280C
GY-OG

GN-OG
CLS23

CLS27
Emergency Services Emergency Services

S255 CLS23 GY-OG S284 CLS27 GN-OG

16 C300 16 C311
CUSTOMER CUSTOMER
ACCESS ACCESS
GY-OG

GN-OG
CLS23

CLS27
140-8 140-9

1 C412 6 C415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
151-36 151-37
TURN

TURN
6 C412 1 C415
BK-GY

BK-GN
GD149

GD351

G401 G404
10-26 10-27 10-29
Hot at
all times 2.2L
BODY
CONTROL
F18 MODULE (BCM)
10A 11-5
13-47

3 C2280B

POWERTRAIN
CONTROL
MODULE (PCM)
23-12

YE-RD
SBP18
CCB15 BN-GN C139 - 37 CCB15 BN-GN C175B
BPS
12

1 3 C278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-30 151-34

4 2 C278

VT-WH

BK-GY
CCB08

GD135
S270

BK-GY
GD135

G304
BODY 10-16
CONTROL
MODULE (BCM)
11-5

C139 - 41
C2280C CCB08 VT-WH S286 CCB08 VT-WH CCB08 VT-WH
STOP LIGHT
SWITCH BPP
58 46
Hot at Hot at
all times all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15 F11 11-5
25A 25A
13-44 13-31

MICRO MICRO

68 C2280C 20 C2280B
trailer tow
POWER
DISTRIBUTION
13-44

GY-VT
CLS53
WH-GN
CLS51

PARKING, PARKING,
REAR AND REAR AND
LICENSE LAMPS LICENSE LAMPS
92-3 92-4
17 C300 17 C311
WH-GN

WH-OG
VT-GN

GY-VT
CLS51

CLS08

CLS53

CLS09
3 2 C412 5 4 C415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
90-5 90-5
92-3 92-4
STOP

STOP
PARK

PARK
6 C412 1 C415
BK-GY

BK-GN
GD149

GD351

G401 G404
10-26 10-27 10-29
REAR DOORS
2.2L
WITHOUT: CUSTOMER ACCESS
BODY
CONTROL
MODULE (BCM)
11-5
CHMSL

55 C2280C
CLS17 YE-GY CLS17 YE-GY

18 C300 18 C311

YE-GY
CLS17
5 C934

5 C421
10 C991

CLS17
1 C4131 late production: high roof

BK
YE-GY
CLS17

10 C411

CLS17
1 C4431

BK
HIGH
MOUNTED 1 C4430
STOPLAMP LH
151-44 HIGH
MOUNTED
STOPLAMP RH
151-44
2 C4431
BK-GY
GD149

2 C4430

GD351
3 C4131 late production: high roof

BK
S405 heated rear window
S403

S402 S404

2 C422
2 C411
GD149 BK-GY C935 - 2 GD149 BK-GY C991 - 2 GD351 BK-GN
GD351 BK
G401 G404
10-27 10-29
LIFTGATE
2.2L
WITHOUT: CUSTOMER ACCESS
BODY
CONTROL
MODULE (BCM)
11-5
CHMSL

55 C2280C

YE-GY
CLS17
CLS17 YE-GY

18 C300 18 C311

YE-GY

YE-GY
CLS17

CLS17
5 C934 10 C991
Not used

CLS17
BK
5
CLS17 C405

1 C475
HIGH
MOUNTED
STOPLAMP
151-45

2 C475
GD149
BK

S400

S401

2 C406 C935 - 2
GD149 BK GD149 BK-GY
G401
10-26
REAR DOORS
2.2L
CUSTOMER ACCESS
BODY
CONTROL
MODULE (BCM)
11-5
CHMSL

55 C2280C
CLS17 YE-GY S285 CLS17 YE-GY

18 C300 18 C311
YE-GY

YE-GY

YE-GY
CLS17

CLS17

CLS17
Camper
5 C934 1 C213 Conversions 10 C991
5 C421 22 C2237

CLS17
BK
Not used
1 C4131 late production: high roof 10 C411
YE-GY
CLS17

CLS17
BK
1 C4431 1 C4430
HIGH HIGH
MOUNTED MOUNTED
STOPLAMP LH STOPLAMP RH
151-44 151-44

2 C4431 2 C4430
BK-GY
GD149

GD351
BK
3 C4131 late production: high roof
S405 heated rear window

S403
S404
S402

2 C422 2 C411
GD149 BK-GY C935 - 2 GD149 BK-GY C991 - 2 GD351 BK-GN
GD351 BK
G401 G404
10-27 10-29
LIFTGATE
2.2L
CUSTOMER ACCESS
BODY
CONTROL
MODULE (BCM)
11-5
CHMSL

55 C2280C

CLS17 YE-GY S285 CLS17 YE-GY

18 C300 18 C311

YE-GY
CLS17
YE-GY

YE-GY
CLS17

CLS17
Camper
1 C213 Conversions
22 C2237
5 C934 10 C991

Not used Not used

CLS17
BK

5 C405
CLS17
BK

1 C475
HIGH
MOUNTED
STOPLAMP
151-45

2 C475
GD149
BK

S400

S401

2 C406 C935 - 2
GD149 BK GD149 BK-GY
G401
10-26
Hot in Start or Run Start/Stop Bus 2.0L
BODY
CONTROL
MODULE (BCM)
F36 F13 11-17
15A 7.5A
13-101 13-102
HS1 CAN - HS1 CAN +

15 8 C02280A 9 10 C02280G

WH-BU
VDB05

VDB04
GY-RD
SBP13

WH
S244
GY-RD
BU-BN
CBP36

SBP13

9 1 C02414
MODULE
STEERING COLUMN COMMUNICATIONS
CONTROL NETWORK
VPWR VBATT MODULE (SCCM) 14-11
151-85

MULTIFUNCTION SWITCH

C02414 VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
4 NETWORK
VDB26 GY-BU 14-14
HS2 CAN -
5

GND GND

10 14 C02414
GD265

GD265
BK

S219
GD265
BK

G0205
10-41
Hot at
all times
BODY
2.0L
CONTROL
MODULE (BCM)
11-17

HAZARD

39 C02280E 19 C02280B
BU-GN

BN-YE
CPL77

CLS32
CLUSTER AND
multi-function PANEL ILLUMINATION
display multi-function
display 71-9
3 C0268 7 C0263

9 C0264

CLN17
BU-GN

BN-YE
CPL77

CLS32

BN
2 1 3 C02039

HAZARD
DOOR FLASHER
LOCK SWITCH
STATUS 151-77 151-81

5 C02039

without: multi-function
multi-function display

BK-VT
GD216
display
BK-GY
GD284

S206

1 C0263
S226
S222
BK-GY
GD284

BK-VT
GD216
G0206 G0201
10-42 10-39
Hot at all times
BODY
2.0L
CONTROL
MODULE (BCM)
11-17

39 C02280F
BU-GN
CLS21

S271 CLS21 BU-GN

B1 C0340 right hand drive

B1 C0339
BU-GN
CLS21

CLS21
BK
8 C0521
6 C01021
HEADLAMP 8 C0517 right hand drive
ASSEMBLY LH
85-10 85-13
EXTERIOR
MIRROR
LH
124-6 124-8
TURN

2 C0517 right hand drive

2 C0521 right hand drive right hand drive

S513 C0340 - B11
4 C01021
GD234 BK S504 GD234 BK C0339 - B11
BK-YE
GD129

GD129 BK-YE

BK-VT
GD234
S125
G0110 G0302
10-36 10-45 10-46
Hot at all times
BODY
2.0L
CONTROL
MODULE (BCM)
11-17

38 C02280F
YE-VT
CLS25

S129 CLS25 YE-VT

B1 C0339 right hand drive

B1 C0340
YE-VT
CLS25

CLS25
BK
8 C0626
6 C01041
HEADLAMP 8 C0622 right hand drive
ASSEMBLY RH
85-11 85-13
EXTERIOR
MIRROR
RH
124-6 124-8
TURN

2 C0622 right hand drive

2 C0626 right hand drive

right hand drive
C0339 - B11
4 C01041
S613
GD239 BK GD239 BK C0340 - B11
BK-GY
GD123

BK-YE
GD239
GD123 BK-GY

S132
G0108 G0306
10-34 10-51
Hot at all times Hot at all times
2.0L
BODY
CONTROL
MODULE (BCM)
11-17

26 52 C02280E

GY-OG

GN-OG
CLS23

CLS27
16 C0300 16 C0311
GY-OG

GN-OG
CLS23

CLS27
1 C0412 6 C0415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
151-99 151-100
TURN

TURN
6 C0412 1 C0415
BK-WH

BK-GN
GD350

G0401 GD351 G0404

10-56 10-57 10-62
Hot at
all times 2.0L
AUXILIARY
JUNCTION
F18 BOX (AJB)
10A 11-11
13-86

POWERTRAIN
CONTROL
MODULE (PCM)

YE-RD
SB118
24-20

CCB15 BN-GN C0139 - 37 CCB15 BN-GN C0175B

BPS
3

1 2 C0278

BRAKE PEDAL
POSITION (BPP)
SWITCH
1) Brake non-applied
2) Brake applied
1 2 1 2 151-93 151-97

4 3 C0278

BK-GN

BK-GY
GD240

GD235
S288 S286
VT-WH
CCB08

BK-GN

BK-GY
GD240

GD235
G0307 G0304
BODY 10-52 10-49
CONTROL
MODULE (BCM)
11-17 left hand drive right hand drive

C0268 - 14 C0139 - 41
C02280A CCB08 VT-WH S260 CCB08 VT-WH CCB08 VT-WH
BOO FEED BPP
1 22
Hot at all times
BODY
2.0L
CONTROL
MODULE (BCM)
11-17

12 C02280C

GY-VT
CLS53

S2017

GY-VT
CLS53
GY-VT
CLS53

PARKING, PARKING,
REAR AND REAR AND
LICENSE LAMPS LICENSE LAMPS
92-9 92-10
17 C0300 17 C0311
WH-GN

WH-OG
VT-GN

GY-VT
CLS51

CLS08

CLS53

CLS09
3 2 C0412 5 4 C0415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
90-16 92-9 90-16 92-10
STOP

STOP
PARK

PARK
6 C0412 1 C0415
BK-WH

BK-GN
GD350

GD351
G0401 G0404
10-56 10-57 10-62
REAR DOORS Hot at all times
BODY
2.0L
CONTROL
MODULE (BCM)
11-17

13 C02280E
CLS17 YE-GY CLS17 YE-GY

S270
18 C0300 18 C0311

YE-GY
CLS17
5 C0934

5 C0421
10 C0991

CLS17
1 C04001 high roof

BK
YE-GY
CLS17

10 C0411
BK
or

CLS17
1 C04431

BK
HIGH
MOUNTED 1 C04430
STOPLAMP LH
151-110 HIGH
MOUNTED
STOPLAMP RH
151-110
2 C04431
BK-WH
GD350

2 C04430
BK
or

GD351
3 C04001 high roof

BK
S405 heated rear window
S403

S402 S404

2 C0422
2 C0411
GD350 BK C0935 - 2 GD350 BK-WH C0991- 2 GD351 BK-GN
GD351 BK
G0401 G0404
10-57 10-62
LIFTGATE Hot at all times 2.0L
BODY
CONTROL
MODULE (BCM)
11-17

13 C02280E
CLS17 YE-GY CLS17 YE-GY

S270
18 C0300 18 C0311

YE-GY

YE-GY
CLS17

CLS17
5 C0934 10 C0991

Not used
CLS17
BK

5 C0405
CLS17
BK

1 C0475
HIGH
MOUNTED
STOPLAMP
151-111

2 C0475
GD350
BK

S400

S401

2 C0406
GD350 BK C0935- 2 GD350 BK-WH
G0401
10-56
Hot at
all times
2.2L
BODY
CONTROL
MODULE (BCM)
F18 11-5
10A
13-47
LIN 1 LSM

69 36 C2280D
POWER
DISTRIBUTION
13-47

GN-VT
YE-RD

VLF25
SBP18

1 5 C205
HEADLAMP
SWITCH
VBATT LIN 1 LSM
151-14 151-18

GND HEADLAMP LEVELING OUT

7 6 C205

VT-GN
VLF22
GD165
BK

5 C210

VT-GN
VLF22
S219
GD165
BK

HEADLAMPS/AUTOLAMPS
85-1
G205
10-8
Hot at Hot at
all times all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15 F11 11-5
25A 25A
13-44 13-31

MICRO MICRO

14 C2280B 66 C2280C
GN-OG
CLS06

Emergency Services

S263 CLS06 GN-OG

26 C2237
GN-OG

BN-YE
CLS06

CLS07
Not used

2 C1021 2 C1041
HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
85-3 85-6 85-4 85-6
PARK

PARK
4 C1021 4 C1041

BK-GY
BK-YE
GD129

GD123

GD129 BK-YE GD123 BK-GY

S125 G110 S132 G108

10-4 10-3
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15
11-5
25A
13-44

MICRO

15 C2280B
rear fog lamps
TURN SIGNAL/ TURN SIGNAL/

VT-GN
STOP/ STOP/

CLS08
HAZARD LAMPS HAZARD LAMPS FOG LAMPS
90-5 90-7 86-3

REVERSING LAMPS
93-1
15 C300

WH-GN
GY-OG

GN-BN

BN-GN
VT-GN
CLS23

CLS10

CLS51

CLS08

CLS45
1 5 3 2 4 C412

REAR LAMP
ASSEMBLY LH
151-36
REVERSE
TURN

PARK
STOP

FOG
6 C412
BK-GY
GD149

G401
10-26 10-27
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F11 11-5
25A
13-31

MICRO

67 C2280C
rear fog lamps
TURN SIGNAL/ TURN SIGNAL/

WH-OG
STOP/ STOP/

CLS09
HAZARD LAMPS HAZARD LAMPS FOG LAMPS
90-5 90-7 86-3

REVERSING LAMPS
93-1
15 C311

WH-OG

WH-BU
GN-OG

GN-BN

GY-VT
CLS27

CLS10

CLS53

CLS09

CLS37
6 2 5 4 3 C415

REAR LAMP
ASSEMBLY RH
151-37
REVERSE
TURN

PARK
STOP

FOG
1 C415
BK-GN
GD351

G404
10-29
Hot at REAR DOORS
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15 11-5
25A
13-44

MICRO

13 C2280B
YE-VT
CLS04

S281 C311 - 14
CLS04 YE-VT
Not used

Emergency Services
YE-VT
CLS04

CLS04 YE-VT CUSTOMER ACCESS

140-11
14 C300
YE-VT
CLS04

C934 - 2 C421 - 2 C495 S415

CLS04 YE-VT CLS04 YE-VT CLS04 YE-VT

YE-VT

YE-VT
CLS04

CLS04
1 C452 1 C462

LICENSE LICENSE
PLATE PLATE
LAMP LH LAMP RH
151-44 151-44

2 C452 2 C462

BK-GY

BK-GY
GD149

GD149
C935 - 2 C422 - 2
GD149 BK-GY GD149 BK-GY GD149 BK-GY GD149 BK-GY

S402 S403 3 S416

G401
10-27
Hot at LIFTGATE
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F15 11-5
25A
13-44

MICRO

13 C2280B
YE-VT
CLS04

S281 C311 - 14
CLS04 YE-VT
Not used
YE-VT
CLS04

Emergency Services
CLS04 YE-VT CUSTOMER ACCESS
140-11
14 C300
YE-VT
CLS04

C934 - 2 C405 - 2 C494 S415

CLS04 BK CLS04 BK CLS04 YE-VT

YE-VT

YE-VT
CLS04

CLS04
1 C452 1 C462

LICENSE LICENSE
PLATE PLATE
LAMP LH LAMP RH
151-45 151-45

2 C452 2 C462

BK-GY

BK-GY
GD149

GD149
C935 - 2 C406 - 2
GD149 BK-GY GD149 BK GD149 BK GD149 BK-GY

S401 S400 3 S416

G401
10-26
Hot in Start or Run 2.0L
AUXILIARY
JUNCTION
F42 BOX (AJB)
5A 11-11
13-74
CB142
GN

S104 BODY
CONTROL
MODULE (BCM)
11-17
CB142

AUTO HEADLAMP HEADLAMP FRONT REAR

LAMP ON OFF PARK FOG FOG DIM - DIM +

CLUSTER AND PANEL

18 C0210 21 15 16 2 20 8 3 7 C02280B ILLUMINATION
71-8

WH-VT
VT-GN

GY-VT
YE-BU

BN-YE

BN-VT
CLN56

CLN55

CLN17
YE-VT
CB142

CLF19

CLF24

CLF23

CLS34

CLF21

CLF57
GN

BN
9 13 12 10 11 14 2 3 6 15 C0205
HEADLAMP
AUTO HEADLAMP HEADLAMP PARK FRONT REAR DIM - DIM + ILLUM SWITCH
VPWR 151-77 151-81
LAMP ON OFF FOG FOG

HEADLAMP ILLUM
LEVELING GND GND

1 4 5 C0205

GD265

GD265
5 C0210

BK
S242
S219
VT-GN

VT-GN
VLF22

VLF22

GD265
BK

85-8 85-8

HEADLAMPS/ G0205
AUTOLAMPS 10-41
2.0L

Hot at all times Hot at all times

BODY
CONTROL
MODULE (BCM)
11-17

24 23 C02280E

GN-OG

BN-YE
CLS06

CLS07
2 C01021 2 C01041
HEADLAMP HEADLAMP
ASSEMBLY LH ASSEMBLY RH
85-10 85-13 85-11 85-13
PARK

PARK
4 C01021 4 C01041

BK-GY
GD123
BK-YE
GD129

GD129 BK-YE GD123 BK-GY

S125 G0110 S132 G0108

10-36 10-34
2.0L
Hot at all times
BODY
CONTROL
MODULE (BCM)
11-17

30 C02280F

rear fog lamps

TURN SIGNAL/ TURN SIGNAL/

VT-GN
STOP/ STOP/

CLS08
HAZARD LAMPS HAZARD LAMPS FOG LAMPS
90-16 90-18 86-6

REVERSING LAMPS
93-3
15 C0300

WH-GN

WH-BU
GY-OG

GN-BN

VT-GN
CLS23

CLS10

CLS51

CLS08

CLS37
1 5 3 2 4 C0412

REAR LAMP
ASSEMBLY LH
151-99
REVERSE
TURN

PARK
STOP

FOG
6 C0412
BK-WH
GD350

G0401
10-56 10-57
2.0L

Hot at all times

BODY
CONTROL
MODULE (BCM)
11-17

37 C02280F
rear fog lamps
TURN SIGNAL/ TURN SIGNAL/

WH-OG
STOP/ STOP/

CLS09
HAZARD LAMPS HAZARD LAMPS FOG LAMPS
90-16 90-18 86-6

REVERSING LAMPS
93-3
15 C0311

WH-OG

WH-BU
GN-OG

GN-BN

GY-VT
CLS27

CLS10

CLS53

CLS09

CLS37
6 2 5 4 3 C0415

REAR LAMP
ASSEMBLY RH
151-100
REVERSE
TURN

PARK
STOP

FOG
1 C0415
BK-GN
GD351

G0404
10-62
REAR DOORS
2.0L

Hot at all times

BODY
CONTROL
MODULE (BCM)
11-17

3 C02280G
YE-VT
CLS04

14 C0300
YE-VT
CLS04

C0934 - 2 C0421 - 2 C0495 S425

CLS04 BK CLS04 BK CLS04 YE-VT

YE-VT

YE-VT
CLS04

CLS04
2 C0452 2 C0462

LICENSE LICENSE
PLATE PLATE
LAMP LH LAMP RH
151-110 151-110

1 C0452 1 C0462

BK-GY

BK-GY
GD149

GD149
C0935 - 2 C0422 - 2
GD149 BK-GY GD149 BK GD149 BK GD149 BK-GY

S402 S403 3 S426

G0401
10-57
LIFTGATE
2.0L

Hot at all times

BODY
CONTROL
MODULE (BCM)
11-17

3 C02280G
YE-VT
CLS04

14 C0300
YE-VT
CLS04

C0934 - 2 C0405 - 2 C0494 S425

CLS04 BK CLS04 BK CLS04 YE-VT

YE-VT

YE-VT
CLS04

CLS04
1 C0452 1 C0462

LICENSE LICENSE
PLATE PLATE
LAMP LH LAMP RH
151-111 151-111

2 C0452 2 C0462

BK-GY

BK-GY
GD149

GD149
C0935 - 2 C0406 - 2
GD149 BK-GY GD149 BK GD149 BK GD149 BK-GY

S401 S400 3 S426

G0401
10-56
Hot at
all times 2.2L
BODY
CONTROL
MODULE (BCM)
F11 11-5
25A
13-31

MICRO

HS CAN - HS CAN +

51 52 C2280D 11 C2280B
customer access

Camper Conversions

GN-BN
CLS10
CLS10 GN-BN C213 C2237
WH-BU

Not used
VDB05

VDB04

15 32
WH

S299

GN-BN
CLS10
GN-BN
CLS10

13 C311
MODULE parking aid camera
COMMUNICATIONS
NETWORK S919
14-3 13 C300
GN-BN

GN-BN
CLS10

CLS10

GN-BN
CLS10
5 C412 2 C415
5 C913
REAR LAMP REAR LAMP
ASSEMBLY LH ASSEMBLY RH
90-5 90-5

GN-BN
CLS10
92-3 92-4
REVERSE

REVERSE
2 C911

REVERSE
6 C412 1 C415
BK-GY

BK-GN

AUTO-DIMMING
GD149

GD351

INTERIOR
MIRROR
G401 G404 124-5 131-7
10-26 10-27 10-29
POWERTRAIN
CONTROL 2.2L
MODULE (PCM)
23-17

C175B VDB04 WH-BU

HS CAN + MODULE
10 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-5
11

C175T C134 - 11 C133 - 5

CET47 BU CET47 BU
REVERSE
52

CET47
BU
1 C169

REVERSING
LAMP SWITCH
151-12

2 C169

BK-YE
GD121
8 C133

BK-YE
GD121
34 C134

S118

BK-YE
GD121
G104
10-1
2.0L
Hot at all times
BODY
CONTROL
MODULE (BCM)
11-17

HS1 CAN - HS1 CAN +

9 10 C02280G 11 C02280C

GN-BN
CLS10
WH-BU
VDB05

VDB04
WH

S299

GN-BN

GN-BN
CLS10

CLS10
MODULE
COMMUNICATIONS
NETWORK
14-11 13 C0300 13 C0311
GN-BN

GN-BN
CLS10

CLS10
5 C0412 2 C0415

REAR LAMP REAR LAMP

ASSEMBLY LH ASSEMBLY RH
90-16 92-9 90-16 92-10
REVERSE

REVERSE
6 C0412 1 C0415
BK-WH

BK-GN
GD350

GD351
G0401 G0404
10-56 10-57 10-62
MANUAL TRANSMISSION 2.0L

POWERTRAIN
CONTROL
MODULE (PCM)
24-23

C0175B VDB04 WH-BU

HS1 CAN + MODULE
60 COMMUNICATIONS
VDB05 WH NETWORK
HS1 CAN - 14-12
61

C0134 - 11 C0133 - 5
CET47 BU CET47 BU
REVERSE
39

CET47
BU
1 C0169

REVERSING
LAMP SWITCH
151-75

2 C0169

BK-YE
GD121
8 C0133

BK-YE
GD121
34 C0134

S118

BK-YE
GD121
G0104
10-32
Hot at Hot at
all times all times
BODY
2.2L
AUXILIARY
JUNCTION CONTROL
BOX (AJB) MODULE (BCM)
F43 11-1 F15
30A 11-5
25A
13-24 13-44

POWER MICRO
DISTRIBUTION
13-24
TRAILER TOW
BU-RD

DETECTION
SB143

19 68 C2280C

2 C3548B
POWER
TRAILER DISTRIBUTION
MODULE 13-44
VBATT 151-26

C3548C CAT13 GN-OG

TRAILER TOW
DETECTION
5

CLS51 WH-GN
STOP LAMPS INPUT
3

VDB06 GY-OG MODULE

MS CAN + COMMUNICATIONS
1 NETWORK
VDB07 VT-OG 14-6
MS CAN -
GND 2

4 C3548C
BK-GY
GD135

S270
BK-GY
GD135

G304
10-16
Hot at
all times 2.2L
AUXILIARY
JUNCTION
BOX (AJB)
F43 11-1
30A
13-24

POWER
DISTRIBUTION
13-24 TRAILER

BU-RD
SB143
SOCKET
151-40

21 C145
C438
SB143 BU-RD C439
TRAILER VBATT
MODULE 9 9
151-26

C3548A C465
CAT09 GN CAT09 GN
RIGHT TURN LAMP RIGHT TURN LAMP
1 5 6 4

CAT23 GY-YE CAT23 GY-YE

VPWR VPWR
2 4 10 10

CAT03 GY-BN CAT03 GY-BN

REVERSE LAMP REVERSE LAMP
6 6 11 8

CAT07 GY-OG CAT07 GY-OG

FOG LAMPS FOG LAMPS
8 2 5 2

CAT06 YE CAT06 YE
LEFT TURN LAMP LEFT TURN LAMP
10 1 3 1

CAT11 BN S411 CAT11 BN

PARK LAMPS LEFT PARK LAMP
12 3 14 7

CAT10 RD CAT11 BN
RIGHT PARK LAMP
LEFT STOP LAMP 13
3 5
CAT10 RD CAT10 RD
RIGHT STOP LAMP STOP LAMPS
7 S413 7 12 6

GD132 BK-VT GD132 BK-VT

GND
1 3
GD132 BK-VT GD132 BK-VT
GND
8 11
GD132 BK-VT GD132 BK-VT GD132 BK-VT
GND
S412 16 13
G400
10-25
Hot at Hot at
all times all times 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F60 F5 11-11
15A 40A
13-85 13-80

GY-RD
SB105 S291
GN-RD

GY-RD
SB160

SB105

2 1 C03548B

TRAILER
MODULE
VBATT VBATT 151-89

BODY
C03548C CONTROL
TRAILER TOW CAT13 GN-OG C02280E MODULE (BCM)
TRAILER TOW
DETECTION DETECTION 11-17
4 7

VDB06 GY-OG MODULE

MS CAN + COMMUNICATIONS
3 NETWORK
VDB07 VT-OG 14-16 14-17
MS CAN -
GND 2

1 C03548C
BK-GN

BK-GY
GD240

GD235

S288 S286
BK-GN

BK-GY
GD240

GD235

G0307 G0304
10-52 10-49

left hand drive right hand drive

Hot at
all times 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F72 11-11
30A
13-80

TRAILER

VT-RD
SB172
SOCKET
151-104

21 C0145
C0438
SB143 BU-RD C0439
TRAILER VBATT
MODULE 9 9
151-89

C03548A C0465
CAT09 GN CAT09 GN
RIGHT TURN LAMP RIGHT TURN LAMP
2 5 6 4

CAT23 GY-YE CAT23 GY-YE

VPWR VPWR
6 4 10 10

CAT03 GY-BN CAT03 GY-BN

REVERSE LAMP REVERSE LAMP
5 6 11 8

CAT07 GY-OG CAT07 GY-OG

FOG LAMPS FOG LAMPS
8 2 5 2

CAT06 YE CAT06 YE
LEFT TURN LAMP LEFT TURN LAMP
1 1 3 1

CAT11 BN S411 CAT11 BN

PARK LAMPS LEFT PARK LAMP
3 3 14 7
CAT11 BN
RIGHT PARK LAMP
13 5
CAT10 RD CAT10 RD
STOP LAMP STOP LAMPS
7 7 12 6

GD480 BK GD132 BK-VT

GND
1 3
GD480 BK GD132 BK-VT
GND
8 11
GD480 BK GD480 BK GD132 BK-VT
GND
S412 16 13
G0409
10-65
Hot at Hot in Start
all times or Run 2.2L
AUXILIARY
JUNCTION
F35 F46 BOX (AJB)
5A 30A 11-1
13-22 13-18
BU-RD
SB135

S290

WH-BU
CB146
A6 C339

power A11 C339

S508 mirrors

CB146
SB135
BK

BK
DRIVER DOOR
WINDOW
8 7 C535A CONTROL SWITCH
151-42

DN UP

ELECTRONICS

3 2 4 1 C535B 3 5 2 4 1 C535A
4 3 right hand

CPW13

CPW12
drive
S504 S504

BK
GD134

GD240
VPW38

VPW39
RPW37

CPW11

CPW10
LPW36

S506 S507

BK
BK

S501 S500
2 6 5 3 1 4 C524 B11 C339 B11 C339
DRIVER DOOR

BK-GN
BK-VT
GD134

GD240
WINDOW A B
REGULATOR
MOTOR
151-42 G302 G307 100-2 100-2
10-13 10-20
M POWER
left hand right hand WINDOWS
drive drive
POWER
WINDOWS Hot in Start
POWER
WINDOWS 2.2L
100-1 or Run 100-1
AUXILIARY
A JUNCTION B
F46 BOX (AJB)
30A 11-1
13-18

CPW12
CPW13

BK
BK

WH-BU
CB146
A15 C339 A14 C339

S251 S250

S290
S2004 S2003

GN-OG
CPW12
WH-BU
CPW13
BN-YE

CB146
A15 A11 A14 C340

CB146
CPW13 BK S601 S605 S606 S600 CPW12 BK

BK
CPW13

CPW12
BK

BK
6 2 3 C604
PASSENGER DOOR
WINDOW
CONTROL SWITCH
151-43

UP DN

4 1 7 C604
CPW20

CPW19

S603 S603
BK

BK
GD240

GD134
BK

2 C608
PASSENGER DOOR
B11 C340 B11 C340 WINDOW
M REGULATOR
BK-GN

BK-VT
GD240

GD134

MOTOR
151-43
G307 G302
10-20 10-13

left hand right hand 1 C608

drive drive
Hot at
Hot at all times
with accessory delay LEFT HAND DRIVE 2.0L
all times relay engaged
BODY
F2 CONTROL
F38 MODULE (BCM)
7.5A 30A
13-90 11-17
13-91

29 36 C02280C

GY-BU
YE-RD

CBP38
SBP02

POWER
CBP38 GY-BU WINDOWS
S295 S259 AB 100-4

A6 A11 C0339

S508

CBP38
SBP02

DRIVER DOOR
BK

BK
WINDOW
8 7 C0535A CONTROL SWITCH
151-106

DN UP

ELECTRONICS

3 2 4 1 C0535B 3 5 2 4 1 C0535A

CPW13

CPW12
S504

BK
VPW38

VPW39
RPW37

CPW11

CPW10
LPW36
BK

GD234
S506 S507

BK
2 6 5 3 1 4 C0524 S501 S500
DRIVER DOOR B11 C0339
WINDOW
REGULATOR
MOTOR A B

BK-VT
GD234
151-106

M 100-4 100-4
G0302
10-45 POWER
WINDOWS
POWER
WINDOWS
LEFT HAND DRIVE POWER
WINDOWS 2.0L
100-3 100-3

A B

POWER

CPW12
CPW13
WINDOWS
100-3

BK
BK
AB
A15 C0339 A14 C0339

S251 S250

S2004 S2003

GN-OG
CPW12
GY-BU
CPW13
BN-YE

CBP38
A15 A11 A14 C0340

CBP38
CPW13 BK S601 S605 S606 S600 CPW12 BK

BK
CPW13

CPW12
BK

BK
6 2 3 C0604
PASSENGER DOOR
WINDOW
CONTROL SWITCH
151-107

UP DN

4 1 7 C0604
CPW20

CPW19
S603
BK

BK
GD240
BK

2 C0608
PASSENGER DOOR
B11 C0340 WINDOW
M REGULATOR
S288 MOTOR
151-107
BK-GN
GD240

1 C0608
G0307
10-52
Hot at
Hot at all times
with accessory delay RIGHT HAND DRIVE 2.0L
all times relay engaged
BODY
F2 CONTROL
F38 MODULE (BCM)
7.5A 30A
13-90 11-17
13-91

29 36 C02280C

GY-BU
YE-RD

CBP38
SBP02

POWER
CBP38 GY-BU WINDOWS
S295 S259 BB 100-6

A6 A11 C0339

S615

CBP38
SBP02

DRIVER DOOR
BK

BK
WINDOW
8 7 C0648A CONTROL SWITCH
151-108

DN UP

ELECTRONICS

4 2 3 1 C0648B 3 5 2 4 1 C0648A

CPW13

CPW12
S613

BK
VPW38

VPW39
RPW37

CPW11

CPW10
LPW36
BK

GD239
S617 S616

BK
2 6 5 3 1 4 C0646 S611 S610
DRIVER DOOR B11 C0339
WINDOW
REGULATOR
MOTOR C D

BK-YE
GD239
151-108

M 100-6 100-6
G0306
10-51 POWER
WINDOWS
POWER
WINDOWS
RIGHT HAND DRIVE POWER
WINDOWS 2.0L
100-5 100-5

C D

POWER

CPW12
CPW13
WINDOWS
100-5

BK
BK
BB
A15 C0339 A14 C0339

S251 S250

S2004 S2003

GN-OG
CPW12
GY-BU
CPW13
BN-YE

CBP38
A15 A11 A14 C0340

CBP38
CPW13 BK S511 S514 S515 S510 CPW12 BK

BK
CPW13

CPW12
BK

BK
6 2 3 C0592
PASSENGER DOOR
WINDOW
CONTROL SWITCH
151-109

UP DN

4 1 7 C0592
CPW20

CPW19
S513
BK

BK
GD234
BK

2 C0565
PASSENGER DOOR
WINDOW
B11 C0340 M REGULATOR
MOTOR
151-109
BK-VT
GD234

1 C0565
G0302
10-46
Hot in Start
or Run 2.2L
BODY
CONTROL
F20 MODULE (BCM)
5A 11-5
13-52

43 C2280D

BODY

YE-VT
CBP20
CONTROL
MODULE (BCM) PASSIVE
11-5 ANTI-THEFT
SYSTEM (PATS)
TRANSCEIVER
151-22

C252 POWER
1
C2280D VRT23 VT-GY RX
PATS RX
1 4
VRT24 YE-OG TX
PATS TX
2 3
GROUND
2

GD165
BK
S219

GD165
BK
G205
10-8 10-42

POWERTRAIN
CONTROL
MODULE (PCM)
23-17

VDB04 WH-BU C175B

VDB04 WH-BU
HS CAN + HS CAN +
MODULE 10
52 14-3 COMMUNICATIONS 14-5 VDB05 WH
VDB05 WH
HS CAN - NETWORK HS CAN -
51 11
Hot at
all times 2.0L
BODY
CONTROL
MODULE (BCM)
11-17

BODY 47 C02280B
CONTROL
MODULE (BCM) PASSIVE
11-17 ANTI-THEFT
SYSTEM (PATS)
TRANSCEIVER

GY-VT
CPK43
151-85

C0252 POWER
1

C02280B VDN01 BU-WH LIN

LIN 1
52 3
GROUND
4

GD265
BK
S219

GD265
BK
G0205
10-41

POWERTRAIN
CONTROL
MODULE (PCM)
24-23

C02280G VDB04 WH-BU VDB04 WH-BU C0175B

HS1 CAN + MODULE HS1 CAN +
10 COMMUNICATIONS 60
NETWORK
VDB05 WH 14-11 14-12 VDB05 WH
HS1 CAN - HS1 CAN -
9 61
BODY
CONTROL 2.2L
MODULE (BCM)
11-5
CABIN LOCK INT CENTRAL LOCK
SWITCH UNLOCK SWITCH

56 25 C2280C

VT-GY

GY-YE
CPL43

CPL42
CLUSTER AND CLUSTER AND
PANEL ILLUMINATION PANEL ILLUMINATION
71-5 71-5
S243

S244

43 42 C2237
GY-YE

VT-GY

GY-YE
CLN17

CLN17
CPL42

CPL43

CPL42
Not used Not used
BN

BN
Emergency Services
A2 B6 B7 C339 B7 B6 A2 C340
CLN17

CLN17
CPL42

CPL43

CPL42
BK

BK
1 4 2 right hand drive 3 1 4 right hand drive

4 1 3 C505
2 4 1 C605
DRIVER PASSENGER
DOOR DOOR
LOCK CONTROL LOCK CONTROL
SWITCH SWITCH
151-42 151-43

2 C505 3 C605

3 right hand drive 2 right hand drive

GD135

right hand drive

left hand drive

C339 - B12 S270

GD135 BK-GY C340 - B12 S270
GD135 BK-GY
right hand drive right hand drive
S502
S602
G304 G304 G304 G304
10-15 10-15 10-15 10-15
BODY
CONTROL 2.2L
AJAR CABIN CABIN CABIN MODULE (BCM)
DRIVER RESET SET UNLOCK 11-5
SWITCH SWITCH SWITCH SWITCH

44 36 20 22 C2280C

34 right hand drive

BU-BN
CPL30
Emergency Services

S266
S258
GN-VT
CPL26

BU-BN

BU-BN
CPL30

CPL30
41 C2237

Not used
GN-VT

YE-GY

BU-BN
VT-BN
CPL26

CPL28

CPL29

CPL30
A B

B4 A8 A9 B5 C339
117-3 117-9 117-10
CPL26

CPL28

CPL29

CPL30
REMOTE KEYLESS
ENTRY AND ALARM
BK

BK
6 7 8 5 right hand drive

3 2 1 4 C525

DRIVER
DOOR
LATCH
151-42

5 C525

4 right hand drive

right hand drive

S502 C339 - B12 S270 right hand drive

GD135 BK GD135 BK GD135 BK-GY GD135 BK-GY
G304 G304
10-15 10-15
BODY
AJAR
CONTROL 2.2L
MODULE (BCM)
PASSENGER 11-5
SWITCH

34 C2280C

44 right hand drive

Emergency Services
REMOTE KEYLESS
S295 ENTRY AND ALARM
117-2
CPL31

A
WH

25 C2237

BU-BN
Not used
CPL31

CPL30
WH

B4 B5 C340
CPL31

CPL30
BK

3 4 right hand drive

6 5 C609

PASSENGER
DOOR
LATCH
151-43

4 C609

5 right hand drive

left hand drive

S602 C340 - B12 S270 right hand drive
GD135 BK GD135 BK GD135 BK-GY
G304 G304
10-15 10-15
Hot at
all times 2.2L
BODY
CONTROL
F2 MODULE (BCM)
15A 11-5
13-48

DRIVER DRIVER
DEADLOCK LOCK
RELAY RELAY
(Non-serviceable) (Non-serviceable) DRIVER
UNLOCK
RELAY
(Non-serviceable)

40 right hand drive 18 39 31 24 23 C2280B

42 27

left hand drive

BK-WH

BK-WH
GD137

GD137

GD137
S289 S298

S256
C D E F

BU-GN
GY-YE

VT-GN
CPL06

CPL02

CPL51
117-7 117-8 117-9 117-9 117-7 117-8

BK-WH
GD137
B17 C339 A16 A17 C339 G303
REMOTE KEYLESS 10-14
ENTRY AND ALARM
CPL06

CPL02

CPL51
BK

BK
3 2 1 right hand drive

6 7 8 C525

DRIVER
DOOR
LATCH
M M 151-42
Hot at Hot at
all times all times 2.2L
BODY
CONTROL
F1 F2 MODULE (BCM)
15A 15A 11-5
13-50 13-48

PASSENGER PASSENGER
DEADLOCK LOCK
RELAY RELAY
(Non-serviceable) (Non-serviceable) PASSENGER
UNLOCK RELAY
(Non-serviceable)

42 right hand drive 27 45 31 24 23 C2280B

40 18

BK-WH

BK-WH
GD137

GD137

GD137
BN-GN
VT-GY
CPL07

CPL65
right hand drive
S240 S239
S256

BN-GN
VT-GY

BU-BN
CPL07

CPL65

CPL66
G H J K

BK-WH
GD137
117-7 117-8 117-10 117-10 117-7 117-8

B17 C340 A16 A17 C340 G303

10-14
REMOTE KEYLESS
ENTRY AND ALARM
CPL07

CPL65

CPL66
BK

BK
6 7 8 right hand drive

3 2 1 C609

PASSENGER
DOOR
LATCH
M M 151-43
BODY
CONTROL
MODULE (BCM)
2.2L
11-5
AJAR AJAR
EPB WARNING LEFT SIDE RIGHT SIDE
LAMP SWITCH SUPPLY DOOR SWITCH DOOR SWITCH

50 C2280D 35 51 C2280C

CPL39

CPL36
GN
YE
right hand drive right hand drive
BU-GN
CPL77

CPL36

CPL39
GN

YE
Emergency Services Emergency Services

S241 right hand drive S267 right hand drive

S267 S241
2 C2039

HAZARD
FLASHER 27 right hand drive 24 right hand drive
DOOR
LOCK SWITCH
90-2 24 C2237 27 C2237
STATUS 6 C300 6 C311
Not used Not used
CPL36

CPL39
GN

YE
5 C2039
1 C958 1 C959

SLIDING DOOR SLIDING DOOR

AJAR SWITCH AJAR SWITCH
LH RH
151-36 151-37
BK-GY
GD184

2 C958 2 C959
BK-GY

BK-BU
GD135

GD352
S226
rear parking
22 C300 aid
S923
BK-GY
GD184

BK-GY
GD135

BK-BU
GD352
G206 G304 G405
10-9 10-15 10-30
LEFT HAND DRIVE Hot at 2.2L
all times
BODY
F1 CONTROL
15A MODULE (BCM)
13-50 11-5

LEFT REAR RIGHT REAR

UNLOCK UNLOCK
RELAY RELAY
(Non-serviceable) (Non-serviceable)

19 38 31 24 23 C2280B
dual sliding doors

REMOTE KEYLESS REMOTE KEYLESS

BK-WH

BK-WH
GD137

GD137

GD137
ENTRY AND ALARM ENTRY AND ALARM

117-4 117-8 117-4 117-8 117-5 117-8 117-5 117-8

C F G K S256
WH-OG

BN-GN

GY-BU
GY-YE

VT-GN

VT-GY
CPL06

CPL02

CPL53

CPL07

CPL65

CPL54

BK-WH
GD137
3 2 1 C706A 3 2 1 C806A
SLIDING SLIDING
DOOR DOOR G303
CONTACT CONTACT 10-14
PLATE LH PLATE RH
151-26 151-27

3 2 1 C706B 3 2 1 C806B
CPL12

CPL11

CPL13

CPL12

CPL11

CPL13
BK

BK
7 5 6 C708 3 2 4 C808

SLIDING SLIDING
DOOR DOOR
LATCH LH LATCH RH
M M 151-26 M M 151-27
RIGHT HAND DRIVE 2.2L
Hot at
all times
BODY
F1 CONTROL
15A MODULE (BCM)
13-50 11-5

LEFT REAR RIGHT REAR

UNLOCK UNLOCK
RELAY RELAY
(Non-serviceable) (Non-serviceable)

19 dual sliding doors 38 31 24 23 C2280B

REMOTE KEYLESS REMOTE KEYLESS

ENTRY AND ALARM ENTRY AND ALARM

BK-WH

BK-WH
GD137

GD137

GD137
117-5 117-7 117-5 117-7 117-4 117-7 117-4 117-7

G K C F
S256

WH-OG
BN-GN

GY-BU

GY-YE

VT-GN
VT-GY

CPL06

CPL02

CPL53
CPL07

CPL65

CPL54

BK-WH
GD137
3 2 1 C706A 3 2 1 C806A

SLIDING SLIDING
DOOR DOOR
CONTACT CONTACT G303
PLATE LH PLATE RH 10-14
151-26 151-27

3 2 1 C706B 3 2 1 C806B
CPL12

CPL11

CPL13

CPL12

CPL11

CPL13
BK

BK
7 5 6 C708 3 2 4 C808

SLIDING SLIDING
DOOR DOOR
LATCH LH LATCH RH
M M 151-26 M M 151-27
LEFT HAND DRIVE REAR DOORS 2.2L
Hot at
all times
BODY
CONTROL
F1 MODULE (BCM)
15A 11-5
13-50

REAR DOOR
UNLOCK
RELAY
(Non-serviceable)

AJAR SWITCH

50 C2280C REMOTE KEYLESS 44 31 24 23 C2280B

ENTRY AND ALARM
BN-VT
CPL81

BK-WH

BK-WH
GD137

GD137

GD137
117-2 117-4 117-4

S257 B D E

35 C300 S256
BU-BN

GY-YE

VT-GN
BN-VT

YE-VT
CPL81

CPL30

CPL06

CPL02

CPL17
BN-VT
CPL81

35 9 38 37 36 C311

BK-WH
GD137
3 C935
4 3 C991 2 5 6 C983
Not used
CPL81

CPL30

CPL06

CPL02

CPL17
G303
BK

BK
10-14
4 3 C411 2 5 6 C410

6 5 3 2 1 C486

REAR
DOOR
LATCH
M M 151-44

rear parking aid

4 C486
GD352 BK C411 - 1 GD352 BK C991 - 1 GD352 BK-BU S923 GD352 BK-BU
G405
10-30
RIGHT HAND DRIVE REAR DOORS 2.2L
Hot at
all times
BODY
CONTROL
F1 MODULE (BCM)
15A
13-50 11-5

REAR DOOR
UNLOCK RELAY
(Non-serviceable)

AJAR SWITCH

50 C2280C 44 31 24 23 C2280B
REMOTE KEYLESS
BN-VT

ENTRY AND ALARM

CPL81

BK-WH

BK-WH
GD137

GD137

GD137
117-2 117-5 117-5
S257
B H J
35 C300 S256

BN-GN
BU-BN

VT-GY
BN-VT

YE-VT
CPL81

CPL30

CPL07

CPL65

CPL17
BN-VT
CPL81

35 9 38 37 36 C311

BK-WH
GD137
3 C935
BU-BN

GY-YE

VT-GN
BN-VT

YE-VT
CPL81

CPL30

CPL06

CPL02

CPL17
Not used
G303
10-14
4 3 C991 2 5 6 C983
CPL81

CPL30

CPL06

CPL02

CPL17
BK

BK
4 3 C411 2 5 6 C410

6 5 3 2 1 C486

REAR
DOOR
LATCH
M M 151-37 151-44

rear parking aid

4 C486 C411 - 1 C991 - 1 S923
GD352 BK GD352 BK GD352 BK-BU GD352 BK-BU
G405
10-30
LIFTGATE 2.2L
Hot at
all times
BODY
CONTROL
F2 MODULE (BCM)
15A 11-5
13-48

LIFTGATE UNLOCK RELAY

(Non-serviceable)

LIFTGATE
RELEASE
AJAR SWITCH SWITCH

31 24 23 41 C2280B 50 53 C2280C
BN-VT

BN-VT
CPL79

CPL81
7 C300
BK-WH

BK-WH

BK-WH
GD137

GD137

CPL45
BN
S257

S256 36 35 C300 35 C311 3 C934

CPL45
BN-VT
CPL81

BK
6 C934 3 C935

3 C405
BK-WH

CPL79

CPL81
GD137

1 C406
BK

4 C991

GD133
CPL45
1 C935
6 C405 3 C406 Not used

BK
G303
10-14
1 3 C4339 2 4 C494 G300
10-11
LIFTGATE

BK-WH
BN-VT

GD150
CPL79
LATCH
151-45
M
1 2 C4216
LIFTGATE
RELEASE
SWITCH
2 C4339 151-45
C406 - 2 C935 - 2
GD149 BK GD149 BK-GY
S401 G401
10-26
Hot at
all times 2.2L
AUXILIARY
JUNCTION
F39 BOX (AJB)
7.5A 11-1
13-23

POWER
DISTRIBUTION
13-23

WH-RD
SB139
39 C311

5 C900

S908 Thatcham category 1 alarm

BODY
CONTROL
MODULE (BCM)
11-5

WH-RD
RADIO

SB139
FREQUENCY
(RF) RECEIVER
151-49

C9026 POWER
3
C311 - 21 C900 - 9
C2280C VPL56 BU-GY VPL56 BU-GY SIGNAL
LIN 0 RFR
1 1

GROUND
2

BK-GN
GD140
S909

7 C913

22 C311

C2280D VDB04 WH-BU BK-GN

GD140

HS CAN + MODULE
52 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-3
51 G306
10-19
ANTI-THEFT ALARM SYSTEM 2.2L
Hot at
all times
BODY
CONTROL
F12 MODULE (BCM)
20A 11-5
13-32 13-37

AJAR MICRO
HOOD
SWITCH

40 C2280C 21 C2280B
WH-BN

GY-VT
CRT17

CRT02
12 C192
WH-BN
CRT17

ANTI-THEFT
ALARM HORN
S305 CRT02 GY-VT C3549 LH
2 C127 151-26
1
HOOD
SWITCH
151-5

1 C127
GD125
BK

6 C192
ANTI-THEFT
ALARM HORN
CRT02 GY-VT C3550 RH
151-27
GD125

1
BK

G109
10-3
THATCHAM CATEGORY 1 ALARM
Hot at
2.2L
Hot at all times
all times
BODY
AUXILIARY CONTROL
JUNCTION F12 MODULE (BCM)
F39 BOX (AJB) 20A 11-5
7.5A 11-1 13-32 13-37
13-23 LIN 2 IMS LIN 2 BBS

POWER 49 C2280C 29 C2280B 47 C2280C

DISTRIBUTION
13-23

VRT26
WH-RD
SB139

VT
39 51 C311

5 C900 4 C913

GN-RD

GY-RD
SRT16
SBP12
S908
WH-RD

VRT26
SB139

3 2 C9800 3 2 C154

INTRUSION ANTI-THEFT
SENSOR ALARM HORN
151-49 WITH INTEGRAL
BATTERY
151-6

1 C9800
BK-GN
GD140

1 C154

S909

7 C913

BK-GY
GD123
22 C311
BK-GN
GD140

G306 G108
10-19 10-3
LEFT HAND DRIVE 2.0L

BODY
CONTROL
MODULE (BCM)
11-17
UNLOCK LOCK
SWITCH SWITCH

4 17 C02280E

VT-GY

GY-YE
CPL43

CPL42
CLUSTER AND CLUSTER AND
PANEL ILLUMINATION PANEL ILLUMINATION
71-12 71-12
S280

S243
GY-YE

VT-GY

GY-YE
CLN17

CLN17
CPL42

CPL43

CPL42
BN

BN
A2 B6 B7 C0339 B7 B6 A2 C0340
CLN17

CLN17
CPL42

CPL43

CPL42
BK

BK
4 1 3 C0505
2 4 1 C0605
FRONT DOOR FRONT DOOR
LOCK LOCK
SWITCH LH SWITCH RH
151-106 151-107

2 C0505 3 C0605
GD240

GD240
BK

C0339 - B12 S288

GD240 BK-GN C0340 - B12 S288
GD240 BK-GN
S502
S603
G0307 G0307
10-52 10-52
RIGHT HAND DRIVE 2.0L

BODY
CONTROL
MODULE (BCM)
11-17
UNLOCK LOCK
SWITCH SWITCH

4 17 C02280E

VT-GY

GY-YE
CPL43

CPL42
CLUSTER AND CLUSTER AND
PANEL ILLUMINATION PANEL ILLUMINATION
71-12 71-12
S280

S243
GY-YE

VT-GY

GY-YE
CLN17

CLN17
CPL42

CPL43

CPL42
BN

BN
A2 B6 B7 C0340 B7 B6 A2 C0339
CLN17

CLN17
CPL42

CPL43

CPL42
BK

BK
4 1 3 C0541
2 4 1 C0632
FRONT DOOR FRONT DOOR
LOCK LOCK
SWITCH LH SWITCH RH
151-109 151-108

2 C0541 3 C0632
GD235

GD235
BK

C0340 - B12
GD235 BK-GY C0339 - B12
GD235 BK-GY
S512
S612 S286
G0304 G0304
10-49 10-49
LEFT HAND DRIVE 2.0L

BODY
CONTROL
AJAR CABIN CABIN CABIN MODULE (BCM)
DRIVER RESET SET UNLOCK 11-17
SWITCH SWITCH SWITCH SWITCH

33 43 30 16 C02280E

BU-BN
CPL30
S279

BU-BN

BU-BN
CPL30

CPL30
GN-VT

YE-GY

BU-BN
VT-BN
CPL26

CPL28

CPL29

CPL30
LA B

B4 A8 A9 B5 C0339
117-19 117-31
CPL26

CPL28

CPL29

CPL30
REMOTE KEYLESS
ENTRY AND ALARM
BK

BK
3 2 1 4 C0525

DRIVER
DOOR
LATCH
151-106

5 C0525

S502 C0339 - B12 S288

GD240 BK GD240 BK GD240 BK-GN
G0307
10-52
RIGHT HAND DRIVE 2.0L

BODY
CONTROL
AJAR CABIN CABIN CABIN MODULE (BCM)
DRIVER RESET SET UNLOCK 11-17
SWITCH SWITCH SWITCH SWITCH

21 43 30 16 C02280E

BU-BN
CPL30
S279

BU-BN

BU-BN
CPL30

CPL30
GN-VT

YE-GY

BU-BN
VT-BN
CPL26

CPL28

CPL29

CPL30
RA B

B4 A8 A9 B5 C0339
117-20 117-31

REMOTE KEYLESS
CPL26

CPL28

CPL29

CPL30
ENTRY AND ALARM
BK

BK
6 7 8 5 C0603

DRIVER
DOOR
LATCH
151-108

4 C0603

S612 C0339 - B12 S286

GD235 BK GD235 BK GD235 BK-GY GD235 BK-GY
G0304
10-49
LEFT HAND DRIVE 2.0L

BODY
CONTROL
AJAR MODULE (BCM)
PASSENGER 11-17
SWITCH

21 C02280E

REMOTE KEYLESS
ENTRY AND ALARM
117-17

BU-BN
CPL31

CPL30
WH

B4 B5 C0340
CPL31

CPL35
BK

6 5 C0609

PASSENGER
DOOR
LATCH
151-107

4 C0609

S603 C0340 - B12 S288

GD240 BK GD240 BK GD240 BK-GN
G0307
10-52
RIGHT HAND DRIVE 2.0L

BODY
CONTROL
AJAR MODULE (BCM)
PASSENGER 11-17
SWITCH

33 C02280E

REMOTE KEYLESS
ENTRY AND ALARM
117-18

BU-BN
CPL31

CPL30
WH

B4 B5 C0340
CPL31

CPL35
BK

3 4 C0502

PASSENGER
DOOR
LATCH
151-109

5 C0502

S512 C0340 - B12

GD235 BK GD235 BK GD235 BK-GY
G0304
10-49
2.0L
Hot at Hot at
all times all times
BODY
CONTROL
MODULE (BCM)
F24 11-17
30A
13-93

DOUBLE LOCK CENTRAL LOCK

RELAY RELAY
(Non-serviceable) (Non-serviceable)

32 35 10 C02280C

GD233

BK
GY-BN
VT-OG
CPL12

CPL11
G0303
10-47

C D

117-23 117-24 117-23 117-24

REMOTE KEYLESS REMOTE KEYLESS

ENTRY AND ALARM ENTRY AND ALARM
2.0L

Hot at Hot at
all times all times
BODY
CONTROL
MODULE (BCM)
F3 11-17
20A
13-98

UNLOCK UNLOCK
PASSENGER DRIVER
RELAY RELAY
(Non-serviceable) (Non-serviceable)

5 27 10 C02280C

GD233
BK
BU-GN
BU-BN
CPL66

CPL51
G0303
10-47

E F

117-25 117-26 117-23 117-24

REMOTE KEYLESS REMOTE KEYLESS

ENTRY AND ALARM ENTRY AND ALARM
LEFT HAND DRIVE 2.0L

REMOTE KEYLESS
ENTRY AND ALARM
REMOTE KEYLESS
ENTRY AND ALARM
117-21 117-21 117-22

C D F

GY-BN

BU-GN
VT-OG
CPL12

CPL11

CPL51
AUXILIARY
JUNCTION
117-25 LS 117-25 LT BOX (AJB)
11-11
F61 F63 F25
15A 15A 7.5A
13-95 13-94 13-98

S2021 S2020

LG LJ

GY-BN

BU-GN
VT-OG
CPL12

CPL11

CPL51
117-28 117-28

REMOTE KEYLESS
B17 C0339 ENTRY AND ALARM A16 A17 C0339
CPL12

CPL11

CPL51
BK

BK
6 7 8 C0525

DRIVER
DOOR
LATCH
M M 151-106
RIGHT HAND DRIVE 2.0L

REMOTE KEYLESS
ENTRY AND ALARM
REMOTE KEYLESS
ENTRY AND ALARM
117-21 117-21 117-22

C D F

GY-BN

BU-GN
VT-OG
CPL12

CPL11

CPL51
AUXILIARY
JUNCTION
117-26 RS 117-26 RT BOX (AJB)
11-11
F62 F64 F25
15A 15A 7.5A
13-97 13-96 13-98

S276 S275

RG O RJ P

GY-BN

BU-GN
VT-OG
CPL12

CPL11

CPL51
117-29 117-31 117-29 117-31

REMOTE KEYLESS
B17 C0339 ENTRY AND ALARM A16 A17 C0339
CPL12

CPL11

CPL51
BK

BK
3 2 1 C0603

DRIVER
DOOR
LATCH
M M 151-108
LEFT HAND DRIVE 2.0L

REMOTE KEYLESS
ENTRY AND ALARM
117-22

BU-BN
CPL66
AUXILIARY
JUNCTION
117-23 LS 117-23 LT BOX (AJB)
11-11
F62 F64 F26
15A 15A 7.5A
13-95 13-94 13-98

S276 S275

LK O LL P

GY-BN
VT-OG

BU-BN
CPL12

CPL11

CPL66
117-28 117-31 117-28 117-31

REMOTE KEYLESS
B17 C0340 ENTRY AND ALARM A16 A17 C0340
CPL12

CPL11

CPL66
BK

BK
3 2 1 C0609

PASSENGER
DOOR
LATCH
M M 151-107
RIGHT HAND DRIVE 2.0L

REMOTE KEYLESS
ENTRY AND ALARM
117-22

BU-BN
CPL66
AUXILIARY
JUNCTION
117-24 RS 117-24 RT BOX (AJB)
11-11
F61 F63 F26
15A 15A 7.5A
13-97 13-96 13-98

S2021 S2020

RK RL

GY-BN
VT-OG

BU-BN
CPL12

CPL11

CPL66
117-29 117-29

REMOTE KEYLESS
B17 C0340 ENTRY AND ALARM A16 A17 C0340
CPL07

CPL65

CPL66
BK

BK
6 7 8 C0502

PASSENGER
DOOR
LATCH
M M 151-109
Hot at
all times 2.0L
BODY
CONTROL
MODULE (BCM)
11-17

AJAR AJAR
LEFT SIDE RIGHT SIDE
DOOR SWITCH DOOR SWITCH

39 46 19 C02280E

19 right hand drive 46 right hand drive

multi-function
display
3 C0268

CPL39
9 C0264

CPL36
YE
right hand drive

GN
right hand drive
BU-GN
CPL77

CPL36
GN

CPL39
2 C02039

YE
HAZARD 6 C0300
DOOR FLASHER
SWITCH 6 C0311

CPL36
LOCK
90-13

GN
STATUS

CPL39
1 C0958

YE
SLIDING DOOR
AJAR SWITCH 1 C0959
5 C02039 LH
151-99
SLIDING DOOR
AJAR SWITCH
RH
151-100
S206 2 C0958
BK-GY
GD284

BK-GY
GD235

2 C0959
1 C0263

BK-GN
GD308
S226 S222 9 C0300
BK-GY

BK-VT
GD284

GD216

S924
BK-GN

BK-GY
GD240

GD235

G0206 G0201
10-42 10-39

BK-GN
GD308
G0307 G0304
without multi-function 10-52 10-49
multi-function display G0405
display left hand drive right hand drive 10-63
LEFT HAND DRIVE Hot at 2.0L
all times
BODY
F16 CONTROL
15A MODULE (BCM)
13-99 11-17

UNLOCK UNLOCK
DRIVER PASSENGER
SLIDING SLIDING
RELAY RELAY
(Non-serviceable) (Non-serviceable)

33 24 10 C02280C
dual sliding doors

REMOTE KEYLESS REMOTE KEYLESS

GD233
ENTRY AND ALARM ENTRY AND ALARM

BK
117-23 117-23 117-25 117-25
G0303
LG LJ LK LL 10-47
WH-OG
GY-BN

GY-BN

GY-BU
VT-OG

VT-OG
CPL12

CPL11

CPL53

CPL12

CPL11

CPL54
3 2 1 C0706A 3 2 1 C0806A
SLIDING SLIDING
DOOR DOOR
CONTACT CONTACT
PLATE LH PLATE RH
151-89 151-90

3 2 1 C0706B 3 2 1 C0806B
GY-BN

GY-BN

GY-BU
VT-OG

VT-GY

VT-OG
CPL12

CPL11

CPL52

CPL12

CPL11

CPL54
7 5 6 C0708 3 2 4 C0808

SLIDING SLIDING
DOOR DOOR
LATCH LH LATCH RH
M M 151-89 M M 151-90
RIGHT HAND DRIVE Hot at 2.0L
all times
BODY
F16 CONTROL
15A MODULE (BCM)
13-99 11-17

UNLOCK UNLOCK
PASSENGER DRIVER
SLIDING SLIDING
RELAY RELAY
(Non-serviceable) (Non-serviceable)

24 33 10 C02280C
dual sliding doors

REMOTE KEYLESS REMOTE KEYLESS

GD233
ENTRY AND ALARM ENTRY AND ALARM

BK
117-26 117-26 117-24 117-24
G0303
RK RL RG RJ 10-47
WH-OG

WH-OG
GY-BN

GY-BN
VT-OG

VT-OG
CPL12

CPL11

CPL53

CPL12

CPL11

CPL53
3 2 1 C0706A 3 2 1 C0806A
SLIDING SLIDING
DOOR DOOR
CONTACT CONTACT
PLATE LH PLATE RH
151-89 151-90

3 2 1 C0706B 3 2 1 C0806B
GY-BN

GY-BN

GY-BU
VT-OG

VT-GY

VT-OG
CPL12

CPL11

CPL52

CPL12

CPL11

CPL54
7 5 6 C0708 3 2 4 C0808

SLIDING SLIDING
DOOR DOOR
LATCH LH LATCH RH
M M 151-89 M M 151-90
BODY Hot at
CONTROL all times 2.0L
MODULE (BCM) AUXILIARY
11-17 JUNCTION
F19 BOX (AJB)
UNLOCK CARGO/LIFTGATE 15A 11-11
13-87
31 C02280C

GN-BN
CPL84

BU-RD
SB119
AUXILIARY
JUNCTION
BOX (AJB)
11-11
EXTERNAL
2 5 4 LOCKING
RELAY

1 3
BK-WH
GD238

YE-VT

YE-VT
CPL17

CPL17
Z ZZ

S287 117-31 117-32 117-31 117-32

BK-GN

BK-GY
GD240

GD235
REMOTE KEYLESS
ENTRY AND ALARM
BK-WH
GD238

G0307 G0304
10-52 10-49

left hand drive right hand drive

G0308
10-54
REAR DOORS REMOTE KEYLESS
ENTRY AND ALARM
2.0L
117-30
BODY
CONTROL
MODULE (BCM) Z
11-17
AJAR
LIFTGATE / REAR CARGO DOOR SWITCH REMOTE KEYLESS
ENTRY AND ALARM
34 C02280E 117-30

REMOTE KEYLESS
BN-VT
CPL81

ENTRY AND ALARM

117-17 117-18 117-24 117-25 117-24 117-25

YE-VT
CPL17
S245 B O P

35 C0300 36 C0300

GY-BN
BU-BN

VT-OG
BN-VT

YE-VT
CPL81

CPL30

CPL12

CPL11

CPL17
BN-VT

BN-VT
CPL81

CPL79
35 9 38 37 36 C0311
3 C0935 6 C0934
4 3 C0991 2 5 6 C0983
Not used Not used
CPL30
CPL81

CPL12

CPL11

CPL17
BK
BK

BK
4 3 C0411 2 5 6 C0410
CPL81

CPL30

CPL12

CPL11

CPL17
BK

BK
6 5 3 2 1 C0486

REAR
DOOR
LATCH
M M 151-110

4 C0486
GD308 BK C0411- 1 GD308 BK C0991 - 1 GD308 BK-GN S924 GD308 BK-GN
G0405
10-63
LIFTGATE 2.0L
BODY
CONTROL
MODULE (BCM)
LIFTGATE 11-17
AJAR RELEASE
LIFTGATE / REAR CARGO DOOR SWITCH SWITCH

34 1 C02280E

REMOTE KEYLESS
ENTRY AND ALARM

CPL45
117-30

BN
BN-VT
CPL81

ZZ
REMOTE KEYLESS
ENTRY AND ALARM
117-30
7 C0300
Z
S245

YE-VT
CPL17

CPL45
BN
35 C0300
BN-VT
CPL81

36 C0300
BN-VT
CPL81

YE-VT
CPL17 3 C0934

BN-VT
CPL79
3 C0935 1 C0406
35 36 C0311

GD236

GD236
CPL45
6 C0934

BK
BK
4 C0991 6 C0983
CPL81

CPL79
Not used Not used
BK

BK
3 C0405
1 C0935
3 C0406 6 C0405

CPL45
BK

BK-GN
3 1 C04339

GD236
LIFTGATE 2 4 C0494
LATCH
151-111 G0300
10-43

BK-WH
M

BN-VT

GD150
CPL79
1 2 C04216

LIFTGATE
2 C04339 RELEASE
SWITCH
C0935 - 2 C0406 - 2 151-111
GD350 BK-WH GD350 BK GD350 BK
S401
G0401
10-56
Start/Stop Bus
BODY 2.0L
CONTROL
F32 MODULE (BCM)
10A 11-17
13-103

22 C02280C

VT-RD
SBP32
RADIO
39 C0311 FREQUENCY
(RF) RECEIVER
151-115
7 C0900

SBP32 VT-RD C09026

VBATT
BODY 6
CONTROL
MODULE (BCM)
11-17
VDB06 GY-OG
MODULE MS CAN +
COMMUNICATIONS 4
NETWORK
14-16 14-18 VDB07 VT-OG
MS CAN -
3

C0268- 7 C0311- 21 C0900 - 9

C02280B VPL56 BU-GY VPL56 BU-GY VPL56 BU-GY
K-LINE SIGNAL
26 2

GROUND
1

BK-GN
GD308
S909

11 C0900

C02280G VDB04 WH-BU S923 rear parking aid

HS1 CAN + MODULE
10 COMMUNICATIONS
NETWORK

BK-GN
GD308
VDB05 WH 14-11
HS1 CAN -
9
G0405
10-63
ANTI-THEFT ALARM SYSTEM 2.0L
Hot at
all times
BODY
CONTROL
F8 MODULE (BCM)
10A 11-17
13-91

AJAR
HOOD
SWITCH

14 C02280F 34 C02280C
WH-BN

GY-VT
CRT17

CRT02
12 C0192
CRT17
BK

ANTI-THEFT
ALARM HORN
S305 CRT02 GY-VT C03549 LH
2 C0127 151-89
1
HOOD
SWITCH
151-68

1 C0127
GD124
BK

S185

6 C0192

ANTI-THEFT
ALARM HORN
S131 CRT02 GY-VT C03550 RH
151-90
1
BK-VT
GD124

G0109
10-35
THATCHAM CATEGORY 1 ALARM
2.0L
Hot at Hot at
all times all times
BODY
CONTROL
F11 F17 MODULE (BCM)
5A 5A 11-17
13-92 13-92
LIN 3 SPL2 LIN 4

15 C02280C 36 C02280E 11 C02280A 37 C02280E

BU-RD

VRT26

VDN04
SBP11

SBP17

VT-RD
RD
VT

S297

8 C0268
27 51 C0311 S137

11 4 C0913

VDN04
VT-RD
SBP17
RD
BU-RD

VRT26
SBP11

3 2 C09800 3 2 C0154

INTRUSION ANTI-THEFT
SENSOR ALARM HORN
151-115 WITH INTEGRAL
BATTERY
151-69

1 C09800
BK-GN
GD308

1 C0154

BK-GY
GD123
S909

11 C0900

S132 left hand drive

S923 rear parking aid

BK-GY
GD123
BK-GN
GD308

G0405 G0108
10-63 10-34
Hot at 2.2L
all times
AUXILIARY
JUNCTION
F39 BOX (AJB)
7.5A 11-1
13-23

POWER
DISTRIBUTION
13-23

WH-RD
SB139
39 C311

5 C900

S908 Thatcham category 1 alarm

BODY
CONTROL
MODULE (BCM)
11-5

WH-RD
RADIO

SB139
FREQUENCY
(RF) RECEIVER
151-49

C9026 POWER
3
C311 - 21 C900 - 9
C2280C VPL56 BU-GY VPL56 BU-GY SIGNAL
LIN 0 RFR
1 1

GROUND
2

BK-GN
GD140
S909

7 C913

22 C311

C2280D VDB04 WH-BU

BK-GN
GD140

HS CAN + MODULE
52 COMMUNICATIONS
VDB05 WH NETWORK
HS CAN - 14-3
51 G306
10-19
Start/Stop Bus
BODY 2.0L
CONTROL
F32 MODULE (BCM)
10A 11-17
13-103

22 C02280C

VT-RD
SBP32
RADIO
39 C0311 FREQUENCY
(RF) RECEIVER
151-115
7 C0900

SBP32 VT-RD C09026

VBATT
BODY 6
CONTROL
MODULE (BCM)
11-17
VDB06 GY-OG
MODULE MS CAN +
COMMUNICATIONS 4
NETWORK
14-16 14-18 VDB07 VT-OG
MS CAN -
3

C0268- 7 C0311- 21 C0900 - 9

C02280B VPL56 BU-GY VPL56 BU-GY VPL56 BU-GY
K-LINE SIGNAL
26 2

GROUND
1

BK-GN
GD308
S909

11 C0900

C02280G VDB04 WH-BU S923 rear parking aid

HS1 CAN + MODULE
10 COMMUNICATIONS
NETWORK

BK-GN
GD308
VDB05 WH 14-11
HS1 CAN -
9
G0405
10-63
Hot in Start
or Run 2.2L
AUXILIARY
JUNCTION
F27 BOX (AJB)
20A 11-1
13-19

GN-BN
CB127
C341F - 1 C3660C - 1
1 BU CB127 GN-BN CB127 GN-BN 1 BU

S294
1 C320 1 C321
S303 right hand drive
HEATED FRONT HEATED FRONT
SEAT SEAT
SWITCH SWITCH
151-46 151-48 151-46 151-48

2 C320 2 C321
BU-WH

BU-WH
2

2
1 C365 1 C335

FRONT SEAT FRONT SEAT

BACKREST BACKREST
HEATER MAT HEATER MAT
151-46 151-46

2 C365 2 C335
BK-WH

BK-WH
3

3
1 C364 1 C334

FRONT SEAT FRONT SEAT

CUSHION CUSHION
HEATER MAT HEATER MAT
151-46 151-46

2 C364 2 C334
C341F - 2 S302 C3660C - 2
4 BK GD182 BK-GY GD182 BK-GY 4 BK

G305
10-18
Hot in Start
or Run 2.0L
AUXILIARY
JUNCTION
F39 BOX (AJB)
20A 11-11
13-73

VT-WH
CB109
C0341F - 1 C03660C - 1
1 BU CB109 VT-WH CB109 VT-WH 1 BU

S253
1 C0320 1 C0321

HEATED FRONT HEATED FRONT

SEAT SEAT
SWITCH SWITCH
151-112 151-114

2 C0320 2 C0321
BU-WH

BU-WH
2

2
1 C0365 1 C0335

FRONT SEAT FRONT SEAT

BACKREST BACKREST
HEATER MAT HEATER MAT
151-112 151-114

2 C0365 2 C0335
BK-WH

BK-WH
3

3
1 C0364 1 C0334

FRONT SEAT FRONT SEAT

CUSHION CUSHION
HEATER MAT HEATER MAT
151-112 151-114

2 C0364 2 C0334
C0341F - 2 S302 C03660C - 2
4 BK GD382 BK-GY GD382 BK-GY 4 BK

G0305
10-50
Hot at LEFT HAND DRIVE 2.2L
all times
AUXILIARY
JUNCTION
F10 BOX (AJB)
30A 11-1
13-25

YE-RD
SB110
2 BK 1 C341E
7

RD
8

FRONT SEAT
CONTROL
3 5 C369 SWITCH
151-47

TILT HEIGHT HORIZONTAL RECLINE LUMBAR

DOWN AFT DOWN

DOWN UP UP FORE UP IN OUT
BK-GY
GD182

6 2 12 1 9 4 8 11 10 7 C369

GN-GY

BK-GY
GN-WH
BK-WH

GN-BU
GN-YE

BK-BU
BK-YE

BU
11

12
10

5
1

4
heated 2 1 3 4 C3050
seats

GN-GY

BK-GY
S302

BU
2

4
3 1 C382 2 1 C363 1 3 C362
2 1 C3187 1 2 C3215
BK-GY
GD182

M M M
M M

FRONT SEAT FRONT SEAT FRONT SEAT

TILT HEIGHT TRACK FRONT SEAT FRONT SEAT
MOTOR ADJUSTMENT MOTOR RECLINER MOTOR POWER
151-47 MOTOR 151-47 151-47 LUMBAR
G305 151-47 ASSEMBLY
10-18 151-47
Hot at RIGHT HAND DRIVE 2.2L
all times
AUXILIARY
JUNCTION
F10 BOX (AJB)
30A 11-1
13-25

YE-RD
2 SB110
1 C341E
BK
7

RD
8

FRONT SEAT
CONTROL
3 5 C369 SWITCH
151-47

TILT HEIGHT HORIZONTAL RECLINE LUMBAR

DOWN DOWN DOWN

UP UP AFT FORE UP IN OUT
BK-GY
GD182

6 2 12 1 9 4 8 11 10 7 C369

GN-GY

BK-GY
GN-WH
BK-WH

GN-BU
GN-YE

BK-BU
BK-YE

BU
11

12
10

5
1

4
heated 2 1 3 4 C3050
seats

GN-GY

BK-GY
S302

BU
2

4
1 3 C382 1 2 C363 1 3 C362
2 1 C3187 1 2 C3215
BK-GY
GD182

M M M
M M

FRONT SEAT FRONT SEAT FRONT SEAT

TILT HEIGHT TRACK FRONT SEAT FRONT SEAT
MOTOR ADJUSTMENT MOTOR RECLINER MOTOR POWER
151-47 MOTOR 151-47 151-47 LUMBAR
G305 151-47 ASSEMBLY
10-18 151-47
LEFT HAND DRIVE
Hot at
all times 2.0L
AUXILIARY
JUNCTION
F57 BOX (AJB)
30A 11-11
13-84

SB157
RD
2 1 C0341E
BK
7

RD
8

FRONT SEAT
CONTROL
3 5 C0369 SWITCH
151-113

TILT HEIGHT HORIZONTAL RECLINE LUMBAR

DOWN AFT DOWN

DOWN UP UP FORE UP IN OUT
BK-GY
GD382

6 2 12 1 9 4 8 11 10 7 C0369

GN-GY

BK-GY
GN-WH
BK-WH

GN-BU
GN-YE

BK-BU
BK-YE

BU
11

12
10

5
1

4
heated 2 1 3 4 C03050
seats

GN-GY

BK-GY
S302

BU
2

4
3 1 C0382 2 1 C0363 1 3 C0362
2 1 C03187 1 2 C03215
BK-GY
GD382

M M M
M M

FRONT SEAT FRONT SEAT FRONT SEAT

TILT HEIGHT TRACK FRONT SEAT FRONT SEAT
MOTOR ADJUSTMENT MOTOR RECLINER MOTOR POWER
151-113 MOTOR 151-113 151-113 LUMBAR
G0305 151-113 ASSEMBLY
10-50 151-113
RIGHT HAND DRIVE
Hot at
all times 2.0L
AUXILIARY
JUNCTION
F57 BOX (AJB)
30A 11-11
13-84

SB157
RD
2 1 C0341E
BK
7

RD
8

FRONT SEAT
CONTROL
3 5 C0369 SWITCH
151-113

TILT HEIGHT HORIZONTAL RECLINE LUMBAR

DOWN DOWN DOWN

UP UP AFT FORE UP IN OUT
BK-GY
GD382

6 2 12 1 9 4 8 11 10 7 C0369

GN-GY

BK-GY
GN-WH
BK-WH

GN-BU
GN-YE

BK-BU
BK-YE

BU
11

12
10

5
1

4
heated 2 1 3 4 C03050
seats

GN-GY

BK-GY
S302

BU
2

4
1 3 C0382 1 2 C0363 1 3 C0362
2 1 C03187 1 2 C03215
BK-GY
GD382

M M M
M M

FRONT SEAT FRONT SEAT FRONT SEAT

HEIGHT TRACK MOTOR FRONT SEAT FRONT SEAT
TILT POWER
MOTOR ADJUSTMENT 151-113 RECLINER MOTOR
MOTOR 151-113 LUMBAR
151-113 ASSEMBLY
G0305 151-113
10-50 151-113
LEFT HAND DRIVE TURN SIGNAL/
STOP/ HAZARD LAMPS 2.2L
Hot at
all times 90-4
AUXILIARY HEATED WINDOW

CLS25
JUNCTION
56-6

BK
F35 BOX (AJB)
5A 11-1

CB103
13-22

BK
C626
CPM20 BK
5

BU-RD
1 8 C626

SB135
CPM21 BK EXTERIOR
MIRROR
A6 C339 RH
7
M M 151-43
CPM23 BK

SB135
BK
6
S508 2 C626
B8 B9 B10 C340

SB135

BN-WH
BK

CPM20

CPM23
CPM21
C340 - B11

YE-VT
GD240 BK

GY
S603
6 C527

BK-GN
GD240
EXTERIOR B8 B9 B10 C339
MIRROR
CONTROL G307
TURN SIGNAL/ 10-20
SWITCH
151-42 STOP/ HAZARD LAMPS
90-3
HEATED WINDOW
L R L R

CLS21
CPM23
56-6

BK
C527

BK
C527 CPM20 BK

CB103
4 U R

BK
5 C521
CPM16 BK
GD134

L
D 7 5 1 8 C521
BK

CPM21 BK
U R
S505 2
CPM17 BK EXTERIOR
L MIRROR
D 1 7 LH
S504
M M 151-42
3 CPM23 BK CPM23 BK
GD134

FOLD
S503 6
BK

2 C521
8 C527
B11 C339 C339 - B11
GD134 BK
POWER MIRRORS
C339 - A7 S505 S504
CPM22 BK CPM22 GY-BN
BK-VT
GD134

BK-VT
A

GD134
124-2

G302 G302
10-13 10-13
LEFT HAND DRIVE POWER FOLDING MIRRORS 2.2L
Hot at
all times
BODY
CONTROL
F7 MODULE (BCM)
7.5A 11-5
13-28

POWER MIRROR POWER MIRROR

UNFOLD RELAY FOLD RELAY
(Non-serviceable) (Non-serviceable)

POWER FOLD
MIRROR SWITCH

31 24 23 6 33 C2280B 39 C2280C
BK-WH

BK-WH

GY-BN
CPM22
GD137

GD137

CPM01

CPM02
YE-GN

BU
A12 A13 C339 POWER MIRRORS
S256 A 124-1
CPM01

CPM02
YE-GN

CPM01

CPM02

BU
BK

BK
4 3 C521
A12 C340 A13 C340

EXTERIOR
MIRROR
M LH
CPM01

CPM02
151-42
BK

BK
4 3 C626
BK-WH
GD137

EXTERIOR
MIRROR
M RH
G303 151-43
10-14
RIGHT HAND DRIVE TURN SIGNAL/
STOP/ HAZARD LAMPS 2.2L
Hot at
all times 90-3
AUXILIARY HEATED WINDOW

CLS21
JUNCTION
56-6

BK
F35 BOX (AJB)
5A 11-1

CB103
13-22

BK
C663
CPM16 BK
5

BU-RD
1 8 C663

SB135
CPM17 BK EXTERIOR
MIRROR
A6 C339 LH
7
M M 151-43
CPM23 BK

SB135
BK
6
S508 2 C663
B8 B9 B10 C340
SB135
BK

CPM16

BU-GN

CPM23
BN-BU

CPM17
GD134 BK C340 - B11

GY
S603
6 C527

BK-VT
GD134
EXTERIOR B8 B9 B10 C339
MIRROR
CONTROL G302
SWITCH TURN SIGNAL/ 10-13
151-42 STOP/ HAZARD LAMPS
90-4

L R L R HEATED WINDOW

CLS25
CPM23
56-6

BK
C527

BK
C527 CPM16 BK

CB103
4 U L

BK
7 C596
CPM20 BK
GD240

R
D 5 5 1 8 C596
BK

CPM17 BK
U L
S505 1
CPM21 BK EXTERIOR
R MIRROR
S504 D 2 7 RH
M M 151-42
3 CPM23 BK CPM23 BK
GD240

FOLD
S503 6
BK

2 C596
8 C527
B11 C339 C339 - B11
GD240 BK
C339 - A7 POWER MIRRORS
CPM22 BK CPM22 GY-BN S505 S504
BK-GN
GD240

BK-GN
B

GD240
124-4

G307 G307
10-20 10-20
RIGHT HAND DRIVE POWER FOLDING MIRRORS 2.2L
Hot at
all times
BODY
CONTROL
F7 MODULE (BCM)
7.5A 11-5
13-29

POWER MIRROR POWER MIRROR

UNFOLD RELAY FOLD RELAY
(Non-serviceable) (Non-serviceable)

POWER FOLD
MIRROR SWITCH

31 24 23 6 33 C2280B 39 C2280C
BK-WH

BK-WH

GY-BN
CPM22
GD137

GD137

CPM01

CPM02
YE-GN

BU
A12 A13 C339 POWER MIRRORS
S256 B 124-3
CPM01

CPM02
YE-GN

CPM01

CPM02

BU
BK

BK
4 3 C596
A12 C340 A13 C340

EXTERIOR
MIRROR
M RH
CPM01

CPM02
151-42
BK

BK
4 3 C663
BK-WH
GD137

EXTERIOR
MIRROR
M LH
G303 151-43
10-14
Hot in Start Hot at
or Run all times 2.2L
AUXILIARY BODY
JUNCTION CONTROL
F29 BOX (AJB) MODULE (BCM)
10A F11
11-1 25A 11-5
13-20
13-31

without: lane departure warning

POWER MICRO
DISTRIBUTION lane departure
CB129 WH-VT S272 warning
13-20

11 C2280B

WH-VT
CB129

GN-BN
CLS10
S910 CB129 WH-VT C913 - 6 CB129 WH-VT C311 - 28
S299
WH-VT
CB129

1 C911

GN-BN
CLS10
AUTO-DIMMING
INTERIOR
VPWR MIRROR
151-50

C911 C913 - 5 S919 C311 - 13

CLS10 GN-BN CLS10 GN-BN
REVERSE
2

SHIELD

VMP19 WH-GN
VIDEO +
4
RMP19 BN-VT
VIDEO - PARKING AID
5 131-7

DMP22

GND

3 C911
GD140 BK-GN S909 GD140 BK-GN C913 - 7 GD140 BK-GN C311 - 22 GD140 BK-GN

G306
10-19
LEFT HAND DRIVE TURN SIGNAL/
STOP/ HAZARD LAMPS 2.0L
Hot at
all times 90-15
BODY HEATED WINDOW

CLS25
F2 CONTROL
56-12

BK
7.5A MODULE (BCM)
13-90 11-17

CB124
BK
C0626
CPM20 BK
29 C02280C
5 1 8 C0626

YE-RD
SBP02
CPM21 BK EXTERIOR
MIRROR
7 RH
S295 M M 151-107
CPM23 BK
A6 C0339
6
2 C0626
B8 B9 B10 C0340
S508
SBP02

BN-WH
CPM20

CPM23
CPM21
C0340 - B11

YE-VT
GD239 BK
BK

GY
6 C0527

BK-YE
GD239
EXTERIOR B8 B9 B10 C0339
MIRROR
CONTROL G0306
TURN SIGNAL/ 10-51
SWITCH
STOP/ HAZARD LAMPS
151-106
90-14
HEATED WINDOW
L R L R

CLS21
CPM23
56-12

BK
C0527

BK
C0527 CPM20 BK

CB124
4 U R

BK
5 C0521
CPM16 BK
GD240

L
D 7 5 1 8 C0521
BK

CPM21 BK
U R
S502 2
CPM17 BK EXTERIOR
L MIRROR
D 1 7 LH
M M 151-106
GD240

3 CPM23 BK CPM23 BK
BK

FOLD
S503 6

B12 C0339 2 C0521

8 C0527

S288 GD234 BK C0339 - B11

POWER MIRRORS
C0339 - A7 S504
CPM22 BK CPM22 GY-BN
BK-GN
GD240

BK-VT
A

GD234
124-7

G0307 G0302
10-52 10-45
Hot at
LEFT HAND DRIVE all times POWER FOLDING MIRRORS 2.0L
BODY
F2 CONTROL
7.5A MODULE (BCM)
13-90 11-17

29 C02280C

YE-RD
SBP02
S295

AUXILIARY
JUNCTION
FOLD BOX (AJB)
4 MIRROR 11-11
MODULE
RELAY

1 2 3 5

GY-BN
CPM22

BK-WH
GD238
124-6 A
POWER MIRRORS

S287

BK-WH
CPM01

CPM02

CPM01

CPM02
YE-GN

YE-GN

GD238
BU

BU
A12 A13 C0339 A12 A13 C0340
G0308
10-54
CPM01

CPM02

CPM01

CPM02
BK

4
BK
4 3 C0521 3 C0626

EXTERIOR EXTERIOR
MIRROR MIRROR
M LH M RH
151-106 151-107
RIGHT HAND DRIVE TURN SIGNAL/
STOP/ HAZARD LAMPS 2.0L
Hot at
all times 90-14
BODY HEATED WINDOW

CLS21
F2 CONTROL
56-12

BK
7.5A MODULE (BCM)
13-90 11-17

CB124
BK
C0517
CPM16 BK
29 C02280C
5 1 8 C0517

YE-RD
SBP02
CPM17 BK EXTERIOR
MIRROR
7 LH
S295 M M 151-109
CPM23 BK
A6 C0339
6
2 C0517
B8 B9 B10 C0340
S615
SBP02

CPM16

BU-GN

CPM23
BN-BU

CPM17
BK
GD234 BK C0340 - B11

GY
S513
6 C0618

BK-VT
GD234
EXTERIOR B8 B9 B10 C0339
MIRROR
CONTROL G0302
SWITCH TURN SIGNAL/ 10-46
151-108 STOP/ HAZARD LAMPS
90-15

L R L R HEATED WINDOW

CLS25
CPM23
56-12

BK
C0618

BK
C0618 CPM16 BK

CB124
4 U L

BK
7 C0622
GD235

CPM20 BK
R
BK

D 5 5
CPM17 BK 1 8 C0622
U L
S612 1
CPM21 BK EXTERIOR
R MIRROR
D
GD235

2 7 RH
M M 151-108
BK

3 CPM23 BK CPM23 BK
FOLD
S614 6
B11 C0339
2 C0622
8 C0618
S286
GD239 BK C0339 - B11
C0339 - A7 POWER MIRRORS
CPM22 BK CPM22 GY-BN S613
BK-GY
GD235

BK-YE
B

GD239
124-9

G0304 G0306
10-49 10-51
Hot at
RIGHT HAND DRIVE all times POWER FOLDING MIRRORS 2.0L
BODY
F2 CONTROL
7.5A MODULE (BCM)
13-90 11-17

29 C02280C

YE-RD
SBP02
S295

AUXILIARY
JUNCTION
FOLD BOX (AJB)
4 MIRROR 11-11
MODULE
RELAY

1 2 3 5

GY-BN
CPM22

BK-WH
GD238
124-8 B
POWER MIRRORS

S287

BK-WH
CPM01

CPM02

CPM01

CPM02
YE-GN

YE-GN

GD238
BU

BU
A12 A13 C0340 A12 A13 C0339
G0308
10-54
CPM01

CPM02

CPM01

CPM02
BK

4
BK
4 3 C0517 3 C0622

EXTERIOR EXTERIOR
MIRROR MIRROR
M LH M RH
151-109 151-108
Hot in Start or Run PROXIMITY WARNING 2.0L
RADAR UNIT
BODY 31-13 31-14
CONTROL 146-3 146-4
MODULE (BCM) CAN - CAN +
F36 11-17
15A
13-101
18 9 C01582

VMF05

VMF04
8 C02280C

BK
BU-BN
CBP36

10 9 C0192

VMF05
GY-BU

VMF04
BN-BU
23 C0311
BU-BN
CBP36

45 44 C0311
S930 rear parking aid

2 1 C0913
6 C0913

VMF04
BN-BU
BU-BN

VMF05
GY-BU
CBP36

1 4 3 C09012
AUTO-DIMMING
INTERIOR
VPWR CAN - CAN + MIRROR
151-115

MODULE
COMMUNICATIONS
NETWORK
C09012 VDB25 GN-OG
HS2 CAN + 14-14
12
VDB26 GY-BU
HS2 CAN - 14-14
GND 13

7 C09012

rear parking aid

S909 C0900 - 11 S923

GD308 BK-GN GD308 BK-GN GD308 BK-GN GD308 BK-GN

G0405
10-63
WITHOUT:
MULTI-FUNCTION DISPLAY 2.2L
Hot at Hot in Run
all times or Acc Hot in Start
BODY IGNITION
CONTROL SWITCH
MODULE (BCM) 13-10 13-11
F16 F21
20A 3A 11-5
13-47 13-52

7 C250
64 42 C2280D

BU-WH
CDC35
S223

BU-GY
VT-RD

CBP21
SBP16

BU-WH
CDC35
1 4 5 C240A

AUDIO
VBATT VPWR START FRONT
CONTROL
MODULE (ACM)
151-16 151-20

C240A CME05 GN-BU STARTING

START SYSTEM
3 20-2 20-3

CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
14 71-2

AUDIO
SHIELD INPUT
VME45 BU C2362 SOCKET
ST INPUT 2L+ ST INPUT 2L+ 151-16 151-20
17 4
RME45 YE-GN
ST INPUT 2L- ST INPUT 2L-
6 3
VME46 BU-GN
ST INPUT 2R+ ST INPUT 2R+
18 1
DME45
STEREO SHIELD
16
GND GND

13 15 C240A
BK-BU
GD114

GD116 BK-VT S222 GD116 BK-VT

G200 G201
10-5 10-6
WITHOUT: 2.2L
MULTI-FUNCTION DISPLAY
AUDIO
FRONT
CONTROL
MODULE (ACM)
151-16 151-20

right hand drive right hand drive

C240A C210 C339 C340 C662 C536

VME07 WH VME07 WH VME07 BK
LF SPKR+
22 28 B14 B14 1 1
RME07 WH-BN RME07 WH-BN RME07 BK
LF SPKR-
10 29 B15 B15 4 4
FRONT DOOR
SPEAKER LH
151-42 151-43

right hand drive right hand drive

C340 C339
VME10 WH-VT VME10 WH-VT VME10 BK C595 C628
RF SPKR+
23 31 B14 B14 1 1
RME10 WH-OG RME10 WH-OG RME10 BK
RF SPKR-
11 30 B15 B15 4 4
FRONT DOOR
SPEAKER RH
151-42 151-43

rear door speaker

C210 C300 C9064

VME09 WH-GN VME09 WH-GN VME09 WH-GN REAR DOOR
LR SPKR+
21 40 33 1 SPEAKER LH
RME09 BN-YE RME09 BN-YE RME09 BN-YE 151-36
LR SPKR-
9 41 34 4

C311
VME12 BN-WH VME12 BN-WH VME12 BN-WH C9066
RR SPKR+ REAR DOOR
24 43 33 1 SPEAKER RH
RME12 BN-BU RME12 BN-BU RME12 BN-BU 151-37
RR SPKR-
12 42 34 4
Hot at
all times
MULTI-FUNCTION DISPLAY 2.2L
BODY
CONTROL
F19 MODULE (BCM)
5A 11-5
13-47

44 C2280D
BU-RD
SBP19

S229
BU-RD
SBP19

1 C2123
FRONT CONTROL/
DISPLAY INTERFACE
BATT MODULE (FCDIM)
151-16 151-20

C2123 VDB13 BU-GY

I CAN + MODULE
4 COMMUNICATIONS
VDB14 VT-GY NETWORK
I CAN - 14-2
5

MFD VMC49 VT-GY INSTRUMENT

SELECT CLUSTER
8 60-6

SYNC

AUDIO
FRONT
C263 CONTROL
VMN07 GY VMN07 GY C240A MODULE (ACM)
NAV VOICE + NAV VOICE +
151-16 151-20
6 4 4
RMN07 VT RMN07 VT
NAV VOICE - NAV VOICE -
12 3 5
GND GND

9 11 C2123
BK-VT

BK-VT
GD116

GD116

GD116 BK-VT
S222 G201
10-6
Hot at
all times
MULTI-FUNCTION DISPLAY 2.2L
BODY
CONTROL
F16 MODULE (BCM)
20A 11-5
13-47

64 C2280D
VT-RD
SBP16

7 C265
VT-RD
SBP16

1 C240A

AUDIO
VBATT FRONT
CONTROL
MODULE (ACM)
151-16 151-20

C240A VDB13 BU-GY

I CAN + MODULE
14 COMMUNICATIONS
VDB14 VT-GY NETWORK
I CAN - 14-2
15

without: SYNC

AUDIO
SHIELD INPUT
VME45 BU C2362 SOCKET
ST INPUT 2L+ ST INPUT 2L+ 151-16 151-20
17 4
RME45 YE-GN
ST INPUT 2L- ST INPUT 2L-
6 3
VME46 BU-GN
ST INPUT 2R+ ST INPUT 2R+
18 1
DME45
STEREO
SHIELD 16

GND

13 C240A
BK-BU
GD114

G200
10-5
AUDIO MULTI-FUNCTION DISPLAY
FRONT
CONTROL
2.2L
MODULE (ACM)
151-16 151-20

right hand drive right hand drive

C240A C265 C210 S252 C339 C340 C662 C536

VME07 WH VME07 BK
LF SPKR+
22 3 28 S253 B14 B14 1 1
RME07 WH-BN RME07 BK
LF SPKR-
10 10 29 B15 B15 4 4
FRONT DOOR
SPEAKER LH
151-42 151-43

front door
tweeter speaker

C300 C9063
VME07 WH FRONT DOOR
TWEETER
32 1 SPEAKER LH
RME07 WH-BN
151-24
40 3

right hand drive right hand drive

S2000 C340 C339

VME10 WH-VT VME10 BK C595 C628
RF SPKR+
23 4 31 S2001 B14 B14 1 1
RME10 WH-OG RME10 BK
RF SPKR-
11 11 30 B15 B15 4 4
FRONT DOOR
SPEAKER RH
151-42 151-43

front door
tweeter speaker

C311
VME10 WH-VT C9065
FRONT DOOR TWEETER
32 1 SPEAKER RH
RME10 WH-OG 151-25
40 3
AUDIO
FRONT MULTI-FUNCTION DISPLAY 2.2L
CONTROL
MODULE (ACM)
151-16 151-20

without: Camper Conversions

rear door speaker

C240A C265 C210 C300 C9064

VME09 WH-GN VME09 WH-GN REAR DOOR
LR SPKR+
21 2 40 33 1 SPEAKER LH
RME09 BN-YE RME09 BN-YE 151-36
LR SPKR-
9 9 41 34 4

C311
VME12 BN-WH VME12 BN-WH C9066
RR SPKR+ REAR DOOR
24 5 43 33 1 SPEAKER RH
RME12 BN-BU RME12 BN-BU 151-37
RR SPKR-
12 12 42 34 4

Camper Conversions

rear door speaker

C240A C265 C210 C214

VME09 WH-GN VME09 WH-GN
LR SPKR+ Not used
21 2 40 2
RME09 BN-YE RME09 BN-YE
LR SPKR- Not used
9 9 41 3

VME12 BN-WH VME12 BN-WH

RR SPKR+ Not used
24 5 43 4
RME12 BN-BU RME12 BN-BU
RR SPKR- Not used
12 12 42 5
SYNC Hot at
all times 2.2L
AUXILIARY
JUNCTION
F37 BOX (AJB)
7.5A 11-1
13-22

GY-RD
SB137
70 C210

6 C263

SB137 GY-RD SB137 GY-RD

S200
1 C2383 1 C2398
MODULE GLOBAL POSITIONING
SYNC COMMUNICATIONS
MODULE [APIM] SYSTEM MODULE (GPSM)
VBATT NETWORK VBATT 151-16 151-20
151-16 151-20
VDB06 GY-OG C2398
UNIVERSAL MS CAN +
SERIAL 2
GY 14-6 VDB07 VT-OG
USB BUS (USB) MS CAN -
MODULE 3
151-16 151-20

C2383 VDB04 WH-BU

HS CAN + MODULE
53 COMMUNICATIONS
NETWORK
VDB05 WH 14-4
HS CAN -
54

VDB13 BU-GY GND

I CAN + MODULE
16 COMMUNICATIONS
NETWORK
VDB14 VT-GY 14-2
I CAN - 6 C2398
17

BK-VT
GD116
PWR PWR
GND GND

37 38 C2383 1 C263
BK-BU

S222
BK-BU
GD114

GD114

BK-VT
GD116
S201

G200 G201
10-5 10-6
SYNC
2.2L
SYNC
MODULE [APIM]
AUDIO 151-16 151-20
FRONT
CONTROL
MODULE (ACM)
151-16 151-20

SHIELD
C240B VME66 VT C2383
STEREO L+ STEREO L+
12 25
RME66 GN-WH
STEREO L- STEREO L-
25 26
VME67 VT-GY
STEREO R+ STEREO R+
13 23
RME67 BN-WH
STEREO R- STEREO R-
26 24
DME66 BK
SHIELD
22

SHIELD
VME80 VT-GN
SYNC ALERT+ SYNC ALERT+
8 3
RME80 BU-GY
SYNC ALERT- SYNC ALERT-
21 4
DME80
SHIELD
21

MICROPHONE
151-50
SHIELD SHIELD
C9221 C219
MIC + VMM13 YE-GN VMM13 YE-GN VMM13 YE-GN
MIC +
A 3 5
RMM13 BK RMM13 BK RMM13 BK
MIC - MIC -
B 2 6
SYNC
2.2L
SYNC
MODULE [APIM]
151-16 151-20

AUDIO
INPUT
SOCKET
151-16 151-20
SHIELD
C2362 VME45 BU C2383
ST INPUT 2L+ STEREO 2L+
4 45
RME45 YE-GN
ST INPUT 2L- STEREO 2L-
3 46
VME46 BU-GN
ST INPUT 2R+ STEREO 2R+
1 47
DME45
STEREO SHIELD
44
WITHOUT: 2.2L
MULTI-FUNCTION DISPLAY
71-3
BK
CLUSTER AND PANEL ILLUMINATION or
RD-WH
or
GY

2 C2999
STEERING WHEEL
SWITCH
RH UPPER
1) Mode
3.01k 2) Seek -
3) Seek +
1 4) Vol +
1k 5) Vol -
151-23
2
475

3
261

4
154

5
147

5 4 3 C2999

BN
GN-WH

S2010

YE
12 11 10 C218B
CLOCKSPRING
151-22 151-23
AUDIO
FRONT
CONTROL
MODULE (ACM)
151-16 151-20 8 7 5 C218A

BK-GY
GD184
AUDIO C240A RME24 BU-WH S226
REMOTE -
20

BK-GY
GD184
AUDIO VME14 GY-YE
REMOTE +
8 G206
10-9
MULTI-FUNCTION DISPLAY 2.2L
CLUSTER AND PANEL ILLUMINATION
BK
71-3
2 C2999
STEERING WHEEL
SWITCH
RH UPPER
1) Right
2) Left
3) Down
1 4) Up
511 5) OK
151-23
2
301

3
182

4
STEERING 121
WHEEL
SWITCH, 5
LH UPPER 68
60-2

3 C2998 1 4 3 C2999
BU-WH
S2012

BN
S2010
BU-WH

BN-WH

BN
3 2 10 C218B
CLOCKSPRING
151-22 151-23

INSTRUMENT 5 C218A
PANEL
CLUSTER (IPC)

BK-GY
GD184
60-1 60-2 STEERING COLUMN
CONTROL
MODULE (SCCM)
151-22
DISPLAY/ C220 RMC27 WH-BN C2414 S226
TRIP GND
6 8

BK-GY
GD184
DISPLAY CMC29 GN-VT
SIGNAL
8 7
G206
10-9
MULTI-FUNCTION DISPLAY 2.2L

CLUSTER AND PANEL ILLUMINATION

BK
71-3
1 C2367
STEERING WHEEL
SWITCH
1600 RH LOWER
1) Seek -
2) Seek +
3) Vol +
4) Vol -
5) Voice / Mute
1 151-23
348

2
220

3
140

4
BODY
CONTROL 88.7
MODULE (BCM)
11-5 5
53.6

RADIO C2280D
ANTI-THEFT
AUDIO 12
3 2 4 C2367
BU-WH
RME24

BN
YE
S2010
late

BN
production
FRONT CONTROL/
DISPLAY INTERFACE 12 11 10 C218B
MODULE (FCDIM)
CME03
YE-GY

CLOCKSPRING
151-16 151-20 151-22 151-23

8 7 5 C218A

BK-GY
C2123 RME24 BU-WH

GD184
AUDIO
REMOTE -
10 S232
AUDIO VME14 GY-YE S226
REMOTE + 7

BK-GY
GD184
G206
10-9
WITHOUT:
MULTI-FUNCTION DISPLAY 2.0L

Hot in Start
Start/Stop Bus or Run Hot in Start
BODY IGNITION
CONTROL SWITCH
MODULE (BCM) 13-72
F33 F23
20A 10A 11-17
13-103 40-5 13-101

7 C0250
22 2 C02280A

BU-WH
CDC35
S221

BN-YE
CBP23
SBP33

BU-WH
CDC35
RD

1 4 5 C0240A

AUDIO
VBATT VPWR START FRONT
CONTROL
MODULE (ACM)
151-79 151-83

C0240A CME05 GN-BU STARTING

SMCS SYSTEM
3 20-5

CLN17 BN CLUSTER AND

ILLUM PANEL ILLUMINATION
14 71-9

GND GND

13 15 C0240A
BK-BU
GD214

GD216 BK-VT S222 GD216 BK-VT

G0200 G0201
10-37 10-38
WITHOUT:
MULTI-FUNCTION DISPLAY 2.0L

AUDIO
FRONT
CONTROL
MODULE (ACM)
151-79 151-83

AUDIO UNIT
ANTENNA
AMPLIFIER
151-116
C0219 - 1 C09021
C0240A CME13 YE-OG CME13 YE-OG
ANTENNA PWR
2 1 1
coaxial cable
AM/FM 3
2

SHIELD SHIELD
C0219 MICROPHONE
C0240A C09221 151-116
VMM13 YE-GN VMM13 YE-GN
MIC + MIC +
19 7 2 2
RMM13 BU RMM13 BK
MIC - MIC -
7 19 3 3

right hand drive

DME45 BK DME45 DME45
SHIELD
16 4

AUDIO
INPUT
VME45 BU C02362 SOCKET
ST INPUT 2L+ ST INPUT 2L+ 151-79 151-83
17 4
RME45 YE-GN
ST INPUT 2L- ST INPUT 2L-
6 3
VME46 BU-GN
ST INPUT 2R+ ST INPUT 2R+
18 1
WITHOUT: 2.0L
MULTI-FUNCTION DISPLAY
AUDIO
FRONT tweeter
CONTROL
MODULE (ACM) C0300
151-79 151-83 VME07 WH C09063
FRONT
32 1 TWEETER
RME07 WH-BN SPEAKER LH
151-87
40 3

WH-BN
VME07

RME07
WH
right hand drive

C0240A C0210 C0339 C0340 C0536

VME07 WH S247 VME07 BK
LF SPKR+
22 28 B14 B14 1
RME07 WH-BN RME07 BK
LF SPKR-
10 29 S290 B15 B15 4
FRONT DOOR
SPEAKER LH
151-106 151-109

right hand drive

S2000 C0340 C0339

VME10 WH-VT VME10 BK C0628
RF SPKR+
23 31 B14 B14 1
RME10 WH-OG RME10 BK
RF SPKR-
11 30 S2001 B15 B15 4
FRONT DOOR
SPEAKER RH
151-107 151-108
WH-OG

WH-VT
VME10
RME10

tweeter
C0311
VME10 WH-VT C09065
FRONT
32 1 TWEETER
RME10 WH-OG SPEAKER RH
151-88
40 3
WITHOUT: 2.0L
MULTI-FUNCTION DISPLAY

REAR SPEAKERS
C09106 C09450
VME09 WH-GN REAR
1 1 TWEETER
RME09 BN-YE SPEAKER
LH
AUDIO 3 3 151-99
FRONT
CONTROL
MODULE (ACM)
151-79 151-83

C09064 REAR
RME09 BN-YE SPEAKER LH
3 151-99
VME09 WH-GN

C0210 C0300
C0240A VME09 WH-GN VME09 WH-GN
LR SPKR+
21 40 33 1
RME09 BN-YE RME09 BN-YE
LR SPKR-
9 41 34 4

C09107 C09451
VME09 BN-GN REAR
1 1 TWEETER
RME09 BN-YE SPEAKER
RH
3 3 151-100

C09066 REAR
RME12 BN-BU SPEAKER RH
3 151-100
VME12 BN-WH

C0311
VME12 BN-WH VME12 BN-WH
RR SPKR+
24 43 33 1
RME12 BN-BU RME12 BN-BU
RR SPKR-
12 42 34 4
WITHOUT: 2.0L
MULTI-FUNCTION DISPLAY
71-10
BK
CLUSTER AND PANEL ILLUMINATION or
RD-WH
or
GY

2 C02999
STEERING WHEEL
SWITCH
RH UPPER
1) Mode
3.01k 2) Seek -
3) Seek +
1 4) Vol +
1k 5) Vol -
151-86
2
475

3
261

4
154

5
147

5 4 3 C02999

BN
GN-WH

S2010

YE
12 11 10 C0218B
CLOCKSPRING
151-85 151-86
AUDIO
FRONT
CONTROL
MODULE (ACM)
151-79 151-83 8 7 5 C0218A

BK-GY
GD284
AUDIO C0240A RME24 BU-WH S226
REMOTE -
20

BK-GY
GD284
AUDIO VME14 GY-YE
REMOTE +
8 G0206
10-42
Start/Stop Bus
BODY MULTI-FUNCTION DISPLAY 2.0L
CONTROL
F32 MODULE (BCM)
10A 11-17
13-103

9 C02280A

VT-RD
SBP32
6 C0264

S207
VT-RD
SBP32

1 C02123A

FRONT CONTROL/
VBATT DISPLAY INTERFACE
MODULE (FCDIM)
151-79 151-83 MESSAGE
CENTER
MFD C02123A VMC49 VT-GY C0253 SWITCH
MFD
SELECT SELECT 60-15
8 5

VDB29 GN-BU
HS3 CAN + MODULE
4 VDB30 WH-GN 14-10 COMMUNICATIONS
HS3 CAN - NETWORK
5
rear view camera
navigation
C02123B navigation
VME19 WH-GN GN
VIDEO +
6 2 RME19 BN-VT BU 145-8 145-9 PARKING AID
VIDEO -
12 4

navigation

AUDIO
VMN07 GY C0240A FRONT
NAV + CONTROL
NAV +
6 4 MODULE (ACM)
RMN07 VT 151-79 151-83
NAV - NAV -
GND GND 5
12

9 11 C02123A
C0263- 1 S222
GD216 BK-VT GD216 BK-VT GD216 BK-VT GD216 BK-VT
G0201
S206 10-39
Start/Stop Bus
MULTI-FUNCTION DISPLAY 2.0L
BODY
CONTROL
F33 MODULE (BCM)
20A 11-17
13-103

22 C02280A
SBP33
RD

7 C0265
SBP33
RD

1 C0240A

AUDIO
VBATT FRONT
CONTROL
MODULE (ACM)
151-79 151-83

C0240A VDB29 GN-BU

HS3 CAN + MODULE
14 COMMUNICATIONS
VDB30 WH-GN NETWORK
HS3 CAN - 14-10
15

GND

13 C0240A
BK-BU
GD214

G0200
10-37
MULTI-FUNCTION DISPLAY 2.0L

AUDIO
FRONT
CONTROL
MODULE (ACM)
151-79 151-83
AUDIO UNIT
ANTENNA
AMPLIFIER
151-116
C0219 - 1 C09021
C0240A CME13 YE-OG CME13 YE-OG
ANTENNA PWR
2 1 1
coaxial cable
AM/FM 3
2

without: SYNC

AUDIO
SHIELD INPUT
C0240A VME45 BU C02362 SOCKET
ST INPUT 2L+ ST INPUT 2L+ 151-79 151-83
17 4
RME45 YE-GN
ST INPUT 2L- ST INPUT 2L-
6 3
VME46 BU-GN
ST INPUT 2R+ ST INPUT 2R+
18 1
DME45
STEREO SHIELD
16
MULTI-FUNCTION DISPLAY 2.0L
AUDIO
FRONT tweeter
CONTROL
MODULE (ACM) C0300
151-79 151-83 VME07 WH C09063
FRONT
32 1 TWEETER
RME07 WH-BN SPEAKER LH
151-87
40 3

WH-BN
VME07

RME07
WH
right hand drive

C0240A C0265 C0210 C0339 C0340 C0536

VME07 WH S247 VME07 BK
LF SPKR+
22 3 28 B14 B14 1
RME07 WH-BN RME07 BK
LF SPKR-
10 10 29 S290 B15 B15 4
FRONT DOOR
SPEAKER LH
151-106 151-109

right hand drive

S2000 C0340 C0339

VME10 WH-VT VME10 BK C0628
RF SPKR+
23 4 31 B14 B14 1
RME10 WH-OG RME10 BK
RF SPKR-
11 11 30 S2001 B15 B15 4
FRONT DOOR
SPEAKER RH
151-107 151-108

WH-OG

WH-VT
VME10
RME10

tweeter
C0311
VME10 WH-VT C09065
FRONT
32 1 TWEETER
RME10 WH-OG SPEAKER RH
151-88
40 3
MULTI-FUNCTION DISPLAY 2.0L

REAR SPEAKERS

AUDIO
FRONT
CONTROL
MODULE (ACM)
151-79 151-83

C0264 C0210 C0300 C09105 REAR

C0240A VME15 GN-BU VME15 GN-BU C09452 MIDDLE
LM SPKR+ SPEAKER LH
8 13 53 51 1 1 151-116
RME15 GY-BU RME15 GY-BU
LM SPKR-
20 14 54 52 2 3

C09453 REAR
C0240B VME16 VT-GY VME16 VT-GY MIDDLE
RM SPKR+
4 15 55 54 3 SPEAKER RH
1
RM SPKR- RME16 YE-GY RME16 YE-GY 151-116
17 16 56 55 4 3
MULTI-FUNCTION DISPLAY 2.0L

REAR SPEAKERS
C09106 C09450
VME09 WH-GN REAR
1 1 TWEETER
RME09 BN-YE SPEAKER
LH
AUDIO 3 3 151-99
FRONT
CONTROL
MODULE (ACM)
151-79 151-83

C09064 REAR
RME09 BN-YE SPEAKER LH
3 151-99
VME09 WH-GN

C0265 C0210 C0300

C0240A VME09 WH-GN VME09 WH-GN
LR SPKR+
21 2 40 33 1
RME09 BN-YE RME09 BN-YE
LR SPKR-
9 9 41 34 4

C09107 C09451
VME09 WH-GN REAR
1 1 TWEETER
RME09 BN-YE SPEAKER
RH
3 3 151-100

C09066 REAR
RME12 BN-BU SPEAKER RH
3 151-100
VME12 BN-WH

C0311
VME12 BN-WH VME12 BN-WH
RR SPKR+
24 5 43 33 1
RME12 BN-BU RME12 BN-BU
RR SPKR-
12 12 42 34 4
SYNC Start/Stop Bus
BODY 2.0L
CONTROL
F32 MODULE (BCM)
10A 11-17
13-103

9 C02280A

VT-RD
SBP32
6 C0264

VT-RD
SBP32
without navigation

SBP32 VT-RD SBP32 VT-RD

S207
1 C02383 1 C02398
MODULE GLOBAL POSITIONING
SYNC COMMUNICATIONS
MODULE [APIM] SYSTEM MODULE (GPSM)
VBATT NETWORK VBATT
151-79 151-83 151-79 151-83
VDB06 GY-OG C02398
UNIVERSAL MS CAN +
14-15 2
GY SERIAL 14-17 VDB07 VT-OG
USB BUS (USB) MS CAN -
MODULE 3
151-79 151-83

C02383 VDB04 WH-BU

HS1 CAN + MODULE
53 COMMUNICATIONS
VDB05 WH NETWORK
HS1 CAN - 14-11 GND
54

6 C02398
VDB29 GN-BU
HS3 CAN +

BK-VT
MODULE

GD216
16 COMMUNICATIONS
VDB30 WH-GN NETWORK
HS3 CAN - 14-10
17 S206

PWR PWR 1 C0263

GND GND
S222

37 38 C02383

BK-VT
GD216
GD214 BK-BU
G0201
S201 G0200 10-39
10-37
SYNC 2.0L
SYNC
MODULE [APIM]
AUDIO 151-79 151-83
FRONT
CONTROL
MODULE (ACM)
151-79 151-83

SHIELD
C0240B VME66 VT C02383
STEREO L+ STEREO L+
12 25
RME66 GN-WH
STEREO L- STEREO L-
25 26
VME67 VT-GY
STEREO R+ STEREO R+
13 23
RME67 BN-WH
STEREO R- STEREO R-
26 24
DME66
SHIELD
22

SHIELD
VME80 VT-GN
SYNC ALERT+ SYNC ALERT+
8 3
RME80 BU-GY
SYNC ALERT- SYNC ALERT-
21 4
DME80
SHIELD
21

MICROPHONE
151-116
SHIELD SHIELD
C09221 C0219
MIC + VMM13 YE-GN VMM13 YE-GN
MIC +
2 2 5
RMM13 BK RMM13 BK
MIC - MIC -
3 3 6
DMM45 DMM13 DMM13
SHIELD
4 29
SYNC 2.0L
SYNC
MODULE [APIM]
151-79 151-83

AUDIO
INPUT
SOCKET
151-79 151-83
SHIELD
C02362 VME45 BU C02383
ST INPUT 2L+ STEREO 2L+
4 45
RME45 YE-GN
ST INPUT 2L- STEREO 2L-
3 46
VME46 BU-GN
ST INPUT 2R+ STEREO 2R+
1 47
DME45
STEREO SHIELD
44
MULTI-FUNCTION DISPLAY 2.0L
CLUSTER AND PANEL ILLUMINATION
BK
71-10
2 C02999
STEERING WHEEL
SWITCH
RH UPPER
1) Right
2) Left
3) Down
1 4) Up
511 5) OK
151-86
2
301

3
182

4
STEERING WHEEL 121
SWITCH,
LH UPPER 5
60-10 68

3 C02998 1 4 3 C02999
BU-WH
S2012

BN
BU-WH S2010

BN-WH

BN
3 2 10 C0218B
CLOCKSPRING
151-85 151-86

5 C0218A

BK-GY
GD284
STEERING COLUMN
CONTROL
MODULE (SCCM)
151-85
S226

BK-GY
GD284
G0206
10-42
MULTI-FUNCTION DISPLAY 2.0L
CLUSTER AND PANEL ILLUMINATION
BK
71-10
1 C02367
STEERING WHEEL
SWITCH
1600 RH LOWER
1) Seek -
2) Seek +
3) Vol +
4) Vol -
5) Voice / Mute
1 151-86
348

2
220

3
140

4
88.7

5
53.6

3 2 4 C02367
GN

BN
YE
S2010

BN
12 11 10 C0218B
CLOCKSPRING
151-85 151-86

STEERING COLUMN
CONTROL
MODULE (SCCM)
151-85 8 7 5 C0218A

BK-GY
GD284
BU-WH

VME14
RME24

GY-YE

C02414 S226
AUDIO -
8

BK-GY
GD284
AUDIO +
7 G0206
10-42
ERA GLONASS
VEHICLE FRONT
EMERGENCY DOOR
MODULE SPEAKER LH
151-21 151-25 151-56 151-59
SHIELD
C2159A C264 C339
VME07 WH VME07 BK C536
LF SPKR+
AUDIO FRONT 11 1 A17 1
CONTROL RME07 WH-BN RME07 BK
MODULE (ACM) LF SPKR-
151-39 151-41 2 A18 4
12

SHIELD 3
C2159B
C240A VME07 WH
LF SPKR + LF SPKR+ 2
22 5
RME07 WH-BN
LF SPKR - LF SPKR-
10 6 FRONT
DOOR
VME10 WH-VT TWEETER
RF SPKR + RF SPKR+ SPEAKER LH
23 1 151-56 151-59
RME10 WH-OG C513
RF SPKR - RF SPKR- VME08 BK
11 2
1
RME08 BK
3

FRONT
DOOR
SPEAKER RH
151-57 151-58

C2159B C340
VME10 WH-VT VME10 BK C628
RF SPKR+
3 5 A17 1
RME10 WH-OG RME10 BK
RF SPKR-
4 6 A18 4

FRONT
DOOR
TWEETER
SPEAKER RH
151-57 151-58
VME11 BK C613
1
RME11 BK
AUDIO DME07 DME07 3
SHIELD
19 9
ERA GLONASS
Hot at Hot in
all times Run or Acc
BODY
CONTROL
F16 F21 MODULE (BCM)
20A 3A 11-6
13-39 13-49

11 2 C2280H

BU-GY
VT-RD

CBP21
SBP16

S299 S233
VT-RD

BU-GY
SBP16

CBP21

1 9 C2159A
VEHICLE
EMERGENCY
VBATT VPWR MODULE
151-21 MODULE
COMMUNICATIONS
NETWORK
14-2
C2159A VDB30 WH
I CAN -
16
VDB29 GN
I CAN +
8

SUPPLEMENTAL
RESTRAINT
SYSTEM
46-1
CR167 YE-VT
ENS
3
GND

13 C2159A

GD215 BK-GY
G201
10-14
ERA GLONASS VEHICLE
EMERGENCY
MODULE
151-21 151-25
EMERGENCY
CALL
SWITCH
151-58 CLUSTER
AND PANEL
ILLUMINATION
C9532 VLN04 VT-GY
71-2
5
C913 C248 C2159A
CMT18 VT-OG CMT18 VT-OG
ECALL
3 14 LIGHT
12 16
CMT10 BU-BN CMT10 BU-BN
ECALL
6 11 11 2 BUTTON
GD382 BK-GY S998

4 21

BK-GY
GD382
G302
SYNC 10-22
MODULE [APIM]
151-38 151-40

C2389A VMT02 GN-OG C2159B

MIC + MIC +
12 8
RMT02 BN-YE
MIC - MIC -
13 9

MICROPHONE
151-58
SHIELD SHIELD
C9221 C913 C260 C2159A
VMT06 YE VMT06 YE VMT06 YE
MIC + MIC +
2 17 17 4
RMT06 BU-OG RMT06 BU-OG RMT06 BU-OG
MIC - MIC -
3 18 18 5
DMT06 DMT06 DMT06 DMT06
SHIELD
16 16 6
Hot in Start REAR PARKING AID 2.2L
or Run
BODY
CONTROL
F4 MODULE (BCM)
5A 11-5
13-52

66 C2280D
CBP04
VT

69 C210

23 C311
CBP04
VT

1 C9071A
PARKING ASSIST
CONTROL
VPWR MODULE (PAM)
151-37

C9071A VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
6 NETWORK
VDB05 WH 14-4
HS CAN -
15

C913
REAR CMP09 BN-BU CMP09 BN-BU C9074 REAR
SOUNDER + PARKING AID
10 9 2 SPEAKER
REAR RMP09 BU-GN RMP09 BU-GN 151-49
SOUNDER -
2 8 1
GND

8 C9071A
BK-BU
GD352

S923
BK-BU
GD352

G405
10-30
PARKING ASSIST
CONTROL
REAR PARKING AID 2.2L
MODULE (PAM)
151-37

C9071C VMP15 YE-GN

ROL SENSOR IN
5
RMP07 GN-WH
SENSOR GND
8
VMP14 WH-OG
RIL SENSOR IN
3
VMP16 YE-GY
RIR SENSOR IN
2
LMP07 BU-WH
SENSOR PWR
11

ROR SENSOR IN
4

VMP17
2 YE-OG 6 4 1 3 5 C431

S406

WH-OG
VMP17

VMP16

VMP14

VMP15
YE-OG

YE-GY

YE-GN
S407

1 2 3 4 5 6 C432
GN-WH

GN-WH
BU-WH

BU-WH
RMP07

RMP07
LMP07

LMP07
1 2 3 C4011 1 2 3 C4009

GN-WH

GN-WH
BU-WH

BU-WH
RMP07

RMP07
LMP07

LMP07
1 2 3 C4012 1 2 3 C4010
REAR OUTER REAR OUTER
PARKING AID PARKING AID
SENSOR RH SENSOR LH
151-41 151-41

REAR INNER REAR INNER

PARKING AID PARKING AID
SENSOR RH SENSOR LH/CENTER
151-41 151-41
FRONT PARKING AID 2.2L

PARKING
AID
PARKING ASSIST CLUSTER AND SWITCH
CONTROL PANEL ILLUMINATION 151-15 151-19
MODULE (PAM) CLN17 BN C2035
151-37 71-4
3

C9071A CMP18 GN-BN C311 CMP18 GN-BN C210 CMP18 GN-BN C2035
PARKING GD184 BK-GY
AID
SWITCH 4 7 62 6 2

PARKING CMP02 GN-BU CMP02 GN-BU CMP02 GN-BU

AID
INDICATION 13 58 61 1
LED GD184 BK-GY
S226
5

BK-GY
GD184
C9071B CMP08 GY-BN CMP08 GY-BN CMP08 GY-BN C2024 FRONT
FRONT SOUNDER + PARKING AID
4 59 64 2 SPEAKER
RMP08 VT-OG RMP08 VT-OG RMP08 VT-OG 151-14 151-18
FRONT SOUNDER -
3 8 63 1

G206
10-9 10-43
EARLY PRODUCTION FRONT PARKING AID 2.2L
PARKING ASSIST
CONTROL
MODULE (PAM)
151-37

C9071B VMP11 BU-GN

FOL SENSOR IN
5
RMP06 YE-OG
SENSOR GND
1
VMP10 WH-BU
FIL SENSOR IN
6
VMP12 BU-GY
FIR SENSOR IN
7
LMP06 VT-GY
SENSOR PWR
2

FOR SENSOR IN
8

VMP13
BU-OG
56 57 55 53 52 54 C311

1 6 3 2 5 4 C110

S196

WH-BU
VMP13
BU-OG

VMP12
BU-GY

VMP10

VMP11
BU-GN
S195

RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
LMP06

LMP06
LMP06

LMP06
1 2 3 C1431 1 2 3 C1430 1 2 3 C1429 1 2 3 C1428

FRONT OUTER FRONT INNER FRONT INNER FRONT OUTER

PARKING AID PARKING AID PARKING AID PARKING AID
SENSOR RH SENSOR RH SENSOR LH SENSOR LH
151-4 151-4 151-4 151-4
LATE PRODUCTION FRONT PARKING AID 2.2L
PARKING ASSIST
CONTROL
MODULE (PAM)
151-37

C9071B VMP11 BU-GN

FOL SENSOR IN
5
LMP06 VT-GY
SENSOR PWR
2
VMP10 WH-BU
FIL SENSOR IN
6
VMP12 BU-GY
FIR SENSOR IN
7
RMP06 YE-OG
SENSOR GND
1
52 55 53 57 54 C311
FOR SENSOR IN
8

VMP13
BU-OG
5 3 2 6 4 C110

56 C311

RMP06
YE-OG

VT-GY
LMP06
1 C110

S196

WH-BU
VMP13
BU-OG

VMP12
BU-GY

VMP10

VMP11
BU-GN
S195

RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
LMP06

LMP06
LMP06

LMP06
1 2 3 C1431 1 2 3 C1430 1 2 3 C1429 1 2 3 C1428

FRONT OUTER FRONT INNER FRONT INNER FRONT OUTER

PARKING AID PARKING AID PARKING AID PARKING AID
SENSOR RH SENSOR RH SENSOR LH SENSOR LH
151-4 151-4 151-4 151-4
Hot in Start PARKING AID CAMERA 2.2L
or Run
AUXILIARY
JUNCTION
BOX (AJB)
F29 11-1
10A
13-20

without: lane departure warning

CB129 WH-VT POWER

DISTRIBUTION
13-20
WH-VT
CB129

S272 lane departure warning

28 C300
WH-VT
CB129

4 C9058

IMAGE
PROCESSING
VPWR MODULE B (IPMB)
151-36

C9058 VDB06 GY-OG MODULE

MS CAN + COMMUNICATIONS
2 NETWORK
VDB07 VT-OG 14-6
MS CAN -
3 REAR
rear doors rear doors PARKING AID
CAMERA
151-44 151-45
WH WH

VMP24 WH C935 VMP24 BK C422 C406 VMP24 BK C495 C494 VMP24 WH C4357
LIN LIN
6 6 6 6 6 6 2
SMP22 YE-VT SMP22 BK SMP22 BK SMP22 YE-VT
POWER POWER
8 8 8 8 5 5 1
GND YE-VT YE-VT

1 C9058
GD133
BK

G300
10-11
PARKING AID CAMERA Hot in Start
2.2L
or Run
AUXILIARY
JUNCTION
F29 BOX (AJB)
10A 11-1
13-20

without: lane departure warning

CB129 WH-VT POWER

DISTRIBUTION
13-20

S272 lane departure warning

WH-VT
CB129
lane departure warning

S910 C913 C311

CB129 WH-VT CB129 WH-VT CB129 WH-VT
6 28
1 C911

AUTO-DIMMING
INTERIOR
VPWR MIRROR
151-50

Hot in reverse
C911 CLS10 GN-BN S919 CLS10 GN-BN CLS10 GN-BN REVERSING LAMPS
REVERSE 93-1
2 5 13

SHIELD SHIELD SHIELD

VMP19 WH-GN VMP19 WH-GN VMP19 WH-GN

VIDEO + A 131-8
4 3 19
RMP19 BN-VT RMP19 BN-VT RMP19 BN-VT
VIDEO - B 131-8 PARKING
5 2 27 AID

DMP22 DMP22 DMP22

C 131-8
1 20
GND

3 C911
GD140 BK-GN S909 GD140 BK-GN GD140 BK-GN GD140 BK-GN
7 22 G306
10-19
PARKING AID CAMERA 2.2L

REAR
PARKING AID
CAMERA
151-44 151-45

SHIELD SHIELD SHIELD SHIELD

PARKING rear doors rear doors
AID
C300 C935 C422 C406 C495 C494
VMP19 VMP19 VMP22 C4357
131-7 A VIDEO +
WH-GN 19 7 7 7 WH-GN 8 8 BU-BN 4

RMP19 RMP19 VMP23

131-7 B VIDEO -
BN-VT 27 10 10 10 BN-VT 9 9 BN-GN 3

DMP22 DMP22 DMP22

131-7 C SHIELD
20 5 5 5 10 10 BK 6

GD140 BK-GN GD140 BK-GN GD140 BK GD140 BK RMP19 BN-VT

RETURN
8 4 4 4 7 7 5
BK-GN BK-GN

G306
10-19
LANE DEPARTURE WARNING
2.2L
Hot in Start Hot at
or Run all times
AUXILIARY BODY
JUNCTION CONTROL
BOX (AJB) MODULE (BCM)
F29 11-1 F18 11-5
10A 10A
13-20 13-47
LIN 1 SWM

69 C2280D 35 C2280D
WH-VT
CB129

SBP18 YE-RD POWER

DISTRIBUTION
13-47
S272

VDN05
YE-GY
YE-RD
SBP18
22 C210
WH-VT
CB129

9 1 C2414

STEERING
COLUMN
VPWR VBATT CONTROL
MODULE (SCCM)
151-22

C2414 VDN05 YE-GY

LIN 1 SWM S216
11
VDN05 YE-GY
LIN 1 SWM
2
SENSOR LANE DEPARTURE WARNING

VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
4 NETWORK
VDB05 WH 14-3
HS CAN -
GND GND 5

10 14 C2414
GD165

GD165
BK

GD165 BK

S219 G205
10-8
LANE DEPARTURE WARNING
Hot in Start
2.2L
or Run
AUXILIARY
JUNCTION
BOX (AJB)
F29 11-1
10A
13-20

S272

WH-VT
CB129

28 C311
WH-VT
CB129

6 C913
WH-VT
CB129

S910 parking aid camera

12 C919
WH-VT
CB129

1 C9039

IMAGE
PROCESSING
VPWR MODULE A (IPMA)
151-50

C9039 VDB04 WH-BU MODULE

HS CAN + COMMUNICATIONS
3 NETWORK
VDB05 WH 14-4
HS CAN -
4

GND

5 C9039 C919 - 7 S909 C913 - 7 C311 - 22

GD140 BK-BU GD140 BK-GN GD140 BK-GN
G306
10-19
TAPED TO HARNESS NEAR T/O TO C145 M
Not used 2.2L
9 C133 without: fuel fired booster heater
without: trailer tow

BU-OG
CBB31

ZA009

ZA010
BK

BK
S152

14 21 C145

BU-OG
CBB31

ZA101

ZA102
OG

BK
1 C134

Not used

TAPED TO HARNESS IN T/O TO C145 F

TAPED TO HARNESS IN T/O TO C139 M

without: rear window wipers

ZA006

ZA003

ZA007

ZA004

ZA008

ZA005

TAPED TO HARNESS IN T/O TO C192 M

without: anti-theft alarm system

15 14 17 21 26 44 C139

ZA001

ZA002

ZA011
BK

BK
CRW02
GY-BU

ZA101

ZA101
BK

1 2 12 C192
TAPED TO HARNESS IN T/O TO C139 F

ZA101

ZA102

ZA103
BK

BK
BATTERY
JUNCTION
BOX (BJB)
REAR WINDOW 11-3
2 WIPER
RELAY TAPED TO HARNESS IN T/O TO C192 F
81-5
EMERGENCY SERVICES
2.2L
Hot at Hot at
all times all times
SVO ANTI-LOCK
AUXILIARY BRAKE SYSTEM
F9 F2 FUSE (ABS) MODULE
20A 20A PANEL 42-3
13-62 13-60 11-9
VSO

2 C135

VMC05
VT-OG
1 C3665

YE-RD
SBF09

SBF02
RD

VMC05
VT-OG
K C2238
1 C3438
Not used S C2238
2 WAY
RADIO
151-58 151-59

VMC05
VT-OG
31 C2237

2 C3438 Not used

BK-WH
GD285

S3011
BK-WH
GD285

G310
10-23
Hot in Start Hot at EMERGENCY SERVICES 2.2L
or Run all times
AUXILIARY SVO
JUNCTION AUXILIARY
F21 BOX (AJB) FUSE
10A F4
11-1 20A PANEL
13-15 11-9
BU-GY 13-61
CB121

4 C3665

M C2238

GN-RD
SBF04
Not used

8 C2239
N C2238
GY-VT
CAP19
BU-GY
CB121

SVO
AUXILIARY
IGNITION FUSE
1 3 RELAY PANEL
11-9
F10 F11 F12
5A 15A
2 5
13-61 13-61

CDC21 BU

YE-OG
CRB10

CRB11
BN
BK-WH
GD285

A J C2238

Not used
S3012 S245
CRB11

CRB11

CRB11
BN

BN
BK-WH
GD285

SUPPLEMENTARY
FUSE BOX
F9 F10 F11 F12 11-10
5A 5A 10A 5A
13-61 13-61 13-61 13-61

S3011

GN-WH
VT-GY

YE-OG
CBS09

CBS10

CBS11

CBS12
BK-WH

BN
GD285

15 16 17 18 C2237
G310
13-24 Not used Not used Not used Not used
EMERGENCY SERVICES
2.2L
Hot at Hot at
all times all times
SVO
F1 F3 AUXILIARY
3A 20A FUSE
13-60 13-60 PANEL
11-9

S3012 S3011

G310

BU-RD
BK-WH

SBF03
GD285
10-23

SVO
AUXILIARY
BEACON FUSE
2 3 RELAY PANEL
11-9

1 5
SBF01

VT-GY

GY-YE
CAP02

CAP01
RD

9 6 1 C2239
CLUSTER AND
PANEL ILLUMINATION
71-7 S9001 C9411
CAP01 GY-YE
2
if equipped

GY-YE

GY-YE
CAP01

CAP01
S9004

2 C9089 2 C9090
VT-GY
CLN17

CAP02
SBF01

FRONT REAR
BN

BEACON BEACON
151-61 151-61
8 2 1 C9434

BEACON
SWITCH
151-61 1 C9089 1 C9090

BK-WH

BK-WH
GD285

GD285
4 C9434 GD285 BK-WH
1
C2239 - 2 S3011
GD285 BK-WH GD285 BK-WH GD285 BK-WH

S9002 G310
10-23
EMERGENCY SERVICES AUXILIARY HEATER
2.2L
Hot at BODY Hot at
all times CONTROL all times
SVO ENGINE MODULE (BCM) SVO
AUXILIARY RUN 11-5 AUXILIARY
FUSE STATUS F5 FUSE
F1 PANEL
3A PANEL 15A
11-9 13-62 11-9
13-60
11 C2280C

BN-YE
CE607

GY-RD
SBF05
S292

BN-YE
CE607

3 C3665
SBF01

SVO
RD

AUXILIARY
38 C2237 WATER FUSE
2 3 HEATER PANEL
RELAY 11-9
Not used

1 5

9 C2239
SBF01

WH-BU
CAA10

BN-VT

BN-VT
CAE03

CAE03
RD

CLUSTER AND
PANEL ILLUMINATION H C2238
71-7 4 7 C2239

BN-VT
CAE03
S9004

1 C9439A

WATER
WH-BU
CAA10
CLN17

CAE03
SBF01

HEATER
151-62
RD

2 8 1 6 C9435

WATER 1 C9439B
HEATER

BK-WH
SWITCH

GD285
151-62

4 C9435 E C2238
GD285 BK-WH GD285 BK-WH C2239 - 2 GD285 BK-WH GD285 BK-WH
G310
S9002 S3011 10-23
EMERGENCY SERVICES UTILITY PACKAGE 2.2L
Hot at Hot at
all times all times
SVO SVO
AUXILIARY AUXILIARY
F1 FUSE F7 FUSE
3A PANEL 15A PANEL
13-60 11-9 11-9
13-62

S3012 S3011
S3013
G310

BK-WH

WH-RD
10-23

GD285

SBF07
SBF01

SVO
RD

AUXILIARY
AUXILIARY FUSE
2 3 RELAY 1 PANEL
11-9

1 5

9 C2239

GN-OG
CAP18
CLS20 BN-BU
SBF01

R C2238
RD

CLUSTER AND

ZA101
PANEL ILLUMINATION

OG
71-7

1 C9441
10 C2239
S9004
AUXILIARY
POWER
SOCKET 1
151-63
GN-OG
CLN17

CAP18
SBF01

2 C9441
RD

OG-YE
ZA102
2 8 1 C9436

AUXILIARY S9020
SWITCH 1
151-63

OG-YE
ZA102
4 C9436 E C2238
GD285 BK-WH GD285 BK-WH C2239 - 2 GD285 BK-WH GD285 BK-WH
G310
S9002 S3011 10-23
EMERGENCY SERVICES UTILITY PACKAGE 2.2L
Hot at BODY Hot at
all times CONTROL all times
SVO MODULE (BCM) SVO
AUXILIARY ENGINE RUN 11-5 AUXILIARY
F1 FUSE STATUS F5 FUSE
3A PANEL 15A PANEL
13-60 11-9 13-62 11-9
11 C2280C

BN-YE
CE607

GY-RD
SBF05
S292
BN-YE
3 C3665
CE607
SBF01
RD

SVO
AUXILIARY
38 C2237 AUXILIARY FUSE
2 3 RELAY 2 PANEL
Not used 11-9

1 5

9 C2239

CAE03 BN-VT

H C2238
SBF01

WH-BU
CAA10

BN-VT
CAE03
RD

CLUSTER AND

OG-BU
ZA103
PANEL ILLUMINATION
71-7 4 7 C2239

1 C9442
S9004
AUXILIARY
POWER
SOCKET 2
151-63
GY-VT

BN-VT
CLN17

CAE03
CAP19
SBF01

2 C9442
RD

OG-GN
ZA104
2 8 1 6 C9437

AUXILIARY S9020
SWITCH 2
151-63

OG-YE
ZA102
4 C9437 E C2238
GD285 BK-WH GD285 BK-WH C2239 - 2 GD285 BK-WH GD285 BK-WH
G310
S9002 S3011 10-23
EMERGENCY SERVICES ROOF MOUNTED TURN SIGNALS 2.2L
Hot at Hot at
all times all times
BODY SVO
CONTROL AUXILIARY
MODULE (BCM) F7 FUSE
F14 PANEL
11-5 15A
25A 11-9
13-43 13-62

MICRO

WH-RD
SBF07
60 C2280C
GY-OG
CLS23

S3013
S255

G C2238

WH-RD
GY-OG
CLS23

SBF07
SVO
AUXILIARY
TURN FUSE
1 3 SIGNAL PANEL
RELAY 11-9
LH S248 GD285 BK-WH
2 5 G207
10-10

BK-WH
GD285
BN-BU
CLS20

SUPPLEMENTARY
BK-WH
GD285

FUSE BOX
F13 11-10
20A
10-10
S3012 R C2238

BK-WH
BN-BU

GD285
CLS20
BK-WH
GD285

28 6 C2237

S3011
ROOF MOUNTED
BN-WH
CLS24

BK-WH
INDICATORS

GD285
LHS
BK-WH

151-64
GD285

C9091 C9091 GD285 BK-WH

G310 1 2 S9014
13-24
EMERGENCY SERVICES ROOF MOUNTED TURN SIGNALS
2.2L
Hot at Hot at
all times all times
BODY SVO
CONTROL AUXILIARY
MODULE (BCM) F7 FUSE
F14
11-5 15A PANEL
25A
13-43 13-62 11-9

MICRO

WH-RD
SBF07
62 C2280C
GN-OG
CLS27

S3013
S284

F C2238

WH-RD
GN-OG
CLS27

SBF07
SVO
AUXILIARY
TURN FUSE
1 3 SIGNAL PANEL
RELAY 11-9
RH S248 GD285 BK-WH
2 5 G207
10-10

BK-WH
GD285
BN-WH
CLS24
BK-WH

SUPPLEMENTARY
GD285

FUSE BOX
F13
20A 11-10
10-10
S3012 P C2238
BN-WH

BK-WH
GD285
CLS24
BK-WH
GD285

29 6 C2237

S3011
ROOF MOUNTED
BN-BU
CLS20

BK-WH
INDICATORS

GD285
RHS
BK-WH

151-64
GD285

C9092 C9092 GD285 BK-WH

G310 1 2 S9014
13-24
EMERGENCY SERVICES 2.2L
Hot at
all times
SVO
AUXILIARY
F6 FUSE
15A PANEL
13-62 11-9

Not used

5 C2239

BN-RD
SBF06
CLF20
WH
SVO
AUXILIARY
WORK FUSE
2 3 LAMP PANEL
RELAY 11-9

1 5

BK-WH
GD285

WH-BU
CRB06
L C2238
S3012
Not used
BK-WH
GD285

S3011
BK-WH
GD285

G310
13-24
EMERGENCY SERVICES
2.2L
Hot at Hot at
all times all times
BODY SVO
CONTROL AUXILIARY
MODULE (BCM) F8 FUSE
F15 PANEL
11-5 10A
25A 11-9
13-44 13-62

MICRO

13 C2280B
YE-VT

VT-RD
CLS04

SBF08
S281
YE-VT
CLS04

B C2238
GN-VT
CLN01

SVO
AUXILIARY
INTERIOR FUSE
1 3 LAMP PANEL
RELAY 11-9

2 5
BK-WH

VT-WH
CLN08
GD238

C D C2238
BK-WH

VT-WH
CLN08
GD285

S248 1 C2237
BK-WH
GD285

Not used

G207
10-10
EMERGENCY SERVICES
2.2L
Hot at Hot at
all times all times
HIGH CURRENT
BATTERY
F12 F14 JUNCTION
60A 60A BOX (BJB)
13-59 11-7
13-59

1 C3670P 1 C3670S

GY-RD
GN-RD

SBF13
SBF12 S246 S247

GY-RD

GY-RD
GN-RD

GN-RD

SBF13

SBF13
SBF12

SBF12

SBF12
SUPPLEMENTARY
FUSE BOX
F1 F2 F6 F7 F8 F3 F4 F5 11-10
10A 5A 7.5A 10A 7.5A 10A 7.5A 7.5A
13-59 13-59 13-59 13-59 13-59 13-59 13-59 13-59
WH-RD

GN-RD

GY-RD
BU-RD
BN-RD
YE-RD

VT-RD

SBS03

SBS04

SBS05
SBS01

SBS02

SBS06

SBS07

SBS08
RD

7 8 12 13 14 9 10 11 C2237

Not used Not used Not used Not used Not used Not used Not used Not used
EMERGENCY SERVICES
2.2L
roof mounted turn signals
ROOF MOUNTED
INDICATORS
LHS
140-8
C9091 GD285 BK-WH
2

ROOF MOUNTED
INDICATORS
RHS
140-9
C9092 GD285 BK-WH S9014

BK-WH
GD285
SVO
AUXILIARY
FUSE Not used Not used Not used Not used
PANEL
11-9
6 5 3 4 2 C2237

INTERIOR
LAMP RELAY
140-11

BK-WH

BK-WH
GD285

GD285

GD285
2

SUPPLEMENTARY
FUSE BOX
F13 F14 F15 F16 F17 11-10
BK-WH
GD238

20A 20A 20A 20A 20A

10-10 10-10 10-10 10-10 10-10

C C2238
BK-WH

BK-WH

BK-WH
GD285

GD285

GD285
BK-WH
GD285

S248
BK-WH
GD285

G207
10-10
EARLY PRODUCTION Hot in Start
or Run 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F48 11-11
10A
HEATING, 13-77
ANTI-LOCK VENTILATION AND
BRAKE SYSTEM AIR CONDITIONING (HVAC)
(ABS) MODULE CONTROL MODULE
42-6 54-16

VS0 START/STOP
DISABLE
SWITCH

2 C0135
29 C02357A
BODY
CONTROL
MODULE (BCM)
11-17

VT-GY
CE937
CLUSTER AND
PANEL ILLUMINATION
71-12
ENGINE RUN

14 C0210
34 C02280F
VMC05
VT-OG

VT-GY

GY-YE
BN-YE
CLN17

CB148
CE937

CE607
BN

1 2 3 4 5 6 7 8 C03665

VSO ILLUM START/STOP ENGINE RUN VPWR GND

DISABLE
SWITCH

BK-GY
GD382
G0305
10-50
LATE PRODUCTION
Hot in Start
or Run
Hot at
all times 2.0L
AUXILIARY
JUNCTION
BOX (AJB)
F48 F58 11-11
HEATING, 10A 15A
ANTI-LOCK VENTILATION AND 13-72 13-79
BRAKE SYSTEM AIR CONDITIONING (HVAC)
(ABS) MODULE CONTROL MODULE
42-6 54-13

VS0 START/STOP
DISABLE
SWITCH

2 C0135
4 C02357A

BODY
CONTROL
MODULE (BCM)

VT-GY
CE937
11-17

CLUSTER AND
PANEL ILLUMINATION
71-11
ENGINE RUN
24 C0210

34 C02280F
VMC05
VT-OG

VT-GY

GY-YE
BN-YE

YE-RD
CLN17

CB148
CE937

CE607

SB158
BN

5 7 4 3 2 6 7 1 C03665

VSO ILLUM START/STOP ENGINE RUN VPWR GND

DISABLE
SWITCH

BK-GY
GD382
G0305
10-49
Hot in Start
or Run REAR PARKING AID 2.0L
BODY
CONTROL
F36 MODULE (BCM)
15A 11-17
13-101

8 C02280C

BU-BN
CBP36

23 C0311

S930
BU-BN
CBP36

1 C09071A
PARKING
ASSIST
VPWR CONTROL
MODULE (PAM)
151-100

C09071A VDB04 WH-BU MODULE

HS1 CAN + COMMUNICATIONS
6 NETWORK
VDB05 WH 14-12
HS1 CAN -
15

C0913
CMP09 BN-BU CMP09 BN-BU C09074 REAR
REAR SOUNDER + PARKING AID
10 9 2 SPEAKER
RMP09 BU-GN RMP09 BU-GN 151-115
REAR SOUNDER -
2 3 1
GND

8 C09071A
BK-GN
GD308

S923
BK-GN
GD308

G0405
10-63
PARKING ASSIST
CONTROL
REAR PARKING AID 2.0L
MODULE (PAM)
151-100

C09071C VMP15 YE-GN

ROL SENSOR IN
5
RMP07 GN-WH
SENSOR GND
8
VMP14 WH-OG
RIL SENSOR IN
3
VMP16 YE-GY
RIR SENSOR IN
2
LMP07 BU-WH
SENSOR PWR
11

ROR SENSOR IN
4

VMP17
YE-OG
2 6 4 1 3 5 C0431

S406

WH-OG
VMP17

VMP16

VMP14

VMP15
YE-OG

YE-GY

YE-GN
S407

1 2 3 4 5 6 C0432
GN-WH

GN-WH
BU-WH

BU-WH
RMP07

RMP07
LMP07

LMP07
1 2 3 C04011 1 2 3 C04009

GN-WH

GN-WH
BU-WH

BU-WH
RMP07

RMP07
LMP07

LMP07
1 2 3 C04012 1 2 3 C04010
REAR OUTER REAR OUTER
PARKING AID PARKING AID
SENSOR RH SENSOR LH
151-105 151-105

REAR INNER REAR INNER

PARKING AID PARKING AID
SENSOR RH SENSOR LH/CENTER
151-105 151-105
FRONT PARKING AID 2.0L

PARKING
AID
PARKING ASSIST CLUSTER AND SWITCH
CONTROL PANEL ILLUMINATION 151-78 151-82
MODULE (PAM) CLN17 BN C02035
151-100 71-11
3

C09071A CMP18 GN-BN C0312 CMP18 GN-BN C0268 CMP18 GN-BN C02035
PARKING GD284 BK-GY
AID
SWITCH 4 5 17 6 2

BK-GY
GD284
PARKING CMP02 GN-BU CMP02 GN-BU CMP02 GN-BU
AID
INDICATION 13 11 18 1
LED
S226
5

BK-GY
GD284
C0210
C09071B CMP08 GY-BN CMP08 GY-BN CMP08 GY-BN C02024 FRONT
FRONT SOUNDER + PARKING AID
4 12 64 1 SPEAKER
RMP08 VT-OG RMP08 VT-OG RMP08 VT-OG 151-77 151-81
FRONT SOUNDER -
3 6 63 2

G0206
10-42
FRONT PARKING AID
2.0L
PARKING ASSIST
CONTROL
MODULE (PAM)
151-100

C09071B VMP11 BU-GN

FOL SENSOR IN
5
RMP06 YE-OG
SENSOR GND
1
VMP10 WH-BU
FIL SENSOR IN
6
VMP12 BU-GY
FIR SENSOR IN
7
LMP06 VT-GY
SENSOR PWR
2

FOR SENSOR IN
8

VMP13
BU-OG
58 54 57 55 59 56 C0311

1 9 3 2 10 4 C0110

S196

WH-BU
VMP13
BU-OG

VMP12
BU-GY

VMP10

VMP11
BU-GN
S195

RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
RMP06

RMP06
VT-GY

YE-OG

VT-GY

YE-OG
LMP06

LMP06
LMP06

LMP06
1 2 3 C01431 1 2 3 C01430 1 2 3 C01429 1 2 3 C01428

FRONT OUTER FRONT INNER FRONT INNER FRONT OUTER

PARKING AID PARKING AID PARKING AID PARKING AID
SENSOR RH SENSOR RH SENSOR LH SENSOR LH
151-67 151-67 151-67 151-67
PARKING AID CAMERA Hot in Start
or Run 2.0L
AUXILIARY
JUNCTION
WITHOUT STOP AND START F44
BOX (AJB)
11-11
10A
13-75

BODY
CONTROL
MODULE (BCM)
11-17
LIN 4

CB144
VT
37 C02280E
VT-WH
VDN04

S263 C02513 BK C02513

5 7

S137
CDC78
VT-BN
VT-WH
VDN04

53 28 C0300

rear doors rear doors

VT-WH
VDN04

CDC78
VT-BN

C0422 - 8 C0495 - 5 REAR

PARKING AID
CAMERA
C0935 CDC78 BK C0406 - 8 CDC78 BK C0494 - 5 SMP22 YE-VT C04357 151-110 151-111
VPWR
8 1

rear doors rear doors

C0422 - 6 C0495 - 6

VDN04 BK C0406 - 6 VDN04 BK C0494 - 6 VMP24 WH

LIN 4
6 2
PARKING AID CAMERA Hot in Start
or Run 2.0L
AUXILIARY
JUNCTION
STOP AND START F44
BOX (AJB)
11-11
10A
13-75

BODY
CONTROL
MODULE (BCM)
11-17
LIN 4

CB144
VT
37 C02280E LOW VOLTAGE
DIRECT CURRENT/
DIRECT CURRENT
(DC/DC) CONVERTER
40-3 40-6
VT-WH
VDN04

S263 C02513 C02513

5 7

S137
CDC78
VT-BN
VT-WH
VDN04

53 28 C0300

rear doors rear doors

VT-WH
VDN04

CDC78
VT-BN

C0422 - 8 C0495 - 5 REAR

PARKING AID
CAMERA
C0935 CDC78 BK C0406 - 8 CDC78 BK C0494 - 5 SMP22 YE-VT C04357 151-110 151-111
VPWR
8 1

rear doors rear doors

C0422 - 6 C0495 - 6

VDN04 BK C0406 - 6 VDN04 BK C0494 - 6 VMP24 WH

LIN 4
6 2
Start/Stop Bus
PARKING AID CAMERA 2.0L
BODY
CONTROL
F32 MODULE (BCM)
10A 11-17
13-103

9 C02280A

VT-RD
SBP32
6 C0264

S207
VT-RD
SBP32

1 C02123A

FRONT CONTROL/
VBATT DISPLAY INTERFACE
MODULE (FCDIM)
151-79 151-83 MESSAGE
CENTER
MFD C02123A VMC49 VT-GY C0253 SWITCH
MFD
SELECT SELECT 60-15
8 5

VDB29 GN-BU
HS3 CAN + MODULE
4 VDB30 WH-GN 14-10 COMMUNICATIONS
HS3 CAN - NETWORK
5

navigation

AUDIO
VMN07 GY C0240A FRONT
NAV + CONTROL
NAV +
6 4 MODULE (ACM)
RMN07 VT 130-18
NAV - NAV -
GND GND 5
12

9 11 C02123A
C0263- 1 S222
GD216 BK-VT GD216 BK-VT GD216 BK-VT GD216 BK-VT
G0201
S206 10-39
PARKING AID CAMERA 2.0L
WITHOUT NAVIGATION

REAR
PARKING AID
CAMERA
FRONT CONTROL/ 151-110 151-111
DISPLAY INTERFACE
MODULE (FCDIM)
151-79 151-83

SHIELD SHIELD SHIELD SHIELD SHIELD

rear doors rear doors

C02123A C0313 C0935 C0422 C0406 C0495 C0494

VMP19 VMP19 VMP22 C04357
VIDEO + VIDEO +
6 WH-GN 1 7 7 7 BK 8 8 BU-BN 4
or
WH-GN

RMP19 RMP19 VMP23

VIDEO - VIDEO -
12 BN-VT 2 10 10 10 BK 9 9 BN-GN 3
or
BN-VT

DMP22 DMP22 DMP22

SHIELD
3 5 5 5 10 10 BK 6

C0300 - 8
GD216 BK-VT GD214 BK-BU GD214 BK GD214 BK RMP19 BN-VT
RETURN
4 4 4 7 7 5

G0201
10-38 10-39
PARKING AID CAMERA 2.0L
NAVIGATION

REAR
PARKING AID
CAMERA
FRONT CONTROL/ 151-110 151-111
DISPLAY INTERFACE
MODULE (FCDIM)
151-79 151-83

SHIELD SHIELD SHIELD SHIELD SHIELD

rear doors rear doors

C02123B C0313 C0935 C0422 C0406 C0495 C0494

VMP19 VMP19 VMP19 VMP22 C04357
VIDEO + VIDEO +
2 GN 1 WH-GN 7 7 7 BK 8 8 BU-BN 4
or
WH-GN

RMP19 RMP19 RMP19 VMP23

VIDEO - VIDEO -
4 BU 2 BN-VT 10 10 10 BK 9 9 BN-GN 3
or
BN-VT

DMP22 DMP22 DMP22 DMP22

SHIELD
3 5 5 5 10 10 BK 6

C0300 - 8
GD216 BK-VT GD214 BK-BU GD214 BK GD214 BK RMP19 BN-VT
RETURN
4 4 4 7 7 5

G0201
10-39
LANE DEPARTURE WARNING 2.0L
Hot in Start or Run Start/Stop Bus
BODY
CONTROL
MODULE (BCM)
F36 F13 11-17
15A 7.5A
13-101 13-102
HS1 CAN - HS1 CAN +

15 8 C02280A 9 10 C02280G

WH-BU
VDB05

VDB04
GY-RD
SBP13

WH
S244

GY-RD
BU-BN
CBP36

SBP13

9 1 C02414
MODULE
STEERING COLUMN COMMUNICATIONS
CONTROL NETWORK
VPWR VBATT MODULE (SCCM) 14-11
151-85

MULTIFUNCTION SWITCH

C02414 VDB25 GN-OG MODULE

HS2 CAN + COMMUNICATIONS
4 NETWORK
VDB26 GY-BU 14-14
HS2 CAN -
5
GND GND

10 14 C02414
GD265

GD265
BK

S219
GD265
BK

G0205
10-41
LANE DEPARTURE WARNING 2.0L

HAPTIC
FEEDBACK
LANE
DEPARTURE
WARNING

6 5 4 C0218B
CLOCKSPRING
151-86

STEERING COLUMN
CONTROL
LIN LDW - MODULE (SCCM)
151-85
1A

LDW +
LANE DEPARTURE WARNING 2.0L
Hot in Start or Run
WITHOUT STOP AND START AUXILIARY
JUNCTION
F44 BOX (AJB)
10A 11-11
13-75

CB144
VT
C0192 - 1 S253 C02513 BK C02513
CDC78 BK CDC78 VT-BN
5 7
10 C01582

PROXIMITY WARNING
RADAR UNIT
VPWR 151-68

C01582 VDB25 BK
HS2 CAN + 14-12 MODULE
8 COMMUNICATIONS
VDB26 BK NETWORK
HS2 CAN - 14-12
7
AUTO-DIMMING
INTERIOR
MIRROR
124-10

C0192 C0311 C0913 C09012

VMF04 BK VMF04 BN-BU VMF04 BN-BU VMF04 BN-BU
CAN + CAN +
9 9 44 1 3
VMF05 BK VMF05 GY-BU VMF05 GY-BU VMF05 GY-BU
CAN - CAN -
18 10 45 2 4

GND

4 C01582
anti-theft alarm system

GD124 BK S185 GD124 BK GD124 BK-VT S131 GD124 BK-VT

6 G0109
10-35
LANE DEPARTURE WARNING 2.0L
Hot in Start or Run
STOP AND START AUXILIARY
JUNCTION
F44 BOX (AJB)
10A 11-11
13-75

LOW VOLTAGE
DIRECT CURRENT/

CB144
DIRECT CURRENT

VT
(DC/DC) CONVERTER
40-3 40-6

C0192 - 1 S253 C02513 C02513

CDC78 BK CDC78 VT-BN
5 7
10 C01582

PROXIMITY WARNING
RADAR UNIT
VPWR 151-68

C01582 VDB25 BK
HS2 CAN + 14-12 MODULE
8 COMMUNICATIONS
VDB26 BK NETWORK
HS2 CAN - 14-12
7
AUTO-DIMMING
INTERIOR
MIRROR
124-10

C0192 C0311 C0913 C09012

VMF04 BK VMF04 BN-BU VMF04 BN-BU VMF04 BN-BU
CAN + CAN +
9 9 44 1 3
VMF05 BK VMF05 GY-BU VMF05 GY-BU VMF05 GY-BU
CAN - CAN -
18 10 45 2 4

GND

4 C01582
anti-theft alarm system

GD124 BK S185 GD124 BK GD124 BK-VT S131 GD124 BK-VT

6 G0109
10-35
FordEtis

Home Vehicle Information Diagnostic Services FordService Training Search

Information Summary Mechanical Repairs Body & Paint Wiring Diagrams Check Sheets

Welcome

Custom 2012, 2.0 EcoBlue (130PS/180PS), Shadow Black (Mica)

2013 TRANSIT
EURO Location Components Connectors Splices Grounds Harnesses

Index
Harnesses
10A933 12B637 12B637 12B637 12B637 12B637
Wiring harness Wiring harness Wiring harness (2.0L) (2.0L) (2.0L)
- Beacon and - Engine - Engine Wiring harness - Wiring harness - Wiring harness -
roof flasher Engine Engine Engine
jumper
12B637 12B637 13B472 13B472 13B472 13B472
(Automatic Wiring harness (rear doors - (rear doors - (liftgate - 2.0L) (rear doors)
transmission - - Engine 2.0L) 2.0L) Wiring harness - Wiring harness -
2.0L) Wiring harness Wiring harness - Rear high mount Rear high mount
Wiring harness - Rear high Rear high mount lamp jumper lamp jumper
- Engine mount lamp lamp jumper
jumper
13B472 13B472 13B472 13B551 13B551 13B576
(rear doors) (liftgate) Wiring harness (rear doors - (late production: (2.0L)
Wiring harness Wiring harness - Roof mounted 2.0L) high roof) Wiring harness -
- Rear high - Rear high turn signals Wiring harness - Wiring harness - Trailer tow
mount lamp mount lamp High mounted High mounted jumper
jumper jumper stoplamp stoplamp
13B576 13B576 13B576 14301 14301 14303
Wiring harness Wiring harness (2.0L) (LHD - 2.0L) (RHD - 2.0L) Wiring harness -
- Trailer tow - Trailer tow Wiring harness Wiring harness - Wiring harness - Engine ground
jumper jumper - Trailer tow Battery to Battery to ground
jumper ground
14303 14334 14334 14334 14334 14334
(2.0L) (Van (LHD - (Van (LHD - (Van (RHD - (Van (RHD - (Van - Low Roof
Wiring harness SWB without SWB without SWB without SWB without - (LWB / SWB
- Engine ground LED) - 2.0L) LED) - 2.0L) LED) - 2.0L) LED) - 2.0L) with LED) - 2.0L)
Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Interior lamp - Interior lamp Interior lamp Interior lamp Interior lamp
feed feed feed feed feed
14334 14334 14334 14334 14334 14334
(Van - Low Roof (Van - Low (Van - Low (Van - High Roof (Van - High Roof (Double Cab in
- (LWB / SWB Roof - (LWB / Roof - (LWB / - (LWB / SWB - (LWB / SWB Van - 2.0L)
with LED) - SWB with LED) SWB with LED) with LED) - 2.0L) with LED) - 2.0L) Wiring harness -
2.0L) - 2.0L) - 2.0L) Wiring harness - Wiring harness - Interior lamp
Wiring harness Wiring harness Wiring harness Interior lamp Interior lamp feed
feed feed
- Interior lamp - Interior lamp - Interior lamp
feed feed feed
14334 14334 14334 14334 14334 14334
(Double Cab in (Double Cab in (Double Cab in ( Kombi - 2.0L) (Bus) ( Kombi - 2.0L)
Van - 2.0L) Van - 2.0L) Van - 2.0L) Wiring harness - Wiring harness - Wiring harness -
Wiring harness Wiring harness Wiring harness Interior lamp Interior lamp Interior lamp
- Interior lamp - Interior lamp - Interior lamp feed feed feed
feed feed feed
14334 14334 14334 14334 14334 14334
(Bus) (Van) (Van) (Van) (Van) ( Bus)
Wiring harness Wiring harness Wiring harness Wiring harness -
Wiring harness - Wiring harness -
- Interior lamp - Interior lamp - Interior lamp Interior lamp Interior lamp Interior lamp
feed feed feed feed feed feed
14334 14334 14334 14334 14334 14335
( Kombi) (Double Cab in ( Bus) ( Kombi) (Double Cab in (2.0L)
Wiring harness Van) Wiring harness Wiring harness -
Van) Wiring harness -
- Interior lamp Wiring harness - Interior lamp Interior lamp Wiring harness - Interior lamp
feed - Interior lamp feed feed Interior lamp
feed feed
14335 14335 14401 14401 14401 14401
Wiring harness Wiring harness Wiring harness Wiring harness - (LHD) (RHD)
- Interior lamp - Interior lamp - Main Main Wiring harness - Wiring harness -
Main Main
14401 14401 14401 14401 14401 14401
(LHD) (LHD) (RHD) (LHD) (RHD) (RHD)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Main - Main - Main Main Main Main
14401 14401 14401 14401 14401 14401
Wiring harness (LHD) (RHD) (LHD) Wiring harness - (RHD)
- Main Wiring harness Wiring harness Wiring harness - Main Wiring harness -
- Main - Main Main Main
14401 14401 14401 14401 14401 14401
(2.0L) (2.0L) (LHD) (LHD - 2.0L) (RHD - 2.0L) (RHD)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Main - Main - Main Main Main Main
14401 14401 14401 14401 14401 14401
(2.0L) (2.0L) (LHD - 2.0L) (RHD - 2.0L) (LHD - 2.0L) (LHD - 2.0L)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Main - Main - Main Main Main Main
14401 14401 14401 14401 14405 14405
(RHD - 2.0L) (LHD - 2.0L) (RHD - 2.0L) (RHD - 2.0L) Wiring harness - Wiring harness -
Wiring harness Wiring harness Wiring harness Wiring harness - Rear lamp Rear lamp
- Main - Main - Main Main
14405 14405 14406 14406 14406 14406
(2.0L) (2.0L) (2.0L) (2.0L) (2.0L) (2.0L)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Rear lamp - Rear lamp - Fuel tank Fuel tank sender Fuel tank sender Fuel tank sender
sender
14406 14406 14406 14517 14517 14659
Wiring harness Wiring harness Wiring harness (LHD) (RHD) Wiring harness -
- Fuel tank - Fuel tank - Fuel tank Wiring harness - Wiring harness - Auxiliary heater
sender sender sender Fuse holder Fuse holder
jumper jumper
14659 14A005 14A005 14A005 14A005 14A069
Wiring harness (2.0L) (LHD) Wiring harness - (2.0L) (2.0L)
- Utility package Wiring harness Wiring harness Body main Wiring harness - Wiring harness -
- Body - Body main Body main Fuel tank jumper
14A303 14A303 14A303 14A631 14A631 14A631
Wiring harness Wiring harness Wiring harness (LHD - 2.0L) (LHD - 2.0L) (RHD - 2.0L)
- Relay feed - Relay feed - Relay feed Wiring harness - Wiring harness - Wiring harness -
Door lock switch Door lock switch Door lock switch
jumper jumper jumper
14A631 14A631 14A631 14B446 14B446 14C007
(RHD - 2.0L) Wiring harness Wiring harness Wiring harness - (2.0L) (LHD)
Wiring harness - Door lock - Door lock Mode assembly Wiring harness - Wiring harness -
- Door lock switch jumper switch jumper Mode assembly Telematics
switch jumper jumper
14C007 14C007 14C007 14D502 14D502 14D502
(RHD) (LHD - 2.0L) (RHD - 2.0L) Wiring harness - (emission (Manual
Wiring harness Wiring harness Wiring harness Transmission requirements: transmission -
- Telematics - Telematics - Telematics stage V) 2.0L)
jumper jumper jumper Wiring harness - Wiring harness -
Transmission Transmission
14D557 14D557 14F238 14G344 14G344 14K024
(2.0L) Wiring harness Wiring harness (2.0L) (2.0L) (LHD)
Wiring harness - Microphone - Blind spot Wiring harness - Wiring harness - Wiring harness -
- Microphone sensor jumper Mic Mic Instrument panel
14K024 14K024 14K024 14K024 14K024 14K024
(LHD) (LHD) (LHD) (RHD) (RHD) (RHD)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Instrument - Instrument - Instrument Instrument panel Instrument panel Instrument panel
panel panel panel
14K024 14K024 14K024 14K024 14K024 14K024
(RHD) Wiring harness (LHD) (RHD) (LHD - 2.0L) (LHD - 2.0L)
Wiring harness - Instrument Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Instrument panel - Instrument Instrument panel Instrument panel Instrument panel
panel panel
14K024 14K024 14K024 14K024 14K024 14K024
(LHD - 2.0L) (LHD - 2.0L) (RHD - 2.0L) (RHD - 2.0L) (RHD - 2.0L) (RHD - 2.0L)
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
- Instrument - Instrument - Instrument Instrument panel Instrument panel Instrument panel
panel panel panel
14K024 14K141 14K141 14K141 14K141 14K141
(2.0L) (2.0L) (LHD) (RHD) Wiring harness - (LHD - 2.0L)
Wiring harness Wiring harness Wiring harness Wiring harness - Tachograph feed Wiring harness -
- Instrument - Tachograph - Tachograph Tachograph feed Tachograph feed
panel feed feed
14K141 15K857 15K857 15K857 15K857 15K867
(RHD - 2.0L) (LHD) (RHD) (LHD - 2.0L) (RHD - 2.0L) Wiring harness -
Wiring harness Wiring harness Wiring harness Wiring harness - Wiring harness - Parking aid
- Tachograph - Parking brake - Parking brake Parking brake Parking brake sensor front
feed switch switch switch switch
15K867 15K868 15K868 15K868 15K868 17N400
(2.0L) (2.0L) (2.0L) Wiring harness - Wiring harness - (liftgate - 2.0L)
Wiring harness Wiring harness Wiring harness Parking aid Parking aid Wiring harness -
- Parking aid - Parking aid - Parking aid sensor rear sensor rear Rear window
sensor front sensor rear sensor rear wiper motor
17N400 18B518 18B518 18B604 18B604 18B604
(liftgate) (2.0L) Wiring harness (2.0L) ( Bus) ( Kombi)
Wiring harness Wiring harness - Heater blower Wiring harness - Wiring harness - Wiring harness -
- Rear window - Heater blower motor Heater control Heater control Heater control
wiper motor motor
18B604 18B684 18B684 18B684 18B684 18B685
(Double Cab in (2.0L) (2.0L) Wiring harness - Wiring harness - (2.0L)
Van) Wiring harness Wiring harness Seat Seat Wiring harness -
Wiring harness - Seat - Seat Heated seats
- Heater control
18B685 18B685 18B685 18C394 18C394 18C394
(2.0L) Wiring harness Wiring harness (rear doors - (rear doors - (rear doors)
Wiring harness - Heated seats - Heated seats 2.0L) 2.0L) Wiring harness -
- Heated seats Wiring harness - Wiring harness - Rear window
Rear window Rear window defrost
defrost defrost
18C394 18E252 19A170 19A170 19A170 19L540
(rear doors) Wiring harness (2.0L) (2.0L) (2.0L) Wiring harness -
Wiring harness - Heater water Wiring harness Wiring harness - Wiring harness - Anti-theft car
- Rear window control valve - Radio Radio speaker Radio speaker alarm feed
defrost jumper speaker jumper jumper jumper
19L540 19L540 19L540 2B325 2B325 2B325
Wiring harness (2.0L) (2.0L) (LHD) (RHD) (LHD - 2.0L)
- Anti-theft car Wiring harness Wiring harness Wiring harness - Wiring harness - Wiring harness -
alarm feed - Anti-theft car - Anti-theft car Brake warning Brake warning Brake warning
alarm feed alarm feed switch switch switch
2B325 2L508 2L508 6M091 6M091 9K499
(RHD - 2.0L) (2.0L) Wiring harness Wiring harness - (2.0L) Wiring harness -
Wiring harness Wiring harness - Brake pad Glow plug Wiring harness - Exhaust
- Brake warning - Brake pad wear sensor Glow plug emission control
switch wear sensor
9K499 9K499
Wiring harness (2.0L)
- Exhaust Wiring harness
emission control - Exhaust
emission
control

Action | Terms
took and
509 ms. onConditions
eccvas1900f-eccvas1900f
Vehicle Repair Location Codes
TO PINPOINT THE ACTUAL VEHICLE LOCATION OF A REPAIR,
THE VEHICLE REPAIR LOCATION CODE IS REQUIRED.
FRONT/REAR DIRECTION
For example, an "X" has been placed in the quadrant of the
FRONT vehicle diagrams indicating the location of the repair. See diagrams.

A B C D E F LOCATION CODE, FOR THE EXAMPLE A5/FU - (UNDER THE

FLOOR OF DRIVER'S LEFT FOOT.)

1
OVER/UNDER DIRECTION
2 RO R = roof line
ENGINE
RU RO = roof
3 over
RU = roof
4 under

B = belt line
5 BO BO = belt
BU over
BU = belt
under

FO F = floor pan
CENTER FU FO = floor
6 over
FU = floor
under

7 RO
RU

8
BO
BU

9
FO
FU

SIDE VIEW
REAR

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