vnx.su escape hybrid - Часть1 PDF

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2007 ENGINE
Engine - 2.3L Hybrid - Escape & Mariner
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Specification
Displacement 2.3L
No. of cylinders 4
Bore/stroke 87.5/94.0
Firing order 1-3-4-2
Oil pressure (hot @ 2,000 rpm)
29-39 psi
200-268 kPa
Oil capacity 4.1 qts + 0.4 qt with filter
Cylinder Block
Cylinder bore diameter
87.5-87.53 mm
(3.444-3.446 in)
Cylinder bore maximum out-of-round
0.008 mm
(0.0003 in)
Main bearing bore diameter
57.018-57.040 mm
(2.244-2.245 in)
Head gasket surface flatness
0.1 mm/general
0.05 mm/200 x 200
(0.003 in/general)
(0.0019 in/7.87 x 7.87)
Piston
Diameter (1)
87.465-87.475 mm
(3.443-3.444 in)
Diameter (2)
87.4725-87.4875 mm
(3.4438-3.4439 in)
Diameter (3)
87.485-87.495 mm
(3.4442-3.4447 in)
Piston-to-bore clearance
0.025-0.045 mm
(0.0009-0.0017 in)
Ring groove width - top
1.203-1.205 mm
(0.0473-0.0474 in)
1.202-1.204 mm

2007 Ford Escape Hybrid
2007 ENGINE Engine - 2.3L Hybrid - Escape & Mariner

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Tuesday, March 31, 2009 12:33:30 PM Page 1 2005 Mitchell Repair Information Company, LLC.
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Ring groove width - 2nd (0.0473-0.0474 in)
Ring groove width - oil
2.501-2.503 mm
(0.0984-0.0985 in)
Piston skirt coating thickness
0.008-0.016 mm
(0.0003-0.0006 in)
Piston Pin
Diameter
20.995-21.0 mm
(0.8265-0.8267 in)
Length
59.6-60.4 mm
(2.346-2.377 in)
Piston-to-pin clearance
0.008-0.016 mm
(0.0003-0.0006 in)
Pin-to-rod clearance Press fit
Cylinder Head
Valve lift @ zero lash (exhaust) 7.7 mm (0.30 in)
Valve lift @ zero lash (intake) 8.8 mm (0.35 in)
Valve guide diameter
5.509-5.539 mm
(0.216-0.218 in)
Valve seat width - intake/exhaust
0.99-1.84 mm
(0.038-0.072 in)
Valve seat angle 45 degrees
Valve seat runout 0.075 mm (0.0029 in)
Valve lash adjuster bore diameter
31.00-31.03 mm
(1.220-1.221 in)
Cam bore diameter
25.015-25.040 mm
(0.984-0.985 in)
Valve
Valve head diameter - intake
34.85-35.15 mm
(1.372-1.383 in)
Valve head diameter - exhaust
29.85-30.15 mm
(1.175-1.187 in)
Valve stem diameter - intake
5.470-5.485 mm
(0.2153-0.2159 in)
Valve stem diameter - exhaust
5.465-5.480 mm
(0.2151-0.2157 in)
Valve stem-to-guide clearance - intake 0.0027 mm (0.00010 in)

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Valve stem-to-guide clearance - exhaust 0.0029 mm (0.00011 in)
Valve face runout 0.05 mm (0.0019 in)
Valve face angle 45 degrees
Valve Spring - Compression Pressure
Intake and exhaust (installed) 38.667 lbs
Intake (valve open) 8.9 mm (0.35 in) of lift 97.032 lbs
Exhaust (valve open) 7.4 mm of lift 93.338 lbs
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
Main bearing journal diameter
51.978-52.002 mm
(2.046-2.047 in)
Production repair
51.730-51.750 mm
(2.036-2.037 in)
Main bearing clearance
0.016-0.047 mm
(0.0006-0.0015 in)
Connecting rod journal diameter
46.978-47.002 mm
(1.849-1.850 in)
Production repair
49.730-49.750 mm
(1.957-1.958 in)
End play
0.220-0.450 mm
(0.007-0.018 in)
Rings
Width - top
1.17-1.185 mm
(0.0460-0.0466 in)
Width - 2nd
1.197-1.199 mm
(0.0471-0.0472 in)
Width - oil
2.38-2.45 mm
(0.093-0.096 in)
Ring gap (in bore) - top
0.16-0.31 mm
(0.006-0.012 in)
Ring gap (in bore) - 2nd
0.33-0.48 mm
(0.012-0.018 in)
Ring gap (in bore) - oil
0.2-0.7 mm
(0.007-0.027 in)
Valve Tappet

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a
No. 3 Journal - Supported by No. 1 and No. 5 journals.

Diameter
30.97-30.98 mm
(1.2192-1.2196 in)
Tappet-to-valve clearance - intake 0.22- 0.28 mm (0.008-0.011 in)
Tappet-to-valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in)
Tappet-to-bore clearance
0.02-0.06 mm
(0.0007-0.0023 in)
Camshaft
Lobe lift - intake -
Lobe lift - exhaust 7.80007 mm (0.307 in)
Runout (1)
a

0.03 mm (0.001 in)
Thrust clearance
0.09-0.24 mm
(0.003-0.009 in)
Journal diameter
24.96-24.98 mm
(0.982-0.983 in)
Journal-to-bore clearance
0.035-0.080 mm
(0.001-0.003 in)
Connecting Rod
Bearing clearance
0.027-0.052
(0.001-0.002 in)
Bearing thickness
1.496-1.520 mm
(0.058-0.059 in)
Crank bore diameter
53.025-53.045 mm
(2.087-2.088 in)
Pin bore diameter
20.965-20.985 mm
(0.825-0.826 in)
Length (center to center) 154.8 mm (6.094 in)
Side clearance
1.95-3.05 mm
(0.076-0.120 in)
Axial clearance
0.14-0.36 mm
(0.005-0.014 in)
All dimensions are in mm unless noted.
Item Specification

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TORQUE SPECIFICATIONS
Motorcraft Metal Surface Cleaner ZC-21 WSE-M5B392-A
Thread Sealant with PTFE TA-24 WSK-M2G350-A2
Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Silicone Brake Caliper Grease and Dielectric
Compound XG-3-A
ESE-M1C171-A
Motorcraft SAE 5W-20 Premium Synthetic
Blend Motor Oil XO-5W20-QSP (US);
Motorcraft SAE 5W-20 Super Premium
Motor Oil CXO-5W20-LSP12 (Canada); or
equivalent
WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant
with Bittering Agent (US only) VC-7-B
(US); CVC-7-A (Canada); or equivalent
(yellow color)
WSS-M97B51-A1
Description Nm lb-ft lb-in
A/C compressor mounting bolts 48 35 -
A/C compressor mounting bolts 25 18 -
A/C manifold tube bolt 20 15 -
A/C tube bracket nut 10 - 89
Air cleaner outlet tube clamps 3 - 27
Belt tensioner bolt 25 18 -
Block-off plate bolts 25 18 -
Camshaft bearing caps
a

- - -
Camshaft position (CMP) sensor bolt 7 - 62
Camshaft sprocket bolt 72 53 -
Catalytic converter-to-cylinder head nuts 47 35 -
Coil-on-plug retaining stud bolts 8 - 71
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 15 -
Crankcase vent oil separator bolts 10 - 89

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Crankshaft position (CKP) sensor 7 - 62
Crankshaft pulley bolt
a

- - -
Cylinder head bolts
a

- - -
Cylinder head temperature (CHT) sensor 12 9 -
EGR tube 55 41 -
Engine front cover bolts
a

- - -
Engine mount bolts 48 35 -
Engine mount bracket-to-engine nuts 115 85 -
Engine mount bracket-to-mount bolt 115 85 -
Engine roll-restrictor bolts (front) 115 85 -
Engine roll-restrictor bolts (rear) 90 66 -
Engine support crossmember bolts 90 66 -
Engine support crossmember nut 175 129 -
Engine timing plug bolt 20 15 -
Engine-to-transmission bolts 48 35 -
Exhaust gas recirculation (EGR) valve assembly bolts 20 15 -
Exhaust manifold studs 17 13 -
Flywheel bolt
a

- - -
Fuel rail bolts 10 - 89
Intake manifold bolts 18 13 -
Knock sensor (KS) 20 15 -
Motor electronics coolant pump bolts 20 15 -
Lateral support crossmember bolts 115 85 -
Oil drain plug 28 21 -
Oil filter adapter bolts 25 18 -
Oil filter cup 33 24 -
Oil level indicator bolt (lower) 47 35 -
Oil level indicator tube bolt (upper) 10 - 89
Oil pan bolts
a

- - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pressure sender 15 11 -
Oil pump drive chain guide bolts (early build) 10 - 89
Oil pump drive chain tensioner shoulder bolts 10 - 89

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a
See procedure for specification.

DESCRIPTION AND OPERATION
ENGINE
The 2.3L (140 CID) 4 cylinder engine has the following features:
Dual overhead camshaft
Four valves per cylinder
Sequential multiport fuel injection (SFI)
Aluminum cylinder head
Aluminum cylinder block
Electronic ignition system with 4 coil-on-plug ignition coils
The 2.3L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-
Oil pump screen and cover assembly 10 - 89
Oil pump sprocket bolt 25 18 -
Oil pump-to-engine block bolts
a

- - -
Powertrain control module (PCM) wiring connector 6 - 53
Rear crankshaft oil seal retainer
a

- - -
Rear main seal mounting plate bolts 10 - 89
Spark plug 12 9 -
Splash shield bolts 9 - 80
Thermostat housing bolts 10 - 89
Timing chain guide bolts 10 - 89
Timing chain tensioner bolts 10 - 89
Transaxle damper bolts 29 21 -
Transaxle mount bolts 90 66 -
Transaxle mount brace 25 18 -
Transaxle mount bracket nut 90 66 -
Transaxle mount bolt 103 76 -
Transaxle mount nuts 90 66 -
Transaxle-to-engine bolts 48 35 -
Valve cover bolts 10 - 89

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on-plug ignition system. The cylinder block is made of aluminum and the bearing caps are
integrated into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower
cylinder block and to the transmission to provide greater strength. The camshafts are mounted in
the cylinder heads and act against valve tappets to open and close the valves. The camshafts are
driven off the front of the cylinder head by one timing chain. The chain is driven by a sprocket
that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron
connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by
the same sprocket that drives the timing chain.
Identification
Always refer to these labels when installation of new parts is necessary, or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification
codes will make sure that the correct parts are obtained. These codes contain all the pertinent
information relating to the dates, optional equipment and revisions. The Ford Master Parts
Catalog contains a complete listing of the codes and their application.
Code Information
The engine code information label, located on the side of the valve cover and the front side of the
valve cover, contains the following.
Engine build date
Engine plant code
Engine code
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine
are covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion
in the cylinders. The 4 solenoid-operated fuel injectors:
are mounted in the intake manifold.
meter fuel into the air intake stream in accordance with engine demand.
are positioned so that their tips direct fuel just ahead of the engine intake valves.
are connected in series with the fuel pressure sensor.
supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

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A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The
fuel pressure sensor:
is positioned upstream from the fuel injectors on the fuel injection supply manifold.
Lubrication System
The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the
oil pan.
Oil is pumped through the oil filter on the left front side of the cylinder block.
Oil enters the main galley where it is distributed to the crankshaft main journals and to the
cylinder head.
From the main journals, the oil is routed through cross-drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main
bearings and connecting rod bearings is slung radially outward to cool and lubricate the
cylinder walls, as well as the entire connecting rod, piston and piston ring assembly.
Engine Cylinder Identification
Fig. 1: Engine Cylinder Identification
Courtesy of FORD MOTOR CO.

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DIAGNOSTIC TESTS
ENGINE
Refer to ENGINE SYSTEM - GENERAL INFORMATION article for basic mechanical
concerns or refer to INTRODUCTION -- HYBRID ENGINES article for driveability
concerns.
GENERAL PROCEDURES
VALVE CLEARANCE CHECK
1. Remove the valve cover. For additional information, refer to Valve Cover.
2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield.
To install, tighten to 9 Nm (80 lb-in).
Fig. 2: Right Splash Shield Bolts
3. Use a feeler gauge to measure the clearance of each valve and record its location.
NOTE: Turn the engine clockwise only, and only use the crankshaft
bolt.
NOTE: Before removing the camshafts, measure the clearance of each
valve at base circle, with the lobe pointed away from the
tappet. Failure to measure all clearances prior to removing the
camshafts will necessitate repeated removal and installation
and wasted labor time.

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Fig. 3: Measuring Each Valve's Clearance Using A Feeler Gauge
4. Select tappets using this formula: tappet thickness = measured clearance + the base tappet
thickness - most desirable thickness.
Select the tappets and mark the installation location.
5. If any tappets do not measure within specifications, install new tappets in these locations.
For additional information, refer to Valve Train Components - Exploded View and
Valve Tappets.
IN-VEHICLE SERVICING
INTAKE MANIFOLD
NOTE: The number on the valve tappet only reflects the digits that
follow the decimal. For example, a tappet with the number
0.650 has the thickness of 3.650 mm.
NOTE: A midrange clearance is the most desirable:
Intake: 0.22-0.28 mm (0.008-0.011 in)
Exhaust: 0.27-0.33 mm (0.010-0.013 in)

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Fig. 4: Exploded View Of Intake Manifold - 1 Of 2 (With Torque Specifications)
Item Part Number Description
1 14A464
Oil pressure sender electrical
connector (part of 12B637)
2 14A464
Temperature manifold absolute
pressure (TMAP) sensor electrical
3 6B018
Block heater electrical harness
connector (if equipped)
Knock sensor (KS) electrical

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Fig. 5: Exploded View Of Intake Manifold - 2 Of 2 (With Torque Specifications)
REMOVAL AND INSTALLATION
4 14A464
connector (male side, part of
12B637)
5 14A464
KS electrical connector (female
side, part of 12B637)
6 9D289 Fuel vapor return hose
7 19D848 Vacuum supply hose
8 W500311 Intake manifold bolt (8 required)
9 -
Crankcase vent hose clamp (part of
6758)
10 6758 Crankcase vent hose
11 9E470
Exhaust gas recirculation (EGR)
tube
12 9424 Intake manifold
13 9461 Intake manifold gasket

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
JACKING AND LIFTING article.
2. Release the fuel pressure. For additional information, refer to FUEL SYSTEM -
GENERAL INFORMATION article.
3. Disable the vehicle high voltage electrical system. For additional information, refer to
HIGH VOLTAGE TRACTION BATTERY article.
4. Remove the fuel rail. For additional information, refer to FUEL CHARGING AND
CONTROLS - 2.3L article.
5. Remove the throttle body. For additional information, refer to FUEL CHARGING AND
CONTROLS - HYBRID article.
6. Remove the accessory drive belt tensioner. For additional information, refer to
ACCESSORY DRIVE - HYBRID article.
7. Remove the oil level indicator and tube. For additional information, refer to Oil Level
Indicator and Tube.
8. Disconnect the oil pressure sender electrical connector.
9. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
10. If equipped, disconnect the block heater electrical harness connector.
11. Disconnect the knock sensor (KS) electrical connector and detach the pin-type retainer.
12. Disconnect the fuel vapor return hose from the intake manifold.
13. Disconnect the vacuum tube.
Depress the quick release locking ring.
Pull the vacuum tube out of the quick release fitting.
CAUTION: Before removing the high voltage cables, the vehicle
electrical system must be completely shut down for at
least 5 minutes to allow for the high voltage capacitors to
discharge.

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Fig. 6: Locating Power Brake Booster Vacuum Tube And Quick Release Locking
Ring
14. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose
clamp and the exhaust gas recirculation (EGR) tube.
To install, tighten to 18 Nm (13 lb-ft).
15. Release the clamp and disconnect the crankcase vent hose.
16. Remove the EGR tube.
17. Remove the intake manifold and gaskets.
18. To install, reverse the removal procedure.
Inspect and install new intake manifold gaskets if necessary.
VALVE COVER
NOTE: There are 3 different size bolts used. Mark the location of the
bolts to make sure they are installed in the correct location.

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Fig. 7: Exploded View Of Valve Cover - 1 Of 2
1 6853 Crankcase vent hose
2 6A957 Engine cover stud (3 required)
3 14A464
Camshaft position (CMP) sensor
electrical connector (part of
12B637)
4 14A464
Fuel rail pressure and temperature
sensor electrical connector (part of
12B637)
5 14A464
Cylinder head temperature (CHT)
sensor electrical connector (part of
12B637)

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Fig. 8: Exploded View Of Valve Cover - 2 Of 2
REMOVAL
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
2. Remove the ignition coil-on-plugs. For additional information, refer to ENGINE
IGNITION - 2.3L article.
3. Disconnect the crankcase vent hose.
6 W500215 Valve cover retainer (14 required)
7 6582 Valve cover
8 6584 Valve cover gasket
CAUTION: During engine repair procedures, cleanliness is extremely
important. Any foreign material, including any material
created while cleaning gasket surfaces, that enters the oil
passages, coolant passages or the oil pan can cause engine
failure.

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4. Remove the 3 engine cover studs.
5. Disconnect the camshaft position (CMP) sensor electrical connector.
6. Disconnect the fuel rail pressure and temperature sensor electrical connector.
7. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
8. Remove the 14 valve cover retainers, the valve cover and gasket.
INSTALLATION
1. Clean and inspect the sealing surfaces.
2. Install the valve cover, gasket and retainers.
Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig. 9: Identifying Valve Cover Bolts Tightening Sequence
3. Connect the CHT sensor electrical connector.
4. Connect the fuel rail pressure and temperature sensor electrical connector.
5. Connect the CMP sensor electrical connector.
6. Install the 3 engine cover studs.
7. Connect the crankcase vent hose.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive
discs or other abrasive means to clean the sealing
surfaces. These tools cause scratches and gouges which
make leak paths.
NOTE: Clean and inspect the gasket. Install a new gasket, if
necessary.

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8. Install the ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION
- 2.3L article.
LOWER END COMPONENTS - EXPLODED VIEW
Fig. 10: Crankshaft Pulley and Crankshaft Front Oil Seal
1 6K340 Crankshaft pulley bolt
2 -
Crankshaft pulley washer (part of
6K340)
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal

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Fig. 11: Flywheel and Crankshaft Rear Oil Seal
1. For additional information, refer to the following procedures.
CRANKSHAFT PULLEY
Special Tools
1 6379 Flywheel bolt (6 required)
2 6477 Flywheel
3 W500215 Engine front cover bolt (4 required)
4 W706284 Oil pan bolt (2 required)
6 6675 Oil pan
7 W500212
Crankshaft rear oil seal with
retainer plate bolt (6 required)
8 6K318
Crankshaft rear oil seal with
retainer plate
Illustration Tool Name Tool Number

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Material
REMOVAL
Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
Timing Peg, Crankshaft 303-507
Holding Fixture, Drive Pinion
Flange
205-126 (T78P-4851-A)
Adapter for 205-126 (205-072-02)
Item Specification
Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-
20 Super Premium Motor Oil CXO-5W20-
LSP12 (Canada); or equivalent
WSS-M2C930-A
CAUTION: Do not loosen or remove the crankshaft pulley bolt without
first installing the special tools as instructed in this
procedure. The crankshaft pulley and the crankshaft timing
sprocket are not keyed to the crankshaft. The crankshaft, the
crankshaft sprocket and the pulley are fitted together by
friction, using diamond washers between the flange faces on
each part. For that reason, the crankshaft sprocket is also
unfastened if you loosen the pulley bolt. Before any repair
requiring loosening or removal of the crankshaft pulley bolt,

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2. Remove the accessory drive belt. For additional information, refer to ACCESSORY
DRIVE - HYBRID article.
3. Remove the valve cover. For additional information, refer to Valve Cover.
4. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston
at TDC.
The hole in the crankshaft pulley should be in the 6 o'clock position.
Fig. 12: Turning Crankshaft Clockwise
the crankshaft and camshafts must be locked in place by the
special service tools, otherwise severe engine damage can
occur.
failure.
CAUTION: Failure to position the No. 1 piston at top dead center
(TDC) can result in damage to the engine. Turn the engine
in the normal direction of rotation only.
CAUTION: The special tool 303-465 is for camshaft alignment only.
Using this tool to prevent engine rotation can result in
engine damage.

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5. Install the special tool in the slots on the rear of both camshafts.
Fig. 13: Identifying Special Camshaft Tool (303-465)
6. Remove the engine plug bolt.
Fig. 14: Locating Engine Plug Bolt
7. Install the special tool.
NOTE: The camshaft timing slots are offset. If the special tool cannot
be installed, rotate the crankshaft one complete revolution
clockwise to correctly position the camshafts.
NOTE: The special tool will contact the crankshaft and prevent it from
turning past TDC. However, the crankshaft can still be rotated
in the counterclockwise direction. The crankshaft must remain
at the TDC position during the crankshaft pulley removal and
installation.

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Fig. 15: Identifying Special Tool (303-507)
8. Assemble the special tools using 4 hardened washers in the locations shown.

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Fig. 16: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
9. Using the special tools and an air impact wrench, remove the crankshaft pulley.
Remove and discard the crankshaft pulley bolt and washer.
Remove the crankshaft pulley.
Fig. 17: Using Special Tools (205-126 And 205-072-02)
INSTALLATION
1. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock
position.
CAUTION: The crankshaft must remain in the TDC position during
removal of the pulley bolt or damage to the engine can
occur. Therefore, the crankshaft pulley must be held in
place with the special tool and the bolt should be
removed using an air impact wrench (1/2-in drive
minimum).
CAUTION: If the crankshaft sprocket diamond washer comes off with
the crankshaft pulley, it must be installed back onto the
crankshaft.
CAUTION: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.

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Fig. 18: Locating Crankshaft Pulley & Hole
2. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and
thread it into the front cover.
Fig. 19: Locating Crankshaft Pulley Bolt
CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to
the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the
crankshaft.

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Fig. 20: Assembling Special Tools (205-126 And 205-072-02)
4. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in
place, tighten the crankshaft pulley bolt in 2 stages:
Stage 1: Tighten to 100 Nm (74 lb-ft).
Stage 2: Tighten an additional 90 degrees (1/4 turn).
installation of the pulley bolt or damage to the engine can
installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.

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5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig. 22: Aligning Crankshaft Pulley Bolt Holes
6. Remove the special tool.
Fig. 23: Identifying Special Tool

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8. Turn the crankshaft clockwise 1 and 3/4 turns.
10. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
NOTE: Only turn the engine in the normal direction of rotation.

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11. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
If it is not possible to install the bolt, the engine valve timing must be corrected by
repeating this procedure.
Fig. 27: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
12. Using the special tool, check the position of the camshafts.
CAUTION: Only hand-tighten the bolt or damage to the front cover
can occur.

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If it is not possible to install the special tool, the engine valve timing must be corrected
by repeating this procedure.

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16. Install the engine plug bolt.
Tighten to 20 Nm (15 lb-ft).
17. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE
- HYBRID article.
18. Install the valve cover. For additional information, refer to Valve Cover.
CRANKSHAFT FRONT SEAL
Special Tools
Material
Installer, Front Oil Seal 303-096 (T74P-6150-A)
Remover, Oil Seal 303-409 (T92C-6700-CH)
Item Specification
Blend Motor Oil
WSS-M2C930-A

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REMOVAL
1. Remove the crankshaft pulley. For additional information, refer to Lower End
Components - Exploded View and Crankshaft Pulley.
2. Using the special tool, remove the crankshaft front oil seal.
occur.
important. Any foreign material (including any material
created while cleaning gasket surfaces) that enters the oil
failure.
CAUTION: Use care not to damage the engine front cover or the
crankshaft when removing the seal.

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Fig. 32: Locating Crankshaft Front Oil Seal And Special Tool (303-409)
INSTALLATION
1. Using the special tool, install the crankshaft front oil seal.
Fig. 33: Installing Crankshaft Front Oil Seal Using Special Tool
2. Install the crankshaft pulley. For additional information, refer to Lower End Components
- Exploded View and Crankshaft Pulley.
FLYWHEEL
REMOVAL
2. Remove the engine. For additional information, refer to Engine.
NOTE: Remove the through bolt from the special tool.
NOTE: Lubricate the oil seal with clean engine oil.

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3. Remove the 6 bolts and the flywheel.
INSTALLATION
1. Install the flywheel and tighten the bolts in the sequence shown in the following 3 stages:
Fig. 34: Identifying Flexplate Bolts Tightening Sequence
2. Install the engine. For additional information, refer to Engine.
CRANKSHAFT REAR SEAL
Special Tools
Material
NOTE: Special bolts are used for installation. Do not use standard
bolts.
Installer, Crankshaft Rear
Main Oil Seal
303-328 (T88P-6701-B1)
Item Specification
Metal Surface Cleaner
ZC-21
WSE-M5B392-A

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REMOVAL
2. Remove the flywheel. For additional information, refer to Flywheel.
3. Remove the 17 bolts and the oil pan.
4. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.
INSTALLATION
1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the
crankshaft.
Fig. 35: Installing Crankshaft Rear Main Oil Seal Using Special Tool (303-328)
2. Install the crankshaft rear oil seal with retainer plate and bolts.
Tighten in the sequence shown to 10 Nm (89 lb-in).
Blend Motor Oil
WSS-M2C930-A
Silicone Gasket and Sealant
TA-30
WSE-M4G323-A4
CAUTION: If the oil pan is not removed, damage to the rear oil seal
retainer joint can occur.

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Fig. 36: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
3. Clean and inspect all the oil pan and cylinder block mating surfaces.
4. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil
pan. Install the 2 oil pan bolts finger-tight.
surfaces. These tools cause scratches and gouges, which
make leak paths. Use a plastic scraping tool and metal
surface cleaner to remove traces of sealant.
NOTE: If the oil pan is not secured within 4 minutes of sealant
application, the sealant must be removed and the sealing area
cleaned with metal surface cleaner. Allow to dry until there is
no sign of wetness, or 4 minutes, whichever is longer. Failure
to follow this procedure can cause future oil leakage.
NOTE: The oil pan must be installed and the bolts tightened within 4
minutes of applying the silicone gasket and sealant.

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Fig. 37: Identifying Rear Oil Pan Bolts
5. Install the 4 bolts.
Tighten to 10 Nm (89 lb-in).
Fig. 38: Locating Bolts
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25
Nm (18 lb-ft).
Fig. 39: Identifying Tightening Sequence Of Oil Pan Bolts
7. Install the flywheel. For additional information, refer to Flywheel.
ENGINE FRONT COVER
Special Tools

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Material
Fig. 40: Exploded View Of Engine Front Cover (With Torque Specifications)
Item Specification
Blend Motor Oil
WSS-M2C930-A
TA-30
WSE-M4G323-A4

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REMOVAL
2 W500221
Coolant pump pulley bolt (3
required)
3 8509 Coolant pump pulley
4 W701625
Accessory drive belt tensioner bolt
(3 required)
5 6B209 Accessory drive belt tensioner
6 14A464
Crankshaft position (CKP) sensor
electrical connector (part of
12B637)
7 W701219 CKP sensor bolts (2 required)
8 6C315 CKP sensor
9 W500215
Engine front cover bolt (22
required)
10 6019 Engine front cover
occur.

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2. Remove the accessory drive belt. For additional information, refer to ACCESSORY
3. Remove the crankshaft pulley. For additional information refer to Crankshaft Pulley.
4. Remove the engine mount. For additional information, refer to Engine Mount.
Fig. 41: Locating Crankshaft Front Oil Seal And Special Tool (303-409)
6. Remove the 3 bolts and the coolant pump pulley.
7. Remove the 3 bolts and the accessory drive belt tensioner.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove and discard the CKP sensor.
10. Remove the bolts and the engine front cover.
failure.
NOTE: Whenever the CKP sensor is removed, a new one must be
installed, using the alignment tool supplied with the new part.

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Fig. 42: Locating Engine Front Cover Bolts
INSTALLATION
1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil
pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front
cover.
disks or other abrasive means to clean sealing surfaces.
These tools cause scratches and gouges which make
leak paths.
NOTE: The engine front cover must be installed and the bolts
tightened within 4 minutes of applying the silicone gasket and
sealant.

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Fig. 43: Locating Silicone Gasket
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following
specifications:
Tighten the 8-mm bolts to 10 Nm (89 lb-in).
Tighten the 13-mm bolts to 48 Nm (35 lb-ft).

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Fig. 44: Identifying Engine Front Cover Bolts Tightening Sequence
5. Install the accessory drive belt tensioner and the 3 bolts.
NOTE: Remove the through-bolt from the special tool.

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6. Install the coolant pump pulley and the 3 bolts.
7. Install the engine mount. For additional information, refer to Engine Mount.
8. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley.
10. Install a new CKP sensor and the 2 bolts.
Do not tighten the bolts at this time.
Fig. 47: Locating CKP Sensor Bolts
can occur.
installed using the alignment tool supplied with the new part.

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11. Adjust the CKP sensor with the alignment tool.
Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
Fig. 48: Locating CKP Sensor Alignment Tool And Bolts
12. Connect the CKP sensor electrical connector.
Fig. 49: CKP Sensor Electrical Connector
14. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE
- HYBRID article.
TIMING DRIVE COMPONENTS
Material
NOTE: The CKP sensor alignment tool is supplied with the new sensor
and is not available separately.
Item Specification

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REMOVAL
2. Remove the engine front cover. For additional information, refer to Engine Front Cover.
3. Remove the timing chain tensioner.
1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the
tensioner.
2. Remove the bolts and timing chain tensioner.
Blend Motor Oil
WSS-M2C930-A
TA-30
WSE-M4G323-A4
occur.
failure.

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Fig. 50: Identifying Paper Clip Into Hole And Bolts
4. Remove the RH timing chain guide.
Fig. 51: Locating RH Timing Chain Guide
5. Remove the timing chain.
Fig. 52: View Of Timing Chain
6. Remove the bolts and the LH timing chain guide.

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Fig. 53: Identifying Bolts And LH Timing Chain Guide
7. Remove the bolts and the camshaft sprockets.
Use the flats on the camshaft to prevent camshaft rotation.
Fig. 54: Locating Cam Holding Area And Sprocket Bolt
INSTALLATION
1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
CAUTION: Do not rely on the Camshaft Alignment Plate to prevent
camshaft rotation. Damage to the tool or the camshaft
can occur.

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Fig. 55: Locating Camshaft Sprocket Bolts
2. Install the LH timing chain guide and the bolts.
3. Install the timing chain.
4. Install the RH timing chain guide.

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5. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
Fig. 59: Locating Timing Chain Tensioner Bolts And Paper Clip
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
engine damage.

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7. Install the engine front cover. For additional information, refer to Engine Front Cover.
VALVE TRAIN COMPONENTS - EXPLODED VIEW
Fig. 61: Exploded View Of Valve Train Components
1 W706283
Camshaft bearing cap bolt (20
required)
2 6A284 Camshaft bearing cap (10 required)

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CAMSHAFTS
Special Tools
Material
REMOVAL
3 6A267 Camshaft (2 required)
4 6500 Valve tappet (16 required)
5 6518 Valve collet (16 required)
6 6514 Valve spring retainer (16 required)
7 6513 Valve spring (16 required)
8 6517 Valve seal (16 required)
Item Specification
TA-30
WSE-M4G323-A4
Blend Motor Oil
WSS-M2C930-A

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2. Disconnect the battery ground cable. For additional information, refer to BATTERY,
MOUNTING AND CABLES article.
3. Depower the vehicle high voltage traction battery electrical system. For additional
information, refer to HIGH VOLTAGE TRACTION BATTERY article.
4. Remove the degas bottle. For additional information, refer to ENGINE COOLING -
HYBRID article.
5. Remove the direct current/direct current (DC/DC) converter. For additional information,
refer to HIGH VOLTAGE CONVERTER/INVERTER article.
6. Check the valve clearance. For additional information, refer to Valve Clearance Check.
7. Remove the accessory drivebelt. For additional information, refer to ACCESSORY
at TDC.
failure.
CAUTION: Do not rotate the camshafts unless instructed to in this
procedure. Rotating the camshafts or crankshaft with timing
components loosened or removed can cause serious damage
to the valves and pistons.
discharge.

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engine damage.

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at the TDC position during the camshaft removal and
installation.

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13. Remove the lower front cover timing hole plug from the engine front cover.
Fig. 67: Locating Lower Front Cover Timing Hole Plug
14. Remove the upper front cover timing hole plug from the engine front cover.
can occur.

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Fig. 68: Locating Upper Front Cover Timing Hole Plug
15. Reposition the special tool to the slot on the rear of the intake camshaft only.
16. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover
timing hole.
Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise
to collapse the timing chain tensioner plunger.
Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the
tensioner arm in the retracted position.
NOTE: Releasing the ratcheting mechanism in the timing chain
tensioner allows the plunger to collapse and create slack in the
timing chain. Installing an M6 x 30 mm (1.18 in) bolt into the
upper front cover timing hole will hold the tensioner arm in a
retracted position and allow enough slack in the timing chain
for removal of the exhaust camshaft gear.

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Fig. 70: Unlocking Chain Tensioner Ratchet Through Lower Front Cover Timing
Hole
18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust
camshaft drive gear.

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Fig. 72: Locating Camshaft Bolt, Bolt And Exhaust Camshaft Drive Gear
19. Remove the timing chain from the intake camshaft drive gear.
Fig. 73: Locating Timing Chain
20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake
camshaft drive gear.

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Fig. 74: Locating Camshaft Bolt And Intake Camshaft Drive Gear
21. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
Fig. 75: Locating Camshaft Lobe
22. Remove the camshafts from the engine.
Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension
is released from the camshaft bearing caps.
CAUTION: Failure to follow the camshaft loosening procedure can
result in damage to the camshafts.

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Remove the bolts and the camshaft bearing caps.
Remove the camshafts.
Fig. 76: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
INSTALLATION
1. Install the camshafts and bearing caps. Tighten the bearing caps in the sequence shown in 3
stages:
Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger tight.
Stage 2: Tighten to 7 Nm (62 lb-in).
CAUTION: Install the camshafts with the alignment slots in the
camshafts lined up so the Camshaft Alignment Plate can
be installed without rotating the camshafts. Make sure
the lobes on the No. 1 cylinder are in the same position
as noted in the removal procedure. Rotating the
camshafts when the timing chain is removed, or installing
the camshafts 180 degrees out of position can cause
severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean
engine oil.

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Fig. 77: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
3. Install the intake camshaft drive gear and hand-tighten the bolt.
Fig. 79: Locating Intake Camshaft Drive Gear Bolt
4. Install the timing chain on the intake camshaft drive gear.

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Fig. 80: Locating Timing Chain
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on
the exhaust camshaft.
Hand-tighten the bolt.
Fig. 81: Locating Exhaust Camshaft Drive Gear Bolt
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the
tensioner arm.
NOTE: The timing chain must be correctly engaged on the teeth of the
crankshaft timing sprocket and the intake camshaft drive gear
in order to install the exhaust camshaft drive gear onto the
exhaust camshaft.
NOTE: Releasing the tensioner arm will remove the slack from the
timing chain release.

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Fig. 82: Locating Camshaft Bolts
engine damage.

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11. Install the upper front cover timing hole plug.
Fig. 86: Locating Upper Front Cover Timing Hole Plug
12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug.

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Install the plug and tighten to 12 Nm (9 lb-ft).
Fig. 87: Locating Lower Front Cover Timing Hole Plug
14. Install the accessory drivebelt. For additional information, refer to ACCESSORY DRIVE
- HYBRID article.
15. Install the valve cover. For additional information, refer to Valve Cover.
16. Install the direct current/direct current (DC/DC) converter. For additional information,
refer to HIGH VOLTAGE CONVERTER/INVERTER article.
17. Install the degas bottle. For additional information, refer to ENGINE COOLING -
HYBRID article.
18. Repower the vehicle high voltage traction battery electrical system. For additional
information, refer to HIGH VOLTAGE TRACTION BATTERY article.
19. Connect the battery ground cable. For additional information, refer to BATTERY,

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VALVE SPRINGS
Special Tools
Material
REMOVAL
Compressor, Valve Spring 303-300 (T87C-6565-A)
Compressor, Valve Spring 303-350 (T89P-6565-A)
Compressor, Valve Spring 303-472 (T94P-6565-AH)
Item Specification
Blend Motor Oil
WSS-M2C930-A
Multi-Purpose Grease
XG-4 and/or XL-5
ESB-M1C93-B
failure.

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2. Remove the camshafts. For additional information, refer to Camshafts.
3. Remove and inspect the valve tappets. For additional information, refer to ENGINE
SYSTEM - GENERAL INFORMATION article.
4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L
article.
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring.
Using the special tools, compress the valve spring and remove the valve collet, using
some grease and a small screwdriver.
Remove the valve spring retainer and the valve spring.
NOTE: If the camshafts and valve tappets are to be reused, mark the
location of the valve tappets to make sure they are assembled
in their original positions.
NOTE: The number on the valve tappets only reflects the digits that
CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not
disconnect the compressed air from the cylinder until the
valve spring, valve spring retainer and valve collet is
installed. Any loss of air pressure will allow the valve to
fall into the cylinder.
NOTE: Place all parts in order to one side.

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Fig. 89: Identifying Special Tools (303-300, 303-350, 303-472)
INSTALLATION
1. Using the special tools, install the valve spring.
Insert the valve spring and the valve spring retainer.
Compress the valve spring and install the valve collet using some grease and a small
screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L
article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to Camshafts.
VALVE SEALS
Special Tools
NOTE: Check the seating of the valve collet.

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Material
REMOVAL
Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)
Remover, Valve Stem Oil
Seal
303-468 (T94P-6510-AH)
Slide Hammer 307-005 (T59L-100-B)
Item Specification
Blend Motor Oil
WSS-M2C930-A
XG-4 and/or XL-5
ESB-M1C93-B

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4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L
article.
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring.
Using the special tools, compress the valve spring and remove the valve collet, using
some grease and a small screwdriver.
Remove the valve spring retainer and the valve spring.
failure.
CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not
disconnect the compressed air from the cylinder until the
valve spring, valve spring retainer and valve collet is
installed. Any loss of air pressure will allow the valve to
fall into the cylinder.
NOTE: Place all parts in order to one side.

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7. Using the special tools, remove and discard the valve seal.
Fig. 92: Identifying Special Tools (307--005, 303--468)
INSTALLATION
1. Install the valve stem seal installation sleeve.
Fig. 93: Identifying Valve Stem Seal Installation Sleeve
2. Using the special tool, install the valve seal.

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3. Using the special tools, install the valve spring.
Insert the valve spring and the valve spring retainer.
Compress the valve spring and install the valve collet using some grease and a small
screwdriver.
4. Disconnect the compressed air supply.
5. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L
article.
6. Repeat the appropriate removal and installation steps for all of the other cylinders.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to Camshafts.
VALVE TAPPETS
NOTE: Check the seating of the valve collet.

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Material
Coat the valve tappets with clean engine oil prior to installation.
CYLINDER HEAD
Special Tools
Item Specification
Blend Motor Oil
WSS-M2C930-A
failure.

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Material
Item Specification
Blend Motor Oil
WSS-M2C930-A
Silicone Gasket Remover
ZC-30
-
Motorcraft Metal Surface Prep
ZC-31
-
TA-30
WSE-M4G323-A4

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Fig. 96: Exploded View Of Cylinder Head
1 14A464
valve electrical connector (part of
12B637)
2 14489
Radio ignition interference
capacitor electrical connector (part
of 12B637)
3 8287 Upper radiator hose clamp
4 8260 Upper radiator hose

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REMOVAL
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM -
3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING
- HYBRID article.
5 W525958 Bypass hose clamp
6 8548 Bypass hose
7 - Heater hose clamp (part of 18K580)
8 18K580 Heater hose
9 -
Engine coolant vent hose clamp
(part of 8W005)
10 8W005 Engine coolant vent hose
11 6065 Cylinder head bolt (10 required)
12 6050 Cylinder head
13 6051 Cylinder head gasket
occur.
failure.

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4. Remove the timing drive components. For additional information, refer to Timing Drive
Components.
6. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension
is released from the camshaft bearing caps.
Remove the bolts and the camshaft bearing caps.

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8. Remove the valve tappets.
9. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM -
10. Remove the intake manifold. For additional information, refer to Intake Manifold.
11. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM
article.
12. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
13. Disconnect the radio ignition interference capacitor electrical connector.
14. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose
from the engine coolant outlet.
15. Remove the bolts and the and the cylinder head.
Discard the bolts and the cylinder head gasket.
INSTALLATION
CAUTION: If the camshafts and valve tappets are to be reused, mark
the location of the valve tappets to make sure they are
assembled in their original positions.
surfaces. These tools cause scratches and gouges that

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1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the
cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for
several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of
silicone gasket remover may be required if residual traces of silicone or gasket
material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or
coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other
foreign material is removed.
3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE
4. Apply silicone gasket and sealant to the locations shown.
Fig. 100: Identifying Silicone Gasket And Sealant Location
make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all
application directions contained on the packaging of the
silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface
prep can be used to clean and prepare the surfaces.

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5. Install a new cylinder head gasket.
6. Install new cylinder head bolts. Tighten the bolts in the sequence shown in the following 5
stages:
Stage 4: Turn 90 degrees.
Stage 5: Turn an additional 90 degrees.
Fig. 101: Identifying Tightening Sequence Of Cylinder Head Bolts
7. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to
the engine coolant outlet.
8. Connect the radio ignition interference capacitor electrical connector.
9. Connect the EGR valve electrical connector.
10. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM
article.
11. Install the intake manifold. For additional information, refer to Intake Manifold.
12. Install the valve tappets in their original positions.
NOTE: The cylinder head bolts are torque-to-yield and must not be
reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
NOTE: Lubricate the valve tappets with clean engine oil.

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Fig. 102: Locating Valve Tappet
13. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages.
Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger tight.
Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
CAUTION: Install the camshafts with the alignment notches in the
camshafts lined up so the camshaft alignment plate can
be installed. Make sure the lobes on the No. 1 cylinder are
in the same position as noted in the removal procedure.
Failure to follow this procedure can cause severe damage
to the valves and pistons.
engine oil.

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15. Install the timing drive components. For additional information, refer to Timing Drive
Components.
16. Fill and bleed the engine cooling system. For additional information, refer to ENGINE
COOLING - HYBRID article.
ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW
Fig. 105: Exploded View Of Oil Filter Element, Oil Filter Adapter and Oil Pressure
Sender (With Torque Specifications)

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Fig. 106: Exploded View Of Oil Pan, Oil Pump Screen and Pickup Tube (With Torque
Specifications)
1 14A464
Oil pressure sender electrical
2 9278 Oil pressure sender
3 6C684 Oil filter drain plug
4 W707718 Oil filter drain plug O-ring seal
5 6A832 Oil filter cover
6 6885 Oil filter cover O-ring seal
7 6774 Oil filter element
8 W500225 Oil filter adapter bolt (4 required)
9 6884 Oil filter adapter
10 6A636 Oil filter adapter gasket
1 6730 Drain plug

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Fig. 107: Exploded View Of Oil Pump (With Torque Specifications)
3 W500122
Oil pan-to-bellhousing bolt (2
required)
4 W500122
Oil pan-to-bellhousing bolt (2
required)
6 6675 Oil pan
7 W706282
Oil pump screen and pickup tube
bolt (2 required)
8 6622 Oil pump screen and pickup tube
9 6625
Oil pump screen and pickup tube
gasket
1 W703651
Oil pump drive chain guide
shoulder bolt (2 required) (early
build)
2 6M256
Oil pump drive chain guide (early
build)

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OIL FILTER ELEMENT
Material
REMOVAL
2. Loosen the oil filter drain plug.
3. Using a cup-style oil filter wrench, loosen the oil filter cover one turn.
4. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter.
Remove and discard the oil filter drain plug O-ring seal.
5. Remove the oil filter cover and oil filter element.
Discard the oil filter element.
Remove and discard the oil filter cover O-ring seal.
INSTALLATION
1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter.
3 W703651
Oil pump drive chain tensioner
shoulder bolt
4 6C271 Oil pump drive chain tensioner
5 6A895 Oil pump drive chain
6 W704397 Oil pump sprocket bolt
7 6652 Oil pump sprocket
8 W703647 Oil pump bolt (4 required)
9 6600 Oil pump
Item Specification
Blend Motor Oil
WSS-M2C930-A
NOTE: Lubricate the oil filter cover O-ring seal with clean engine oil.

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2. Install a new oil filter cover O-ring seal.
3. Install a new oil filter element and the oil filter cover.
Using a cup-style oil wrench, tighten to 33 Nm (24 lb-ft).
4. Install a new oil filter drain plug O-ring seal.
5. Install the oil filter drain plug.
OIL FILTER ADAPTER
2. Remove the oil filter element. For additional information, refer to Oil Filter Element.
3. Remove the 5 bolts and the RH splash shield.
5. Remove the 4 bolts and the oil filter adapter.
CAUTION: Do not over tighten the oil filter cover. Over tightening the
oil filter cover may damage the cover or O-ring seal and
result in a oil leak.
NOTE: Lubricate the oil filter drain plug O-ring seal with clean engine
oil.
CAUTION: Do not over tighten the oil filter drain plug. Over
tightening the oil filter drain plug may damage the drain
plug, O-ring seal or cover and result in a oil leak.
NOTE: Discard the gasket.

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ENGINE OIL PRESSURE (EOP) SWITCH
Material
4. Remove the oil pressure sender.
Apply thread sealant with PTFE to the oil pressure sender threads.
OIL PAN
Material
REMOVAL
2. Drain the engine oil, then install the drain plug.
Item Specification
Thread Sealant with PTFE
TA-24
WSK-M2G350-A2
Item Specification
Motorcraft Metal Surface Cleaner
ZC-21
WSE-M5B392-A
Blend Motor Oil
WSS-M2C930-A
TA-30
WSE-M4G323-A4

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3. Remove the oil level indicator and tube. For additional information, refer to Oil Level
Indicator and Tube.
5. Remove the 4 oil pan-to-bellhousing bolts.
INSTALLATION
1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
Position the oil pan and install the 2 rear oil pan bolts finger-tight.
3. Using a suitable straightedge, align the front surface of the oil pan flush with the front
make leak paths. Use a plastic scraping tool to remove
traces of sealant.

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surface of the engine block.
Fig. 109: Aligning Front Surface Of The Oil Pan
4. Install the remaining oil pan bolts.
Tighten in the sequence shown to 25 Nm (18 lb-ft).
5. Install the 4 oil pan-to-bellhousing bolts.

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7. Install the oil level indicator and tube. For additional information, refer to Oil Level
Indicator and Tube.
8. Fill the engine with clean engine oil.
OIL PUMP SCREEN AND PICKUP TUBE
2. Remove the oil pan. For additional information, refer to Engine Lubrication
Components - Exploded View and Oil Pan.
3. Remove the 2 bolts and the oil pump screen and pickup tube.
OIL PUMP
Material
REMOVAL
NOTE: Discard the gasket and clean and inspect the gasket mating
surfaces.
Item Specification
Blend Motor Oil
WSS-M2C930-A
TA-30
WSE-M4G323-A4
Motorcraft Metal Surface Cleaner
ZC-21
WSE-M5B392-A
NOTE: Early build engines are equipped with an oil pump drive chain
guide. Late build engines do not have an oil pump drive chain
guide. Also, late build engines use an updated design for the oil

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All vehicles
1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to
3. Drain the engine oil, then install the drain plug.
4. Remove the 4 oil pan-to-bellhousing bolts.
6. Remove the 2 bolts and the oil pump screen and pickup tube.
Early build vehicles
7. Remove the oil pump drive chain tensioner and guide.
1. Release the tension on the tensioner spring.
2. Remove the 2 shoulder bolts and the tensioner.
3. Remove the 2 shoulder bolts and the guide.
Fig. 111: Locating Oil Pump Bolts
pump drive chain and tensioner. Therefore, the oil pump drive
components are not interchangeable between early build and late
build engines.
NOTE: Discard the gasket and clean and inspect the gasket mating
surfaces.

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Late build vehicles
8. Remove the oil pump drive chain tensioner.
Release the tension on the tensioner spring.
Remove the tensioner and the 2 shoulder bolts.
Fig. 112: Locating Shoulder Bolts & Tensioner
All vehicles
9. Remove the chain from the oil pump sprocket.
10. Remove the bolt and oil pump sprocket.
11. Remove the 4 bolts and the oil pump.
INSTALLATION
All vehicles
1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
NOTE: Clean the oil pump and cylinder block mating surfaces with
metal surface cleaner.

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Fig. 113: Identifying Oil Pump Bolts Tightening Sequence
2. Install the oil pump sprocket and bolt.
3. Install the chain onto the oil pump sprocket.
Late build vehicles
4. Install the oil pump drive chain tensioner shoulder bolt.
Fig. 114: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
5. Install the oil pump drive chain guide and the shoulder bolts.

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Fig. 115: Installing Oil Pump Drive Chain Guide And Shoulder Bolts
All vehicles
6. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder
bolt.
Fig. 116: Locating Oil Pump Chain Tensioner
7. Install the oil pump screen and pickup tube and the 2 bolts.
8. Clean all mating surfaces with metal surface cleaner.
make leak paths. Use a plastic scraping tool to remove
traces to sealant.

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9. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan.
Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
10. Using a suitable straight edge, align the front surface of the oil pan flush with the front

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11. Install the remaining oil pan bolts.
Tighten in the sequence shown to 25 Nm (18 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts.

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OIL LEVEL INDICATOR AND TUBE
Material
Fig. 120: Exploded View Of Oil Level Indicator and Tube (With Torque Specifications)
Item Specification
Blend Motor Oil
WSS-M2C930-A
1 6750 Oil level indicator
2 W50581 Oil level indicator tube bolt (upper)
3 W500032 Oil level indicator tube bolt (lower)
4 6754 Oil level indicator tube
5 6754-B Oil level indicator tube O-ring seal

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3. Remove the lower oil level indicator tube bolt.
4. Remove the oil level indictor.
5. Remove the upper bolt and the oil level indicator tube.
6. Remove and discard the oil level indicator tube O-ring seal.
Lubricate a new O-ring seal with clean engine oil.
ENGINE MOUNT
Special Tools
Three-Bar Engine Support Kit 303-F072

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Fig. 121: Exploded View Of Engine Mount (With Torque Specifications)
2. Remove the engine coolant degas bottle. For additional information, refer to ENGINE
1 W520413 A/C tube bracket nut
2 19A579 A/C tube bracket
3 19A579 A/C tube bracket
4 19835 A/C tube
5 12D305 A/C tube
6 W710824 Engine mount bracket bolt
7 N807144
Engine mount bracket nut (3
required)
8 6A094 Engine mount bracket
9 W500233 Engine mount bolt (3 required)
10 6068 Engine mount

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3. Remove the DC-to-DC converter. For additional information, refer to HIGH VOLTAGE
CONVERTER/INVERTER article.
Fig. 122: Supporting Engine With Special Tool
5. Remove the engine mount bracket bolt.
6. Use the special tool to raise the engine 25 mm (0.98 in).
Fig. 123: Supporting Engine With Special Tool
7. Remove the 3 nuts and the engine mount bracket.
8. Remove the A/C tube bracket nut.
9. Rotate the A/C tube brackets off of the studs.
Reposition the A/C tubes to access the engine mount bolt.

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10. Remove the 3 bolts and the engine mount.
REMOVAL
ENGINE
Special Tools
All vehicles
Heavy Duty Floor Crane 014-00071 or equivalent
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Powertrain Lift (014-00765)
Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or
equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any
type when working on or near any fuel-related components.
Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in
personal injury.

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2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM -
5. Drain the cooling system. For additional information, refer to ENGINE COOLING -
HYBRID article.
6. Drain the motor electronics cooling system. For additional information, refer to
TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
7. Remove the intake manifold. For additional information, refer to Intake Manifold.
8. Remove the engine air cleaner. For additional information, refer to INTAKE AIR
DISTRIBUTION AND FILTERING - HYBRID article.
9. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM
article.
11. Remove the LH front drive halfshaft. For additional information, refer to FRONT DRIVE
HALFSHAFTS article.
All wheel drive (AWD) vehicles
12. Remove the transfer case. For additional information, refer to TRANSFER CASE -
POWER TRANSFER UNIT (PTU) article.
Front wheel drive (FWD) vehicles
13. Remove the front drive intermediate halfshaft. For additional information, refer to FRONT
DRIVE HALFSHAFTS article.
14. Remove the bolts and the lateral support crossmember.

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Fig. 124: Identifying Lateral Support Crossmember And Bolts
All vehicles
15. Remove the oil filter element. For additional information, refer to Engine Lubrication
Components - Exploded View and Oil Filter Element in this section.
16. Drain the engine oil.
17. Disconnect the heater hoses from the heater core.
Fig. 125: Locating Heater Hoses
18. Detach the heater hose retaining clip from the transaxle mount stud.

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Fig. 126: Heater Hose Retaining Clip
19. Disconnect the upper radiator and coolant vent hoses.
Fig. 127: Upper Radiator & Coolant Vent Hoses
20. Disconnect the following electrical connectors:
Transaxle mount control solenoid
Purge valve
Fig. 128: Transaxle Mount Control Solenoid & Purge Valve Electrical Connectors

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21. Disconnect the engine control harness.
Release the powertrain control module (PCM) connector.
Remove the harness retaining nut.
Fig. 129: Powertrain Control Module (PCM) Connector & Nut
22. Disconnect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
Fig. 130: Engine Control Harness Electrical Connectors
23. Remove the bolt and disconnect the transaxle harness electrical connector.
Fig. 131: Transaxle Harness Electrical Connector & Bolt

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24. Disconnect the DC-to-DC converter electrical connector and pin-type retainer.
Fig. 132: DC-To-DC Converter Electrical Connector
25. Remove the 3 nuts and position aside the DC-to-DC converter.
Fig. 133: DC-To-DC Converter & Nuts
26. Disconnect and remove the fuel supply tube and evaporative emissions (EVAP) tube.
Fig. 134: Fuel Supply Tube And Evaporative Emissions (EVAP) Tube

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27. If equipped, position the block heater wiring harness aside.
Detach the 3 harness retainer clips.
Route the harness through the radiator support into the engine compartment.
Fig. 135: Block Heater Wiring Harness
28. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position
the auxiliary coolant pump aside.
Fig. 136: Auxiliary Coolant Pump Electrical Connector & Bolts
29. Remove the bolts and the transaxle control snow shield.
NOTE: Parts removed from view for clarity.

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Fig. 137: Transaxle Control Splash Shield
30. Disconnect the transaxle control cable.
Release the transaxle control cable from the control lever.
Remove the nuts from the transaxle control cable bracket.
Fig. 138: Selector Lever Cable Bracket Nuts
31. Disconnect the pin-type retainer.
Fig. 139: Pin-Type Retainer

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32. Disconnect the pin-type retainer and position the transaxle control cable aside.
33. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type
retainer.
Fig. 141: Motor Electronics Coolant Temperature Sensor Electrical Connector
34. Disconnect the transaxle coolant hoses.
Fig. 142: Transaxle Coolant Hoses

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35. Remove the nut and the ground cable.
Fig. 143: Ground Cable & Nut
36. Remove the 2 bolts and position the motor electronics coolant pump and ground strap aside.
Fig. 144: Motor Electronics Coolant Pump & Ground Strap
37. Disconnect the lower radiator hose from the radiator.
Fig. 145: Locating Lower Radiator Hose

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38. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the
A/C compressor aside and support the compressor with a length of mechanic's wire.
Fig. 146: A/C Compressor Electrical Connector & Bolts
39. Remove the front roll restrictor bolt.
Fig. 147: Front Roll Restrictor Bolt
40. Remove the rear roll restrictor bolt.
Fig. 148: Rear Insulator Bolt

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41. Remove the nut, bolts and the engine support crossmember.
Discard the nut.
Fig. 149: Engine Support Crossmember & Fasteners
42. Remove the 2 transaxle-to-engine bolts.
Fig. 150: Transaxle-To-Engine Bolts
NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts
for correct installation.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts

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44. Using the special tools, secure the engine to the lift table.
Fig. 152: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Fig. 153: Engine Mount Bracket Bolt
CAUTION: Due to the weight of the transaxle, special care should be
taken to mount the powertrain securely to the lift table.

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46. Remove the nuts and the engine mount bracket.
Fig. 154: Engine Mount Bracket Nuts
47. Remove the RH transaxle mount bracket nut.
Fig. 155: Right Transaxle Mount Bracket Nut
48. Remove the bolts and the RH transaxle mount bracket.
Fig. 156: Right Transaxle Mount Bracket Bolts

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49. Remove the bolt, nut and the rear transaxle mount brace.
Fig. 157: Rear Transaxle Mount Brace & Bolts
50. Remove the nuts, bolt and rear transaxle mount.
Fig. 158: Rear Transaxle Mount & Fasteners
51. Lower the engine and transaxle from the vehicle.
52. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
53. Disconnect the high voltage wiring harness electrical connector.
Fig. 159: High Voltage Wiring Harness Electrical Connector

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54. Disconnect the 2 high voltage wiring harness electrical connectors and position the harness
aside.
Fig. 160: High Voltage Wiring Harness Electrical Connectors
55. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
56. Remove the bolts and the transaxle damper.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts
NOTE: Due to packaging requirements the correct bolt must be used
at the damper locations.
NOTE: The damper contains a clutch which is designed to slip briefly
during vehicle operation. It is essential that no grease, oil or
cleaning solvents be allowed to contaminate the slip clutch. Do
not use grease on transmission input shaft. Should the damper
become contaminated, a new damper must be installed.

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Fig. 161: Transaxle Damper Bolts
DISASSEMBLY
ENGINE
Special Tools
Spreader Bar
303-D089 (D93P-6001-A3)
or equivalent
Engine Stand 014-00232 or equivalent

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Flange
205-126 (T78P-4851-A)
Adapter for 205-126 (205-072-02)
occur.
created while cleaning gasket surfaces that enters the oil
passages, coolant passages or the oil pan, can cause engine
failure.

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All vehicles
1. Remove the 6 bolts and the flywheel.
Fig. 162: Flywheel Bolts
2. Mount the engine on a suitable stand.
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
CAUTION: Due to the precision fit and timing of the balancer shaft
assembly, it cannot be removed from the engine block.
NOTE: For additional information, refer to the exploded views under
engine assembly.
build engines.

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Fig. 163: Crankshaft Position (CKP) Sensor Electrical Connector
4. Remove the bolt and the engine wiring harness connector bracket.
Fig. 164: Engine Wiring Harness Connector Bracket & Bolt
5. Detach the engine wiring harness pin-type retainer.
Fig. 165: Engine Wiring Harness Pin-Type Retainer
6. Remove the 3 bolts and the accessory drive belt tensioner.

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Fig. 166: Accessory Drive Belt Tensioner & Bolts
7. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
Fig. 167: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-
Plug
8. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor
electrical connector.
Fig. 168: Locating Cylinder Head Temperature Sensor Electrical Connector And
Rubber Boot
9. If equipped, disconnect the block heater electrical connector.

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Fig. 169: Block Heater Electrical Connector
10. Disconnect the radio ignition interference capacitor electrical connector.
Fig. 170: Radio Ignition Interference Capacitor Electrical Connector
11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector and remove the
engine control wiring harness from the engine.
Fig. 171: Exhaust Gas Recirculation (EGR) Valve Electrical Connector
12. Remove the 3 bolts and the coolant pump pulley.

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Fig. 172: Locating Coolant Pump Pulley Bolts
13. Remove the 3 bolts and the coolant pump.
Fig. 173: Locating Coolant Pump Bolts
14. Disconnect the coolant hose.
Fig. 174: Coolant Hose
15. Remove the 3 bolts and the thermostat housing.

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Fig. 175: Thermostat Housing & Bolts
16. Disconnect the coolant hose.
Fig. 176: Locating Coolant Bypass Hose
17. Remove the bolt and the knock sensor (KS).
Fig. 177: Locating KS And Bolt
18. Remove the 8 bolts and the crankcase vent oil separator.

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Fig. 178: Locating Crankcase Vent Oil Separator And Bolts
19. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
Fig. 179: Oil Filter Adapter & Bolts
20. Disconnect and remove the coolant hoses.
Fig. 180: Coolant Hoses
21. If equipped, remove the block heater.

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Fig. 181: Locating Block Heater
22. Remove the engine cover studs.
Fig. 182: Engine Cover Studs
23. Remove the crankcase vent tube and the coil-on-plugs.
Fig. 183: Locating Crankcase Vent Tube And Coil-On-Plugs
CAUTION: Only use hand tools when removing or installing the
spark plugs, damage can occur to the cylinder head or

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24. Remove the spark plugs and the CHT sensor.
Discard the CHT sensor.
Fig. 184: Locating Cylinder Head Temperature Sensor And Spark Plugs
25. Remove the bolts and the valve cover.
Fig. 185: Locating Valve Cover Bolts
at TDC.
spark plug.

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engine damage.

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at the TDC position during the crankshaft pulley removal and
installation.

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Fig. 190: Assembling Special Tools (205-126 And 205-072-02) And Hardened
Washers
31. Using the special tools and an air impact wrench, remove the crankshaft pulley.
Remove and discard the crankshaft pulley bolt and washer.
Remove the crankshaft pulley.
removal of the pulley bolt or damage to the engine can
removed using an air impact wrench (1/2-in drive
minimum).
CAUTION: If the crankshaft sprocket diamond washer comes off with
the crankshaft pulley, it must be installed back onto the
crankshaft.

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Fig. 192: Identifying Special Tool (303--409) And Crankshaft Front Oil Seal
33. Remove and discard the CKP sensor.
installed using the alignment tool supplied with the new part.

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Fig. 193: Locating CKP Sensor
34. Remove the bolts and the engine front cover.
Fig. 194: Locating Engine Front Cover Bolts
35. Remove the timing chain tensioner.
1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the
tensioner.
2. Remove the bolts and timing chain tensioner.

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Fig. 195: Identifying Paper Clip Into Hole And Bolts
36. Remove the RH timing chain guide.
37. Remove the timing chain.
38. Remove the bolts and the LH timing chain guide.

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39. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the
camshaft sprockets.
Fig. 199: Locating Cam Holding Area And Sprocket Bolt
40. Remove the oil pump drive chain tensioner and guide.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the shoulder bolt.
3. Remove the guide.
CAUTION: Do not rely on the Camshaft Alignment Plate to prevent
camshaft rotation. Damage to the tool or the camshaft
can occur.

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Fig. 200: Locating Oil Pump Bolts
Late build vehicles
41. Remove the oil pump chain tensioner.
Release the tension on the tensioner spring.
Remove the tensioner and the 2 shoulder bolts.
Fig. 201: Locating Shoulder Bolts & Tensioner
All vehicles
42. Remove the oil pump chain and sprockets.
1. Remove the bolt.
2. Remove the chain and sprockets.
NOTE: Remove the crankshaft sprocket diamond washers located in
front of and behind the crankshaft sprocket.
NOTE: The oil pump chain sprocket must be held in place.

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Fig. 202: Identifying Bolt, Chain And Sprockets
43. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat
until all the tension is released.
Remove the camshaft bearing caps.

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45. Remove the cylinder head.
Remove and discard the cylinder head bolts.
Remove the cylinder head.
Remove and discard the cylinder head gasket.
Fig. 205: Locating Cylinder Head Bolts
46. Remove the cylinder head alignment dowels.
Fig. 206: Identifying Cylinder Head Alignment Dowels

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47. Remove the bolts and the oil pan.
Fig. 207: Locating Oil Pan Bolts
48. Remove the bolts and the rear crankshaft seal.
Fig. 208: Locating Rear Crankshaft Seal Bolts
49. Remove the bolts, oil pump pickup tube and gasket.
Fig. 209: Locating Oil Pump Pickup Tube Bolts

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50. Remove the bolts and the oil pump.
Fig. 210: Locating Oil Pump Assembly & Bolts
51. Remove the bolts and the block-off plate.
Fig. 211: Block-Off Plate & Bolts
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
CYLINDER HEAD
Special Tools

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Material
Remover, Valve Stem Oil
Seal
303-468 (T94P-6510-AH)
Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)
Slide Hammer 307-005 (T59L-100-B)
Item Specification
Blend Motor Oil
WSS-M2C930-A
XG-4 and/or XL-5
ESB-M1C93-B

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Fig. 212: Exploded View Of Cylinder Head Components
1 W500225
valve bolt (2 required)
2 9D475 EGR valve
3 9D476 EGR valve gasket
4 W500015 Coolant outlet bolt (4 required)
5 8K556 Coolant outlet
6 8255 Coolant outlet gasket
7 6G004
sensor
8 12405 Spark plug (4 required)
13 6517 Valve seal (16 required)
14 6505 Intake valve (8 required)

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DISASSEMBLY
1. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve.
Discard the gasket.
2. Remove the 4 bolts and the coolant outlet.
Discard the gasket.
3. Remove and discard the cylinder head temperature (CHT) sensor.
4. Remove the spark plugs.
5. Remove the valve tappets.
6. Using the special tools, compress the valve springs and remove the valve collets, valve
spring retainers and the valve springs.
7. Inspect the components, if necessary. For additional information, refer to ENGINE
8. Remove the valves.
9. Using the special tools, remove and discard the valve seals.
15 6507 Exhaust valve (8 required)
CAUTION: If the components are to be reinstalled, they must be installed
in the same positions. Mark the components removed for
locations.
NOTE: Use a small screwdriver and grease to remove the valve
collets.

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Fig. 214: Identifying Special Tools (307--005, 303--468)
10. Inspect the valves. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION article. Install new parts, as necessary.
ASSEMBLY
1. Install the valves.
2. Using the special tool, install the valve seals.
NOTE: Coat the valve stems with clean engine oil.
NOTE: Use the protector provided with the replacement kit to prevent
damage to the valve seals. Lubricate the valve stems and
guides with clean engine oil.
NOTE: Check the seating of the valve collets.

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3. Using the special tools, install the valve springs.
Insert the valve springs and the valve spring retainers.
Compress the valve springs and install the valve collets, using grease and a small
screwdriver.
4. Install the valve tappets.
5. Install the spark plugs.
6. Install a new CHT sensor.
7. Using a new gasket, install the coolant outlet and bolts.
8. Install the EGR valve, using a new gasket.
ASSEMBLY
ENGINE
Special Tools
NOTE: Coat the valve tappets with clean engine oil.

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Spreader Bar
303-D089 (D93P-6001-A3)
or equivalent
Flange
205-126 (T78P-4851-A)
Adapter for 205-126 (205-072-02)
Installer, Crankshaft Rear
Main Oil Seal
303-328 (T88P-6701-B1)

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Material
Item Specification
Blend Motor Oil
WSS-M2C930-A
Metal Surface Cleaner
ZC-21
WSE-M5B392-A
TA-30
WSE-M4G323-A4
Motorcraft Silicone Gasket Remover
ZC-30
-
Motorcraft Metal Surface Prep
ZC-31
-
Silicone Brake Caliper Grease and
Dielectric Compound
XG-3-A
ESE-M1C171-A
Motorcraft Premium Gold Engine Coolant
with Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or
equivalent (yellow color)
WSS-M97B51-A1
High-Temp 4x4 Front Axle and Wheel
Bearing Grease
E8TZ-19590-A
ESA-M1C198-A

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Fig. 217: Exploded View Of Lower Engine Block Components
1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
3 6477 Flywheel
4 7550 Transaxle damper
5 6675 Oil pan
6 6622 Oil pump screen and pickup tube
7 8575 Thermostat assembly
8 6A785 Crankcase vent oil separator

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Fig. 218: Exploded View Of Front Engine Block Components
9 6884 Oil filter adapter
10 6A636 Oil filter adapter gasket

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1 8620 Accessory drive belt
2 6B209 Accessory drive belt tensioner
3 19D629 A/C compressor
4 8501 Coolant pump
5 6A340 Crankshaft pulley bolt
6 6316 Crankshaft pulley
8 6C315 Crankshaft position (CKP) sensor
9 6019 Engine front cover
10 6K254 Timing chain tensioner
11 6K255 Timing chain tensioner arm
12 6268 Timing chain
13 6K297 Timing chain guide
14 6C271 Oil pump drive chain tensioner
15 6M256
Oil pump drive chain guide (early
bird)
16 6A895 Oil pump drive chain
17 6652 Oil pump drive gear
18 6378 Diamond washer
19 6306 Crankshaft sprocket
20 6378 Diamond washer
21 6600 Oil pump

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Fig. 219: Exploded View Of Cylinder Head Components
1 12A366 Coil-on-plug assembly
2 6M293 Valve cover

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3 12K073 Camshaft position (CMP) sensor
4 6766 Oil filler cap
5 6M293 Valve cover gasket
6 6A284 Camshaft bearing cap
7 6A272 Camshaft (exhaust)
8 6A271 Camshaft (intake)
13 6A517 Valve stem seal (16 required)
14 6G004
sensor
15 12405 Spark plug (4 required)
16 6065 Cylinder head bolt (10 required)
18 6505 Exhaust valve (8 required)
19 6507 Intake valve (8 required)
20 6051 Head gasket
22 6C251 Camshaft sprocket (2 required)
23 9448 Catalytic converter gasket
24 5E211 Catalytic converter
25 6765 Oil fill extension

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Fig. 220: Exploded View Of Intake Manifold Components
1 9288 Fuel supply tube
2 8K556 Coolant outlet
3 9D475
valve
4 9F991 Electronic throttle body
5 6051 Cylinder head gasket
7 12A699 Knock sensor (KS)

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All vehicles
8 6754
Oil level indicator and tube
assembly
9 9424 Intake manifold
10 9439 Intake manifold gasket
11 8A582 Coolant hose
13 9F593 Fuel injector (4 required)
14 9H487 Fuel rail
occur.
created while cleaning gasket surfaces that enters the oil
passages, coolant passages or the oil pan, can cause engine
failure.
build engines.

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1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
at the TDC position until the timing drive components and
crankshaft pulley are installed.

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4. Install the block-off plate and bolts.
Fig. 223: Block-Off Plate & Bolts
5. Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2
stages:
NOTE: Clean the oil pump and cylinder block mating surfaces with
metal surface cleaner.

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Fig. 224: Identifying Oil Pump Bolts Tightening Sequence
6. Install a new oil pump pickup tube gasket and the pickup tube.
Fig. 225: Locating Oil Pump Pickup Tube Bolts
7. Using the special tool, install the crankshaft rear main oil seal.
Fig. 226: Installing Crankshaft Rear Main Oil Seal Using Special Tool (303-328)

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8. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
Fig. 227: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
9. Clean and inspect all mating surfaces.
10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
Install the oil pan.
Install the 2 oil pan bolts finger-tight.
make leak paths. Use a plastic scraping tool and metal
surface cleaner to remove traces of sealant.

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11. Using a suitable straightedge, align the front surface of the oil pan flush with the front
12. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.

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13. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder
block.
Fig. 231: Identifying Cylinder Head Alignment Dowels
14. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the
surfaces. These tools cause scratches and gouges that
make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.
CAUTION: Observe all warnings and cautions and follow all
application directions contained on the packaging of the
silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface
prep can be used to clean and prepare the surfaces.

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cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for
several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of
silicone gasket remover may be required if residual traces of silicone or gasket
material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or
coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.
Fig. 232: Identifying Silicone Gasket And Sealant Location
16. Install a new head gasket.
Fig. 233: Locating Head Gasket
NOTE: The cylinder head bolts are torque-to-yield and must not be
reused. New cylinder head bolts must be installed.

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17. Install new cylinder head bolts. Tighten the bolts in the sequence shown in the following 5
stages:
Stage 4: Turn 90 degrees.
Stage 5: Turn an additional 90 degrees.
Fig. 234: Identifying Tightening Sequence Of Cylinder Head Bolts
18. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in the
following 3 stages:
Stage 1: Tighten 1 turn at a time until tight.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
CAUTION: Install the camshafts with the alignment slots in the
camshafts lined up so the Camshaft Alignment Plate can
be installed without rotating the camshafts. Make sure
the lobes on the No. 1 cylinder are in the same position
as noted in the disassembly procedure. Rotating the
camshafts when the timing chain is removed, or installing
the camshafts 180 degrees out of position, can cause
severe damage to the valves and pistons.
engine oil.

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Fig. 235: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
19. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil
pump sprocket.
The crankshaft sprocket flange must be facing away from the engine block.
Fig. 236: Locating Washers, Oil Pump Chain & Sprockets
20. Install the oil pump chain, sprocket and bolt.
NOTE: Install a crankshaft sprocket diamond washer on both sides of
the crankshaft sprocket.

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Fig. 237: Locating Oil Pump Chain, Sprocket And Bolt
Late build vehicles
21. Install the oil pump drive chain tensioner shoulder bolt.
Fig. 238: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
22. Install the oil pump drive chain guide and the shoulder bolts.

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Fig. 239: Installing Oil Pump Drive Chain Guide And Shoulder Bolts
All vehicles
23. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the
shoulder bolt.
Fig. 240: Locating Oil Pump Chain Tensioner
engine damage.

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25. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
26. Install the LH timing chain guide and the bolts.
27. Install the timing chain.

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28. Install the RH timing chain guide.
29. Using the edge of a vise, compress the timing chain tensioner plunger.
Fig. 246: Locating Timing Chain Tensioner Plunger
CAUTION: Do not compress the ratchet assembly. This will damage
the ratchet assembly.

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30. Using a small pick, push back and hold the ratchet mechanism.
Fig. 247: Holding Ratchet Mechanism Using Small Pick
31. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig. 248: Pushing Ratchet Arm Back Into Tensioner Housing
32. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and
the plunger in during installation.
Fig. 249: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet
Assembly

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33. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
Fig. 250: Locating Timing Chain Tensioner Bolts And Paper Clip
engine damage.
disks or other abrasive means to clean sealing surfaces.
These tools cause scratches and gouges which make
leak paths.

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35. Clean and inspect the mounting surfaces of the engine and the front cover.
36. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil
pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front
cover.
Fig. 252: Locating Silicone Gasket
37. Install the engine front cover. Tighten the bolts in the sequence shown, to the following
specifications:
Tighten the 8-mm bolts to 10 Nm (89 lb-in).
Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
NOTE: The engine front cover must be installed and the bolts
tightened within 4 minutes of applying the silicone gasket and
sealant.

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Fig. 253: Identifying Engine Front Cover Bolts Tightening Sequence
NOTE: Remove the through-bolt from the special tool.
CAUTION: Do not install the crankshaft pulley bolt at this time.

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39. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock
position.
Fig. 255: Locating Crankshaft Pulley & Hole
Fig. 256: Locating Crankshaft Pulley Bolt
NOTE: Apply clean engine oil on the seal area before installing.
CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to
the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the
crankshaft.

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Fig. 257: Assembling Special Tools (205-126 And 205-072-02)
42. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in
place, tighten the crankshaft pulley bolt in 2 stages:
Stage 2: Tighten an additional 90 degrees (1/4 turn).
installation of the pulley bolt or damage to the engine can
installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.

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46. Turn the crankshaft clockwise 1 and 3/4 turns.
48. Turn the crankshaft clockwise until the crankshaft contacts the special tool.

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49. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
If it is not possible to install the bolt, the engine valve timing must be corrected.
50. Using the special tool, check the position of the camshafts.
If it is not possible to install the special tool, the engine valve timing must be
can occur.

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corrected.
52. Install a new CKP sensor and the 2 bolts.
Do not tighten the bolts at this time.
NOTE: Whenever the crankshaft position (CKP) sensor is removed, a
new one must be installed using the alignment tool supplied
with the new part.

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Fig. 267: Locating CKP Sensor
53. Adjust the CKP sensor with the alignment tool.
Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
Fig. 268: Locating CKP Sensor Alignment Tool And Bolts
NOTE: The CKP sensor alignment tool is supplied with the new sensor
and is not available separately.

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57. Clean the valve cover gasket surface with metal surface cleaner.
surfaces. These tools cause scratches and gouges which
make leak paths.

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Fig. 272: Locating Silicone Gasket Applying Area
59. Install the valve cover.
Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
Fig. 273: Identifying Valve Cover Bolts Tightening Sequence
60. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
Tighten the CHT sensor to 12 Nm (9 lb-ft).
Tighten the spark plugs to 12 Nm (9 lb-ft).
NOTE: The valve cover must be secured within 4 minutes of silicone
gasket application. If the valve cover is not secured within 4
minutes, the sealant must be removed and the sealing area
cleaned with metal surface cleaner.

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Fig. 274: Locating Cylinder Head Temperature Sensor And Spark Plugs
61. Install the coil-on-plugs, bolts and the crankcase vent tube.
Fig. 275: Locating Crankcase Vent Tube And Coil-On-Plugs
62. Install the 3 engine cover studs.
Fig. 276: Engine Cover Studs
NOTE: Apply dielectric compound to the inside of the coil-on-plug
boots.

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63. If equipped, install the block heater.
Fig. 277: Locating Block Heater
64. Install the coolant hoses.
Fig. 278: Coolant Hoses
65. Install the oil filter adapter with a new gasket.
NOTE: Clean the gasket mating surfaces with metal surface cleaner.

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Fig. 279: Oil Filter Adapter & Bolts
66. Install the crankcase vent oil separator and the KS.
Tighten the oil separator bolts to 10 Nm (89 lb-in).
Tighten the KS to 20 Nm (15 lb-ft).
Fig. 280: Locating Crankcase Vent Oil Separator, KS And Bolts
67. Install the coolant hose.
NOTE: The knock sensor (KS) must not touch the crankcase vent oil
separator.

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Fig. 281: Locating Coolant Bypass Hose
68. Install the thermostat housing.
Fig. 282: Thermostat Housing & Bolts
69. Install the coolant hose.
Fig. 283: Coolant Hose
70. Install the coolant pump and bolts.
NOTE: Clean and inspect the thermostat housing gasket. Replace if
necessary.
NOTE: Clean the coolant pump mating surface with metal surface
cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

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Fig. 284: Locating Coolant Pump Bolts
71. Install the coolant pump pulley and bolts.
Fig. 285: Locating Coolant Pump Pulley Bolts
72. Position the engine control wiring harness on the engine and connect the exhaust gas
recirculation (EGR) valve electrical connector.
Fig. 286: Exhaust Gas Recirculation (EGR) Valve Electrical Connector

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73. Connect the radio ignition interference capacitor electrical connector.
Fig. 287: Radio Ignition Interference Capacitor Electrical Connector
74. If equipped, connect the block heater electrical connector.
Fig. 288: Block Heater Electrical Connector
75. Connect the CHT sensor and install the rubber boot.
76. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.

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Fig. 289: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-
Plug
77. Install the accessory drive belt tensioner.
Fig. 290: Accessory Drive Belt Tensioner & Bolts
78. Attach the engine wiring harness pin-type retainer.
Fig. 291: Engine Wiring Harness Pin-Type Retainer
79. Install the engine wiring harness connector bracket.

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Fig. 292: Engine Wiring Harness Connector Bracket & Bolt
80. Connect the CKP sensor electrical connector.
Fig. 293: Crankshaft Position (CKP) Sensor Electrical Connector
81. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
82. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3
stages:
NOTE: Special bolts are used for installation. Do not use standard
bolts.

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Fig. 294: Identifying Flexplate Bolts Tightening Sequence
INSTALLATION
ENGINE
Special Tools
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Powertrain Lift (014-00765)
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or
equivalent

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Material
All vehicles
1. Install the transaxle damper.
Fig. 295: Transaxle Damper Bolts
Item Specification
Blend Motor Oil
WSS-M2C930-A
personal injury.
NOTE: Due to packaging requirements the correct bolt must be used
NOTE: The damper contains a clutch which is designed to slip briefly
during vehicle operation. It is essential that no grease, oil or
cleaning solvents be allowed to contaminate the slip clutch. Do
not use grease on transmission input shaft. Should the damper
become contaminated, it must be replaced.

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2. Using the engine crane and spreader bar, position the engine and transaxle together. Install
the 6 transaxle-to-engine bolts.
3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
Fig. 297: High Voltage Wiring Harness Electrical Connectors
4. Connect the high voltage wiring harness electrical connector.
CAUTION: When positioning the engine to the transaxle, care must
be taken to maintain alignment of the damper spline with
the transaxle input shaft.
NOTE: Transaxle removed from view for clarity.

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Fig. 298: High Voltage Wiring Harness Electrical Connector
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
Fig. 299: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount.
Tighten the nuts to 90 Nm (66 lb-ft).
Tighten the bolt to 103 Nm (76 lb-ft).

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Fig. 300: Rear Transaxle Mount & Fasteners
9. Install the rear transaxle mount brace.
Fig. 301: Rear Transaxle Mount Brace & Bolts
10. Install the RH transaxle mount bracket.
Fig. 302: Right Transaxle Mount Bracket Bolts

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11. Install the RH transaxle mount bracket nut.
Fig. 303: Right Transaxle Mount Bracket Nut
12. Install the engine mount bracket.
Fig. 304: Engine Mount Bracket Nuts
13. Install the engine mount bracket bolt.

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Fig. 305: Engine Mount Bracket Bolt
14. Install the 2 transaxle-to-engine bolts.
16. Install the engine support crossmember.
Tighten the bolts to 90 Nm (66 lb-ft).
Tighten the new nut to 175 Nm (129 lb-ft).

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Fig. 308: Engine Support Crossmember & Fasteners
17. Install the rear roll restrictor bolt.
Fig. 309: Rear Insulator Bolt
18. Install the front roll restrictor bolt.
Fig. 310: Front Roll Restrictor Bolt

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19. Install the A/C compressor and connect the A/C compressor electrical connector.
Fig. 311: A/C Compressor Electrical Connector & Bolts
20. Connect the lower radiator hose to the radiator.
Fig. 312: Locating Lower Radiator Hose
21. Position the motor electronics coolant pump and the ground strap. Install the 2 bolts.
Fig. 313: Motor Electronics Coolant Pump & Ground Strap

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22. Install the ground cable and nut.
Fig. 314: Ground Cable & Nut
23. Connect the transaxle coolant hoses.
Fig. 315: Transaxle Coolant Hoses
24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.

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Fig. 316: Motor Electronics Coolant Temperature Sensor Electrical Connector
25. Position the transaxle control cable and connect the pin-type retainer.
26. Connect the pin-type retainer.
27. Connect the transaxle control cable.
Install the transaxle control cable bracket and the 2 nuts finger tight.
Attach the transaxle control cable to the control lever.

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Fig. 319: Selector Lever Cable Bracket Nuts
28. Position the control lever between the 2 casting ribs on the transaxle case.
Fig. 320: Selector Lever Between 2 Ribs On Transaxle Case
29. Place the gear selector lever in the D position.
30. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
31. To verify the correct cable adjustment, observe the control lever on the transaxle while an
assistant shifts the gear selector lever to each range position ending in the D position.
32. Install the transaxle control snow shield.

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Fig. 321: Transaxle Control Splash Shield
33. Install the auxiliary coolant pump and connect the electrical connector.
Fig. 322: Auxiliary Coolant Pump Electrical Connector & Bolts
34. If equipped, install the block heater wiring harness.
Route the harness through the radiator support.
Attach the 3 harness retainer clips.

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Fig. 323: Block Heater Wiring Harness
35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
Fig. 324: Fuel Supply Tube And Evaporative Emissions (EVAP) Tube
36. Position the DC-to-DC converter in place and install the 3 nuts.
Fig. 325: DC-To-DC Converter & Nuts
37. Connect the DC-to-DC converter electrical connector and pin-type retainer.

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Fig. 326: DC-To-DC Converter Electrical Connector
38. Connect the transaxle harness electrical connector and install the bolt.
Fig. 327: Transaxle Harness Electrical Connector & Bolt
39. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
Fig. 328: Engine Control Harness Electrical Connectors
40. Connect the engine control harness.

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Engage the powertrain control module (PCM) connector.
Install the harness retaining nut.
Fig. 329: Powertrain Control Module (PCM) Connector & Nut
41. Connect the following electrical connectors:
Transaxle mount control solenoid
Purge valve
Fig. 330: Transaxle Mount Control Solenoid & Purge Valve Electrical Connectors
42. Connect the upper radiator and coolant vent hoses.

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Fig. 331: Upper Radiator & Coolant Vent Hoses
43. Attach the heater hose retaining clip to the transaxle mount stud.
Fig. 332: Heater Hose Retaining Clip
44. Connect the heater hoses to the heater core.
Fig. 333: Locating Heater Hoses
Front wheel drive (FWD) vehicles

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45. Install the lateral support crossmember.
46. Install the front drive intermediate halfshaft. For additional information, refer to FRONT
DRIVE HALFSHAFTS article.
All wheel drive (AWD) vehicles
47. Install the transfer case. For additional information, refer to TRANSFER CASE -
POWER TRANSFER UNIT (PTU) article.
All vehicles
48. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE
HALFSHAFTS article.
49. Install the oil filter element. For additional information, refer to Engine Lubrication
Components - Exploded View and Oil Filter Element in this section.
50. Install the engine coolant degas bottle. For additional information, refer to ENGINE

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51. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM
article.
52. Install the engine air cleaner. For additional information, refer to INTAKE AIR
DISTRIBUTION AND FILTERING - HYBRID article.
53. Install the intake manifold. For additional information, refer to Intake Manifold.
54. Enable the vehicle high voltage electrical system. For additional information, refer to
57. Fill and bleed the motor electronics cooling system. For additional information, refer to
TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
58. Fill and bleed the cooling system. For additional information, refer to ENGINE

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2006 ENGINE
Engine Ignition - 2.3L - Escape & Mariner
SPECIFICATIONS
ENGINE IGNITION
The electronic ignition (El) system is a coil-on-plug ignition system. The coil-on-plug ignition system consists
of the following components:
Coil-on-plugs
Spark plugs
Crankshaft position (CKP) sensor
Camshaft position (CMP) sensor
The coil-on-plugs:
change low voltage signals from the powertrain control module (PCM) to high voltage pulses.
supply the high voltage pulses to the spark plugs.
are connected directly to each spark plug.
The spark plugs:
change high voltage pulses into a spark which ignites the fuel and air mixture.
The CKP sensor:
is a variable reluctance sensor.
is triggered by a 36-minus-l tooth trigger wheel mounted on the crankshaft.
provides base timing and crankshaft speed (rpm) to the PCM.
Item Specification
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Ignition coil bolts 8 - 71
Spark plugs 12 9 -

2006 ENGINE Engine Ignition - 2.3L - Escape & Mariner

Toshiba
Friday, J une 12, 2009 12:10:58 PM Page 1 2005 Mitchell Repair Information Company, LLC.
Toshiba
http://vnx.su
The CMP sensor:
is a variable reluctance sensor.
provides camshaft rotational location information to the PCM.
DIAGNOSIS AND TESTING
ENGINE IGNITION
Refer to the INTRODUCTION - GASOLINE .
ENGINE IGNITION COMPONENTS - EXPLODED VIEW

Toshiba
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Fig. 1: Engine Ignition Components - Exploded View (With Torque Specifications & Part Numbers)
IGNITION COIL-ON-PLUG
MATERIAL SPECIFICATIONS
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
Item Specification
Compound XG-3-A
ESE-M1C171-A

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2. Disconnect the ignition coil electrical connectors.
3. Remove the bolts and the ignition coils.
Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to
the spark plugs.
SPARK PLUGS
MATERIAL CHART
Removal
1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
2. Disconnect the ignition coil electrical connectors.
3. Remove the bolts and the ignition coils.
4. Remove the spark plugs.
Installation
1. Inspect the spark plugs.
Item Specification
Compound XG-3-A
ESE-M1C171-A
CAUTION: Only use hand tools when removing or installing the spark plugs, or
damage can occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well
before removing the spark plugs.

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Fig. 2: Inspecting Spark Plugs
2. Adjust the spark plug gap as necessary.

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Fig. 3: Identifying Spark Plug Gap
3. Install the spark plugs and tighten to 12 Nm (9 lb-ft).
4. Install the ignition coils and bolts and tighten to 8 Nm (71 lb-in).
5. Connect the ignition coil electrical connectors.
6. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
CAUTION: Only use hand tools when removing or installing the spark plugs, or
damage can occur to the cylinder head or spark plug.
NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil
boots before attaching to the spark plugs.

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2005 ENGINE PERFORMANCE
Engine Emission Control - Hybrid - Escape & Mariner
SPECIFICATIONS
ENGINE EMISSION CONTROL
The engine emission control system consists of the:
positive crankcase ventilation (PCV) system.
exhaust gas recirculation (EGR) system.
Positive Crankcase Ventilation (PCV) System
The PCV system uses intake manifold vacuum to ventilate blow-by fumes from the crankcase and
return the fumes to the intake manifold for combustion. The PCV valve varies the amount of
blow-by gases returned to the intake manifold based on available engine vacuum. The PCV valve
also prevents the entry of combustion backfiring into the crankcase.
Exhaust Gas Recirculation
The EGR system returns a small amount of exhaust gas into the intake manifold. This reduces the
overall combustion temperature. Cooler combustion temperatures provide a significant reduction
Exhaust gas recirculation (EGR) valve assembly
bolts
25 18 -
Crankcase vent oil separator bolts 10 - 89
Motor electronics coolant pump bolts 7 - 62
CAUTION: Do not remove any part of the engine emission control
system. Operating the engine without the engine emission
control system intact will reduce fuel economy and engine
ventilation. This will weaken engine performance and shorten
engine life.

2005 ENGINE PERFORMANCE Engine Emission Control - Hybrid - Escape & Mariner

MY
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of the oxides of nitrogen (NOx) in the exhaust emissions.
The engine incorporates a stepper motor-controlled EGR valve which receives its signal from the
PCM. Engine coolant is used to cool the EGR valve. The EGR valve and stepper motor are
serviced as an assembly.
The amount of recirculated exhaust gas depends on:
engine rpm.
intake manifold vacuum.
exhaust backpressure.
engine coolant temperature.
throttle position.
Exhaust Emission Control System
The vehicle emission control information (VECI) decal is located on the upper radiator support
and shows:
components of the emission control system.
the correct vacuum hose routing.
the color stripe of the vacuum hoses.
EXHAUST GAS RECIRCULATION (EGR) VALVE

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Fig. 1: Identifying Exhaust Gas Recirculation Component With Torque Specifications
JACKING AND LIFTING .
2. Drain the cooling system. For additional information, refer to ENGINE COOLING -
HYBRID .
3. Disconnect the EGR valve electrical connector.
4. Disconnect the coolant hose from the EGR valve.
5. Remove the 2 bolts and the EGR valve.
Discard the gasket.

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Clean and inspect the EGR gasket mating surfaces.
7. Fill and bleed the cooling system. For additional information, refer to ENGINE
COOLING - HYBRID .
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM COMPONENTS - EXPLODED VIEW
VIEW
Fig. 2: Removing Positive Crankcase Ventilation (PCV) System Components With
Torque Specifications
1. For additional information, refer to the procedures in this article.

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POSITIVE CRANKCASE VENTILATION (PCV) VALVE
2. Remove the intake manifold. For additional information, refer to ENGINE - HYBRID
2.3L .
3. Disengage the positive crankcase ventilation (PCV) valve cap from the 2 tabs and remove
the PCV valve.
Fig. 3: Identifying Positive Crankcase Ventilation
CRANKCASE VENT OIL SEPARATOR

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2.3L .
3. Remove the 8 bolts and the crankcase vent oil separator.
Clean the engine block mating surface.

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Symptom Charts - Hybrid Engines
DIAGNOSTIC TESTS
PINPOINT TEST QT: STEP 1: POWERTRAIN CONTROL MODULE (PCM)/TRANSAXLE
CONTROL MODULE (TCM) QUICK TEST
QT1 CARRY OUT THE NETWORK TEST
Carry out all the safety steps required to run the vehicle tests.
Complete the preliminary checks looking for obvious concerns that may relate to the
symptom. Check items such as those listed:
related electrical connectors or fuses
vacuum lines (leaks, routing)
air intake system (leaks, restrictions)
fuel quality (octane, contamination, winter/summer blend)
WARNING: This vehicle is equipped with high voltage cables,
components, and wiring. The high voltage warning labels
containing the high voltage symbol are located on each high
voltage component. High voltage cables, and wiring are
orange in color. Certified rubber insulating gloves and a face
shield must be worn when working with the high voltage
cables, components, or wiring. The key must be cycled to the
OFF position for a minimum of 5 minutes, and the high
voltage traction battery service disconnect plug placed in the
servicing/shipping position before disconnecting the high
voltage cables. Failure to follow these instructions may
result in personal injury or death.
Do not disconnect, disable, or touch the high voltage cables,
components, or wiring during the module reprogramming
procedure because high voltage is present. The high voltage
warning labels containing the high voltage symbol are
located on each high voltage component. High voltage
cables, and wiring are orange in color. Failure to follow these
instructions may result in personal injury or death.

2007 ENGINE PERFORMANCE Symptom Charts - Hybrid Engines

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engine cooling system (engine operating at proper temperature)
motor electronics cooling system
Access any related OASIS or TSB information.
Carry out the network test.
Does the network test pass?
QT2 CARRY OUT THE PCM AND TCM QUICK TEST
Complete the PCM quick test to access any DTCs. Note any key on engine off (KOEO), key
on engine running (KOER) (if engine runs) and continuous memory (MIL and non-MIL)
DTCs.
Complete the TCM quick test to access any DTCs. Note any KOEO and continuous memory
DTCs.
Are any PCM or TCM DTCs present?
NOTE: If the scan tool being used does not support the network test,
an alternative method is to attempt communication with each
module on the controller area network (CAN) link.
Yes No
GO to QT2.
If only the PCM or the TCM has a
communication concern:
refer to PINPOINT TEST QA .
All others:
Go to MODULE COMMUNICATIONS
NETWORK article to diagnose the network
concern.
NOTE: If unable to access the diagnostic trouble codes (DTCs), refer to
PINPOINT TEST QA . For additional information on retrieving
malfunction indicator lamp (MIL) and non-MIL DTCs, refer toQUICK
TEST .
NOTE: Do not carry out consecutive quick tests without turning the key to
OFF position for a minimum of 15 seconds.
Yes No

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STEP 2: NO DIAGNOSTIC TROUBLE CODE (DTC) PRESENT SYMPTOM
CHART INDEX
Driveability
Driveability - Performance While Driving Concerns
If DTC P0106, P1A0C, P2195 or P2279 is
retrieved and the engine runs rough or
backfires, check the positive crankcase
ventilation (PCV) system for damage, leaks,
cracks or a disconnected PCV valve or hose.
Repair as necessary.
GO toDIAGNOSTIC TROUBLE CODE
(DTC) CHARTS AND DESCRIPTIONS
for direction to repair any DTCs after noting
the following:
REPAIR DTCs in the following order (for
each mode, begin diagnosis with the first
DTC output).
Any PCM KOEO DTCs
Any PCM KOER DTCs
Any TCM KOEO DTCs
Any PCM continuous memory DTCs
(retrieve any available freeze frame
data and disregard any identical/related
continuous DTCs or DTCs already
repaired).
Any TCM continuous memory DTCs
(retrieve any available freeze frame
data and disregard any identical/related
continuous DTCs or DTCs already
repaired).
GO to STEP 2: NO DIAGNOSTIC
TROUBLE CODE (DTC) PRESENT
SYMPTOM CHART INDEX for direction
to the proper symptom chart in STEP 3: NO
DIAGNOSTIC TROUBLE CODE (DTC)
PRESENT SYMPTOM CHARTS.
NOTE:
If the symptom is not listed, REFER to applicable
article or refer to PINPOINT TEST Z (for
intermittent PCM or TCM system diagnostics).
System/Symptom Chart Number
Engine/Vehicle Starting
Concerns
No start/Vehicle disabled CHART NUMBER: 2
No start/Normal crank CHART NUMBER: 3
Unique Idle Concerns Rolling idle CHART NUMBER: 1

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Note: OASIS identifiers (the x means any number (1-9) can be used) xxx4xx=during idle,
xxx5xx=during acceleration, xxx6xx=during cruise, xxx7xx=during deceleration.
Additional Driveability Concerns
Electrical
Engine
Vehicle Stalls/Quits Idle, Acceleration, Cruise CHART NUMBER: 1
Engine Runs Rough CHART NUMBER: 1
Engine Misses CHART NUMBER: 1
Vehicle Buck/Jerk CHART NUMBER: 1
Vehicle Hesitation/Stumble CHART NUMBER: 1
Vehicle Surge CHART NUMBER: 1
Engine Backfires CHART NUMBER: 4
Vehicle Lack/Loss of Power CHART NUMBER: 5
Engine Spark Knock CHART NUMBER: 6
Poor Fuel Economy CHART NUMBER: 7
Emissions Compliance CHART NUMBER: 8
Warning Indicators
Malfunction indicator lamp
(MIL)
CHART NUMBER: 9
Hazard indicator lamp CHART NUMBER: 9
Powertrain malfunction
indicator (wrench) lamp
CHART NUMBER: 9
Temperature warning
indicator lamp
CHART NUMBER: 9
Check fuel cap indicator lamp CHART NUMBER: 9
Climate Control
Lack of A/C cooling, A/C not
functioning
CHART NUMBER: 16
A/C always on, A/C
compressor runs continuously
CHART NUMBER: 16
High oil consumption CHART NUMBER: 10

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STEP 3: NO DIAGNOSTIC TROUBLE CODE (DTC) PRESENT SYMPTOM
CHARTS
CHART 1
Engine Runs Rough
Engine Misses
Vehicle Stalls/Quits: Idle, Acceleration, Cruise
Vehicle Buck/Jerk
Vehicle Hesitation/Stumble
Vehicle Surge
Unique Idle Concerns: Rolling Idle
Oil System Concerns Leaks CHART NUMBER: 10
Cooling System Concerns
Electric engine cooling fan(s)
does not operate (low,
medium or high speed)
CHART NUMBER: 11
Electric engine cooling fan(s)
always runs
CHART NUMBER: 12
Exhaust System Concerns
Visible smoke CHART NUMBER: 13
Odor (sulfur or rotten egg
smell)
CHART NUMBER: 17
Fuel System Concerns
Fuel odor, engine
compartment
CHART NUMBER: 14
Engine Noise (Under Hood) CHART NUMBER: 15
NOTE: The engine may stall if left running while refueling, or it may restart
if the key is not cycled to ACC or OFF position before refueling.
Advise the customer to turn the engine off while refueling to avoid
contamination or damage to the EVAP system.
SYSTEM/COMPONENT
REFERENCE (Pinpoint Test
unless noted)
LONGFT1 value low (-):
Continue diagnosis.
Concentrate checks in areas that

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Check the following parameter identification
(PID)s:
LONGFT1 (value between -20 and +20)
VPWR (value between 10.5 and 17.0
volts, and within 0.5 volt of battery
voltage)
cause the engine to run rich.
LONGFT1 value high (+):
Continue diagnosis.
Concentrate checks in areas that
cause the engine to run lean.
VPWR not between 10.5 and
17.0 volts:
REFER to GENERATOR
AND REGULATOR .
VPWR between 10.5 and 17.0
volts, but not within 0.5 volt
of battery voltage:
CHECK B(+) supply to the
powertrain control module
(PCM) power relay. CHECK
the VPWR circuit between the
PCM and the PCM power relay.
CHECK the PWR GND
circuits.
Mass Air Flow (MAF) Sensor
refer to PINPOINT TEST
DC .
Secondary Ignition System refer to PINPOINT TEST JB .
Fuel Delivery System
HC .
Exhaust System
HF .
Positive Crankcase Ventilation (PCV) System
HG .
Evaporative Emissions (EVAP) System
CHECK for EVAP system
blockages (engine stalls) or
leaks (other symptoms). REFER
to EVAPORATIVE
EMISSIONS - HYBRID .
Base Engine
REFER to ENGINE - 2.3L
HYBRID .

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CHART 2
- Engine/Vehicle Starting Concerns: No Start/Vehicle Disabled
CHART 3
- Engine/Vehicle Starting Concerns: No Start/Normal Crank
Intake Air System
HU .
Additional Testing refer to PINPOINT TEST Z .
Additional Checks:
Correct PCM vehicle identification (VID)
block information. Refer to Section 2,
FLASH ELECTRICALLY
ERASABLE PROGRAMMABLE
READ ONLY MEMORY
(EEPROM) .
Be aware of the engine RPM/speed
limiting functions of the PCM (look for
incorrect high vehicle speed signal from
ABS).
Driveline and electronically controlled
continuously variable transaxle (CVT)
A/C system (for surge with A/C on)
Speed control system (for surge with
speed control on)
REFER to applicable article.
SYSTEM/COMPONENT
unless noted)
Ignition switch inputs to the PCM, power and
ground to the modules, the traction battery
contactor status, and the vehicle mode.
AA .
SYSTEM/COMPONENT
unless noted)
Visual. CHECK with the

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CHART 4
- Engine Backfires
CHART 5
- Vehicle Lack/Loss of Power
Add-on Anti-Theft Devices
customer.
Fuel/Ignition
A .
Exhaust System (restrictions)
HF .
Base Engine
HYBRID .

Additional Testing
Z .
SYSTEM/COMPONENT
unless noted)
Secondary Ignition
JB .
HC .
Base Engine
HYBRID .
Exhaust System
HF .
Additional Testing
Z .
NOTE: Verify the symptom is reported under normal driving conditions
without excessive engine/vehicle load. Also, be aware of the engine
RPM/speed limiting functions of the PCM.

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SYSTEM/COMPONENT REFERENCE (Pinpoint Test unless noted)
Air Cleaner Element Visual
Check the following PIDs:
LONGFT1 (value between -
20 and +20)
Continue diagnosis.
Concentrate checks in areas that cause the
engine to run rich.
Continue diagnosis. Concentrate checks in
areas that cause the engine to run lean.
Fuel Delivery System refer to PINPOINT TEST HC .
Mass Air Flow (MAF) Sensor refer to PINPOINT TEST DC .
Exhaust System refer to PINPOINT TEST HF .
Base Engine REFER to ENGINE - 2.3L HYBRID .
Transaxle
REFER to AUTOMATIC
TRANSAXLE/TRANSMISSION -
ELECTRONICALLY CONTROLLED
CONTINUOUSLY VARIABLE
TRANSMISSION (ECVT) .
Motor Electronics Cooling System
REFER to
TRANSAXLE/TRANSMISSION
COOLING - HYBRID .
Brake System (brake drag or
binding)
REFER to BRAKE SYSTEM -
GENERAL INFORMATION .
Additional Checks:
Customer driving habits
Correct PCM vehicle
identification (VID) block
information. Refer to Section
2, FLASH
ELECTRICALLY
ERASABLE
Visual. REFER to the appropriate article.

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CHART 6
- Engine Spark Knock
PROGRAMMABLE
READ ONLY MEMORY
(EEPROM) .
Engine RPM/speed limiting
functions of the PCM (look
for an incorrect high vehicle
speed signal from the ABS
module).
SYSTEM/COMPONENT
unless noted)
Verify the engine operates at the normal
temperature.
Visual. REFER to ENGINE
COOLING - HYBRID , to
diagnose any cooling system
concerns that are present.
Verify correct coolant level and coolant
concentration.
REFER to ENGINE
COOLING - HYBRID , for
proper fill concentrations and
fill procedures.
Mass Air Flow (MAF) Sensor
DC .
Base Engine
HYBRID .
HC .
PCV System
HG .
Engine Oil Quality Visual
Knock Sensor
DG .

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CHART 7
- Poor Fuel Economy
stop/go driving
improper tire pressure/size
vehicle loads (such as trailer towing)
extended winter warm-up conditions
high speed driving
regenerative braking disabled
high traction battery temperatures
improper axle ratio
road/weather conditions
aftermarket add-ons
short run operations
customer expectations
NOTE: Since driving styles can have a significant influence on fuel
economy, verify the concern before starting an in-depth diagnosis.
Also, the following external factors may contribute to poor fuel
economy conditions:
Transaxle Fluid Level
Visual. REFER to AUTOMATIC
areas that cause the engine to run rich.

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Check the following PIDs:
LONGFT1 (value between -
20 and +20)
VPWR (value between 10.5
and 17.0 volts, and within 0.5
volt of battery voltage)
areas that cause the engine to run lean.
VPWR not between 10.5 and 17.0 volts:
REFER to GENERATOR AND
REGULATOR .
VPWR between 10.5 and 17.0 volts, but
not within 0.5 of battery voltage:
CHECK the B+ supply to the power relay.
CHECK the VPWR circuit between the
PCM and the power relay. CHECK the
PWR GND circuits.

Verify the engine operates at
normal temperature.
Visual. REFER to ENGINE COOLING -
HYBRID , to diagnose any cooling system
concerns that are present.
Fuel System
refer to PINPOINT TEST HC .

Exhaust System refer to PINPOINT TEST HF .
Automatic Transaxle
REFER to AUTOMATIC
PCV System refer to PINPOINT TEST HG .
Additional Checks:
Correct PCM vehicle
identification (VID) block
information. Refer to Section
2, FLASH
ELECTRICALLY
ERASABLE
PROGRAMMABLE
READ ONLY MEMORY
(EEPROM) .
Brake drag
REFER to the appropriate article.

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CHART 8
- Emissions Compliance
CHART 9
- Warning Indicators: Malfunction Indicator Lamp (MIL), Hazard Indicator Lamp,
Powertrain Malfunction Indicator (Wrench) Lamp, Temperature Warning Indicator Lamp,
Check Fuel Cap Indicator Lamp
Base engine concerns
Incorrect PCV valve
Contaminated MAF sensor
Intake air system

SYSTEM/COMPONENT
unless noted)
Emissions Related Systems
EM .
NOTE:
If the symptom is both MIL ON and exhaust emission test
failure, GO directly to Chart 8.
If the vehicle is disabled, GO directly to Chart 2.
If the engine is a no start, GO directly to Chart 3.
If the engine runs rough at idle, GO directly to Chart 1.
SYSTEM/COMPONENT
REFERENCE (Pinpoint Test unless
noted)
Verify the fuel filler cap is properly
tightened.
Visual
Instrument Cluster
REFER to INSTRUMENT
CLUSTER .

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CHART 10
- Oil System Concerns: High Oil Consumption, Leaks
CHART 11
- Cooling System Concerns: Electric Engine Cooling Fan(s) Does Not Operate (Low,
Medium or High Speed)
CHART 12
- Cooling System Concerns: Electric Engine Cooling Fan(s) Always Runs
SYSTEM/COMPONENT
unless noted)
PCV System

HG .
Base Engine

HYBRID .
Additional Checks
External leaks
Proper dipstick
Proper oil viscosity
Visual
Electric Cooling Fan
Components
refer to PINPOINT TEST KF .
Cooling System REFER to ENGINE COOLING - HYBRID .
Motor Electronics Cooling
System
REFER to TRANSAXLE/TRANSMISSION
COOLING - HYBRID .
NOTE: This chart is intended to only diagnose an electric engine cooling
fan that always runs with a cool engine and the A/C and defroster
off.

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CHART 13
- Exhaust System Concerns: Visible Smoke
CHART 14
- Fuel System Concerns: Fuel Odor, Engine Compartment
Electric Cooling Fan
Components/ACPSW
refer to PINPOINT TEST KF .
Cooling System REFER to ENGINE COOLING - HYBRID .
Motor Electronics Cooling
System
REFER to TRANSAXLE/TRANSMISSION
COOLING - HYBRID .
NOTE: Black smoke indicates a rich fuel mixture, blue smoke indicates
burning oil, and white smoke indicates water in the combustion
chamber.
SYSTEM/COMPONENT
unless noted)
Base Engine
HYBRID .
Black Smoke
HC .
Ignition System
Black Smoke
JB .
PCV System
Blue Smoke
HG .
SYSTEM/COMPONENT
noted)
EVAP System
CHECK for EVAP system leaks.
REFER to EVAPORATIVE
Fuel System
Visual. REFER to FUEL TANK
AND LINES - HYBRID .

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CHART 15
- Engine Noise (Under Hood)
CHART 16
- Climate Control: Lack of A/C Cooling, A/C Not Functioning, A/C Always On, A/C
Compressor Runs Continuously
CHART 17
- Exhaust System Concerns: Odor (Sulfur or Rotten Egg Smell)
NOTE: Attempt to identify the source of the noise. If the noise is from a
source other than those listed below, refer to STEP 2: NO
DIAGNOSTIC TROUBLE CODE (DTC) PRESENT SYMPTOM CHART
INDEX (for noise such as spark knock) or the applicable article.
SYSTEM/COMPONENT
unless noted)
Secondary Ignition System
Snap noise that may be due to secondary ignition
arcing.
CHECK the condition of
the coil-on-plug (COP)
spark plug boots.
SYSTEM/COMPONENT
noted)
A/C System
If sent here from another article with
a WACF PID indicating a fault (or
YES), GO toDIAGNOSTIC
TROUBLE CODE (DTC)
CHARTS AND DESCRIPTIONS
and follow the direction for KOEO
DTC P0645.
For all others, REFER to
CLIMATE CONTROL SYSTEM
- GENERAL INFORMATION
AND DIAGNOSTICS -
HYBRID .

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NOTE: A slight sulfur smell may be normal. Catalysts with less than 8,000-
16,000 kilometers (5,000-10,000 miles) (new vehicle or catalyst) are
likely to have a sulfur smell due to the highly active state of new
catalysts. Installing a new catalyst may actually make the symptom
worse.
SYSTEM/COMPONENT
noted)
Check for any driveability or exhaust
smoke symptoms
GO to Step 2: No Diagnostic
Trouble Code (DTC) Present
Symptom Chart Index for
direction to repair other symptoms.
Fuel Delivery System refer to PINPOINT TEST HC .
EVAP System
CHECK for EVAP system leaks.
REFER to EVAPORATIVE
Fuel Source
Talk with the customer. Since sulfur
content can vary in different fuels,
suggest trying a different fuel source.

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Reference Values - Hybrid Engines
REFERENCE VALUE SYMPTOM CHART
The Reference Value Symptom Chart is used to provide guidance in selecting the appropriate
PID or measured signal related to the fault area. Select a symptom from the symptom chart along
with the category number and go to the PID/Measured Signal Chart. For multiple symptoms,
select the symptom that is most evident.
SYMPTOM CHART
Symptom occurs during Symptom
Category
Number
STARTUP: No Start/Vehicle Disabled 0
No Start/Normal Crank 1

IDLE: MIL 5
Stalls/Quits 6
Rolling 9
Rough 11
Misses 12
Backfires 13

ACCELERATION: Stalls/Quits 6
Misses 12
Bucks/Jerks 14
Backfires 13
Hesitation/Stumble 15
Lack/Loss of Power 16
Surge 17
Spark Knock 18
Cooling System Temperature 19
Poor Fuel Economy 20
Emissions Compliance 21

CRUISE: Stalls/Quits 6

2007 ENGINE PERFORMANCE Reference Values - Hybrid Engines

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REFERENCE VALUE PID/MEASURED SIGNAL CHART
The listing reflects PIDS and/or measured values which may reveal a possible concern within
each system shown. Match the category number with the related PID/measured signal and go to
the Typical Diagnostic Reference Value Charts.
PID/MEASURED SIGNAL CHART
Misses 12
Bucks/Jerks 14
Backfires 13
Lack/Loss of Power 16
Surge 17
Spark Knock 18
Cooling System Temperature 19
Poor Fuel Economy 20
Emissions Compliance 21
TRANSAXLE OPERATION:
(AUTOMATIC)
Engagement Concerns 22
Category Number Related PIDS/Measured Signals
5-9-17 ACCS
5-17 ACP
1-16-21 APP1/APPS1
1-16-21 APP2/APPS2
1-16-21 APP3/APPS3
9 ARPMDES
0-6 BPO
18-19 CHT
18-19 CHT V
1-6-11-12-13-14-15-17 CKP
1-5-6-11-12-13-14-15-16-17-20-
21
CMP
0-6 CONTACT
5-6-9-11-12-15-16-18-20-21 EGRMC1-4
5-6-9-11-15-16-20-21 EGRMDSD
5-6-11-21 EVAPCV
5-6-11-21 EVAPPDC

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1 thru 21 FP
1 thru 21 FRP
1 thru 21 FRP _V
1 thru 21 FRT
1 thru 21 FRT_V
5 FTP
5 FTP_V
0-6-16-19 GCLTEMP
22 PRNDL_T
0-6 GENMODE
0-6 GSDN
0-6 GTQ_CMD
0-6 GTQ_OUT
0-6 G_INV_V
0-6-16-19 G_PHTEMP
0-6 G_SDN_A
0-6 G_SDN_C
9 G_SPEED
19 HFC
1 thru 21 HTR11/12
0-6 HVBAT_V
0-6 HV_AMP
5-22 IAT
5-22 IAT_V
0-6 IGN_R
0-6 IGN_R/S
6-11-12-14 thru 18-20-21 INJ x F
0-6 ISDN1
0-6 ISDN2
0-6 ISP_R
0 ISP_R/S
5-16-18-19-20-21 KS(+)/KS1
19 LFC
1 thru 21 LONGFT1
1 thru 21 MAF
1 thru 21 MAF V
1 thru 21

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Some signals are only measured and will require the use of a digital multimeter (DMM).
TYPICAL DIAGNOSTIC REFERENCE VALUES
MAP
1 thru 21 MAP_ V
0-6-16-19 MCLTEMP
6-16-19 MECP
6-16-19 MECP_V
16-19 MECT
16-19 MECT_V
19 MFC
0-6 MSDN
0-6 MTQ_CMD
0-6 MTQ_OUT
0-6 M_INV_V
0-6-16-19 M_PHTEMP
0-6 M_SDN_A
0-6 M_SDN_C
1 thru 21 O2S11/12
0-6-22 PRNDL_T
1 thru 21 RPM
1 thru 21 SHRTFT1/12
15-16-18-19-20-21 SPRKADV
1-16-21 TACM(-)
1-16-21 TACM(+)
0-6-16-19 TFT
0-6 TGAC
0-6 TMAC
1-16-21 TP1
1-16-21 TP2
0-6-22 TR-A1
0-6-22 TR-A2
0-6-22 TR-A3
0-6 VEHMODE
1-5-6-11-12-13-14 VPWR

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NOTES:
The footnotes are referenced throughout the Typical Diagnostic Reference Value Charts. A letter
in parentheses next to a value indicates supplemental information is applicable.
The Typical Diagnostic Reference Value Charts do not display fault PIDs. These are PIDs which
indicate a hard fault with the circuit. They display a value of YES or NO and are PIDs ending
with an F.
The Typical Diagnostic Reference Value Charts do not display limited operating strategy (LOS)
PIDs. These are PIDs which indicate what LOS mode that vehicle is in. They display a value of
YES or NO.
Reference values may vary +/-20%, depending on operating conditions and other factors. RPM
values are axle and tire dependent.
For the downstream heated exhaust gas oxygen (HO2S12) sensor, greater activity will result
when the catalyst monitor is active.
Refer to the ACRONYMS AND DEFINITIONS for technical terms applicable to Ford Motor
Company products.
Refer toPARAMETER IDENTIFICATION (PID) , for PID descriptions.

A. A/C on.
B. Cooling fan on (single, low or high speed).
C. The heated exhaust gas oxygen sensors (HO2S) should switch from rich to lean at least once
every 3 seconds. The HO2S voltage should toggle above and below 0.450 DCV and never
be a negative value. Valid HO2S switching only occurs during closed loop fuel control.
D. The downstream HO2S will stay close to a constant voltage when the catalyst monitor is off
(positive value only). When the catalyst monitor is on, HO2S will switch rich to lean above
and below 0.450 DCV and never be a negative value.
E. Brake pedal applied.
F. Ignition key in START position.
G. Value is dependent upon ambient air temperature and may fall outside of range.
H. Gear selector in PARK position.
I. Traction battery power off requested.

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J. Transaxle control module (TCM) requesting powertrain malfunction indicator (wrench) on.
K. TCM requesting hazard indicator on.
L. Powertrain control module (PCM) requesting generator motor shutdown.
M. PCM requesting traction motor shutdown.
N. Engine must be running or cranking.
O. Heater on.
P. Engine speed between 900 and 1,200 RPM.
Q. Gear selector in DRIVE position.
2.3L 4V ESCAPE HYBRID
Fig. 1: Identifying 150 Pin PCM Harness Connectors/Terminals
TYPICAL DIAGNOSTIC REFERENCE VALUES
PCM
Sensors /
Inputs
PCM
Pin /
PID
only
Measured/PID Values
Units
Measured / PID
KOEO Hot Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
A/CT B1
2.6-2.9 /
89-102
2.6-2.9 / 89-
102
2.6-2.9 / 89-
102
2.6-2.9 / 89-
102
DCV / DEG
ACRSW B2
VBAT /
ON
0.1 / OFF
(A)
VBAT / ON VBAT / ON DCV / ON-OFF
A/CFDS /
ACFDS _P
B3 0.1 / NO
VBAT /
YES (A)
0.1 / NO 0.1 / NO DCV / YES-NO
APP1 B5 4.1 4.1 3.6-4.1 3.6-4.1 DCV
BOO B8 0/OFF
VBAT (E)/
ON
0/OFF 0/OFF DCV/ON-OFF
FTP_V / FTP B9 2.6 / 0 2.6 / 0 2.6 / 0 2.6 / 0 DCV / IN-H2O

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ACCS B15 0.1 / OFF
VBAT / ON
(A)
0.1 / OFF 0.1 / OFF DCV / ON-OFF
APP2 B17 1.5 1.5 1.5-2.0 1.5-2.4 DCV
BPS B20 VBAT 0.1 / (E) VBAT VBAT DCV
ISP-RS /
IGN_R/S
B21 0.1 / NO 0.1 / NO 0.1 / NO 0.1 / NO DCV / YES-NO
ISP-R /
IGN_R
B22
VBAT /
YES
VBAT /
YES
VBAT /
YES
VBAT /
YES
DCV / YES-NO
BPO_Hz /
BPO
B24 2 / NO 6 / YES (I) 2 / NO 2 / NO Hz / YES-NO
ACP B26
VBAT /
OPEN
VBAT /
OPEN
VBAT /
OPEN
VBAT /
OPEN
DCV / OPEN -
CLOSED
APP3 B28 0.9 0.9 0.9-1.3 0.9-1.8 DCV
MAF_V B32 0 1.3-1.6 1.4-1.8 1.5-2.4 DCV
IAT_V / IAT
(G)
B39
1.7-3.5 /
120-50
1.7-3.5 /
120-50
1.7-3.5 /
120-50
1.7-3.5 /
120-50
DCV / DEG
FPM B46
0.1-
VBAT /
18-22
0.1-VBAT /
18-22
0.1-VBAT /
18-22
0.1-VBAT /
18-22
DCV/%
FRT_V / FRT
(G)
E6
0.5-3 /
210-110
0.5-3 / 210-
110
0.5-3 / 210-
110
0.5-3 / 210-
110
DCV / DEG
TP2 E8 1-1.3 0.7-1 .8-1.2 1-1.6 DCV
CMP E10 0 5-7 9-13 14-19 Hz
TP1 E19 4.1-4.4 4.4-4.4 4.0-4.3 3.5-3.8 DCV
MAP_V E23 4 2.5 3.51 1.42 DCV
FRP_V / FRP E27 2.9 / 41 2.9 / 41 2.9 / 41 2.9 / 41 DCV / PSI
HO2S11 /
O2S11 (C)
E30 0 Switching Switching Switching DCV
KS(+) / KS1 E32 0 0 0 0 DCV
CHT_V / CHT
(G)
E33 3.5 / 194 3.5 / 194 3.5 / 194 3.5 / 194 DCV / DEG
HO2S12 /
O2S12
E42 0.1 (D) (D) (D) DCV
CKP(+) E34 0 600-660 725-755 1100-1300 Hz
MECT_V T3 2.6 2.6 3.3 3.2 DCV
TGAC /
T5 300 / 0
295-300 / (- 270-300 / (- 270-300 / (-
Hz / Lb-ft

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GTQ_CMD )5-0 )22-0 )22-0
TMAC /
MTQ_OUT
T7 300 / 0
295-300 / (-
)5-0
295-300 / (-
)5-0
295-300 / (-
)5-0
Hz / Lb-ft
TR-A1 T16
4.25-4.80
(H)
4.25-4.80
(H)
1.60-2.15
(Q)
1.60-2.15
(Q)
DCV
TR-A2 T28
0.50-1.10
(H)
0.50-1.10
(H)
3.25-3.75
(Q)
3.25-3.75
(Q)
DCV
DCE_F T34
0.1/NO
FAULT
0.1/NO
FAULT
0.1/NO
FAULT
0.1/NO
FAULT
DCV/FAULT-
NO
TR-A3 T39
0.25-.75
(H)
0.25-.75 (H)
2.65-3.15
(Q)
2.65-3.15
(Q)
DCV
A/CLPCS T43 VBAT VBAT VBAT VBAT DCV
BPO PID NO NO NO NO YES/NO
LOAD PID 50 20-25 35-40 22-45 %
RPM PID 0 1050-1100 1250-1460 1950-2775 RPM
PCM
Actuators /
Outputs
PCM
Pin /
PID
only
Measured / PID Values
Units
Measured /
PID
KOEO Hot Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
FP B12 9.6 / 75 2.9 / 23 3/24 3.1/25 DCV / %
EVAPCV /
CANV
B13 0-10 / 0-100 0-10 / 0-100 0-10 / 0-100 0-10 / 0-100 Hz / %
WAC /
ACCR
B25 VBAT / OFF 1.5 / ON (A) VBAT / OFF VBAT / OFF
DCV / OFF-
ON
PSR B27 0.1 / ON 0.1 / ON 0.1 / ON 0.1 / ON
DCV / ON-
OFF
FTIV B29 VBAT / 0 VBAT / 0 VBAT / 0 VBAT / 0 DCV / %
MFC/FC2 B33 VBAT / OFF 0.1 / ON (B) VBAT / OFF VBAT / OFF
DCV / ON-
OFF
EVMV B34 0 0 500-900 500-900 mA
HFC/FC3 B37 VBAT / OFF 0.1 / ON (B) VBAT / OFF VBAT / OFF
DCV / ON-
OFF
LFC/FC1 B38 VBAT / OFF 0.1 / ON (B) VBAT / OFF VBAT / OFF
DCV / ON-
OFF
CD1A
(CYL1)
E1 VBAT VBAT VBAT VBAT DCV

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INJ1 (CYL1) E3 0 3-6 4.5-5.5 7-8 mS
EGRMC1 E4 VBAT VBAT VBAT VBAT DCV
EGRMC3 E5 VBAT 1 VBAT VBAT DCV
CD3B
(CYL3)
INJ2 (CYL2) E14 0 3-6 4.5-5.5 7-8 mS
EGRMC2 E15 1 VBAT 1 VBAT DCV
EGRMC4 E16 VBAT VBAT VBAT 1 DCV
CD4C
(CYL4)
INJ3 (CYL3) E26 0 3-6 4.5-5.5 7-8 mS
CD2D
(CYL2)
INJ4 (CYL4) E37 0 3-6 4.5-5.5 7-8 mS
TACM(+) E47 10.9 10-11 11.5-12 VBAT DCV
TACM(-) E48 VBAT VBAT VBAT 11-12 DCV
HTR11 E49 VBAT / OFF 0.1 / ON 0.1 / ON 0.1 / ON
DCV / ON-
OFF
HTR12 E50 VBAT / OFF 0.1 / ON 0.1 / ON 0.1 / ON
DCV / ON-
OFF
MECP V /
MECP
T4 0.1 / ON 0.1 / ON 0.1 / ON 0.1 / ON
DCV / ON-
OFF
GSDN /
G_SDN
T9 62 0 (L) 62 62 Hz
MSDN T11 62 0 (M) 62 62 Hz
A/CRDV /
ACRDV
T22 VBAT/OFF VBAT/OFF VBAT/OFF VBAT/OFF
DCV/ON-
OFF
HPCR /
HPUMP
T23 VBAT / OFF 0.1 / ON(O) VBAT / OFF VBAT / OFF
DCV / ON-
OFF
DCE T44 VBAT / ON VBAT / ON VBAT / ON VBAT / ON
DCV / ON-
OFF
CTO T46 0 36 (N) 40-45 (N) 65-75 (N) Hz
EGRMDSD PID 3 0-9 1-11 9-25 STEP
FUELPW1 PID 0 3-6 4.5-5.5 7-8 mS
G_SDN PID NO YES (L) NO NO YES-NO
LONGFT1 PID (-)20 - (+)20 (-)20 - (+)20 (-)20 - (+)20 (-)20 - (+)20 %

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Transaxle Connector C1458A -
Fig. 2: Transaxle Connector C1458A - Terminals
Transaxle Connector C1458B -
M_SDN PID NO YES (M) NO NO YES-NO
Other
PCM
Pin /
PID
only
Units Measured /
PID
KOEO Hot Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
KAPWR B45 VBAT VBAT VBAT VBAT DCV
VPWR
B35 /
B36
VBAT VBAT VBAT VBAT DCV
VREF
B40 /
E40
5 5 5 5 DCV

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Fig. 3: Transaxle Connector C1458B - Terminals
TCM
Inputs
TCM
Pin /
PID
only
Units
Measured /
PID
KOEO Hot Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
ISDN 1 A6
VBAT /
CHARGE
VBAT /
CHARGE
VBAT /
CHARGE
VBAT /
CHARGE
DCV /
CHARGE
CTO /
ENG_CTO
B1 0 / 0
36 / 1050-
1100 (N)
42 / 1250 (N)
65-75 / 1950-
2100(N)
Hz / RPM
MSDN B5 62 0 (M) 62 62 Hz
ISDN 2 B7
VBAT /
CHARGE
VBAT /
CHARGE
VBAT /
CHARGE
VBAT /
CHARGE
DCV /
CHARGE
GSDN B10 62 0 (L) 62 62 Hz
ABS_STAT PID
NOT
ACTIVATED
NOT
ACTIVATED
NOT
ACTIVATED
NOT
ACTIVATED
ACTIVATED /
NOT
ACTIVATED
ARPMDES PID 0 1050-1100 1250-1350 1950-2100 RPM
CONTACT PID CLOSED CLOSED CLOSED CLOSED
OPEN /
CLOSED
GCLTEMP PID 70-170 70-170 70-170 70-170 DEG
GENMODE PID TORQUE SPEED SPEED SPEED MODE
GTQ_OUT PID 0 (-)5 - 0 (-)12 - (-)10 (-)25 - (-)20 Lb-ft
G_INV_V PID 300-350 300-350 300-350 300-350 DCV

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G_PHTMP PID 95-115 95-115 95-115 95-115 DEG
G_SDN_A PID OFF ON (L) OFF OFF ON-OFF
G_SDN_C PID OFF ON (L) OFF OFF ON-OFF
G_SPEED PID 0 3600-3700 (-)550
(-)2700 - (-)
2500
RPM
HVBAT_V PID 300-350 300-350 300-350 300-350 DCV
HVINTLCK PID OFF OFF OFF OFF ON-OFF
HV_AMP PID 0 (-)10-0 0-2 0-2 AMP
MCLTEMP PID 70-170 70-170 70-170 70-170 DEG
MECT PID 70-170 70-170 70-170 70-170 DEG
MTQ_CMD PID 0 0 (-)2 (-)6 Lb-ft
M_INV_V PID 300-350 300-350 300-350 300-350 DCV
M_PHTEMP PID 70-170 70-170 70-170 70-170 DEG
M_SDN_A PID OFF ON (M) OFF OFF ON-OFF
M_SDN_C PID OFF ON (M) OFF OFF ON-OFF
M_SPEED PID 0 0 3900-4000 7000 RPM
PRNDL_T PID PARK (H) PARK (H) DRIVE (Q) DRIVE (Q)
SHIFTER
POSITION
RPM PID 0 1050-1100 1250-1350 1950-2100 RPM
TFT PID 70-170 70-170 70-170 70-170 DEG
TORQUE PID 550-620 20-120 280-310 670 LB-FT
TQ_DSD PID 0 0 93 210-230 Nm
VEHMODE PID READY DRIVING DRIVING DRIVING MODE
VSS PID 0 0 30 55 km/h
TCM Outputs
TCM
Pin /
PID
only
Units Measured /
PID
KOEO
Hot
Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
TMAC /
MTQ_OUT
B4 300 / 0
295-
300 / (-
)5-0
295-300 /
(-)5-0
295-300 /
(-)5-0
Hz / Nm
TGAC /
GTQ_CMD
B9 300 / 0
295-
300 / (-
)5-0
270-300 /
(-)22-0
270-300 /
(-)22-0
Hz / Nm
TCM_CAU PID OFF ON (J) OFF OFF ON / OFF

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TCM_HAZ PID OFF ON (K) OFF OFF ON / OFF
Other
PCM
Pin /
PID only
Units Measured /
PID KOEO Hot Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
PSR A4 / A5 VBAT VBAT VBAT VBAT DCV
B+ A12 VBAT VBAT VBAT VBAT DCV
VBAT PID VBAT VBAT VBAT VBAT DCV
TBCM Outputs
PID
only
PID Values
PID
KOEO
Hot
Idle
48 KM/H
(30 MPH)
89 KM/H
(55 MPH)
BAT_SOC PID 40-60 40-60 40-60 40-60 %

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2007 ELECTRICAL
High Voltage Traction Battery - Hybrid - Escape & Mariner
SPECIFICATIONS
HIGH-VOLTAGE TRACTION BATTERY
The high voltage system has a floating ground. When the engine is operating or the vehicle is
moving, the high voltage generator begins to generate high voltage alternating current (AC)
electricity. High voltage AC electricity can be consumed or generated by the motor generator, the
Item Specification
High Voltage Traction Battery
Battery amps rating 5.5 amp/hr
Voltage 330 volts
Low Voltage Battery
Battery amps rating 52 amp/hr
Voltage 12 volts
40-pin low voltage connector bolt 5 - 44
A/C return duct assembly screws 2 - 18
Electronically controlled continuously variable transmission
(eCVT) shift cable nut
8 - 71
High-voltage cables bracket nuts 8 - 71
High-voltage cables conduit nuts 8 - 71
High-voltage cables shield bolt 9 - 80
High-voltage cables shield nuts 9 - 80
High-voltage cables to eCVT bolt 9 - 80
High-voltage traction battery (HVTB) bolts 55 41 -
Low-voltage battery tray bolts 9 - 80
Low-voltage battery wedge clamp bolt 9 - 80
Park brake cable bracket bolts 8 - 71

2007 ELECTRICAL High Voltage Traction Battery - Hybrid - Escape & Mariner

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traction motor, or a combination of both motors. Excess high voltage current is converted from
high voltage AC to high voltage direct current (DC) electrical power inside the motor generator
unit and transmitted through the high voltage cables. The high voltage DC electrical power is
converted to low voltage DC electrical power through the DC/DC converter. This low voltage
DC electrical power is then supplied to the 12 volt battery through the low voltage battery cables.
12 Volt Battery
The 12 volt battery is a standard automotive battery. It is a DC source connected in a negative
ground system. The battery case is sealed, with 2 vent holes to release gases. The battery has 3
major functions:
Storage of electricity for later use.
Voltage stabilizer for the electrical system.
Temporary power source when electrical loads exceed the DC/DC converter output current.
High Voltage Traction Battery (HVTB)
The HVTB is a 216-397 volts DC source connected in a floating ground system. The battery
receives, stores, and delivers high voltage electrical power when required. It contains the battery
control module (BCM), which controls the higher functions of the battery. The BCM also
estimates the state of charge, estimates the power available, and controls the battery temperature.
The BCM controls the battery temperature by activating or deactivating the fans contained within
the HVTB, and by activating or deactivating the air conditioning system for the HVTB. Also
contained within the HVTB is a low voltage charger that is used during the jump start procedure.
For information about the jump start procedure, refer to the Owner Literature.
Motor Generator
The motor generator is contained in the electronically controlled continuously variable
transmission (eCVT). It functions to generate high voltage electricity and as the starter motor.
The motor generator is connected to the HVTB with the high voltage cables. The motor generator
is an internal part of the eCVT and it can not be repaired, only replaced as a new assembly.
DC/DC Converter
The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts)
CAUTION: Before placing the vehicle in a paint booth, the HVTB must be
removed to avoid heat damage. Refer to the High-Voltage
Traction Battery (HVTB).

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DC power to low voltage (12 volts) DC power while maintaining electrical isolation between the
2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to
the vehicle low voltage battery systems. The PCM controls the operation of the DC/DC converter
through an enable input from the PCM to the DC/DC converter. Refer to HIGH VOLTAGE
Regenerative Brakes
The regenerative braking system is designed to recapture some of the energy from braking. It
accomplishes this through the use of the traction motor and motor generator, which recapture
energy during braking. This recaptured energy is used to charge the HVTB. The regenerative
brake system is a series system. A series system is one in which powertrain braking is used first,
up to the limits of the powertrain torque capacity and battery capacity. After optimum
regeneration is used, the friction brakes are applied to supplement braking demands. The series
regenerative braking system also contains the ABS module within the same unit.
DIAGNOSTIC TESTS
Special Tools
Inspection and Verification
Vehicle Communication Module
(VCM) and Integrated
Diagnostic System (IDS)
software with appropriate
hardware, or equivalent scan tool

73III Automotive Meter 105-R0057 or equivalent
Flex Probe Kit 105-R025B
WARNING: Wear high-voltage insulated safety gloves and a face shield

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1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
VISUAL INSPECTION CHART
when working with high-voltage batteries or cables. The
high-voltage insulated safety gloves should be of the
appropriate safety and protection rating. Inspect the gloves
before use and always wear them with the leather outer
glove. Any hole in the rubber insulating glove is a potential
entry point for high-voltage. Failure to follow these
instructions may result in serious personal injury or death.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes
before removing high-voltage cables. High-voltage cables
and wiring are orange in color. The nominal high-voltage
traction battery voltage (HVTB) is 330 V DC. Failure to follow
these instructions may result in serious personal injury or
death.
WARNING: Depower the high-voltage traction battery (HVTB) before
carrying out any removal or installation procedures affecting
the high-voltage battery system. Failure to follow this
instruction may result in serious personal injury or death.
WARNING: When servicing the high-voltage system, establish a buffer
zone per the specified procedure. Failure to follow this
NOTE: Verify the service disconnect plug is properly inserted and locked
into the lock position.
Mechanical Electrical
Battery junction box
(BJB) fuse(s):
4 (7.5A)
5 (5A)
26 (50A)

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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. Verify the 12 volt battery condition. Refer to BATTERY, MOUNTING AND CABLES
article.
5. If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
6. If the scan tool does not communicate with the VCM:
check the VCM connection to the vehicle.
check the scan tool connection to the VCM.
Battery mode door
High voltage cables
Electronically
controlled
continuously variable
transmission (eCVT)
Power sustain relay
Smart junction box
(SJB) fuse 27 (5A)
Circuitry
Ignition relay
Jump start switch
Battery compartment
thermistor
Battery compartment
thermal expansion
valve (TXV)
DC/DC converter
eCVT
Inertia switch(es)
High voltage traction
battery (HVTB)
Battery control
module (BCM)
12 volt battery
NOTE: Make sure to use the latest scan tool software release.
NOTE: The vehicle communication module (VCM) LED prove out
confirms power and ground from the DLC are provided to the
VCM.

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refer to MODULE COMMUNICATIONS NETWORK article, No power to the
scan tool, to diagnose no communication with the scan tool.
7. If the scan tool does not communicate with the vehicle:
verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
refer to MODULE COMMUNICATIONS NETWORK article to diagnose no
response from the PCM.
8. Carry out the network test.
If the scan tool responds with no communication for one or more modules, refer to
MODULE COMMUNICATIONS NETWORK article.
If the network test passes, retrieve and record continuous memory DTCs.
9. If the DTCs retrieved are related to a driveability concern, refer to INTRODUCTION --
HYBRID ENGINES article before proceeding to the next step.
10. If the DTCs retrieved are related to the concern, go to the Battery Control Module (BCM)
DTC Chart to continue diagnosis.
11. If the DTCs retrieved are not found in the Battery Control Module (BCM) DTC Chart, refer
to the DTC Chart in MULTIFUNCTION ELECTRONIC MODULES article.
12. If no DTCs related to the concern are retrieved, go to Symptom Chart.
BATTERY CONTROL MODULE (BCM) DTC CHART
DTC Description Source Action
B1016
Jump Start Control
Module Fault
Battery
control
module
(BCM)
Go to Pinpoint Test K.
B1143
Excessive Battery
Contactor Close
Requests
BCM
If other DTCs are also present, address them
first, If DTC B1143 is the only DTC present,
go to Pinpoint Test M.
B1239
Air Flow Blend Door
Driver Circuit Failure
BCM
REFER to CLIMATE CONTROL
SYSTEM - GENERAL INFORMATION
AND DIAGNOSTICS - HYBRID article.
B1342
Electronic Control Unit
(ECU) is Faulted
BCM
INSTALL a new high voltage traction
battery (HVTB). REFER to High-Voltage
Traction Battery.
B2950
Air Conditioning System
BCM

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Fault AND DIAGNOSTICS - HYBRID article.
C1862 Contactor Circuit Failure BCM Go to Pinpoint Test G.
P0535
A/C Evaporator
Temperature Sensor
Circuit
BCM
P0A0A
High-Voltage System
Inter-Lock Circuit
BCM
REFER to INTRODUCTION -- HYBRID
ENGINES article.
P0A1F
Battery Energy Control
Module
BCM Go to Pinpoint Test I.
P0A27
Hybrid Battery Power
Off Circuit
BCM Go to Pinpoint Test F.
P0A7D
Hybrid Battery Pack
State of Charge Low
BCM Go to Pinpoint Test J.
P0A7E
Hybrid Battery Pack
Over-Temperature
BCM Go to Pinpoint Test C.
P0A80
Install a new Hybrid
Battery Pack (End of
Useful Life)
BCM
INSTALL a new HVTB. REFER to High-
Voltage Traction Battery.
NOTE:
The customer may choose to not replace the
battery pack due to the cost of replacement. If a
new high-voltage traction battery (HVTB) is not
installed, the customer will experience reduced
fuel economy and reduced power, which will
eventually lead to a failure of the HVTB.
P0A81
Hybrid Battery Pack
Cooling Fan 1 Control
Circuit
BCM Go to Pinpoint Test D.
P0A8B
14 Volt Power Module
System Voltage
BCM Go to Pinpoint Test E.
P0A8D
System Voltage Low
P0A8E
System Voltage High
NOTE:
Before installing a new service disconnect plug,
first verify the plug is properly inserted and in
the lock position.

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P0A95 High Voltage Fuse BCM
CHECK the recorded BCM DTCs from
the on-demand self test.
VERIFY if the HV fuse is good.
MEASURE the resistance of the HV
fuse. A good fuse's resistance value
should be less than 1 ohm. If the HV
fuse has resistance greater than 1 ohm,
the following subsystems and HV
harnesses on the high voltage circuit
must be evaluated for a short:
HV Battery System
Transaxle
DC/DC converter
HV wiring
REFER to HIGH VOLTAGE
CONVERTER/INVERTER article
for short verification in the transaxle,
DC/DC converter, and HV wiring
harnesses connecting these components
on the high voltage circuit.
If there are no problems found with the
transaxle, DC/DC converter or HV
wiring harnesses, VERIFY if DTC
P0A1F is present, if yes, go to
Pinpoint Test I.
NOTE:
In case of a blown HV fuse, do not insert a new
service disconnect plug until it is confirmed that
there is no problem in the HV battery system.
CARRY OUT the following steps:
P0A95 High Voltage Fuse BCM
If DTC P0A1F is present with DTC P0A95,
CLEAR the DTCs. REPEAT the on-demand
self test.
P0A96
Hybrid Battery Pack
Cooling Fan 2 Control
Circuit
BCM Go to Pinpoint Test D.
If DTC P0A9B is retrieved and the service

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P0A9B
Hybrid Battery
Temperature Sensor
Circuit
BCM
light (yellow wrench) is ON, CLEAR the
DTCs and REPEAT the self-test. If DTC
P0A9B is retrieved again, and the service
light (yellow wrench) is ON, INSTALL a
new HVTB. REFER to High-Voltage
Traction Battery.
P0AA6
Hybrid Battery Voltage
System Isolation Fault
BCM Go to Pinpoint Test H.
P0AA7
Hybrid Battery Voltage
Isolation Sensor Circuit
BCM
CLEAR the DTCs and REPEAT the self-test.
If the DTC is still present, INSTALL a new
HVTB. REFER to High-Voltage Traction
Battery.
P0AAC
Hybrid Battery Pack Air
Temperature Sensor A
Circuit
BCM
If only DTC P0AAC is retrieved, CLEAR
the DTC and RETURN the vehicle to the
customer. If DTC P0AAC is retrieved with
DTCs P0AB1 and P0A9B, INSTALL a new
Battery.
P0AB1
Hybrid Battery Pack Air
Temperature Sensor B
Circuit
BCM
If only DTC P0AB1 is retrieved, CLEAR the
DTC and RETURN the vehicle to the
customer. If DTC P0AB1 is retrieved with
DTCs P0AAC and P0A9B, INSTALL a new
Battery.
P0ABF
Hybrid Battery Pack
Current Sensor Circuit
Open
BCM
If only DTC P0ABF is retrieved, CLEAR the
customer. If DTC P0ABF is retrieved with
DTC P0AC0, with both the service light
(yellow wrench) and the MIL ON,
P0AC0
Hybrid Battery Pack
Current Sensor Circuit
Range/Performance
BCM
If only DTC P0AC0 is retrieved, CLEAR the
customer. If DTC P0AC0 is retrieved with
DTC P0ABF, with both the service light
(yellow wrench) and the MIL ON,

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P0AE1
Hybrid Battery
Precharge Contactor
Circuit
NOTE: This DTC is set
by a no-start, caused
when the contactor
precharge circuit fails
and the HVTB
contactors do not close.
A low 12 volt battery
may also cause this DTC.
The red triangle in the
instrument cluster (IC)
will illuminate. This
DTC is also set by a fault
in the DC/DC enable
circuit, the high voltage
bus, eCVT or the
DC/DC inverter.
BCM
CLEAR the DTCs and REPEAT the self-test.
If the DTC P0A11 is present, REFER to
INTRODUCTION -- HYBRID ENGINES
article. If the DTC is in continuous memory,
AND is accompanied by a customer concern
of a no-start, INSTALL a new HVTB.
REFER to High-Voltage Traction Battery.
P2533
Ignition Switch
Run/Start Position
Circuit
BCM Go to Pinpoint Test L.
P2612
A/C Refrigerant
Distribution Valve
Control Circuit Low
BCM
P2613
A/C Refrigerant
Distribution Valve
Control Circuit High
BCM
U0001
High Speed CAN
Communication Bus
BCM
REFER to MODULE
COMMUNICATIONS NETWORK
article.
U0073
Control Module
Communication Bus Off
BCM
REFER to MODULE
article.
U0100
Lost Communication
With PCM
BCM
REFER to MODULE
article.
Lost Communication CHECK for a CAN bus fault. REFER to

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For a complete list of powertrain DTCs, refer to INTRODUCTION -- HYBRID ENGINES
article.
Symptom Chart
Symptom Chart
U0101
with eCVT Transmission
Control Module (TCM)
BCM
MODULE COMMUNICATIONS
NETWORK article.
U0300
Internal Control Module
Software Incompatibility
BCM
FLASH the BCM with the latest software.
REFER to MODULE CONFIGURATION
article. If the concern is still present,
U0401
Invalid Data Received
From PCM
BCM
ENGINES article for active and on-demand
PCM DTCs.
U0402
Invalid Data Received
From TCM
BCM
ENGINES article for active and on-demand
TCM DTCs.
Condition Possible Sources Action
No communication
with the battery
control module
(BCM)
Fuse(s)
Circuitry
REFER to MODULE
COMMUNICATIONS
NETWORK article.
The charging
system warning
indicator is on with
the engine running
and the charging
system voltage
does not increase -
battery icon ON,
low voltage
charging system at
the DC/DC
Electronically
controlled
continuously
variable
transmission
(eCVT)
Low state of
charge of the low
voltage and high
voltage batteries
DC/DC converter
interlock circuit
(s)
REFER to INTRODUCTION --
HYBRID ENGINES article.

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converter
High voltage
cable(s)
BCM
PCM
The charging
system warning
the engine running
and the charging
system voltage
does not increase -
battery icon ON
DC/DC converter
interlock circuit
(s)
High voltage
cable(s)
Low voltage
cable(s)
12 volt battery
DC/DC converter
The charging
system warning
the engine running
and the charging
system voltage
does increase -
battery icon ON
Instrument cluster
(IC)
Climate control
system
BCM
PCM
The charging
system warning
indicator is off
with the ignition
switch in the RUN
position and the
engine is off
IC
REFER to INSTRUMENT
CLUSTER article.
The high-voltage
traction battery
(HVTB) is noisy
HVTB internal
cooling fans (part
of the HVTB)
HVTB
Air leakage from
the climate
control system
Go to Pinpoint Test A.
Audio unit

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Pinpoint Test A: The High-Voltage Traction Battery (HVTB) Is Noisy
Refer to SYSTEM WIRING DIAGRAMS (Escape) or SYSTEM WIRING DIAGRAMS
(Mariner) for schematic and connector information.
Normal Operation
With the key in the ON position and the engine running, the high-voltage traction battery
(HVTB) has 2 internal cooling fans that circulate air through the HVTB.
Possible Causes
Radio interference
Generator (part
of the
electronically
controlled
continuously
variable
transmission
[eCVT])
DC/DC converter
Go to Pinpoint Test B.
The low-voltage
battery is
discharged or
battery voltage is
low
12 volt battery
DC/DC converter
12 volt battery
cables
REFER to HIGH VOLTAGE
CONVERTER/INVERTER article
to diagnose the DC/DC converter.
The engine does
not crank at key
ON with no BCM
DTCs present.
Inertia fuel
shutoff (IFS)
switch open
circuit
Power sustain
relay
CHECK the IFS switch circuits at
the BCM C4227a -7 and -23 harness
side for voltage greater than 10 volts
with key ON. If both circuits have
greater than 10 volts, REFER to
PCED to diagnose the IFS switch; if
not, repair the circuit(s). TEST the
system for normal operation.
NOTE: The battery fans may continue running for approximately 15
seconds after the key is turned to the OFF position. Once the fans
turn off, they do not start again until the key is cycled to the ON
position.

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HVTB internal cooling fans (part of the HVTB)
HVTB
Air leakage from poor sealing of the climate control system
PINPOINT TEST A: THE HIGH VOLTAGE TRACTION BATTERY (HVTB) IS NOISY
A1 CHECK THE INTERNAL FANS
Key in START position.
WARNING: Wear high-voltage insulated safety gloves and a face
shield when working with high-voltage batteries or
cables. The high-voltage insulated safety gloves should
be of the appropriate safety and protection rating.
Inspect the gloves before use and always wear them with
the leather outer glove. Any hole in the rubber insulating
glove is a potential entry point for high-voltage. Failure
to follow these instructions may result in serious
personal injury or death.
before removing high-voltage cables. High-voltage
cables and wiring are orange in color. The nominal high-
voltage traction battery voltage (HVTB) is 330 V DC.
Failure to follow these instructions may result in serious
carrying out any removal or installation procedures
affecting the high-voltage battery system. Failure to
follow this instruction may result in serious personal
injury or death.
WARNING: When servicing the high-voltage system, establish a
buffer zone per the specified procedure. Failure to follow
this instruction may result in serious personal injury or
death.

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With the key in the ON position and the engine ON or OFF, use a stethoscope or
equivalent listening device to probe the HVTB area for unusual or excessive noise.
Compare the noise to a similar vehicle.
Is the noise coming from the HVTB internal cooling fans?
YES : INSTALL a new HVTB. REFER to High-Voltage Traction Battery. TEST
the system for normal operation.
NO : REFER to NOISE, VIBRATION AND HARSHNESS article to continue
diagnosis.
Pinpoint Test B: Radio Interference
Normal Operation
With the engine running and the audio unit ON (the audio unit MUST be original equipment
manufactured), there should be minimal interference audible from the speakers (compare to a
similar vehicle).
Possible Causes
Audio unit
NOTE: The engine must have started at least once for the cooling
fans to have cycled on.
NOTE: Verify the HVTB rear lift eye cap plug is correctly
positioned and not damaged.
NOTE: Verify the A/C return duct between the HVTB and the
climate control system is correctly positioned and not
damaged.
NOTE: The cooling fans may run at various speeds due to varying
vehicle and HVTB conditions. The fan speed increases
with increased temperature and may run at 40% to 100%
duty cycle. A fan running at 40% duty cycle is much quieter
than the same fan running at 100% duty cycle. During the
on demand self-test, the fans run at 100% duty cycle.

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Generator (part of the electronically controlled continuously variable transmission (eCVT)
DC/DC converter
PINPOINT TEST B: RADIO INTERFERENCE
B1 VERIFY THE DC/DC CONVERTER IS THE SOURCE OF THE RADIO
INTERFERENCE
Key in OFF position.
Connect the diagnostic tool.
injury or death.
death.

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With the engine running, Active Command the DCE Enable PID to OFF.
Is interference present with the DCE Enable PID OFF?
YES : INSTALL a new DC/DC converter. REFER to HIGH VOLTAGE
CONVERTER/INVERTER article. TEST the system for normal operation.
NO : Go to B2.
B2 VERIFY THE GENERATOR IS THE SOURCE OF THE RADIO
INTERFERENCE
Key in ACCESSORY position.
With the key in the ACC position, note any audio interference.
Is the interference present with the key in the ACC position?
YES : REFER to INFORMATION AND ENTERTAINMENT SYSTEMS article
to continue diagnosis of the audio system.
NO : INSTALL a new eCVT. REFER to AUTOMATIC
TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED
CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article. TEST the
Pinpoint Test C: DTC P0A7E - Hybrid Battery Pack Over Temperature
Normal Operation
With the key in the ON position and the engine ON or OFF, the vehicle climate control system is
used to maintain a specific temperature range of the high-voltage traction battery (HVTB). There
are 2 internal fans in the HVTB that circulate climate controlled air within the HVTB so it can
maintain a specific temperature range. A battery compartment thermistor is hardwired to the
HVTB for the battery compartment temperature input. The HVTB also monitors the battery
compartment blend door actuator in order to determine in which direction the HVTB operates
the battery blend door motor. The battery blend door controls whether the air flowing into the
battery compartment is fresh air or recirculated air. A battery thermal expansion solenoid valve
also controls the refrigerant pressure, thereby controlling the incoming air temperature. The ideal
temperature for the HVTB is 25C (77F) with a desired range of 20C (68F) to 30C (86F).
The DTC window is -40C (-40F) to 55C (131F). If the HVTB temperature exceeds 57C
(138F), the vehicle may shut down. If the HVTB temperature varies from this DTC window
range, a DTC may be flagged. Also, a failure of any of the internal HVTB climate control
components/circuitry may cause a DTC to be flagged.

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Possible Causes
Vehicle climate control system
HVTB
Clogged air filter
PINPOINT TEST C: DTC P0A7E - HYBRID BATTERY PACK OVER TEMPERATURE
C1 VERIFY THE VEHICLE CLIMATE CONTROL SYSTEM IS OPERATING
CORRECTLY
injury or death.
death.

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Start the engine.
Turn the A/C system to MAX A/C.
With the engine running at 2,000 RPM, place a thermometer in the center climate
control outlet vents and monitor the outlet temperature.
Is the outlet temperature between 0C - 9C (32F - 48F)?
YES : Go to C2.
NO : REFER to CLIMATE CONTROL SYSTEM - GENERAL
INFORMATION AND DIAGNOSTICS - HYBRID article to continue diagnosis of
the vehicle climate control system.
C2 VERIFY THE HVTB INTERNAL FANS ARE OPERATIONAL
Carry out the battery control module (BCM) On-Demand Self Test.
With the key in the ON position and the engine ON or OFF (the engine must have run
at least once after the key was cycled to ON), verify the HVTB internal fans are
operational.
Are the HVTB internal fans operating correctly?
YES : Go to C3.
NO : Go to Pinpoint Test D.
C3 CHECK THE HVTB TEMPERATURE
Start the engine.
Enter the following diagnostic mode on the diagnostic tool: BCM PIDs
With the engine running, monitor the BCM temperature PID and the BCM
temperature Delta PID.
NOTE: Allow the climate control system to reach normal
operating temperature (stabilized).
NOTE: Use a stethoscope or equivalent listening device to probe
the HVTB area.
NOTE: The cooling fans may cycle on or off with the key in the ON
position and the engine ON or OFF.

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Is the BCM temperature PID less than 55C (131F) and the BCM temperature
Delta PID greater than 20?
YES : Go to C4.
NO : REFER to CLIMATE CONTROL SYSTEM - GENERAL
INFORMATION AND DIAGNOSTICS - HYBRID article to continue diagnosis of
the vehicle climate control system.
C4 CHECK FOR CORRECT BCM OPERATION
Disconnect both of the BCM electrical connectors.
Check for:
corrosion.
pushed-out pins.
Connect both of the BCM connectors and make sure they seat correctly.
Operate the system and verify the concern is still present.
Is the concern still present?
NO : The system is operating correctly at this time. The concern may have been caused
by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test D: DTCs P0A81, P0A96 - Hybrid Battery Pack Cooling Fans 1 and 2 Control Circuits
Normal Operation
With the key in the ON position and the engine ON or OFF (the engine must have started at least
once after the key was cycled to ON), 2 internal fans to the high-voltage traction battery (HVTB)
circulate air within the HVTB so it can maintain a specific temperature range. A failure of the
cooling fan(s) or their associated circuits causes one (or both) of the DTCs to be flagged.
Possible Causes
NOTE: This pinpoint test step only addresses the 6-pin and 40-pin
connectors for the BCM. It is not necessary to disconnect the
high voltage connectors when following this pinpoint test step
procedure.

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Fuse
Circuitry
Cooling fan 1 or 2 (part of HVTB)
HVTB
PINPOINT TEST D: DTC P0A81, P0A96 - HYBRID BATTERY PACK COOLING FANS 1 AND 2 CONTROL CIRCUITS
D1 VERIFY THE HIGH VOLTAGE TRACTION BATTERY (HVTB) INTERNAL
FANS ARE OPERATIONAL
injury or death.
death.

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Carry out the battery control module (BCM) On-Demand Self Test.
With the key in the ON position and the engine ON or OFF (the engine must have run
at least once after the key was cycled to ON), verify the HVTB internal fans are
operational.
Are the HVTB internal fans operating correctly?
NO : TURN the key to OFF and Go to D2 .
D2 CHECK CIRCUIT 3800 (LG/BK) FOR VOLTAGE
Disconnect: BCM C4227a
Fig. 1: Checking Circuit For Voltage
Measure the voltage between BCM C4227a pins, harness side and ground as follows:
NOTE: Use a stethoscope or equivalent listening device to probe
the HVTB area.
NOTE: The cooling fans may cycle on or off with the key ON,
engine ON or OFF.
Pin Circuit
4
3800
(LG/BK)
5
3800
(LG/BK)

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Is the voltage greater than 10 volts?
YES : Go to D3.
NO : VERIFY the battery junction box (BJB) fuse 26 (50A) is OK. If OK, REPAIR
the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal
operation.
D3 CHECK CIRCUIT 57 (BK) FOR AN OPEN
Fig. 2: Checking Circuit For Open
Measure the resistance between BCM C4227a pins, harness side and ground as
follows:
Is the resistance less than 5 ohms?
YES : Go to D4.
NO : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system
for normal operation.
D4 CHECK FOR CORRECT BCM OPERATION
6
3800
(LG/BK)
Pin Circuit
35
57
(BK)
36
57
(BK)
37
57
(BK)

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Check for:
corrosion.
pushed-out pins.
Pinpoint Test E: DTCs P0A8B, P0A8D, P0A8E - 14 Volt Power Module System Voltage
Normal Operation
With the key in the ON position and the engine ON or OFF (the engine must have started at least
once after the key was cycled to ON), the planetary gear set in the electronically controlled
continuously variable transmission (eCVT) engages the generator (also in the eCVT), which
charges the high-voltage traction battery (HVTB) and supplies high-voltage to the DC/DC
converter. The DC/DC converter steps the voltage down to 12 volts (operating range of 13.35 -
16 volts). The DC/DC converter charges the low voltage battery which is used to power the PCM
and low voltage components.
Possible Causes
12 volt battery
HVTB
PINPOINT TEST E: DTC P0A8B, P0A8D, P0A8E - 14 VOLT POWER MODULE SYSTEM VOLTAGE
procedure.

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E1 CHECK THE HISTORY OF THE VEHICLE
Verify if the low-voltage battery has recently had the terminals disconnected/cleaned
or if a new low-voltage battery has been recently installed. If so, DTCs P0A8B,
P0A8D, and P0A8E may have been flagged.
Has the low-voltage battery recently had the terminals disconnected/cleaned or
has the low-voltage battery recently been replaced?
YES : CLEAR the DTCs. REPEAT the self-test. If the self-test passes, RETURN the
vehicle to the customer until the concern can be verified.
NO : Go to E2.
injury or death.
death.

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E2 VERIFY THE INTEGRITY OF THE LOW-VOLTAGE BATTERY
Carry out the 12-Volt Battery Condition Test to determine if the battery can hold a
charge and is OK for use. Refer to BATTERY, MOUNTING AND CABLES
article.
Does the battery pass the condition test?
YES : Go to E3.
NO : INSTALL a new 12 volt battery. REFER to 12 Volt Battery. TEST the system
E3 CHECK THE BATTERY CONTROL MODULE (BCM) DTCS
Check the recorded BCM DTCs from the continuous and on-demand self tests.
Are the following DTCs retrieved: P0A8B, P0A8D or P0A8E?
YES : Go to E4.
NO : REFER to INTRODUCTION -- HYBRID ENGINES article to continue
diagnosis.
E4 CHECK FOR 12 VOLT INPUT ON CIRCUIT 16 (RD/LG)
Key in ON position.
Check the voltage between BCM C4227a-10, circuit 16 (RD/LG), harness side and
ground.
Check the voltage between BCM C4227a-11, circuit 16 (RD/LG), harness side and
ground.
YES : Go to E5.
NO : REPAIR the circuit(s) as necessary. CLEAR the DTCs. REPEAT the self-test.
TEST the system for normal condition.

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E5 CHECK FOR CORRECT BCM OPERATION
Check for:
corrosion.
pushed-out pins.
Pinpoint Test F: DTC P0A27 - Hybrid Battery Power Off Circuit
Normal Operation
With the engine running, the battery power off (BPO) function may be triggered by the front
and/or rear inertia fuel shut off (IFS) switches opening, a high-voltage interlock circuit opening
or the electrical interlock (EL I) circuit opening (fuse protected by the battery junction box
[BJB] fuse 5 [5A]). The IFS switch opens and causes the BPO mode to occur, no DTCs are set.
Also, if the IFS switch is open, a power reset indicator in the instrument cluster (IC) illuminates.
The PCM monitors the frequency signal that the battery control module (BCM) sends out on the
BPO circuit 3003 (VT/WH).
DTC P0A27 Hybrid Battery Power Off Circuit - the BCM will set this DTC if any of the
following conditions are met:
BCM detects a thermistor temperature greater than 57C (134F) for at least one
second
procedure.

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Contactor control is reported as closed, while contactor status confirmed is reported as
open for 10 seconds
High-voltage traction battery (HVTB) is overheated.
It is possible for the PCM to set DTC P0A28 (Hybrid Battery Power Off Circuit Low) as a
continuous fault.
Possible Causes
Fuse
Circuitry (to the PCM)
HVTB
PINPOINT TEST F: DTC P0A27 - HYBRID BATTERY POWER OFF CIRCUIT
F1 CHECK THE BCM DTCs
injury or death.

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Is DTC P0A7E or P0A1F also retrieved?
YES : REFER to the Battery Control Module (BCM) DTC Chart to continue
diagnosis of DTC P0A7E or P0A1F.
NO : Go to F2.
F2 CHECK THE EL I CIRCUIT 3997 (DG) FOR AN OPEN OR SHORT TO
GROUND
Disconnect: BJB Fuse 5 (5A)
Fig. 4: Checking Circuit For Open Or Short To Ground
Measure the resistance between the output cavity of BJB fuse 5 (5A) and BCM
death.

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C4227a-14, circuit 3997 (DG), harness side; and between the output cavity of BJB
fuse 5 (5A) and ground.
Is the resistance less than 5 ohms between the BJB and the BCM; and greater
than 10,000 ohms between the BJB and ground?
YES : VERIFY that the BJB fuse 5 (5A) is OK; if OK, go to F3 .
F3 CHECK THE BATTERY POWER OFF (BPO) CIRCUIT FOR AN OPEN AND
SHORT TO GROUND
Fig. 5: Checking Circuit For Open Or Short To Ground
Measure the resistance between BCM C4227a-8 and PCM C175b-24 circuit 3003
(VT/WH), and between BCM C4227a-8 harness side and ground.
Is the resistance less than 5 ohms on circuit CDC05 (GY/VT) between the BCM
and PCM; and greater than 10,000 ohms between the BCM circuit CDC05
(GY/VT) and ground?
YES : Go to F4 .
TEST the system for normal operation.
F4 CHECK THE BATTERY POWER OFF (BPO) CIRCUIT FOR A SHORT TO
VOLTAGE
Key in ON position.

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Measure the voltage between BCM C4227a-8 circuit 3003 (VT/WH), harness side and
ground.
Is any voltage present?
YES : REPAIR the circuit(s) as necessary. CLEAR the DTCs. REPEAT the self-test.
NO : Go to F5 .
F5 CHECK CIRCUIT 570 (BK/WH) FOR AN OPEN
Check the resistance between BCM C4227a-30 and C4227a-31, circuit 570
(BK/WH), harness side and chassis ground.
YES : Go to F6.

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F6 CHECK FOR CORRECT BCM OPERATION
Disconnect BCM electrical connectors C4227a and C4227b.
Check for:
corrosion.
pushed-out pins.
Connect BCM electrical connectors C4227a and C4227b and make sure they seat
correctly.
the system for normal operation
Pinpoint Test G: DTC C1862 - Contactor Circuit Failure
Normal Operation
With the key in the ON position and the engine ON or OFF (the engine must have run at least
once after the key was cycled to ON), the battery control module (BCM) monitors the contactors
continuously. During a power down (key OFF) sequence, one or both of the contactors may set
this DTC if they fail.
Possible Causes
High-voltage traction battery (HVTB)
Service disconnect plug
PINPOINT TEST G: DTC C1862 - CONTACTOR CIRCUIT FAILURE
high-voltage connectors when following this pinpoint test step
procedure.

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G1 INSPECT THE SERVICE DISCONNECT PLUG FOR AN OPEN
Remove the service disconnect plug and inspect for an open. Make sure that the HV
fuse resistance is less than 1 ohm. If the HV fuse is open, refer to DTC P0A95 for
instructions. Refer to High-Voltage Traction Battery Systems Depowering.
Is the service disconnect plug open?
YES : NOTE: Do not install service disconnect plug until it is confirmed that the HV
battery system is OK.
injury or death.
death.

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INSTALL a new service disconnect plug. REFER to High-Voltage Traction Battery
Systems Depowering. CLEAR the DTCs. REPEAT the self-test. TEST the system for
normal operation.
NO : Go to G2.
G2 CHECK FOR A HARD FAULT
Key in ON position.
Clear the DTCs. Cycle the key twice, starting the engine each time. Repeat the self-
test.
Is DTC C1862 still present?
YES : Go to G3.
NO : RETURN the vehicle to the customer until the concern can be verified.
G3 CHECK FOR CORRECT BCM OPERATION
Check for:
corrosion.
pushed-out pins.
Pinpoint Test H: DTC P0AA6 - Hybrid Battery Voltage System Isolation Fault
procedure.

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Normal Operation
once after the key was cycled to ON), the battery control module (BCM) monitors the electrical
isolation (leakage resistance) between the high-voltage system and the vehicle chassis. A
resistance value of less than 190,000 ohms (for 10 seconds or greater) is a failure. The normal
resistance value is between 950,000 - 1,330,000 ohms. DTC P0AA6 is flagged if the BCM
detects a high voltage leakage of less than 190,000 ohms for 10 seconds or greater. If the BCM
detects a high voltage leakage of less than 66,000 ohms (with no time frame) the vehicle is not
allowed to restart.
Possible Causes
DC/DC converter wiring harness (high voltage)
DC/DC converter
High-voltage cables
High-voltage traction battery (HVTB)
Electronically controlled continuously variable transmission (eCVT)
Moisture/water penetration of high-voltage connectors
PINPOINT TEST H: DTC P0AA6 - HYBRID BATTERY VOLTAGE SYSTEM ISOLATION FAULT
H1 MONITOR THE LEAKAGE RESISTANCE PIDS

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Start the engine.
With the engine running, monitor the BCM leakage resistance PIDs.
Do the PIDs read less than 190,000 ohms for more than 10 seconds?
YES : Go to H2.
NO : CLEAR the DTCs. REPEAT the self-test. If the DTC is not present at this time,
INSPECT the high voltage system for any physical damage. REPAIR as necessary.
RETURN the vehicle to the customer.
H2 CHECK THE HIGH-VOLTAGE DC/DC CONVERTER WIRING HARNESS
With the key in the OFF position, wait for a minimum of 5 minutes.
Disconnect: Service Disconnect Plug
Install a new DC/DC converter wiring harness. Refer to HIGH VOLTAGE
Connect: Service Disconnect Plug
Start the engine.
injury or death.
death.
NOTE: Clear the DTCs or the vehicle may not start.

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YES : Go to H3.
NO : CLEAR the DTCs. REPEAT the self-test. TEST the system for normal
operation.
H3 CHECK THE DC/DC CONVERTER
Install a new DC/DC converter. Refer to HIGH VOLTAGE
Start the engine.
YES : Go to H4.
operation.
H4 CHECK THE HVTB TO TCM HIGH-VOLTAGE CABLES
Install a new HVTB to TCM high voltage cable. Refer to High-Voltage Cables.
Key in ON position.

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YES : Go to H5.
operation.
H5 CHECK THE HVTB
Install a new HVTB. Refer to High-Voltage Traction Battery.
Key in ON position.
YES : INSTALL a new eCVT. REFER to AUTOMATIC
TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED
CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article. CLEAR the
DTCs. REPEAT the self-test. TEST the system for normal operation.
operation.
Pinpoint Test I: DTC P0A1F - Battery Energy Control Module Has Internal Errors
Normal Operation
once after the key was cycled to ON), the battery control module (BCM) monitors the current,
voltage, temperature and leakage resistance of the 25 individual nickel metal hydride battery
modules within the high-voltage traction battery (HVTB). The BCM also controls the contactors.
DTC P0A1F is flagged if there are any internal errors of the HVTB caused by sensor failure,
control module failure, or other severe related faults internal to the HVTB.
Possible Causes

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Service disconnect plug
HVTB
PINPOINT TEST I: DTC P0A1F - BATTERY ENERGY CONTROL MODULE
I1 CHECK THE SERVICE DISCONNECT PLUG
injury or death.
death.
NOTE: Make sure the service disconnect plug is correctly inserted
and locked into the lock position.

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Inspect the service disconnect plug for physical or electrical damage. Make sure that
the HV fuse resistance is 1 ohm or less. If the HV fuse is open, refer to DTC P0A95
for instructions.
Is the service disconnect plug free of any damage?
YES : Go to I2.
NO : REFER to DTC P0A95 action in the Battery Control Module (BCM) DTC
Chart.
I2 CHECK THE BCM DTCs
Are any or all of the DTCs P0A8B, P0A8D, P0A8E also present?
YES : Go to Pinpoint Test E.
NO : Go to I3.
I3 CHECK FOR CORRECT BCM OPERATION
Check for:
corrosion.
pushed-out pins.
Connect both of the BCM electrical connectors and make sure they seat correctly.
Pinpoint Test J: DTC P0A7D - Hybrid Battery Pack State of Charge Low
procedure.

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Normal Operation
The battery control module (BCM) monitors the high voltage traction battery (HVTB) state of
charge when the key is in the ON or OFF position. The DTC P0A7D can only be set when the
key is first turned to the ON position, or when the key is in the START position. This condition
may occur if the vehicle has been stored for an extended period of time.
Possible Causes
HVTB
Vehicle stored for an extended period of time
PINPOINT TEST J: DTC P0A7D - HYBRID BATTERY PACK STATE OF CHARGE LOW
J1 CARRY OUT THE JUMP START PROCEDURE
injury or death.

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Carry out the jump start procedure. If the vehicle fails to start, cycle the key and carry
out the jump start procedure a second time.
Does the vehicle start?
NO : CARRY OUT the jump start procedure 2 more times. If the vehicle still does not
start, go to J2 .
YES : CLEAR the DTCs. REPEAT the self-test.
J2 CHECK FOR CORRECT BCM OPERATION
death.
NOTE: For optimum operation, during the jump start procedure,
the low voltage battery should have a battery charger
attached and on to make certain the low voltage battery
does not become drained to the point where the jump start
procedure may fail.
NOTE: For additional jump start information, refer to the Owner's
Literature.
NOTE: When the vehicle starts, use the diagnostic tool to monitor
the Battery Pack State Of Charge PID until it reaches 30%.
With the Battery Pack State Of Charge PID at a minimum of
30%, the vehicle can be driven.
NOTE: The vehicle (and the HVTB) must be at room temperature
for the jump start procedure to have the optimum effect.
NOTE: Make sure the HVTB is adequately charged before
releasing the vehicle to the customer.
procedure.

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Check for:
corrosion.
pushed-out pins.
Pinpoint Test K: DTC B1016 - Jump Start Control Module Fault
Normal Operation
When the jump start button is momentarily pressed, the jump start control module within the high-
voltage traction battery (HVTB) uses the low-voltage battery during a 10-minute process (8-
minute charge plus 2 minutes rest) to step up the low voltage in an effort to charge the high-
voltage battery to the point where it may start the engine. With the high-voltage battery state of
charge at 30%, the vehicle can be driven.
Possible Causes
Fuse
Circuit 176 (PK/LG) short to ground
Circuit 3800 (LG/BK) open or short to ground
Circuit 57 (BK) open
Jump start switch
NOTE: If the jump start switch is pressed and held for longer than 6
seconds, the jump start process aborts. The LED flashes for
approximately 2 minutes before another jump start can be
attempted. The jump start switch needs to be pressed only
momentarily.

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HVTB
PINPOINT TEST K: DTC B1016 - JUMP START CONTROL MODULE FAULT
K1 CHECK THE JUMP START SWITCH
Disconnect: Jump Start Switch C2342
injury or death.
death.

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Fig. 8: Checking Jump Start Switch
Measure the resistance between jump start switch C2342 pins 2 and 6, component side,
while pressing and releasing the switch.
Is the resistance less than 5 ohms with the switch pressed and greater than
10,000 ohms with the switch released?
YES : Go to K2.
NO : INSTALL a new jump start switch. CLEAR the DTCs. REPEAT the self-test.
K2 CHECK CIRCUIT 176 (PK/LG) FOR A SHORT TO GROUND
Disconnect: Battery Control Module (BCM) C4227a
Fig. 9: Checking Circuit For Short To Ground
Measure the resistance between jump start switch C2342-6, circuit 176 (PK/LG),
harness side and ground.
Is the resistance greater than 10,000 ohms?
YES : Go to K3.

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K3 CHECK CIRCUIT 3800 (LG/BK) FOR VOLTAGE
Measure the voltage between BCM C4227a pins, harness side and ground as follows:
YES : Go to K4.
NO : VERIFY the battery junction box (BJB) fuse 26 (50A) is OK. If OK, REPAIR
the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal
operation.
K4 CHECK CIRCUIT 57 (BK) FOR AN OPEN
Pin Circuit
4
3800
(LG/BK)
5
3800
(LG/BK)
6
3800
(LG/BK)

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Measure the resistance between BCM C4227a pins, harness side and ground as
follows:
YES : Go to K5.
K5 CHECK FOR CORRECT BCM OPERATION
Disconnect BCM C4227a and C4227b.
Check for:
corrosion.
pushed-out pins.
Connect both of the BCM electrical connectors C4227a and C4227b and make sure
Pin Circuit
35
57
(BK)
36
57
(BK)
37
57
(BK)
NOTE: This pinpoint test step addresses only the 40-pin connectors
for the BCM. It is not necessary to disconnect the high voltage
connectors when following this pinpoint test step procedure.

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they seat correctly.
by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the
Pinpoint Test L: DTC P2533 - Ignition Switch Run/Start Position Circuit
Normal Operation
At all times, the battery control module (BCM) monitors the ignition run/start input circuit. If
there is no voltage detected on this circuit to the BCM with the key in the ON position and the
engine ON or OFF, DTC P2533 is flagged.
Possible Causes
Fuse
Circuitry
HVTB
PINPOINT TEST L: DTC P2533 - IGNITION SWITCH RUN/START POSITION CIRCUIT
L1 RETRIEVE THE DTCs

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Key in ON position.
Is DTC P2612 also present?
YES : REFER to CLIMATE CONTROL SYSTEM - GENERAL
INFORMATION AND DIAGNOSTICS - HYBRID article.
NO : Go to L2.
L2 CHECK THE BCM IGNITION CIRCUIT INPUT AND BATTERY ZONE
VALVE CONTROL CIRCUIT
Key in ON position.
injury or death.
death.

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Measure the voltage between BCM C4227a-19, circuit 3206 (LG/YE), harness side
and ground.
Measure the voltage between BCM C4227a-33, circuit 214 (PK/LB), harness side and
ground.
Is the voltage 10 volts or greater?
YES : Go to L3.
NO : If circuit 3206 (LG/YE) or both 3206 (LG/YE) and 214 (PK/LB) have less than
10 volts, VERIFY the smart junction box (SJB) fuse 27 (5A) is OK. If OK, REPAIR
the circuit as necessary. CLEAR the DTCs. REPEAT the self-test. If only circuit 214
(PK/LB), CHECK the battery zone valve control. REFER to CLIMATE
CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS -
HYBRID article.
L3 CHECK FOR CORRECT BCM OPERATION
Check for:
corrosion.
pushed-out pins.
procedure.

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Pinpoint Test M: DTC B1143 - Excessive Battery Contactor Close Requests
Normal Operation
When the key is turned to the ON position, the PCM sends a request to the battery control module
(BCM) over the controller area network (CAN) communication link to close the high-voltage
traction battery (HVTB) contactors. If the PCM sends multiple requests (100 requests in 4
minutes or less) to the BCM, DTC B1143 is set in the BCM.
Possible Causes
Rapid key cycling/excessive contactor close requests
CAN communication link
PCM
BCM
PINPOINT TEST M: DTC B1143 - EXCESSIVE BATTERY CONTACTOR CLOSE REQUESTS
M1 CHECK FOR RAPID KEY CYCLING

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Key in ON position.
Clear the BCM DTCs from the continuous and on-demand self tests.
Key in ON position.
Wait 5 minutes.
Enter the following diagnostic mode on the diagnostic tool: Retrieve DTCs again,
making certain to retrieve on-demand DTCs and continuous memory DTCs
Is DTC B1143 still present?
YES : Go to M2.
NO : RETURN the vehicle to the customer. The concern may have been caused by
rapid key cycling.
M2 CHECK THE CAN COMMUNICATION LINK
Are any CAN communication link DTCs (Uxxx) present?
injury or death.
death.
NOTE: On Demand DTCs may not yield the DTC B1143. Continuous
memory DTCs must be retrieved to verify the DTC B1143 is not
present.

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YES : REFER to MODULE COMMUNICATIONS NETWORK article to
continue diagnosis of the communication network.
NO : Go to M3.
M3 CHECK FOR CORRECT PCM OPERATION
Disconnect all of the PCM electrical connectors.
Check for:
corrosion.
pushed-out pins.
Connect all of the PCM electrical connectors and make sure they seat correctly.
YES : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS -
HYBRID article. CLEAR the BCM DTCs. CYCLE key to OFF, then ON and leave
ON for 5 minutes. TEST the system for normal operation. If vehicle does not start, go
to M4 .
M4 CHECK FOR CORRECT BATTERY CONTROL MODULE (BCM)
OPERATION
Check for:
corrosion.
pushed-out pins.
YES : INSTALL a new BCM. REFER to High-Voltage Traction Battery. CLEAR
the BCM DTCs. CYCLE key to OFF, then ON and leave ON for 5 minutes. TEST the
Component Tests

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12-Volt Battery - Drain Test
Check for current drains on the battery in excess of 50 milliamps (mA) (0.050 amp) with all the
CAUTION: To prevent damage to the meter, do not crank the engine or
operate accessories that draw more than 10A.
CAUTION: If equipped with the CD6 audio unit, precautions must be
taken when the battery has been disconnected. When
reconnecting the battery, make sure no interruption of power
occurs for 30 seconds. If power is interrupted during the first
30 seconds, permanent damage to the CD6 audio unit will
result.
NOTE: No production vehicle should have more than a 50 milliamp (mA) or
0.050 amp draw with the key in the OFF position.
NOTE: The 12-Volt Battery - Drain Test can not be carried out while the
jump start procedure for the high-voltage battery is being carried
out. Drain testing of the low-voltage battery during a jump start
procedure may result in a failed 12-Volt Battery - Drain Test.
NOTE: Many modules draw 10 mA (0.010 amp) or more continuously.
NOTE: Use an in-line ammeter between the battery positive or negative
post and its respective cable.
NOTE: Typically, a drain of approximately 1 amp can be attributed to an
engine compartment lamp, glove compartment lamp, or interior
lamp staying on continually. Other component failures or wiring
shorts may be located by selectively pulling fuses to pinpoint the
location of the current drain. When the current drain is found, the
meter reading falls to an acceptable level. If the drain is still not
located after checking all the fuses, it may be due to the generator.
NOTE: To accurately test the drain on a battery, an in-line digital ammeter
must be used. Use of a test lamp or voltmeter is not an accurate
method due to the number of electronic modules.

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electrical accessories off and the vehicle at rest. Current drains can be tested with the following
procedure:
1. Make sure the battery junction box (BJB) and the smart junction box (SJB) are accessible
without turning on interior and underhood lights.
2. Drive the vehicle at least 5 minutes and over 48 km/h (30 mph) to turn on and exercise the
vehicle systems.
3. Allow the vehicle to sit with the key OFF for at least 40 minutes to allow the modules to
time out/power down.
4. Connect a fused (10A) jumper wire between the negative battery cable and the negative
battery post to prevent the modules from resetting and to catch capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the
jumper wire.
6. Connect the tester between the negative battery cable and the post. The meter must be
capable of reading milliamps and should have a 10 amp capability.
7. Remove the jumper wire.
8. If the draw is found to be excessive, pull the fuses from the BJB/SJB one at a time and note
the current drop. Do not reinstall the fuses until you are finished testing.
9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery
without passing through the junction boxes. Disconnect these circuits if the draw is still
excessive.
NOTE: It is very important that continuity is not broken between the
battery and the negative battery cable when connecting the
meter. If this happens, the entire procedure must be repeated.
NOTE: If the meter settings need to be switched or the test leads need
to be moved to another jack, the jumper wire must be
reinstalled to avoid breaking continuity.
NOTE: Amperage draw varies from vehicle to vehicle depending on
the equipment package. Compare to a similar vehicle for
reference.
NOTE: No production vehicle should have more than a 50 mA (0.050
amp) draw.

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12-Volt Battery - Electronic Drains Which Shut Off When the Battery Cable is Disconnected Test
1. Repeat the steps of the 12-Volt Battery - Drain Test.
2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the
key to ON for a moment and then OFF. Wait a few minutes for the illuminated entry lamps
to turn off, if equipped.
3. Connect the ammeter and read the amperage draw.
The current reading (current drain) should be less than 50 mA (0.050 amp). If the current
drain exceeds 50 mA (0.050 amp) after a few minutes, and if this drain did not show in
previous tests, the drain is most likely caused by an inoperative electronic component. As in
previous tests, remove the fuses from the BJB and the SJB one at a time to locate the
problem circuit.
GENERAL PROCEDURES
BUFFER ZONE

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1. Position the vehicle in the repair bay.
2. Position 4 orange cones around the corners of the vehicle to mark off a 1 m (3 ft) perimeter
around the vehicle.
Fig. 13: Positioning 4 Orange Cones Around Corners Of Vehicle
3. Do not allow any unauthorized personnel into the buffer zone during repairs involving the
high-voltage system. Only personnel trained for repair on the high-voltage system are to be
permitted in the buffer zone.
RUBBER INSULATING GLOVES TESTING
death.

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1. Roll the glove up from the open end until the lower portion of the glove begins to balloon
from the resulting air pressure. If the glove leaks any air, it must not be used.
2. The gloves should not be used if they show any signs of wear and tear.
3. The leather gloves must always be worn over the rubber insulating gloves in order to protect
them.
4. The rubber insulating gloves must be class "00" and meet all of the American Society for
Testing and Materials (ASTM) standards.
HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING
death.
NOTE: The high-voltage insulated safety gloves must be recertified every 6
months to remain within Occupational Safety and Health
Administration (OSHA) guidelines.

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1. Set up the buffer zone around the vehicle. For additional information, refer to Buffer
Zone.
2. Remove the service disconnect plug.
1. Rotate the service disconnect plug from the lock (1) position to the unlock (2)
position.
2. Remove the service disconnect plug and place in the servicing shipping (3) position.
Fig. 14: Service Disconnect Plug
death.
CAUTION: Place the service disconnect plug into the servicing
shipping position while the high-voltage traction battery
(HVTB) is being removed and/or while the high-voltage
system is having repairs carried out. If the service
disconnect plug is left out and placed on the bench or
toolbox, dirt or other contaminants may enter the HVTB,
which can cause damage.

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3. Insert the service disconnect plug into the servicing shipping position. This disconnects the
HVTB.
Fig. 15: Service Disconnect Plug In Servicing Shipping Position
4. To connect, reverse the disconnect procedure.

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Fig. 16: Exploded View Of High-Voltage Traction Battery (With Torque Specifications)
1 W500212
A/C return duct assembly screws (5
required)
2 19479 A/C return duct assembly
3 -
6-pin low voltage electrical
connector (part of 14405)
4 -
40-pin low voltage connector bolt
(part of 14405)
5 W520413
High-voltage cables shield nuts (2

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required)
6 W500230 High-voltage cables shield bolt
7 W706713
High-voltage cables shield plastic
rivet/screw
8 14A099 High-voltage cables shield
9 14B322
High-voltage cables electrical
connector
10 W710255
High-voltage traction battery bolts
(9 required)
11 10B759 High-voltage traction battery
death.

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1. Depower the HVTB. For additional information, refer to High-Voltage Traction Battery
Systems Depowering.
2. Remove the rear cargo area carpet insert.
3. Remove the 5 A/C return duct assembly screws.
4. Remove the A/C return duct assembly.
5. From the left rear door opening, fold the left rear seat backrest down and disconnect the 6-
pin low voltage electrical connector.
6. Loosen the bolt and disconnect the 40-pin low voltage connector.
7. From the right rear door opening, fold the right rear seat cushion forward and remove the 2
high-voltage cables shield nuts (access the shield nuts through the slotted opening in the
carpet).
NOTE: A replacement high-voltage traction battery (HVTB) may have a low
state of charge that is insufficient to start the vehicle. If this occurs,
follow the instructions for the jump start procedure in the Owner's
Literature.
NOTE: When installing, tighten the screws on the HVTB first or an
airflow loss to the HVTB may occur.
NOTE: Due to clearance issues, the 6-pin connector must be
disconnected first during the removal process and connected
last during the installation process.
NOTE: Due to clearance issues, the 40-pin connector must be
disconnected last during the removal process and connected
first during the installation process.

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Fig. 17: High-Voltage Cables Shield Nuts
8. Fold the right rear seat backrest down and remove the high-voltage cables shield bolt, then
remove the scrivet.
Fig. 18: High-Voltage Cables Shield & Fasteners
9. Remove the high-voltage cables shield.
10. Press the locking tab down and rotate the locking lever upward until the aligning dowels are
disengaged from the locking lever to remove the high-voltage cables electrical connector.
11. Remove the 9 HVTB bolts.
NOTE: The attaching bolts have a conductive coating on them and are
serrated under the head flange. These features ground the
HVTB to the vehicle, which is required for electro-magnetic
compatibility (EMC). If a bolt(s) is lost or damaged, a new bolt
(s) must be installed with the identical type of bolt.
NOTE: Hand-start all of the bolts before tightening them to

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12. With an assistant, attach a chain or suitable lifting device to the 3 lift points and lift the
HVTB off the 2 alignment dowels using a floor crane. Remove the HVTB from the vehicle.
specification.
NOTE: The 2 front lift points are the eyelets on each front corner and
the rear lift point is beneath the cap plug in the center rear of
the HVTB.
NOTE: Remove the cap plug to expose the center (rear) lifting
attachment point. Make certain to reinstall this plug during the
HVTB installation procedure to avoid noise, vibration, and
harshness (NVH) issues.
NOTE: Attach 3 M10 x 1.5 x 35 eyebolts to the 3 HVTB lift points.
Obtain the eyebolts locally.
NOTE: Make certain the HVTB does not mar or damage the interior
panels during removal. There is only 6 mm (0.23 in) clearance
on each side. Cover the battery mounting brackets with
protective padding.
NOTE: Do not strike the headliner with the HVTB (or floor crane)
during removal.
NOTE: Inspect the HVTB tray drain grommet located in the floor pan
underneath the HVTB. Replace it if necessary.
NOTE: Failure to install the rear lift eye cap plug may result in noise,
vibration and harshness (NVH) issues.

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Fig. 19: High-Voltage Traction Battery Lift Points
HIGH-VOLTAGE CABLES

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Fig. 20: Exploded View Of High-Voltage Cables (With Torque Specifications)
1 W520413
High-voltage cables shield nuts (2
required)

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2 W500230 High-voltage cables shield bolt
3 W706713
High-voltage cables shield plastic
rivet/screw
4 14A099 High-voltage cables shield
5 14B322
High-voltage cables electrical
connector
6 140303
High-voltage cables floorpan
grommet
7 W707375
Park brake cable bracket bolts (2
required)
8 2A604 Park brake cable bracket
9 W520412
High-voltage cables conduit nuts
(right side inner frame rail and
floorpan) (5 required)
10 W520412
High-voltage cables bracket nuts
(bulkhead) (2 required)
11 W500224
High-voltage cables to the
electronically controlled
continuously variable transmission
(eCVT) bolt
12 140303
High-voltage cables connection to
eCVT
13 140303 High-voltage cables

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1. Depower the high-voltage traction battery (HVTB). For additional information, refer to
High-Voltage Traction Battery Systems Depowering.
2. From the right rear door opening, fold the right rear seat cushion forward and remove the 2
high-voltage cables shield nuts (access the shield nuts through the slotted opening in the
carpet).
3. Fold the right rear seat backrest down and remove the high-voltage cables shield bolt.
4. Remove the high-voltage cables shield plastic rivet/screw.
5. Remove the high-voltage cables shield.
6. Press the locking tab down and rotate the locking lever upward until the aligning dowels are
disengaged from the locking lever to remove the high-voltage cables electrical connector.
8. Remove the high-voltage cables floorpan grommet.
9. Remove the 2 bolts and the park brake cable bracket.
10. Remove the 5 high-voltage cables conduit nuts (right side inner frame rail and floorpan).
11. Lower the vehicle.
12. Remove the 2 high-voltage cables bracket nuts (bulkhead). (Access the nuts through the
engine compartment.)
death.

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13. Remove the nut and the eCVT shift cable.
14. Remove the high-voltage cables to the eCVT bolt.
15. Rotate the locking lever rearward until the alignment dowels are disengaged from the
locking lever and remove the high-voltage cables connection to the eCVT.
12 VOLT BATTERY
Fig. 21: Exploded View Of 12 Volt Battery (With Torque Specifications)

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1. Disconnect the 12-volt battery. For additional information, refer to BATTERY,
2. Remove the battery wedge clamp and bolt.
3. Remove the battery.
4. Remove the 4 bolts and the battery tray.
1 10576
Low-voltage battery wedge clamp
and bolt
2 10655 Battery
3 W503923-S439
Low-voltage battery tray bolts (4
required)
4 10723 Battery tray
WARNING: Batteries contain sulfuric acid and produce explosive gases.
Work in a well-ventilated area. Do not allow the battery to
come in contact with flames, sparks or burning substances.
Avoid contact with skin, eyes or clothing. Shield eyes when
working near the battery to protect against possible
splashing of acid solution. In case of acid contact with skin
or eyes, flush immediately with water for a minimum of 15
minutes, then get prompt medical attention. If acid is
swallowed, call a physician immediately. Failure to follow
these instructions may result in serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or
with hands on opposite corners. Excessive pressure on the
battery end walls may cause acid to flow through the vent
caps, resulting in personal injury and/or damage to the
vehicle or battery.

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2007 ENGINE
Starting System - Escape & Mariner
SPECIFICATIONS
STARTING SYSTEM
The starting system consists of the following:
Starter motor
Starter motor relay
Transmission range (TR) sensor (automatic transaxle)
Clutch pedal position (CPP) switch (manual transaxle)
Battery
Item Specification
Normal engine cranking speed 200-250 rpm
Starter motor maximum load current draw 800 amps
Starter circuit maximum voltage drop (engine
at normal operating temperature)
0.5 volt
Starter motor no load current draw 60-80 amps
Starter motor normal load current draw 130-190 amps
Ground strap nut (2.3L) 25 18 -
LH splash shield bolts 9 - 80
Starter motor bolts (3.0L) 27 20 -
Starter motor solenoid battery cable nut (2.3L) 12 9 -
Starter motor solenoid battery cable nut (3.0L) 12 9 -
Starter motor stud bolts (2.3L) 35 26 -
Starter solenoid wire nut (2.3L) 5 - 44
Starter solenoid wire nut (3.0L) 5 - 44
Transmission shift cable bracket bolts 23 17 -

2007 ENGINE Starting System - Escape & Mariner

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Ignition switch
When the starter solenoid is energized, a magnetic field is created in the starter solenoid
windings. The iron plunger core is drawn into the starter solenoid coil, and a drive lever and pin
connected to the starter drive engages the drive pinion gear to the flywheel ring gear. When the
plunger is pulled all the way in, its contact disc closes the circuit between the battery and the
motor feed terminals. This sends current to the motor, and the drive pinion gear cranks the
flywheel to start the engine. When current flows to the starter motor, the starter solenoid pull-in
coil is bypassed, and the hold-in coil keeps the drive pinion gear engaged with the flywheel until
the ignition switch is released from the START position.
An overrunning clutch in the starter drive protects the starter motor from excessive speeds during
the brief period before the driver releases the ignition switch from the START position as the
engine starts.
Vehicles equipped with a manual transaxle have a clutch pedal position (CPP) switch mounted on
the clutch pedal bracket. The CPP switch prevents operation of the starter motor unless the clutch
is fully depressed.
Vehicles equipped with an automatic transaxle have a transmission range (TR) sensor mounted on
the transaxle. The TR sensor prevents operation of the starter motor unless NEUTRAL or PARK
is selected.
DIAGNOSTIC TESTS
STARTING SYSTEM
Special Tools
73III Automotive Meter 105-R0057 or equivalent
Vehicle Communication Module
(VCM) and Integrated
Diagnostic System (IDS)
software with appropriate
hardware, or equivalent scan tool

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Hybrid
For Hybrid starting system diagnostics, refer to INTRODUCTION -- HYBRID ENGINES
article.
Principles of Operation
Starting System - Anti-Theft Intervention
The starting system is electronically controlled by the passive anti-theft system (PATS). The
PATS recognizes the correct electronically coded ignition key and signals the PCM to provide a
ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby
allowing the starter motor to activate.
Inspection and Verification
1. Verify the customer concern by operating the starting system to duplicate the conditions.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
VISUAL INSPECTION CHART
Alternator, Regulator, Battery
and Starter Tester (ARBST)
010-00725 or equivalent
WARNING: Always disconnect the battery ground cable at the battery
before disconnecting the starter motor battery terminal lead.
If a tool is shorted at the starter motor battery terminal, the
tool can quickly heat enough to cause a skin burn. Failure to
follow this instruction may result in serious personal injury.
NOTE: When working on the starter system, make sure the anti-theft
system is operational.
Mechanical Electrical
Battery
Battery junction box
(BJB) fuses:
1 (25A)

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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, connect the scan tool to the data link connector (DLC).
5. If the scan tool does not communicate with the VCM:
check the VCM connection to the vehicle.
check the scan tool connection to the VCM.
refer to MODULE COMMUNICATIONS NETWORK article, No Power To The
Scan Tool, to diagnose no communication with the scan tool.
6. If the scan tool does not communicate with the vehicle:
verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
refer to MODULE COMMUNICATIONS NETWORK article to diagnose no
response from the powertrain control module (PCM).
7. Carry out the network test.
If the scan tool responds with no communication for one or more modules, refer to
MODULE COMMUNICATIONS NETWORK article.
Starter motor
Brackets
16 (25A)
17 (50A)
Smart junction box
(SJB) fuse:
4 (10A)
Wiring harness
Starter relay
Anti-theft system
Loose or corroded
connections
NOTE: Make sure to use the latest scan tool software release.
NOTE: The vehicle communication module (VCM) LED prove out
confirms power and ground from the DLC are provided to the
VCM.

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If the network test passes, retrieve and record continuous memory diagnostic trouble
codes (DTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern, go to Starter and Passive Anti-Theft
System (PATS) Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to
MULTIFUNCTION ELECTRONIC MODULES article.
10. If no DTCs related to the concern are retrieved, go to Symptom Chart.
PASSIVE ANTI-THEFT SYSTEM (PATS) - DIAGNOSTIC TROUBLE CODE (DTC)
CHART
DTC Description Source Action
B1213
Anti-Theft Number of
Programmed Keys is
Below Minimum
PCM
REFER to ANTI-THEFT -
PATS article.
B1232
Transceiver Module
Antenna Failure Memory
Failure in the PCM
PCM
PATS article.
B1342 ECU is Defective PCM
CLEAR the DTCs. REPEAT the
self-test. If DTC B1342 is
retrieved again, INSTALL a
powertrain control module
(PCM). REFER to
ELECTRONIC ENGINE
CONTROLS - 2.3L article,
ELECTRONIC ENGINE
CONTROLS - 3.0L (4V) article
or ELECTRONIC ENGINE
CONTROLS - HYBRID article.
CLEAR the DTCs. REPEAT the
self-test.
B1600
Passive Anti-Theft System
(PATS) Key Transponder
is Not Received
PCM
PATS article.
B1601
PATS Received Incorrect
Key-Code From Key
Transponder
PCM
PATS article.
B1602
PATS Received Invalid
Format of Key-Code
PCM

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Symptom Chart
Symptom Chart
From Key Transponder PATS article.
B1681
PATS Transceiver
Module Signal is Not
Received
PCM
PATS article.
B2103 Antenna Not Connected PCM
PATS article.
B2431
Key Program Failure
(Defective Key or
Transceiver)
PCM
VERIFY if the correct PATS key
is being used. If the PATS key is
defective, USE a new key for
programming.
Condition Possible Sources Action
The engine does
not crank
Battery
Fuse(s)
Starter motor
Circuitry
Starter motor relay
Anti-theft system
TR sensor
Go to Pinpoint Test A.
The engine cranks
slowly
Battery
Starter motor
Circuitry
CARRY OUT the Starter
Motor Component Test.
Unusual starter
noise
Starter motor mounting
Starter motor
Incorrect starter drive
engagement
Go to Pinpoint Test B.
The starter spins
but the engine
does not crank
Starter motor
INSPECT the starter motor
mounting and engagement.
REPAIR as necessary.

Damaged flywheel/ring
gear teeth
INSPECT the flywheel/ring
gear for damaged, missing
or worn teeth. REPAIR as

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Pinpoint Tests
Pinpoint Test A: The Engine Does Not Crank
Normal Operation
Under normal operation, constant power is supplied to the starter relay on circuit 16 (RD/LG).
When the key is placed in the START position, with the vehicle in PARK or NEUTRAL, the TR
sensor (automatic transmission) provides power to the starter relay coil on circuit 1093 (TN/RD).
When the key is placed in the START position, with the vehicle in PARK or NEUTRAL and
with the clutch pedal depressed, the clutch cutoff switch (manual transmission) provides power to
the starter relay coil on circuit 1093 (TN/RD). The PCM provides ground to the starter relay coil
on circuit 32 (RD/LB) to the starter relay. When the coil of the relay is energized, it sends power
to the starter motor on circuit 33 (WH/PK).
Possible Causes
Battery
Fuse(s)
Ignition switch
Starter relay
Anti-theft system
Circuitry
PINPOINT TEST A: THE ENGINE DOES NOT CRANK
A1 CHECK THE CONDITION OF THE PATS
Observe the PATS warning indicator.
Does the indicator flash when attempting to start the vehicle?
YES : REFER to ANTI-THEFT - PATS article to diagnose the PATS DTCs.
NO : Go to A2.
A2 CHECK THE BATTERY
Check the battery condition and charge. Refer to BATTERY, MOUNTING AND
CABLES article.
necessary.

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Is the battery OK?
YES : Go to A3.
NO : CHARGE or INSTALL a new battery as necessary. REFER to BATTERY,
MOUNTING AND CABLES article. TEST the system for normal operation.
A3 CHECK THE BATTERY GROUND CABLE
Fig. 1: Checking Battery Ground Cable
Measure the voltage between the positive battery post and the battery ground cable
connection at the engine.
YES : Go to A4.
NO : INSTALL a new battery ground cable. REFER to BATTERY, MOUNTING
AND CABLES article. TEST the system for normal operation.
A4 CHECK STARTER MOTOR GROUND
Fig. 2: Checking Starter Motor Ground
Measure the voltage between the positive battery post and the starter motor case.

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YES : Go to A5.
NO : CLEAN the starter motor mounting flange and make sure the starter motor is
correctly mounted. TEST the system for normal operation.
A5 CHECK THE POWER SUPPLY TO THE STARTER MOTOR
Fig. 3: Checking Power Supply To Starter Motor
Measure the voltage between starter motor C197A, circuit 2037 (RD) and ground.
YES : Go to A6.
NO : INSTALL a new positive battery cable. REFER to BATTERY, MOUNTING
AND CABLES article. TEST the system for normal operation.
A6 CHECK THE STARTER MOTOR B-PIN
Fig. 4: Checking Starter Motor B-PIN
Connect one end of a fused (30A) jumper wire to starter motor C197A, circuit 2037
(RD). Momentarily connect the other end of the jumper to starter motor C197B,

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circuit 33 (WH/PK).
Did the starter motor engage and the engine crank?
YES : Go to A7.
NO : INSTALL a new starter motor. REFER to Starter Motor - 2.3L or Starter
Motor - 3.0L. TEST the system for normal operation.
A7 CHECK THE STARTER MOTOR RELAY
Disconnect: Starter Motor Relay
Carry out the component test on the starter motor relay.
Is the starter motor relay OK?
YES : Go to A8.
NO : INSTALL a new starter motor relay. TEST the system for normal operation.
A8 CHECK STARTER MOTOR RELAY POWER
Measure the voltage between the battery junction box (BJB) starter motor relay pin
30, circuit 16 (RD/LG) harness side and ground.

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YES : Go to A9.
NO : REPAIR the circuit. TEST the system for normal operation.
A9 CHECK THE START SIGNAL TO THE STARTER MOTOR RELAY
Measure the voltage between the BJB starter motor relay pin 85, circuit 1093
(TN/RD), harness side and ground with the ignition switch in the START position.
YES : Go to A10.
NO : For A/T, go to A14 .
For M/T, go to A18 .
A10 CHECK THE GROUND SIGNAL TO THE STARTER RELAY
NOTE: For manual transaxle, fully disengage the clutch.

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Measure the voltage between the BJB starter relay pin 85, circuit 1093 (TN/RD) and
pin 86, circuit 32 (RD/LB), while placing the ignition switch in the START position.
YES : Go to A12.
NO : Go to A11.
A11 CHECK CIRCUIT 32 (RD/LB) FOR AN OPEN
Disconnect: PCM C175B

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Measure the resistance between the BJB starter relay pin 86, circuit 32 (RD/LB),
harness side and PCM C175B-2, circuit 32 (RD/LB), harness side.
YES : INSTALL a new PCM.
A12 CHECK THE CIRCUIT TO THE STARTER MOTOR
Disconnect: Starter Solenoid C197b

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Measure the resistance between starter solenoid S-terminal C197b, circuit 33
(WH/PK) harness side and the BJB starter motor relay pin 87, circuit 33 (WH/PK)
harness side.
YES : REINSTALL the starter motor relay. Go to A13 .
A13 CHECK THE STARTER MOTOR GROUND CIRCUIT
Connect: Starter Solenoid C197b
Carry out the Starter Motor - Ground Circuit Test. Refer to the component test.
Is the starter motor ground circuit OK?
YES : CARRY OUT the Starter Motor - Motor Feed Circuit test. REFER to
Component Tests.
NO : REPAIR or INSTALL a new battery ground cable and/or engine ground cable as
necessary. TEST the system for normal operation.
A14 CHECK THE LINKAGE ADJUSTMENT

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Check the transaxle linkage adjustment. Refer to AUTOMATIC
TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - CD4E article.
Is the linkage adjustment OK?
YES : Go to A15.
NO : ADJUST the linkage. TEST the system for normal operation.
A15 VERIFY THE TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT
Verify the TR sensor adjustment. Refer to AUTOMATIC
TRANSAXLE/TRANSMISSION - CD4E article.
Does the TR sensor need adjustment?
YES : ADJUST the TR sensor. TEST the system for normal operation.
NO : Go to A16.
A16 CHECK THE VOLTAGE TO THE TR SENSOR
Disconnect: TR Sensor C167
Measure the voltage between TR sensor C167-4, circuit 306 (TN/LB), harness side
and ground with the ignition switch in the START position.
YES : Go to A17.
A17 CHECK THE CIRCUIT BETWEEN THE TR SENSOR AND THE STARTER
MOTOR RELAY

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Measure the resistance between TR sensor C167-9, circuit 1093 (TN/RD), harness side
and the BJB starter motor relay pin 85, circuit 1093 (TN/RD) harness side.
YES : INSTALL a new TR sensor. REFER to AUTOMATIC
TRANSAXLE/TRANSMISSION - CD4E article. TEST the system for normal
operation.
A18 CHECK THE VOLTAGE TO THE CLUTCH CUTOFF SWITCH
Disconnect: Clutch Cutoff Switch C2072

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Measure the voltage between clutch cutoff switch C2072-1, circuit 306A (TN/LB),
harness side and ground with the ignition switch in the START position.
YES : Go to A19.
A19 CHECK THE CIRCUIT BETWEEN THE CLUTCH CUTOFF SWITCH AND
THE STARTER MOTOR RELAY

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Measure the resistance between clutch cutoff switch C2072-2, circuit 1093 (TN/RD)
harness side and the BJB starter motor relay pin 85, circuit 1093 (TN/RD) harness
side.
YES : INSTALL a new clutch cutoff switch. TEST the system for normal operation.
Pinpoint Test B: Unusual Starter Noise
Possible causes
Loose starter motor mounting bolts or brackets
Worn or damaged flywheel ring gear
Worn or damaged starter motor drive gear
PINPOINT TEST B: UNUSUAL STARTER NOISE
B1 CHECK THE STARTER MOUNTING
Inspect the starter motor mounting bolts and brackets for looseness.
Is the starter motor mounted correctly?
YES : Go to B2.
NO : INSTALL the starter motor correctly. REFER to Starter Motor - 2.3L or
Starter Motor - 3.0L. TEST the system for normal operation.
B2 CHECK FOR ENGINE NOISE
Turn the ignition switch to the OFF position.
Connect a fused jumper wire from the B-terminal to the S-terminal of the starter
motor. Engage the starter motor and verify that the noise is due to the starter operation.
Is the noise due to the starter motor engagement?
YES : Go to B3.
NO : REFER to ENGINE SYSTEM - GENERAL INFORMATION article to
continue the diagnosis.
B3 CHECK FOR UNUSUAL WEAR
Remove the starter motor. Refer to Starter Motor - 2.3L or Starter Motor - 3.0L.
Inspect the ring gear for damaged or worn teeth.

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Is the noise due to flywheel ring gear tooth damage?
YES : INSTALL a new flywheel ring gear. EXAMINE the starter pinion teeth. If
damaged, INSTALL a new starter motor. REFER to Starter Motor - 2.3L or Starter
NO : INSTALL a new starter motor. REFER to Starter Motor - 2.3L or Starter
Component Tests
Connect the 73III Automotive Meter at the component terminal rather than at the wiring end
connector. Making a connection at the wiring end connector could result in false readings because
the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor - Motor Feed Circuit
1. Make sure the battery is fully charged. Carry out a battery load test. Refer to BATTERY,
2. Disconnect the inertia fuel shutoff (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S-terminal and the battery
positive (+) terminal.
4. Connect the 73III Automotive Meter positive lead to the battery positive (+) post. Connect
the negative lead to the M-terminal.
Fig. 14: Identifying Starter Motor - Motor Feed Circuit
WARNING: Always disconnect the battery ground cable at the battery
before disconnecting the starter motor battery terminal lead.
If a tool is shorted at the starter motor battery terminal, the
tool can quickly heat enough to cause a skin burn. Failure to
follow this instruction may result in serious personal injury.

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5. Engage the remote starter switch. Read and record the voltage. The voltage reading should
be 0.8 volt or less.
6. If the voltage reading is 0.8 volt or less, go to the Starter Motor - Ground Circuit
Component Test.
7. If the voltage reading is greater than 0.8 volt, this is an indication of excessive resistance in
the connections, the positive battery cable or in the starter solenoid. Move the 73III
Automotive Meter negative lead to the starter solenoid B-terminal and repeat the test. If the
voltage reading at the B-terminal is lower than 0.8 volt, the concern is either in the
connections at the starter solenoid or in the solenoid contacts.
8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections
and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage
drop reading is still greater than 0.8 volt when checked at the M-terminal and less than 0.8
volt when checked at the B-terminal, the concern is in the solenoid contacts. Install a new
starter motor.
9. If the voltage reading taken at the solenoid B-terminal is still greater than 0.8 volt after
cleaning the cables and the connections at the solenoid, the concern is either in the positive
(+) battery cable connection or in the positive battery cable itself. Clean the positive (+)
battery cable connection. If this does not solve the problem, install a new positive battery
cable. For additional information, refer to BATTERY, MOUNTING AND CABLES
article.
Starter Motor - Ground Circuit
A slow cranking condition can be caused by resistance in the ground or return portion of the
cranking circuit. Check the voltage drop in the ground circuit as follows:
1. Connect the 73III Automotive Meter positive lead to the starter motor housing (the
connection must be clean and free of rust or grease). Connect the negative lead to the
negative (-) battery terminal.
Fig. 15: Identifying Starter Motor - Ground Circuit

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2. Engage the remote starter switch and crank the engine. Read and record the voltage reading.
The reading should be 0.5 volt or less.
3. If the voltage is more than 0.5 volt, clean the negative cable connections at the battery, the
body ground connections and the starter ground connections. Retest.
4. If the voltage is more than 0.5 volt, install a new cable. If the voltage reading is less than 0.5
volt and the engine still cranks slowly, install a new starter motor.
STARTER MOTOR - 2.3L
Fig. 16: Exploded View Of Starter Motor - 2.3L (With Torque Specifications)
1 14488
Starter motor solenoid terminal
cover
2 N805320 Starter motor solenoid wire nut
3 N621939
Starter motor solenoid battery cable
nut

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3. Remove the 7 retainers and the LH splash shield.
Fig. 17: View Of LH Splash Shield And Retainers
4. Remove the starter solenoid wire nut.
5. Remove the starter solenoid battery cable nut and disconnect the starter motor solenoid
terminal cover and cables.
4 13A506
Wiring harness retainer (part of
12B637)
5 N802001 Ground strap nut
6 14463 Ground strap (part of 14A280)
7 N801472 Starter motor stud bolts (2 required)
8 11000 Starter motor
WARNING: When performing maintenance on the starting system, be
aware that heavy gauge leads are connected directly to the
battery. Make sure protective caps are in place when
maintenance is completed.

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6. Disconnect the wiring harness retainer and position aside the wiring harness.
7. Remove the ground strap nut and position aside the strap.
8. Remove the 2 starter motor stud bolts.
Install the upper and lower starter motor stud bolts finger-tight.
Tighten the upper bolt to 35 N.m (26 lb-ft).
Tighten the lower bolt to 35 N.m (26 lb-ft).
STARTER MOTOR - 3.0L
Fig. 18: Exploded View Of Transmission Shift Cable Bracket (With Torque
Specifications)
1 7E395
Transmission shift cable-to-manual
lever
2 W500023
Transmission shift cable bracket
bolt (2 required)

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Fig. 19: Exploded View Of Starter Motor - 3.0L (With Torque Specifications)
2. Remove the air cleaner. For additional information, refer to INTAKE AIR
DISTRIBUTION AND FILTERING - 3.0L (4V) article.
3 - Wire harness retainer
4 7B299 Transmission shift cable bracket
5 N805320 Starter motor solenoid wire nut
6 N621939
Starter motor solenoid battery cable
nut
7 14488
Starter motor solenoid wire
terminal cover
8 W500035 Starter motor bolts (2 required)
9 11000 Starter motor

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3. Disconnect the transmission shift cable-to-manual lever.
4. Remove the 2 transmission cable bracket bolts and detach the wire harness retainer and
position aside the transmission cable and bracket.
5. Remove the starter motor solenoid wire nut.
6. Remove the starter motor solenoid battery cable nut and position aside the cables.
7. Remove the 2 bolts and the starter motor.
To install, tighten to 27 N.m (20 lb-ft).

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2007 TRANSMISSIONS
Clutch - Escape & Mariner
SPECIFICATIONS
CLUTCH
The clutch system includes:
flywheel
clutch disc
clutch pressure plate
clutch master cylinder
clutch slave cylinder
hydraulic line
clutch pedal
The clutch system transmits fluid pressure to the slave cylinder, which in turn moves the clutch
diaphragm spring.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master
cylinder.
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate.
The clutch disc has a hub which is splined to the input shaft. The clutch disc has friction material
where it contacts the flywheel and the clutch pressure plate. Torsion springs on the flywheel help
absorb the engine torque pulses. The clutch pressure plate applies pressure to the clutch disc,
holding it tightly against the surface of the flywheel. In the engaged position, the diaphragm
spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted
to the input shaft.
When the clutch pedal is pressed, the slave cylinder with an integral release bearing pushes the
diaphragm spring center of the clutch pressure plate toward the flywheel. The diaphragm spring
Description Nm lb-ft
Clutch pressure plate bolts 29 21

2007 TRANSMISSIONS Clutch - Escape & Mariner

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pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to
the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the
engine torque from the transaxle and enabling the gears to be changed.
DIAGNOSTIC TESTS
CLUTCH
Refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL
INFORMATION article.
CLUTCH DISC AND PRESSURE PLATE
Special Tools
Clutch Aligner 308-020 (T74P-7137-K)
Flywheel Holding Tool 303-103 (T74P-6375-A)

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Fig. 1: Exploded View Of Clutch Disc & Pressure Plate (With Torque Specifications)
REMOVAL
1. Remove the transaxle. For additional information, refer to MANUAL
TRANSAXLE/TRANSMISSION article.
1 -
Clutch pressure plate bolts (6
required)
2 7563 Clutch pressure plate
3 7550 Clutch disc

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2. Using the special tool, lock the flywheel to the engine.
Fig. 2: Special Tool
3. Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and
spring ends that are higher or lower than the rest.
Fig. 3: Diaphragm Spring Fingers
4. Remove the bolts, clutch pressure plate and clutch disc.
WARNING: The clutch disc and clutch pressure plate are heavy and
may fall if not held when the bolts are removed. Failure
to follow this instruction may result in serious personal
injury.
CAUTION: Loosen the bolts evenly to prevent pressure plate
damage.
CAUTION: Do not use cleaners with a petroleum base and do not
immerse the clutch pressure plate in solvent.

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5. Using a suitable commercial alcohol based solvent, clean the clutch pressure plate.
6. Inspect the clutch pressure plate surface for burn marks, scores, flatness or ridges. For
additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND
CLUTCH - GENERAL INFORMATION article.
7. Inspect the clutch disc for:
oil or grease saturation
worn or loose facings
warpage or loose rivets at the hub
wear or rust on the splines
8. Check the clutch disc runout and wear. For additional information, refer to MANUAL
TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION
article.
INSTALLATION
1. Using the special tool, position the clutch disc on the flywheel.
Fig. 4: Special Tool
CAUTION: If the clutch disc is saturated with oil, inspect the rear
engine crankshaft seal for leakage. If leakage is found,
install a new seal prior to clutch disc installation. For
additional information, refer to ENGINE - 2.3L article.
NOTE: Use an emery cloth to remove minor imperfections in the clutch
disc lining surface.
NOTE: Install a new clutch disc if any of the following conditions are
present.

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2. Position the clutch pressure plate on the flywheel and install the clutch pressure plate bolts.
Tighten to 29 Nm (21 lb-ft) in sequence.
Fig. 5: Clutch Pressure Plate Bolt Torque Sequence
3. Install the transaxle. For additional information, refer to MANUAL
TRANSAXLE/TRANSMISSION article.

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2005 TRANSMISSIONS
Automatic Transaxle/Transmission - Electronically Controlled Continuously Variable
Transmission (eCVT) - Hybrid Escape
SPECIFICATIONS
Item Specification
Sealant
Thread Sealant With PTFE TA-24 WSK-M2G350-A2
Fluid
Motorcraft MERCONMulti-Purpose (ATF) Transmission
Fluid XT-2-QDX
MERCON
Motorcraft Premium Gold Engine Coolant VC-7-A (in
California and Oregon VC-7-B, in Canada VC-7-C) or
equivalent (yellow color)
WSS-M97B51-A1
Fluid Capacities
Motor electronics cooling system
3.5L (3.7 quarts)
approximate dry fill
capacity
Transmission selector lever bolt (4 required) 25 18 -
Shift cable bracket nut (2 required) 23 17 -
Transaxle control cable nut (2 required) 22 16 -
Transaxle control splash shield bolt (2 required) 22 16 -
Shift cable grommet nut (2 required) 11 8 -
Manual control lever retaining nut 10 - 89
Transaxle damper bolts (6 required) 25 21 -
Transaxle-to-engine bolt (10 required) 47 35 -
RH engine mount bracket nut (2 required) 90 66 -
Lateral support crossmember bolt (4 required) 115 85 -

2005 TRANSMISSIONS Automatic Transaxle/Transmission - Electronically Controlled Continuously Variable

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Front roll restrictor-to-lateral support
crossmember bolt
90 66 -
Rear roll restrictor-to-lateral support
crossmember bolt
90 66 -
Engine support crossmember bolt (2 required) 90 66 -
Engine support crossmember nut 150 111 -
Front insulator bolt 90 66 -
Front insulator bolt (2 required) 90 66 -
Rear transaxle mount bolt 90 66 -
Rear transaxle mount nut (2 required) 90 66 -
Rear insulator mount bracket bolt (3 required) 25 18 -
Rear mount heat shield nut (2 required) 38 28 -
Rear mount nut (4 required) 90 66 -
Upper insulator support bolt (2 required) 25 18 -
Upper support bolt 90 66 -
Upper support nut (2 required) 90 66 -
Front wheel drive link shaft assembly bracket (4
required)
47 35 -
All-wheel drive link shaft assembly bracket bolt
(6 required)
47 35 -
Link shaft bearing assembly-to-bracket nut (2
required)
28 21 -
Catalytic converter bracket bolt (2 required) 25 18 -
Catalytic converter bracket nut (2 required) 25 18 -
PTO housing assembly-to-transmission bolt (3
required)
70 52 -
PTO housing assembly-to-transmission bolt (1
required)
47 35 -
Motor electronics coolant pump bolt (2 required) 20 15 -
Motor electronics cooler bolt (2 required) 6 - 53
Motor electronics coolant temperature sensor 20 15 -
Auxiliary coolant pump bolts 10 - 89
Transaxle coolant tube fittings (inlet/outlet) 50 37 -
Transaxle ground cable nut 20 15 -
Transaxle harness retainer bolt 25 18 -
Fill plug 40 30 -

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TRANSAXLE DESCRIPTION
Transaxle Components
The electronically controlled, continuously variable transmission (eCVT) has the following
internal components:
kW traction motor
kW generator
One-way clutch
Planetary gearset
Range Selection
Drain plug 40 30 -
A/C compressor connector retainer 25 18 -
Engine control harness retainer nut (2 required) 6 - 53

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Fig. 1: Identifying Range Selection
Park
With the range selector in PARK:
the parking pawl locks the output shaft to the case.
the engine may be started.
the ignition key can be removed.
the ignition switch can be cycled from OFF to START or RUN.
Reverse
With the range selector in REVERSE:
the vehicle may be operated in a rearward direction.
reversing lamps are illuminated.
if the vehicle is not started, there is no reverse gear engagement.

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Neutral
With the range selector in NEUTRAL:
no power flows through the transmission.
the output shaft is disengaged from the drive wheels.
Drive
The range selector DRIVE position provides:
low speed driving.
acceleration.
cruise conditions.
deceleration.
maximum fuel economy during normal operation.
If the vehicle is not started, there is no forward gear engagement.
Low
The range selector LOW position provides:
engine braking.
improved traction on slippery roads.
If the vehicle is not started, there is no forward gear engagement.
Shift Interlock System
The shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The
shift interlock system has a shift lock actuator mounted on the floor shifter assembly. If the
ignition switch is in the RUN position, the shift actuator is continually on unless the brake pedal
is depressed.
External Controls
The external control of the continuously variable transmission (eCVT) is mechanically controlled
by a cable connected to the floor shifter. The floor shifter position determines park, reverse,
neutral, drive, and low modes.
Motor Electronics Cooling System

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The vehicle uses a pump driven cooling system (referred to as the motor electronics cooling
system) to transfer heat generated by the CVT and the hybrid electric vehicle (HEV) battery pack
to the atmosphere. The system uses a coolant-to-air radiator design.
The motor/electronics cooling system has the following components:
Fig. 2: Identifying Motor/Electronics Cooling System And Component
DIAGNOSIS AND TESTING
DIAGNOSTICS
NOTE: The vacuum hose from the old engine support rear lower insulator
should not be re-used. The new rear lower engine support insulator
does not have a vacuum hose on it. The port will need to be capped
off. If the vehicle has a cap on the upper port of the vacuum
solenoid, the rear lower engine support has already been changed.

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Refer to INTRODUCTION- HYBRID ESCAPE article.
GENERAL PROCEDURES
TRANSMISSION FLUID DRAIN AND REFILL
Material
MATERIAL
Drain and Fill
1. With the vehicle in DRIVE, position it on a hoist. For additional information, refer to
2. Turn the ignition to the OFF position.
3. Remove the splash shield retainers and remove the LH splash shield.
Fig. 3: Locating Retainers For LH Splash Shield
4. Place a suitable container under the transaxle drain plug.
Item Specification
MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX
(US); XT-2-LM12 (Canada)
MERCON
Thread Sealant with PTFE TA-24
WSK-M2G350-
A2
CAUTION: Use only clean automatic transmission fluid specific for this
transmission. Do not use any supplemental transmission fluid
additives or cleaning agents. The use of these products can
cause internal transmission components to fail, which will
affect the operation of the transmission.

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Fig. 4: Removing Drain Plug And Drain Fluid
5. Remove the drain plug and drain the fluid.
6. Remove the fill plug on the side of the transaxle.
NOTE: If an integral problem is suspected, drain the fluid through a
paper filter. A small amount of metal or friction particles may
be found from normal wear. However, if excessive metal and
friction particles are present, internal service will be required.

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Fig. 5: Removing Fill Plug On Side Of Transaxle
7. Install the drain plug.
After the fluid has been drained, clean the drain plug threads and apply a small amount
of pipe sealant.
8. Fill the transaxle with clean automatic transmission fluid as specified until the level reaches
the bottom of the fill plug hole.
9. Install the fill plug.
10. Install the LH splash shield and the retainers.
NOTE: Clean the area around the fill plug for transmission fluid that
may have spilled on the transaxle case.

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IN-VEHICLE REPAIR
DIFFERENTIAL SEALS - LH
Special Tool(s)
SPECIAL TOOL DESCRIPTION
Remover, Input Shaft Oil Seal 308-375

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Material
MATERIAL
Slide Hammer 100-001 (T50T-100-A)
Installer, LH Halfshaft Fluid Seal 205-115
Item Specification
MERCON

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Removal
3. Remove the retainers and remove the LH splash shield.
WSK-M2G350-
A2

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5. Remove the LH halfshaft.
6. Using the special tools, remove and discard the LH differential seal.

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Fig. 9: Removing And Discard LH Differential Seal
Installation
1. Using the special tool, install the LH differential seal.

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Fig. 10: Installing LH Differential Seal
2. Install the LH halfshaft.
3. Using a small amount of pipe sealant on threads, install the transaxle drain plug.

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Fig. 11: Installing Transaxle Drain Plug

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Fig. 12: Installing Fill Plug
7. Start the engine and check for correct forward and reverse operation.
DIFFERENTIAL SEALS - RH
Special Tool(s)
NOTE: The check and fill plug is located on the left side of the
transaxle near the front.
NOTE: The transaxle fluid is checked and filled by removing the plug
and adding fluid until it runs out.

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Remover, Input Shaft Oil Seal 308-375
Slide Hammer 100-001 (T50T-100-A)

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Material
MATERIAL
Removal
3. Remove the retainers and remove the LH splash shield.
Installer, RH Halfshaft Fluid Seal 308-
382
Item Specification
MERCON
WSK-M2G350-
A2

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5. Remove the RH halfshaft.
6. Using the special tools, remove and discard the RH differential seal.

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Fig. 15: Removing And Discard RH Differential Seal
Installation
1. Using the special tool, install the RH differential seal.

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Fig. 16: Installing RH Differential Seal
2. Install the RH halfshaft.
3. Using a small amount of pipe sealant on threads, install the transaxle drain plug.

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Fig. 17: Installing Transaxle Drain Plug

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Fig. 18: Installing Fill Plug
7. Start the engine and check for correct forward and reverse operation.
TRANSMISSION INSULATOR AND RETAINER - EXPLODED VIEW
NOTE: The check and fill plug is located on the left side of the
transaxle near the front.
NOTE: The transaxle fluid is checked and filled by removing the plug
and adding fluid until it runs out.

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Fig. 19: Identifying Transmission Insulator And Retainer - Upper With Torque
Specifications

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Fig. 20: Identifying Transmission Insulator And Retainer - Rear With Torque
Specifications

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Fig. 21: Identifying Transmission Insulator And Retainer - Lower With Torque
Specifications
1. For additional information, refer to the PROCEDURES.

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TRANSMISSION INSULATOR AND RETAINER - UPPER
1. Remove the air cleaner assembly.
2. Support the transaxle with a suitable floor jack.
3. Remove the bolts and the bracket.
Fig. 22: Removing Bolts And Bracket
4. Remove the nuts, bolt and the insulator.
To install, tighten the nuts to 90 Nm (66 lb-ft).
To install, tighten the bolt to 90 Nm (66 lb-ft).

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Fig. 23: Removing Nuts, Bolt And Insulator
TRANSMISSION INSULATOR AND RETAINER - LOWER
3. Remove the splash shield retainers and remove the LH splash shield.

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5. Remove the front insulator bolt.

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Fig. 26: Removing Front Insulator Bolt
6. Remove the rear insulator bolt.

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Fig. 27: Removing Rear Insulator Bolt
7. Remove the nut, bolts and the crossmember.
To install, tighten the front bolts to 90 Nm (66 lb-ft) and the rear nut to 150 Nm (111
lb-ft).

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Fig. 28: Removing Nut, Bolts And Crossmember
8. Remove the lower rear insulator bolt and remove it from the bracket.

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Fig. 29: Removing Lower Rear Insulator Bolt And Bracket
TRANSMISSION INSULATOR AND RETAINER - REAR
Special Tool(s)
Adapter for 303-290A (Support Leg) 303-
290A-03A

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Adapter for 303-290A (Lifting Hook)
303-290A-12

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2. Install the special tools.
Support Bar, Engine 303-290A
Adapters for 303-290A 303-290-01

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Fig. 30: Removing/Installing Special Tools

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Fig. 31: Installing Special Tool
4. Disconnect the heater hose retaining clip from the transaxle mount stud.

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Fig. 32: Disconnecting Heater Hose Retaining Clip From Transaxle Mount Stud
5. Remove insulator nut.

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Fig. 33: Removing Insulator Nut
6. Remove the 3 bolts and the bracket.

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Fig. 34: Removing Bolts And Bracket
7. Remove the nuts, heat shield, and insulator.

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Fig. 35: Removing Nuts, Heat Shield, And Insulator

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8. Remove the vacuum hose from the bottom of the insulator.
Fig. 36: Removing Vacuum Hose From Bottom Of Insulator
NOTE: The new rear transmission does not have or use the vacuum
hose. The vacuum port will need to be plugged off.

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Fig. 37: Removing And Discard Vacuum Hose From Vacuum Solenoid
9. Remove and discard the vacuum hose from the vacuum solenoid.
10. Install the protective cap on the top port of the vacuum solenoid.

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Fig. 38: Installing Protective Cap On Top Port Of Vacuum Solenoid
REMOVAL
TRANSAXLE
Heavy Duty Floor Crane 014-00071 or
equivalent

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Spreader Bar 303-D089 (D93P-6001-A3)
or equivalent

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Powertrain Lift 014-00765
Lifting Bracket Set, Engine 303-D095
(D94L-6001-A) or equivalent

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All vehicles
personal injury.
WARNING: To prevent exposure to high voltage, do not for any reason
open the electronically controlled, continuously variable
transmission (eCVT) cover. Failure to follow these
instructions may result in personal injury.

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2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-
GENERAL INFORMATION .
MOUNTING AND CABLES .
HIGH VOLTAGE TRACTION BATTERY .
5. Drain the engine cooling system. For additional information, refer to ENGINE COOLING
- HYBRID .
6. Drain the motor electronics cooling system. For additional information, refer to
TRANSAXLE-TRANSMISSION COOLING - HYBRID .
7. Remove the engine air cleaner. For additional information, refer to INTAKE AIR
DISTRIBUTION AND FILTERING - HYBRID .
2.3L .
9. Remove the catalytic converter. For additional information, refer to EXHAUST
SYSTEM .
COOLING - HYBRID .
11. Remove the LH front drive halfshaft. For additional information, refer to FRONT DRIVE
HALFSHAFTS .
12. Remove the front drive intermediate halfshaft. For additional information, refer to FRONT
DRIVE HALFSHAFTS .
discharge.

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4WD vehicles
14. Remove the driveshaft. For additional information, refer to DRIVESHAFT .
15. Remove the 3 transfer case heat shield bolts and the transfer case heat shield.

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Fig. 40: Removing Transfer Case Heat Shield Bolts And Transfer Case Heat Shield
16. Remove the bolts and the transfer case-to-engine bracket.

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Fig. 41: Removing Bolts And Transfer Case-To-Engine Bracket
17. Disconnect the transfer case vent hose and position it aside.

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Fig. 42: Disconnecting Transfer Case Vent Hose
18. Remove the 4 transfer case-to-transaxle bolts and remove the transfer case.

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Fig. 43: Removing Transfer Case-To-Transaxle Bolts And Transfer Case

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All vehicles
19. Disconnect the heater hoses from the heater core.
Fig. 44: Locating Heater Hoses At Heater Core
20. Detach the heater hose retaining clip from the transaxle mount stud.
Fig. 45: Detaching Heater Hose Retaining Clip From Transaxle Mount Stud

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21. Disconnect the upper radiator and coolant vent hoses.
Fig. 46: Disconnecting Upper Radiator And Coolant Vent Hoses
22. Disconnect the engine control harness.
Release the powertrain control module (PCM) connector.
Remove the harness retaining nut.

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Fig. 47: Removing Harness Retaining Nut
23. Remove the nut and the ground strap from the PCM stud.

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Fig. 48: Removing Nut And Ground Strap From PCM Stud
24. Disconnect the engine control harness electrical connector and the pin-type retainer.

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Fig. 49: Disconnecting Engine Control Harness Electrical Connector And Pin-Type
Retainer
25. Remove the selector lever cable fasteners from the stud bolts on the transaxle.

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Fig. 50: Removing Selector Lever Cable Fasteners From Stud Bolts On Transaxle

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26. Remove the bolt and disconnect the transaxle harness electrical connector.
Fig. 51: Removing Bolt And Disconnect Transaxle Harness Electrical Connector
27. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness
retainer.

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Fig. 52: Disconnecting Low Voltage Electrical Connectors And Engine Harness-To-
Body Harness Retainer
28. Disconnect the DC-to-DC converter electrical connector and the harness retainers.

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Fig. 53: Disconnecting DC-TO-DC Converter Electrical Connector And Harness
Retainers
29. Remove the 3 nuts and position aside the DC-to-DC converter.

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Fig. 54: Removing Nuts
30. If equipped, position the block heater wiring harness aside.
Detach the 3 harness retainer clips.
Route the harness through the radiator support into the engine compartment.

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Fig. 55: Detaching Harness Retainer Clips
31. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position
the auxiliary coolant pump aside.

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Fig. 56: Disconnecting Auxiliary Coolant Pump Electrical Connector
32. Disconnect the electrical connector and the wiring harness retainer from the steering gear.

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Fig. 57: Disconnecting Electrical Connector And Wiring Harness Retainer From
Steering Gear
33. Remove the bolts and the transaxle control splash shield.

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Fig. 58: Locating Bolts And Transaxle Control Snow Shield
34. Disconnect the transaxle control cable.
Release the transaxle control cable from the control lever.
Remove the nuts from the transaxle control cable bracket.

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Fig. 59: Removing Nuts From Transaxle Control Cable Bracket
35. Disconnect the selector lever cable from the retainer.

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Fig. 60: Disconnecting Selector Lever Cable From Retainer
36. Disconnect the motor electronics coolant temperature sensor electrical connector and pin-
type retainer.

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Fig. 61: Disconnecting Motor Electronics Coolant Temperature Sensor Electrical
Connector And Pin-Type Retainer
37. Disconnect the transaxle coolant hoses.

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Fig. 62: Disconnecting Transaxle Coolant Hoses
38. Remove the 2 harness fasteners, the nut and the ground cable.

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Fig. 63: Removing Harness Fasteners, Nut And Ground Cable
39. Remove the 2 bolts and position the motor electronics coolant pump aside.

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Fig. 64: Removing Bolts
40. Disconnect the lower radiator hose from the radiator.
Fig. 65: Locating Lower Radiator Hose At Radiator
41. Remove the bolts and position the A/C compressor aside using a suitable length of
mechanic's wire.

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Fig. 66: Positioning A/C Compressor Aside Using Suitable Length Of Mechanic'S
Wire
42. Remove the front roll restrictor bolt.

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Fig. 67: Removing Front Roll Restrictor Bolt
43. Remove the rear roll restrictor bracket bolts.

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Fig. 68: Removing Rear Roll Restrictor Bracket Bolts
44. Remove the nut, bolts and the engine support crossmember.

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Fig. 69: Removing Nut, Bolts And Engine Support Crossmember

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Fig. 70: Removing Transaxle-To-Engine Bolts

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Fig. 71: Removing Transaxle-To-Engine Bolts
Fig. 72: Identifying Engine Lift Table
NOTE: Due to the weight of the transaxle, special care should be taken
to mount the powertrain securely to the lift table.

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Fig. 73: Removing Engine Mount Bracket Bolt
49. Remove the nuts and the engine mount bracket.

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Fig. 74: Removing Nuts And Engine Mount Bracket
50. Remove the RH transaxle mount bracket nut.

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Fig. 75: Removing RH Transaxle Mount Bracket Nut
51. Remove the bolts and the RH transaxle mount bracket.

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Fig. 76: Removing Bolts And RH Transaxle Mount Bracket
52. Remove the bolts and the rear transaxle mount brace.

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Fig. 77: Removing Bolts And Rear Transaxle Mount Brace
53. Remove the nuts, bolt and rear transaxle mount.

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Fig. 78: Removing Nuts, Bolt And Rear Transaxle Mount
54. Lower the engine and transaxle from the vehicle.
55. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
56. Disconnect the high voltage wiring harness electrical connector.

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Fig. 79: Disconnecting High Voltage Wiring Harness Electrical Connector
57. Remove the wiring harness retainers and the wiring harness from the transaxle cover stud
bolts.

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Fig. 80: Removing Wiring Harness Retainers And Wiring Harness From Transaxle
Cover Stud Bolts
58. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
CAUTION: The damper contains a clutch which designed to slip
briefly during vehicle operation. It is essential that no
grease, oil or cleaning solvents be allowed to
contaminate the slip clutch. Do not use grease on
transmission input shaft or input shaft splines.
Should the damper become contaminated it must be
replaced.
NOTE: Due to packaging requirements, the correct bolt must be used

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Fig. 81: Removing Bolts And Transaxle Damper
59. Remove the bolts and the transaxle damper.
INSTALLATION
TRANSAXLE

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Heavy Duty Floor Crane 014-00071 or
equivalent
Spreader Bar 303-D089 (D93P-6001-A3)
or equivalent

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Powertrain Lift 014-00765
Lifting Bracket Set, Engine 303-D095
(D94L-6001-A) or equivalent

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All vehicles
personal injury.
WARNING: To prevent exposure to high voltage, do not for any reason
open the electronically controlled, continuously variable
transmission (eCVT) cover. Failure to follow these
instructions may result in personal injury.
CAUTION: The damper contains a clutch which designed to slip

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1. Install the transaxle damper.
Fig. 82: Installing Transaxle Damper
briefly during vehicle operation. It is essential that no
grease, oil or cleaning solvents be allowed to
contaminate the slip clutch. Do not use grease on
transmission input shaft or input shaft splines.
Should the damper become contaminated it must be
replaced.
NOTE: Due to packaging requirements, the correct bolt must be used
CAUTION: When positioning the engine to the transaxle, care must

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2. Using the engine crane and spreader bar, position the engine and transaxle together. Install
the 6 transaxle-to-engine bolts.
Fig. 83: Installing Transaxle-To-Engine Bolts
3. Position the wiring harness in place and install the wiring harness fasteners on the transaxle
stud bolts.
be taken to maintain alignment of the damper spline with
the transaxle input shaft.
NOTE: Transaxle removed from view for clarity.

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Fig. 84: Installing Wiring Harness Fasteners On Transaxle Stud Bolts
4. Connect the high voltage wiring harness electrical connector.

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Fig. 85: Connecting High Voltage Wiring Harness Electrical Connector
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
Fig. 86: Identifying Engine Lift Table

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7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount.
Fig. 87: Installing Rear Transaxle Mount
9. Install the rear transaxle mount bracket.

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Fig. 88: Installing Rear Transaxle Mount Bracket
10. Install the RH transaxle mount bracket.

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Fig. 89: Installing RH Transaxle Mount Bracket
11. Install the RH transaxle mount bracket nut.

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Fig. 90: Installing RH Transaxle Mount Bracket Nut
12. Install the engine mount bracket.

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Fig. 91: Installing Engine Mount Bracket
13. Install the engine mount bracket bolt.

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Fig. 92: Installing Engine Mount Bracket Bolt

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16. Install the engine support crossmember nut and bolts.

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Fig. 95: Installing Engine Support Crossmember Nut And Bolts
17. Position the roll restrictor bracket on the transaxle and install the rear roll restrictor bracket
bolts.

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Fig. 96: Installing Rear Roll Restrictor Bracket Bolts
18. Install the front roll restrictor bolt.

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Fig. 97: Installing Front Roll Restrictor Bolt
19. Install the A/C compressor.

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Fig. 98: Installing A/C Compressor
20. Connect the lower radiator hose to the radiator.
Fig. 99: Locating Lower Radiator Hose At Radiator
21. Install the motor electronics coolant pump.

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Fig. 100: Installing Motor Electronics Coolant Pump
22. Install the wiring harness fasteners, the ground cable and nut.

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Fig. 101: Installing Wiring Harness Fasteners, Ground Cable And Nut
23. Connect the transaxle coolant hoses.

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Fig. 102: Connecting Transaxle Coolant Hoses
24. Connect the motor electronics coolant temperature sensor electrical connector and pin-type
retainer.

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Fig. 103: Connecting Motor Electronics Coolant Temperature Sensor Electrical
Connector And Pin-Type Retainer
25. Install the selector lever cable in the retainer.

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Fig. 104: Installing Selector Lever Cable Retainer
26. Connect the transaxle control cable.
Install the transaxle control cable bracket and the 2 nuts finger tight.
Attach the transaxle control cable to the control lever.

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Fig. 105: Installing Transaxle Control Cable Bracket And Nuts Finger Tight
27. Position the control lever between the 2 casting ribs on the transaxle case.

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Fig. 106: Positioning Control Lever Between Casting Ribs On Transaxle Case
28. Place the selector lever in the D position.
29. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
30. To verify the correct cable adjustment, observe the control lever on the transaxle while an
assistant shifts the selector lever to each range position ending in the D position.
31. Install the transaxle control splash shield.

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Fig. 107: Locating Bolts And Transaxle Control Snow Shield
32. Connect the steering gear electrical connector and wiring harness retainer.

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Fig. 108: Connecting Steering Gear Electrical Connector And Wiring Harness
Retainer
33. Install the motor auxiliary coolant pump and connect the electrical connector.

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Fig. 109: Installing Motor Auxiliary Coolant Pump And Connect Electrical
Connector
34. If equipped, install the block heater wiring harness.
Route the harness through the radiator support.
Attach the 3 harness retainer clips.

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Fig. 110: Attaching Harness Retainer Clips
35. Position the DC-to-DC converter in place and install the 3 nuts.

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Fig. 111: Positioning DC-To-DC Converter
36. Connect the DC-to-DC converter electrical connector and the wiring harness retainers.

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Fig. 112: Connecting DC-To-DC Converter Electrical Connector And Wiring
Harness Retainers
37. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness
retainer.

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Fig. 113: Connecting Low Voltage Electrical Connectors And Engine Harness-To-
Body Harness Retainer
38. Connect the transaxle harness electrical connector and install the bolt.

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Fig. 114: Connecting Transaxle Harness Electrical Connector
39. Install the selector lever cable fasteners on the transaxle stud bolts.

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Fig. 115: Installing Selector Lever Cable Fasteners On Transaxle Stud Bolts

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40. Connect the engine control harness electrical connector and the pin-type retainer.
Fig. 116: Connecting Engine Control Harness Electrical Connector And Pin-Type
Retainer
41. Install the ground strap on the PCM stud and install the nut.

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Fig. 117: Installing Ground Strap On PCM Stud
42. Connect the engine control harness.
Engage the powertrain control module (PCM) connector.
Install the harness retaining nut.

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Fig. 118: Installing Harness Retaining Nut
43. Connect the upper radiator and coolant vent hoses.

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Fig. 119: Connecting Upper Radiator And Coolant Vent Hoses
44. Attach the heater hose retaining clip to the transaxle mount stud.

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Fig. 120: Attaching Heater Hose Retaining Clip To Transaxle Mount Stud
45. Connect the heater hoses to the heater core.
Fig. 121: Locating Heater Hoses At Heater Core
4WD vehicles
46. Position the transfer case in place and install the 4 bolts.

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Fig. 122: Positioning Transfer Case In Place

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47. Connect the transfer case vent hose.
Fig. 123: Connecting Transfer Case Vent Hose
48. Position the transfer case-to-engine support bracket and install the bolts.

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Fig. 124: Positioning Transfer Case-To-Engine Support Bracket
49. Install the transfer case heat shield and the bolts.

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Fig. 125: Installing Transfer Case Heat Shield And Bolts
50. Install the driveshaft. For additional information, refer to DRIVESHAFT .
All vehicles
51. Install the lateral support crossmember and the 4 bolts.

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52. Install the front drive intermediate halfshaft. For additional information, refer to FRONT
DRIVE HALFSHAFTS .
53. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE
HALFSHAFTS .
54. Install the engine coolant degas bottle. For additional information, refer to ENGINE
COOLING - HYBRID .
55. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
56. Install the intake manifold. For additional information, refer to ENGINE - HYBRID 2.3L .
57. Install the engine air cleaner. For additional information, refer to INTAKE AIR
DISTRIBUTION AND FILTERING - HYBRID .
58. Enable the vehicle high voltage electrical system. For additional information, refer to
HIGH VOLTAGE TRACTION BATTERY .
MOUNTING AND CABLES .
60. Reset the passive anti-theft system (PATS). For additional information, refer to ANTI-
THEFT - PATS .
61. Check and fill the transmission fluid level. For additional information, refer to

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TRANSMISSION FLUID DRAIN AND REFILL.
62. Fill and bleed the motor electronics cooling system. For additional information, refer to
TRANSAXLE-TRANSMISSION COOLING - HYBRID .
63. Fill and bleed the engine cooling system. For additional information, refer to ENGINE
COOLING - HYBRID .

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