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Ford EXPLORER 2004 Technical Training Manual
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Ford EXPLORER 2004 Technical Training Manual

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See also: Owner's Manual
FCSD
Technical Training
INTERACTIVE STUDY GUIDE
2004
EXPLORER/MOUNTAINEER
NEW MODEL TECHNICIAN
TRAINING
FCS-13854-DL
2004 EXPLORER/MOUNTAINEER NEW MODEL TECHNICIAN TRAINING COURSE
12-AUG-03
CODE: 30N23F0

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Summary of Contents for Ford EXPLORER 2004

  • Page 1 FCSD Technical Training INTERACTIVE STUDY GUIDE 2004 EXPLORER/MOUNTAINEER NEW MODEL TECHNICIAN TRAINING FCS-13854-DL 2004 EXPLORER/MOUNTAINEER NEW MODEL TECHNICIAN TRAINING COURSE 12-AUG-03 CODE: 30N23F0...
  • Page 3 The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc.
  • Page 4 – Ford Multimedia Training (FMT) – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are ‘‘the Best in the Business’’...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ....................... Intro-1 Technical Training ......................Intro-1 Ground Rules for Successful Completion ..............Intro-1 Logging On ........................Intro-2 Keypad Operation......................Intro-3 In-Dealership Training Map ..................Intro-4 Purpose......................... Intro-5 Agenda.......................... Intro-5 LESSON 1: OVERVIEW......................1-1 Objectives .......................... 1-1 Exterior Features .......................
  • Page 6 TABLE OF CONTENTS NOTES 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 7: Introduction

    The distance learning course you are about to take is intended to give you new knowledge and information about diagnosing and servicing Ford and Lincoln/Mercury vehicles. We hope you will apply this knowledge and information to ‘‘Fix It Right The First Time’’ as part of the effort to satisfy our customer, the owners of Ford and Lincoln/Mercury products.

  • Page 8: Logging On

    INTRODUCTION LOGGING ON Your response keypad transmits data and voice between you and the host site via telephone lines and satellite. It is your ‘‘lifeline,’’ connecting you to the instructor as well as to other participants. Using the keypad, you can become fully involved in the seminar, asking questions and contributing relevant comments.

  • Page 9: Keypad Operation

    INTRODUCTION KEYPAD OPERATION CALL Key • Press the CALL key if you have a question or comment. This places you in the call queue. The system indicates your name and location to the instructor. • It takes approximately 60 seconds for the instructor to respond. If you change your mind about asking the question, simply press the CALL key again.

  • Page 10: In-Dealership Training Map

    INTRODUCTION IN-DEALERSHIP TRAINING MAP Intro-4 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 11: Purpose

    INTRODUCTION PURPOSE The purpose of this FORDSTAR course is to provide Ford and Lincoln/Mercury service technicians with the knowledge needed to understand new systems, new or updated components and unique diagnostic and service procedures for the 2004 Explorer/Mountaineer. AGENDA The information in this course is presented in the following lessons: •...
  • Page 12 INTRODUCTION NOTES Intro-6 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 13: Lesson 1: Overview

    LESSON 1: OVERVIEW OBJECTIVES • Identify the new exterior features. • Identify the new interior features. • Identify the new mechanical and chassis features. • Identify the proper lifting and jacking points. • Identify the maintenance check points. • Identify the 17-character Vehicle Identification Number (VIN) coding. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 14: Exterior Features

    LESSON 1: OVERVIEW Exterior Features Explorer and Mountainer Exterior The optional exterior features include: • New exterior badging. • Revised body side moulding. • New front and rear bumper cladding. 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 15: Interior Features

    LESSON 1: OVERVIEW Interior Features Explorer/Mountaineer Interior Interior optional features include: • Quad bucket seating. • Six-way power driver and passenger seats. • 40/20/40 second row seat with three-point center restraint and headrest. • ‘‘Moduleless’’ heated front seats. • Second-generation air curtain (canopy). •...

  • Page 16: Mechanical And Chassis Features

    LESSON 1: OVERVIEW Mechanical and Chassis Features Mechanical and chassis features include: • A 4.0L SOHC V6 and 4.6L 2V V8 engine. • A 5R55S transmission. • Tire Pressure Monitoring System (TPMS). • Advance Trac stability assist. 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 17: Lifting And Jacking

    LESSON 1: OVERVIEW Lifting and Jacking Lifting and Jacking Points Explorer and Mountaineer lifting and jacking points are the same as those on the 2003 models. When jacking or lifting the Explorer and Mountaineer, be sure to observe all of the Workshop Manual cautions and warnings. CAUTION: Never place a jack or lift under the fuel tank or differential cover.

  • Page 18: Maintenance Check Points

    Item Description Item Description Power steering fluid reservoir Brake fluid reservoir Engine oil dipstick Battery It is important to check fluid levels at the recommended maintenance intervals. Always use Ford-specified fluids and lubricants. 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 19 LESSON 1: OVERVIEW Maintenance Check Points 4.0L SOHC V6 (2 of 2) Item Description Item Description Engine coolant reservoir Air filter assembly Engine oil fill cap Windshield washer reservoir 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...
  • Page 20 Item Description Item Description Brake fluid reservoir Engine oil dipstick Battery Power steering fluid reservoir It is important to check fluid levels at the recommended maintenance intervals. Always use Ford-specified fluids and lubricants. 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 21 LESSON 1: OVERVIEW Maintenance Check Points 4.6L 2V V8 (2 of 2) Item Description Item Description Engine coolant reservoir Air filter assembly Engine oil fill cap Windshield washer reservoir 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 22: Identification Codes

    Code Definition Ford Motor Company, USA, multi-purpose vehicle Ford Motor Company (Mercury), USA, multi-purpose vehicle • Brake Type/Gross Vehicle Weight Rating (GVWR) The fourth VIN position is the vehicle brake type and GVWR code. All vehicles use hydraulic brakes. This code may also identify the vehicle safety restraint system.
  • Page 23 LESSON 1: OVERVIEW • Vehicle Line, Series, Body Type VIN position five through seven indicate the vehicle line, series and body type. Code Definition Explorer, 4x2, XLS, multi-purpose vehicle Explorer, 4x2, XLT, multi-purpose vehicle Explorer, 4x2, Eddie Bauer, multi-purpose vehicle Explorer, 4x2, Limited, multi-purpose vehicle Mountaineer, 4x2, multi-purpose vehicle Explorer, 4x4, XLS, multi-purpose vehicle...
  • Page 24 VIN positions 12 through 17 are an alphanumeric code for the vehicle build sequence. This is also the vehicle serial and warranty number. Vehicle Identification Codes Code Definition A00001-E99999 Ford J00001-L99999 Mercury 1-12 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 25: Lesson 2: Chassis

    LESSON 2: CHASSIS OBJECTIVES • Identify new features of the suspension system. • Identify new features of the steering system. • Identify new features of the driveline system. • Identify new features of the brake system. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 26: Suspension System

    LESSON 2: CHASSIS Suspension System The Explorer and Mountaineer front suspension system is a coil spring-over-shock design similar to that of the Aviator. • The Explorer and Mountaineer suspension however, has the following improvements: – Redesigned shock absorbers. – Redesigned coil springs. –...
  • Page 27 LESSON 2: CHASSIS Front Shock Absorbers Front Shock Absorbers The shock absorbers for the front suspension have been changed. • The valving in the shocks have been changed from rod displaced valving to full displaced valving. • The shocks lengths and attachment points for the suspension have not changed. •...
  • Page 28 LESSON 2: CHASSIS Front Shock Absorber Upper Insulators And Coil Spring Front Shock Absorber Upper Insulators And Coil Spring Item Description Item Description Insulator Coil Spring The front shock absorber upper insulators have been improved. • The upper insulator thickness has been increased from 2mm to 10mm (0.08-0.39 inch). •...
  • Page 29 LESSON 2: CHASSIS Rear Suspension Rear Suspension The rear suspension also features a coil spring-over-shock system. The major differences on the 2004 MY Explorer and Mountaineer rear suspension are: • Redesigned shock absorbers. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...
  • Page 30 LESSON 2: CHASSIS Rear Shock Absorbers Rear Shock Absorbers The shock absorbers for the rear suspension have been changed. • The valving in the shocks have been changed from rod displaced valving to full displaced valving. • The shocks lengths and attachment points for the suspension have not changed. •...

  • Page 31: Steering System

    LESSON 2: CHASSIS Steering System Outer Tie Rod Ends The outer tie rod end was modified to improve steering feel. • Overall length was increased by 4mm (0.157 inch) – Because of this change, it is important to service this component with the appropriate part number. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 32: Driveline System

    Driveline System Rear Differential The Explorer and Mountaineer driveline system is similar to that of the 2003 Aviator. It uses a Dana 30 front differential. The rear differential is an 8.8-inch Ford axle. • Features of the driveline system include: –...
  • Page 33 LESSON 2: CHASSIS Driveline Indexing Indexing the Rear of the Rear Driveshaft Always index the driveshafts before removal to avoid creating a vibration. Indexing the Explorer and Mountaineer front and rear driveshafts is done using the same procedure as the 2003 MY Explorer and Mountaineer.
  • Page 34 LESSON 2: CHASSIS Driveline System Lubricants Refer to the chart for lubricants when servicing the Explorer and Mountaineer driveline. Item Specification Front Axle Motorcraft SAE 80W-90 Premium Axle Lubricant WSP-M2C197-A XY-80W90-QL Rear Axle High Performance 75W-140 Rear Axle Lubricant WSL-M2C192-A XY-75W140-QL Driveshaft Slip Yoke Premium Long-Life Grease XG-1-C...

  • Page 35: Brake/Stability Assist Systems

    LESSON 2: CHASSIS Brake/Stability Assist Systems Dual Piston Caliper The features of the base Explorer and Mountaineer brake system include: • Dual-piston front calipers. • Single-piston rear calipers. • Drum-in-hat type rear disc brake. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 2-11...
  • Page 36 LESSON 2: CHASSIS Electronic Brake Distribution (EBD) Hydraulic Control Unit (HCU) Electronic Brake Distribution (EBD) acts like an electronic proportioning valve to control rear brake pressure. When EBD is disabled, the amber ABS warning indicator and the red brake warning indicator illuminate. 2-12 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 37 LESSON 2: CHASSIS Identifying 4-Channel and 3-Channel ABS Systems 4-Channel Rear Speed Sensor The Explorer and Mountaineer four-wheel disc brake system is available with two different ABS systems: a standard 3-channel system and an optional 4-channel system. • The four-channel system is a requirement of stability assist/traction control. •...
  • Page 38 LESSON 2: CHASSIS Stability Assist Module Stability Assist Module The stability assist module simultaneously manages the anti-lock braking, traction control and engine control systems to maintain vehicle control during deceleration and acceleration. The stability assist module signals the Hydraulic Control Unit (HCU) to open and close the appropriate solenoid valves when it detects: •...
  • Page 39 LESSON 2: CHASSIS Normal Stability Assist System Characteristics When the ignition switch is put in the RUN position, the stability assist module conducts a preliminary electrical check. Then at approximately 20 km/h (12 mph), the hydraulic pump motor turns on for about one-half second. •...
  • Page 40 LESSON 2: CHASSIS Traction Control Traction control on vehicles equipped with a four-channel system operates in the following manner: • At speeds under 100 km/h (62 mph), when a drive wheel looses traction, the stability assist module/ECU signals the PCM to reduce engine torque, while simultaneously applying and releasing the appropriate brake caliper(s) to maintain traction.
  • Page 41 LESSON 2: CHASSIS Quick Assist Braking (With Stability Assist) The Explorer and Mountaineer use a software program called Quick Assist to provide a faster introduction of brake boost during emergency stops. Components of the standard vacuum assist work with the Pedal Travel Sensor (PTS), brake pressure transducers, active booster solenoid and release switch to accomplish this function.
  • Page 42 LESSON 2: CHASSIS Active Booster Active Booster Quick assist includes the following unique components: • New tandem dual-port stability assist master cylinder with pressure transducers. • Active brake booster with integral solenoid and a brake booster release switch The main components of the active brake booster operate in the same way as any conventional brake booster. What makes the active brake booster unique is that it can be activated by the stability assist module using the active booster solenoid.
  • Page 43 LESSON 2: CHASSIS Stability Assist Sensors Yaw/Lateral/Longitudinal Accelerometer Sensor The stability assist module uses data from the following sensors to help the vehicle driver maintain directional stability: • The Yaw/Lateral/Longitudinal Accelerometer Sensor includes the following sensors in one location that measures: –...
  • Page 44 LESSON 2: CHASSIS Yaw Rate Sensor The yaw rate sensor measures the relative vehicle motion around the vertical axis through its center of gravity. In other words, it tells the stability assist module if the vehicle is oversteering. Lateral Accelerometer The lateral accelerometer measures the acceleration as the vehicle slides sideways and is incorporated into the same unit as the yaw rate sensor.
  • Page 45 LESSON 2: CHASSIS Additional Sensors In addition to the yaw, lateral, longitudinal sensor cluster, the ABS/traction control/stability control systems use the following sensors: • Brake Pedal Position (BPP) sensor • Primary brake pressure sensor • Secondary brake pressure sensor • Brake Pedal Position (BPP) sensor •...
  • Page 46 LESSON 2: CHASSIS Stability Assist System Calibration/Configuration The stability assist module must be calibrated/configured whenever a component specific to the stability assist system is disconnected or a new component is installed. • An active/fail lamp flashing may also indicate that the stability assist module needs calibration/configuration. •...
  • Page 47 LESSON 2: CHASSIS The stability assist system calibration/configuration includes calibrating/configurating the module and sensors. Stability Assist Calibration Codes Description C1277 Steering wheel angle 1 and 2 circuit failure C1278 Steering wheel angle 1 and 2 signal fault C1279 Yaw rate sensor circuit failure C1280 Yaw rate sensor signal fault C1281...
  • Page 48 LESSON 2: CHASSIS Diagnostic Trouble Codes The following two pages list the DTCs associated with the stability assist feature. Description B1342 ECU is defective B1483 Brake pedal input circuit failure B1676 Battery pack voltage out of range B2477 Module configuration failure B2734 Pedal travel sensor (PTS) supply error B2736...
  • Page 49 LESSON 2: CHASSIS The following is a continuation of the DTCs associated with the stability assist feature. Description C1440 Pressure transducer main/primary input signal faulted C1516 Roll rate sensor signal fault C1517 Roll rate sensor circuit failure C1730 Reference voltage out of range (+5 V) C1805 Mismatched PCM and/or stability assist module C1960...

  • Page 50: Adjustable Pedals

    LESSON 2: CHASSIS Adjustable Pedals Adjustable Pedals For added driver comfort, the Explorer and Mountaineer may be equipped with optional power adjustable pedals. The memory feature remembers the pedal positions for three different drivers. • The adjustable pedal system includes the following components: –...

  • Page 51: Objectives

    LESSON 3: POWERTRAIN OBJECTIVES • Identify new features of the engine systems. • Identify new features of the powertrain control-engine performance systems. • Identify new features of the fuel systems. • Identify new features of the automatic transmission - 5R55S. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 52: Engine

    LESSON 3: POWERTRAIN Engine LEV I Defined Starting in the northeastern states in the 2000 model year and nationally in 2001, new cars and light light-duty trucks must meet tailpipe standards that are more stringent than EPA can mandate prior to model year 2004. These standards will be enforceable in the same manner as any other federal new motor vehicle program.
  • Page 53 LESSON 3: POWERTRAIN 4.0L SOHC V-6 Engine 4.0L SOHC V-6 Engine The Explorer and Mountaineer can be equipped with a 4.0-liter, SOHC, V-6 engine with: • 210 hp and 254 lb-ft of torque. To meet U.S. government LEV I emission requirements and to accomodate new features, many components of the 4.0L SOHC V6 have been modified.
  • Page 54 LESSON 3: POWERTRAIN 4.6L 2V V-8 Engine 4.6L 2V V-8 Engine The Explorer and Mountaineer can be equipped with a 4.6-liter 2V V-8 engine with: • 239 horsepower and 282 ft-lb of torque. To meet U.S. government LEV II emission requirements and to accomodate new features, many components of the 4.6L 2V V8 have been modified.
  • Page 55 LESSON 3: POWERTRAIN • The cylinder bore finish, taper and roundness tolerances: – Improve and increase the longevity of the piston ring-to-cylinder wall seal. – Assist in the reduction in engine oil consumption. – Improve the life of the catalytic converter substrate to meet LEV II requirements for the full useful life of the vehicle.
  • Page 56 • Is not compatable with orange Organic Acid Technology (OAT) coolant. Always use Ford-specified coolants and chemicals when servicing the Explorer and Mountaineer cooling system. The following table details the specifications for the hybrid cooling system. Cooling System Specification Table...
  • Page 57 LESSON 3: POWERTRAIN Fan And Shroud Assembly Fan And Shroud Assembly (4.6L Shown) The mechanically driven fan measures 493mm (19.4 inches) vs. 457mm (18 inches) for the 2003 models. • The size was increased to improve A/C performance. • All hardware and torque specifications are carryover. •...

  • Page 58: Powertrain Controls - Engine Performance

    – This style of PCM utilizes 150 pins instead of the more common 104-pin PCM. – This style of PCM is similar to the PCM used in the 2003 Ford Thunderbird and Lincoln LS. – Since there is no breakout box for both PCMs, be sure to use a DVOM and flex probes for diagnostic electrical checks.
  • Page 59 LESSON 3: POWERTRAIN Exhaust Gas Recirculation System Module (ESM EGR) EGR System Module Components Item Description Item Description Valve seat DP and MAP transducer Pin/pintle Upstream DP pick-up port Diaphragm Exhaust flow direction EGR spring The Explorer and Mountaineer use a revised Differential Pressure Feedback (DPFE) Exhaust Gas Recirculation (EGR) system.
  • Page 60 LESSON 3: POWERTRAIN The upstream port is now located directly on the EGR valve, just beyond the pintle. The downstream port is now located on the intake manifold. This arrangement results in the downstream port measuring Manifold Absolute Pressure (MAP). This allows the downstream port reading from the ESM to not only be used for measuring EGR flow, but also as a MAP input to the other modules.
  • Page 61 LESSON 3: POWERTRAIN ESM Connector The following list details how the six-pin harness connector is wired: • Pin 1 — EVR Signal (output from PCM) • Pin 2 — VREF • Pin 3 — MAP signal (input) • Pin 4 — VPWR •...
  • Page 62 LESSON 3: POWERTRAIN Electronic Throttle Control (ETC) Generation II 4.0L Electronic Throttle Body (ETB) The 2004 4.0L SOHC V6 and 4.6L 2V V8 engines are among the first engines with full-authority, Electronic Throttle Control (ETC). The main reason for using the ETC system is to improve driveability. The ETC system is a drive-by-wire system that completely eliminates the need for a conventional throttle cable between the throttle pedal and the throttle body.
  • Page 63 LESSON 3: POWERTRAIN – Throttle plate driver motor. – Dual throttle position (TP) sensors. – Gear train. NOTE: The PCM reduces the rate of throttle plate opening when the vehicle is in reverse or 4x4 mode. The vehicle may seem to ‘‘hesitate’’ when the throttle is applied and there may be a different sensation when in Reverse or 4x4 mode.
  • Page 64 LESSON 3: POWERTRAIN ETB Driver Motor ETB Driver Motor Item Description Item Description Throttle body Driver motor Cruise control is now a function of the ETC, performed by the ETB. • The PCM determines and controls the throttle angle required to: –...
  • Page 65 LESSON 3: POWERTRAIN Repair Repair concerns for the ETC system consist of components replacement only, such as the throttle body, APP sensors and the PCM. NOTE: Refer to the appropriate section in the Workshop Manual for complete details. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 3-15...
  • Page 66 LESSON 3: POWERTRAIN New PCM Contains Several New Processors The Black Oak Power PC is the main microprocessor which contains engine and transmission control logic including the desired throttle angle and OBD-II logic. • The PCM includes the following new functions: –...
  • Page 67 LESSON 3: POWERTRAIN Throttle Plate Position Controller (TPPC) The function of the Throttle Plate Position Controller, or TPPC, watches for certain failure modes and stores the appropriate code. • The following DTCs pertain to the TPPC: – P2107 - TPPC - Processor fault, faulty command from the Black Oak PCM to TPPC. No FMEM or amber wrench or Message Center text, Pedal Follower with RPM Guard.
  • Page 68 LESSON 3: POWERTRAIN Accelerator Pedal Position Sensor (APPS) Accelerator Pedal Position Sensor (APPS) The system includes an Accelerator Pedal Position Sensor (APPS) assembly. • The APPS assembly: – Is located at the top of the accelerator pedal. – Contains three analog pedal position sensors. 3-18 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 69 LESSON 3: POWERTRAIN APPS Pedal Travel The driver actuates the accelerator pedal in the usual manner. The APPS is not adjustable. No adjustment is required because pedal position and relative movement is calculated within the PCM. • APPS 1 voltage is in the range of 4.10 to 0.95 volts: –...
  • Page 70 LESSON 3: POWERTRAIN • When APPS 1 and 2 disagree, diagnostics are performed. APPS 3 is used as a redundant check. – The APPS, not the TP sensors, is now the best indication of driver demand. – When APPS 1 and APPS 3 disagree, diagnostics are performed. APPS 2 is used as a redundant check. 3-20 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 71 LESSON 3: POWERTRAIN Operation Inside an APPS Item Description Item Description Throttle pedal lever Throttle return springs APPS wiper arm APPS 1-3 and ground The main reason for using the ETC system is to improve driveability. • Based on vehicle speed, throttle response to accelerator pedal movement is adjusted by the PCM. –...
  • Page 72 LESSON 3: POWERTRAIN Accelerator Pedal Position Sensor (APPS) Check The Accelerator Pedal Position Sensor (APPS) check watches for certain failure modes and stores the appropriate DTC. • The following DTCs apply to the accelerator pedal position sensors: Description P2122 APPS 1 circuit Low Input (ETC light, Selects APPS 2, non-MIL) P2123 APPS 1 circuit High Output (ETC light, selects APPS 2, non-MIL) P2121...
  • Page 73 LESSON 3: POWERTRAIN Electronic Throttle Body Motor Item Description Item Description Throttle motor cover Throttle return spring Throttle drive gear Reduction gear The new electronic throttle body controls throttle plate angle to perform several functions. • Functions include: – Idle speed control. –...
  • Page 74 LESSON 3: POWERTRAIN • The throttle system has the necessary safety features to monitor correct operation of all components. • The PCM uses TP1 for large throttle angle changes and TP2 for small throttle angle changes because it has better resolution. –...
  • Page 75 LESSON 3: POWERTRAIN TP Sensor Tracks in the ETB (Shown in Cutaway) Item Description Item Description Throttle body TP sensor tracks TP sensor TP sensor leads Two resistive-track throttle position (TP) sensors are mounted to the single throttle shaft. • Both sensors rotate as a unit.
  • Page 76 LESSON 3: POWERTRAIN Throttle Position (TP) Sensor Check The Throttle Position (TP) sensor check watches for certain failure modes and stores the appropriate DTC. • The following DTCs apply to the throttle position sensor: Description P0122 TP low input (MIL, ETC light, pedal follower with RPM guard) P0123 TP 1 high input (MIL, ETC light, pedal follower with RPM guard) P0121...
  • Page 77 LESSON 3: POWERTRAIN Warning Lamps Warning Lamps Item Description Item Description Amber warning wrench Stability assist In the event of a failure mode, the driver receives malfunction warning lamps on the instrument cluster. • The instrument cluster uses the following to warn the driver of a fault: –...
  • Page 78 LESSON 3: POWERTRAIN IPC and PCM are Monitored by E-Quizzer The Independent Plausibility Check (IPC) function in the PCM monitors ETC inputs and outputs and takes the FMEM action. The IPC and PCM are subject to several potential failure modes. Therefore, if the E-Quizzer determines that the IPC or PCM function is impaired in any way, it takes appropriate Failure Mode and Effects Management (FMEM) action.
  • Page 79 LESSON 3: POWERTRAIN ETC System Diagnosis Two or more failed APP sensors trigger a Failure Mode and Effects Management (FMEM) mode resulting in high idle. • The PCM has new failure modes in the ETC System. The ETC system, in some diagnostic information, may be referred to as the Throttle Actuator Control System (TACS).
  • Page 80 LESSON 3: POWERTRAIN Forced Engine Shut Down Mode The Forced Engine Shut Down mode is the most critical mode. • In the Forced Engine Shutdown Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ •...
  • Page 81 LESSON 3: POWERTRAIN Forced Limited RPM and Forced Idle Mode The Forced Limited RPM and Forced Idle Mode is the second mode. • In the Forced Limited RPM and Forced Idle Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ •...
  • Page 82 LESSON 3: POWERTRAIN Forced Limited RPM Mode The Forced Limited RPM Mode is the third failure mode. • In the Forced Limited RPM Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ •...
  • Page 83 LESSON 3: POWERTRAIN Forced Idle Mode The Forced Idle Mode is the fourth failure mode. • In the Forced Idle Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ • The fail-safe action is: –...
  • Page 84 LESSON 3: POWERTRAIN Forced Limited Power Mode Forced Limited Power Mode is the fifth failure mode. • In the Forced Limited Power Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ • The fail-safe action is: –...
  • Page 85 LESSON 3: POWERTRAIN No Effect on Driveability Mode No Effect on Driveability Mode is the sixth failure mode. • In the No Effect on Driveability Mode, the warning to the driver is: – Amber wrench or Message Center text ‘‘Engine Failsafe Mode.’’ •...
  • Page 86 LESSON 3: POWERTRAIN Electronic Throttle System The Electronic Throttle System operates by watching for certain failure modes and stores the appropriate DTC. • The following DTCs can be set by the Electronic Throttle System: – P0606 - PCM processor failure. –...

  • Page 87: Fuel System

    LESSON 3: POWERTRAIN Fuel System Pulse Damper Pulse Damper A redesigned pulse damper, mounted on the fuel rail, reduces evaporative emissions. Features of the pulse damper are: • A non-permeable diaphragm. – Because of this change, it is important to service this component with the correct part number. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 3-37...
  • Page 88 LESSON 3: POWERTRAIN Fuel Pressure Gauge Adaptor Fuel Pressure Gauge Adaptor (4.6L) The fuel pressure test port (Schrader valve) has been deleted to meet LEV I and LEV II emission standards. • To physically check fuel pressure, use special tool 310-122 Connector, Fuel Pressure Gauge and the following Workshop Manual procedure.
  • Page 89 LESSON 3: POWERTRAIN Fuel Pressure Sensor (FPS) Fuel Pressure Sensor (FPS) The Fuel Pressure Sensor (FPS) senses the pressure difference between the fuel injection supply manifold and the intake manifold, and provides the PCM with the current fuel injection supply manifold pressure. The return fuel line to the fuel tank has been deleted in this type of fuel system.
  • Page 90 LESSON 3: POWERTRAIN Fuel Rail The fuel rail and injectors are similar to those used on other electronic returnless fuel systems. The Explorer and Mountaineer are equipped with an Electronic Returnless Fuel System (ERFS). The system includes a: • Redesigned fuel rail. •...
  • Page 91 LESSON 3: POWERTRAIN Electronic Returnless Fuel System ERFS Block Diagram Operation and features of the ERFS are as follows: 1. The fuel delivery system is enabled during crank or running mode once the PCM receives a crankshaft position (CKP) sensor signal. 2.
  • Page 92 LESSON 3: POWERTRAIN 7. There are three filtering or screening devices in the fuel delivery system. The intake sock is a fine, nylon mesh screen mounted on the intake side of the fuel pump. The fuel filter assembly is located between the FP and the fuel rail.
  • Page 93 LESSON 3: POWERTRAIN Electronic Vapor Management Valve (EVMV) Electronic Vapor Management Valve (EVMV) Electronic Vapor Management Valve (EVMV) hose ends have been changed to SAE style (vs barbed push on connection). 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 3-43...
  • Page 94 LESSON 3: POWERTRAIN Carbon Canister (4.6L) Carbon Canister (4.6L) The carbon canister used on the 4.6L engine package has been improved to meet LEV II emission requirements. • The canister uses a single 3.0L housing verses two 1.5L canisters used on the 4.0L engine package. •...
  • Page 95 LESSON 3: POWERTRAIN Bleed Canister (4.6L) Bleed Canister (4.6L) The bleed canister captures any hydrocarbons that may migrate out of the main canister during hot temperature performance. • Prevents these migrating hydrocarbons from getting into the atmosphere. • No special tool or diagnostics are required. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 3-45...
  • Page 96 LESSON 3: POWERTRAIN Fuel And Vapor Lines Fuel And Vapor Lines (4.6L Shown) The fuel and vapor line have been modified to comply with LEV I and LEV II emission standards. • Vapor lines – Routing is carryover. – The fuel tank end is common with previous model Explorer and Mountaineer, and the end has an SAE quick-connect.
  • Page 97 LESSON 3: POWERTRAIN • Fuel lines – 4.0L equipped vehicles have SAE type connectors at fuel filler and fuel rail. – 4.6L equipped vehicles have a new style upper fuel line bracket (at the transmission bell housing). – 4.6L connectors are all carryover. –...
  • Page 98 LESSON 3: POWERTRAIN Fuel Filler Pipe Fuel Filler Pipe The fuel filler pipe has been modified to meet LEV I and LEV II emission standards. • 4.0L equipped vehicles use a carryover main fill pipe, lower fill hose and 1/8-turn cap. •...
  • Page 99 LESSON 3: POWERTRAIN Fuel Tank Fuel Tank The fuel tank used on the 4.6L vehicle has been modified to meet LEV II emmision standards. • The fuel tank used on the 4.0L application meets LEV I emmisions standards. • New one port sender flange with no return line from the filter back to the pump. –...
  • Page 100 LESSON 3: POWERTRAIN Fuel Pump Sender Tool Fuel Pump Sender Tool The sender flange is attached with a cam lock design retainer. • 4.6L equipped vehicles require the use of special tool 310-123: wrench, fuel tank sender for removal. • The 4.0L uses a carryover tool.

  • Page 101: Transmission System

    LESSON 3: POWERTRAIN Transmission System 5R55S Transmission The Explorer and Mountaineer are equipped with the 5R55S transmission. Diagnosis and service procedures are mostly unchanged from previous model years. Minor 5R55S changes for the Explorer and Mountaineer include: • Improved calibrations for shift feel and timing. •...
  • Page 102 LESSON 3: POWERTRAIN Transmission Shift Strategy Mechanical throttle versus Electronic Throttle Control (ETC) for transmission operation works in the following way: • With mechanical throttle vehicles, the accelerator pedal is connected by cable to the throttle plate and the driver controls airflow into the engine directly.

  • Page 103: Lesson 4: Electrical

    LESSON 4: ELECTRICAL OBJECTIVES • Identify new features of the module communication networks. • Identify new features of the instrument cluster. • Identify new features of the climate controlled seats. 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03...

  • Page 104: Module Communication Networks

    LESSON 4: ELECTRICAL Module Communication Networks The Explorer and Mountaineer use the following module networks: • UART-Based Protocol (UBP) • International Standards Organization (ISO) 9141 • High-speed Controller Area Network (CAN) • Audio Control Protocol (ACP) The following is a chart that compares network communication features of the 2004 MY to the 2003 MY Explorer and Mountaineer.
  • Page 105 LESSON 4: ELECTRICAL UART-Based Protocol (UBP) The UBP network is a single-wire network that allows inter-module communication. The UBP network will not operate if shorted to power or ground. The modules on the UBP network are: • Instrument Cluster (IC) •...
  • Page 106 LESSON 4: ELECTRICAL ISO 9141 The ISO 9141 network is used for diagnostic tests. It does not allow inter-module communication and does not operate if shorted to power or ground. The modules on the ISO network are: • Restraints Control Module/Advanced Restraint Module (RCM/ARM) •...
  • Page 107 LESSON 4: ELECTRICAL High-Speed Controller Area Network (CAN) The high-speed CAN network allows inter-module communication and still operates if one wire is shorted to ground or power. The CAN provides high communication speed needed for the Interactive Vehicle Dynamics (IVD) system. The modules on the CAN network are: •...
  • Page 108 LESSON 4: ELECTRICAL Audio Control Protocol (ACP) The ACP network allows communication between the following: • Radio • DVD Unit For a list of related DTCs, refer to the appropriate section of the PC/ED Manual. 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 109: Tire Pressure Monitoring System (Tpms)

    LESSON 4: ELECTRICAL Tire Pressure Monitoring System (TPMS) TPMS Module The tire pressure monitoring system (TPMS) monitors the air pressure in all tires (except for the spare). The TPMS components are: • The TPMS module that is located behind the right-hand C-pillar trim panel. •...
  • Page 110 LESSON 4: ELECTRICAL TPMS Service Kit TPMS Service Kit If the sensors require service, a TPMS service kit is available. The service kit number is 2L2Z-1565-AA. The kit includes: • one special valve cap • one nickel-plated valve core • one grommet •...
  • Page 111 LESSON 4: ELECTRICAL TPMS Warning System Messages Conditions WARNING — TIRE VERY LOW One or more tires has very low pressure. When this warning message is displayed, a warning chime sounds and a telltale lights continuously, reminding the driver to stop the vehicle as soon as safely possible and check the tires for correct pressure, leaks and damage.
  • Page 112 LESSON 4: ELECTRICAL TPMS Diagnosis The TPMS system requires new procedures for diagnosis and tire service. This training course highlights the procedures and service requirements in some detail, but is not intended to take the place of the Workshop Manual. Refer to Section 204-04 in the Workshop Manual for full details.
  • Page 113 LESSON 4: ELECTRICAL Tire Pressure Adjustments and Customer Satisfaction Vehicles equipped with a Tire Pressure Monitoring System (TPMS) periodically monitor the air pressures in each tire. The TPMS informs (via the TPMS light) the customer of low tire pressure when the tire pressure is 6 psi (+/- 2 psi) below the cold tire placard pressure.
  • Page 114 LESSON 4: ELECTRICAL TPMS Removal and Installation TPMS Sensor TPMS removal requires special procedures to prevent damage to the TPMS sensors. CAUTION: Do not remove the valve stem core to relieve the tire pressure. If the valve stem core is inadvertently removed from the valve stem, a new nickel-plated core must be installed.
  • Page 115 LESSON 4: ELECTRICAL TPMS Sensor — 270 Degrees from Contact Arm 5. Index-mark the valve stem and wheel weight positions. 6. Lubricate the bead of the tire. 7. Dismount the outside bead of the tire from the rim. 8. Remove the tire pressure sensor. NOTE: If replacing the tire, continue with normal replacement procedures and move to step 9 only after mounting the inside bead of the new tire onto the rim.
  • Page 116 LESSON 4: ELECTRICAL TPMS Sensor Training TPMS Sensor Training The tire pressure sensors do not need to be trained at pre-delivery, but the procedure must be performed after servicing any TPMS component. The tire pressure sensor training procedure must be performed on one vehicle at a time, in an area with minimal radio frequency noise.
  • Page 117 LESSON 4: ELECTRICAL NOTE: If the learn mode is successfully entered, the horn will sound once to indicate to begin the sensor training. The sequence, starts on the left front, goes to the right front, then the right rear, and is completed on the left rear tire.

  • Page 118: Instrument Cluster

    LESSON 4: ELECTRICAL Instrument Cluster Instrument Cluster The Explorer and Mountaineer instrument cluster is a configurable Instrument Cluster (IC). • It is essentially the same as the 2003 MY Explorer and Mountaineer with the addition of CAN communications, the TPMS and ETC warning lamp. The IC includes: –...
  • Page 119 LESSON 4: ELECTRICAL The IC is connected to the CAN and UART-Based Protocol (UBP) networks. • On the CAN network, the IC communicates with the: – PCM – TPMS – 4x4 Module (part of the PCM) – ABS • On the UBP network, the IC communicates with: –...
  • Page 120 LESSON 4: ELECTRICAL New Cluster Graphics New Cluster Graphics Item Description Item Description TPMS indicator ETB indicator (‘‘amber wrench’’) Stability assist indicator The 2004 Explorer and Mountaineer feature new cluster graphics including: • TPMS indicator • Stability assist indicator 4-18 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 121 LESSON 4: ELECTRICAL Instrument Cluster Self-Diagnostic Mode Diagnostics can be entered using a diagnostic scan tool or through the on-demand self-diagnostic mode. To enter the instrument cluster self-diagnostic mode: 1. Turn the engine off. 2. Simultaneously depress and hold the message center RESET and SETUP buttons. 3.
  • Page 122 LESSON 4: ELECTRICAL Self-Test Mode Message Center Cluster Display Description TEST Initial entry display into self-test mode. GAUGES SWEEP Carries out gauge sweep of all gauges, then displays the present gauge values. Also carries out the checksum test on ROM and EEPROM. All segments illuminated Illuminates all odometer segments.
  • Page 123 LESSON 4: ELECTRICAL Self-Test Mode (Cont.) Message Center Cluster Display Description OIL PRESSURE, ### Displays the last analog/digital reading of the oil pressure switch contact resistance, oil gauge will indicate present level. BRAKE FLUID AD, # Displays the brake fluid level received from the ABS module.
  • Page 124 LESSON 4: ELECTRICAL IC DTCs For reference, DTCs associated with the IC are: Description B1201 Fuel sender circuit failure B1204 Fuel sender circuit short to ground B1205 EIC switch-1 assembly circuit failure B1209 EIC switch-2 assembly circuit failure B1255 Air temperature external sensor circuit open B1257 Air temperature external sensor circuit short to ground B1317...

  • Page 125: Climate Controlled Seats

    LESSON 4: ELECTRICAL Climate Controlled Seats Heated Seats Heated Seats The heated seats are now ‘‘module-less’’. • The heating pads are now controlled directly by their respective heated seat switches. – When the heated seat switch is in the ON position, the heated seat feature will be enabled. –...
  • Page 126 LESSON 4: ELECTRICAL Quad Seating Package Quad Seating Package The quad seating feature (similar to Aviator) has been added to the list of seating options. • The 2004 Explorer/Mountaineer second row seating options are as follows: – A 40/20/40 seating arrangement, where there are three seperate seating surfaces. –...

  • Page 127: Appendix: Essential Special Service Tools

    APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS ESSENTIAL SPECIAL SERVICE TOOLS 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 Appendix-1...
  • Page 128 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS NOTES Appendix-2 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...
  • Page 129 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 Appendix-3...
  • Page 130 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS Appendix-4 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

  • Page 131: Glossary Of Terms

    APPENDIX: GLOSSARY OF TERMS GLOSSARY OF TERMS 2004 Explorer/Mountaineer New Model Technician Training 12-AUG-03 Appendix-5...
  • Page 132 APPENDIX: GLOSSARY OF TERMS NOTES Appendix-6 12-AUG-03 2004 Explorer/Mountaineer New Model Technician Training...

This manual is also suitable for:

Mountaineer 2004