303-14-1 Electronic Engine Controls 303-14-1

SECTION 303-14 Electronic Engine Controls

VEHICLE APPLICATION:2007.50 Transit
CONTENTS PAGE

DESCRIPTION AND OPERATION

Electronic Engine Controls................................................................................................. 303-14-2
Vehicles with 2.3L Duratec-HE (MI4).................................................................................. 303-14-2
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine................................................... 303-14-5
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel engine................................................... 303-14-7

DIAGNOSIS AND TESTING

Electronic Engine Controls................................................................................................. 303-14-9

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Principles of Operation....................................................................................................... 303-14-9
MIL Code List..................................................................................................................... 303-14-12
Inspection and Verification.................................................................................................. 303-14-16

REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) — Vehicles Without: PCM Security Shield.................. 303-14-17
Cylinder Head Temperature (CHT) Sensor — 2.4L Duratorq-TDCi (Puma) Diesel........... 303-14-18
Camshaft Position (CMP) Sensor — 2.4L Duratorq-TDCi (Puma) Diesel.......................... 303-14-19
Knock Sensor (KS) — 2.3L Duratec-HE (MI4)................................................................... 303-14-20
Camshaft Position (CMP) Sensor....................................................................................... 303-14-21
Heated Oxygen Sensor (HO2S)......................................................................................... 303-14-22
Engine Coolant Temperature (ECT) Sensor — 2.3L Duratec-HE (MI4)............................. 303-14-23
Catalyst Monitor Sensor..................................................................................................... 303-14-24
Manifold Absolute Pressure (MAP) Sensor........................................................................ 303-14-25
Crankshaft Position (CKP) Sensor — 2.3L Duratec-HE (MI4)........................................... 303-14-26
Crankshaft Position (CKP) Sensor — 2.4L Duratorq-TDCi (Puma) Diesel........................ 303-14-28
303-14-2 Electronic Engine Controls 303-14-2
DESCRIPTION AND OPERATION

Electronic Engine Controls

Vehicles with 2.3L Duratec-HE (MI4)

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3

E67910

Item Description Item Description

1 Camshaft position (CMP) sensor 3 Throttle body

2 Manifold absolute pressure and 4 Crankshaft position (CKP) sensor

temperature (MAPT) sensor 5 Heated oxygen sensor (HO2S)

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303-14-3 Electronic Engine Controls 303-14-3
DESCRIPTION AND OPERATION

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3

E67911

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303-14-4 Electronic Engine Controls 303-14-4
DESCRIPTION AND OPERATION
Item Description Item Description
1 Knock sensor (KS) 3 Catalyst monitor sensor
2 Engine coolant temperature (ECT) sensor

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303-14-5 Electronic Engine Controls 303-14-5
DESCRIPTION AND OPERATION
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine

1 2

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3

5 4

E71770

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303-14-6 Electronic Engine Controls 303-14-6
DESCRIPTION AND OPERATION
Item Description Item Description
1 Cylinder head temperature (CHT) sensor 4 Camshaft position (CMP) sensor
2 Mass air flow (MAF) sensor 5 Manifold absolute pressure and
temperature (MAPT) sensor
3 Crankshaft position (CKP) sensor

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303-14-7 Electronic Engine Controls 303-14-7
DESCRIPTION AND OPERATION
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel engine

1 2

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4

E73099

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303-14-8 Electronic Engine Controls 303-14-8
DESCRIPTION AND OPERATION
Item Description
1 Manifold absolute pressure and
temperature (MAPT) sensor
2 Mass air flow (MAF) sensor
3 Cylinder head temperature (CHT) sensor
4 Crankshaft position (CKP) sensor
5 Engine oil level sensor
6 Camshaft position (CMP) sensor

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303-14-9 Electronic Engine Controls 303-14-9
DIAGNOSIS AND TESTING

Electronic Engine Controls

General Equipment Drive Cycle
Worldwide Diagnostic System (WDS) A drive cycle commences when the engine is
started (cold or warm) and ends when the engine
is switched off.
Principles of Operation
Trip
European On-Board Diagnostics (EOBD)
A trip begins when the engine is started and is
EOBD is a diagnostic system integrated into the complete when all the EOBD monitors have
powertrain control module (PCM). This system completed a self-test. This may take place over a
continuously monitors vehicle emission number of drive cycles. On diesel variants, the
components. The system includes a malfunction information gathered from one drive cycle is not
indicator lamp (MIL) which indicates when there is carried over to a subsequent cycle or cycles.
a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC When a concern has been rectified, particularly
memory can be accessed using a generic scan after electronic engine control components have
tool or WDS. been changed, the DTC memory, which is part of

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the EEPROM must be cleared of all trouble codes.
EOBD is mandated within European Union When the DTC memory has been cleared, the code
regulations from the year 2000 for passenger P1000 (known as the readiness code) is set in the
vehicles with petrol engines and from 2003 PCM memory, which indicates that since the
onwards for passenger vehicles with diesel EEPROM has been cleared, not all of the
engines. monitoring systems have completed their tests.
EOBD Functions: P1000 can only be cleared by carrying out a trip,
which includes driving the vehicle under variable
• Establishes when and how emissions control
conditions of speed, load and time so that all of the
faults must be indicated.
monitors are completed. As P1000 will not
• Actuates emission control malfunction indicator illuminate the MIL it is not necessary to carry out
lamp (MIL) and fault memory. the trip before returning the vehicle to the customer.
• Indicates operating conditions in which the
concern occurred (freeze frame data). Freeze Frame Data
• Standardized output of operating data such as When a concern is detected, various data is stored
engine speed, engine coolant temperature etc. depending on application including:
• Standardized names and abbreviations for • Diagnostic trouble code.
components and systems.
• Vehicle speed.
• Standardized DTCs for all manufacturers.
• Engine coolant temperature.
• Standardized communication with the diagnostic
• Engine speed.
equipment.
• Engine load.
• Standardized 16-pin data link connector (DLC)
in area of the instrument panel. • Mixture formation trim value (trim value for
engine wear) (All except vehicles with diesel
• Concern display must be possible using a
engine).
generic scan tool.
• State of oxygen sensor control (open and closed
EOBD consists of the following elements: loop) (All except vehicles with diesel engine).
Warm-up Cycle • Distance covered since the concern was first
registered.
The warm-up cycle is an operation that consists of
key on, engine start and a coolant temperature Monitors
increase of 22°C, exceeding 71°C on completion.
The purpose of the monitors is to continuously
check the operation of the emission related sensors
and actuators. It then establishes if they are
operating within specified tolerances. All monitors

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303-14-10 Electronic Engine Controls 303-14-10
DIAGNOSIS AND TESTING
carry out their functions in such a way as to be • High Pressure Fuel Injection Pump.
unnoticeable by the driver of the vehicle. Each one • Exhaust Gas Recirculation (EGR) Valve Monitor.
is carried out under specific conditions of load,
• Fuel Injectors.
speed and engine temperature. The
Comprehensive Component Monitor, Combustion • Turbocharger.
Misfire Monitor and Air/Fuel Ratio Monitor operate • Combustion Noise Monitor.
continuously. The remaining monitors are only • Barometric Pressure (BARO) Sensor.
invoked under certain operating conditions. On
diesel variants, all of the monitors operate under Combustion Misfire Monitor (All except vehicles
normal driving conditions: There are no monitors with diesel engine)
which intervene and cause special operating The combustion misfire monitor operates
modes to enable the monitors to work. Some diesel independently of the others, and can detect misfires
monitors are non-continuous. This means that in caused by the ignition system, fuel system or
a drive cycle, monitoring is done as and when mechanical engine components. As each cylinder
suitable driving conditions exist and potential faults fires, a characteristic crankshaft acceleration is
are accumulated and compared with acceptance produced. The monitor detects irregularities in the
criteria. Examples of this type are the turbocharger acceleration pattern using the crankshaft position
boost pressure and exhaust gas recirculation (CKP) sensor, thus detecting the misfire. It can
(EGR) monitors on vehicles with common rail fuel also detect which cylinder has misfired.

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injection. Combustion misfires can be categorized as follows:
Comprehensive Component Monitor (CCM) Type A: These can cause catalytic converter
When the CCM detects a component operating out damage due to excessive internal temperatures.
of tolerance, it sets a Diagnostic Trouble Code If a certain number of misfires occur over a
(DTC), which is stored in the EEPROM. If the same pre-determined number of engine revolutions, the
concern is confirmed during the next trip the MIL MIL will be switched on to alert the driver of the
will be switched on. The CCM monitors many concern.
components, sub-systems and signals. The Type B: These can lead to an increase in emissions
following is a list of those that can effect emissions to a point above the EOBD threshold. If the misfire
depending on application: is detected during a second trip, over a
• Electronic Ignition (EI) System. pre-determined number of engine revolutions, the
MIL will be switched on. If the misfire does not
• Crankshaft Position (CKP) Sensor. occur over the next three trips, the MIL will be
• Ignition Coil. extinguished
• Electronic Throttle Control Unit.
Air/Fuel Ratio (AFR) Monitor (All except vehicles
• Camshaft Position (CMP) Sensor.
with diesel engine)
• Air Conditioning (A/C) Clutch.
The HO2S fitted before the catalytic converter
• Idle Air Control (IAC) Valve.
(upstream) measures the oxygen content of the
• Mass Air Flow (MAF) Sensor. exhaust gas and the variations in it. This then
• Manifold Absolute Pressure (MAP) Sensor. enables the PCM to adjust the opening times of
• Intake Air Temperature (IAT) Sensor. the fuel injectors to maintain the correct AFR. This
is known as Short Term Fuel Trim (STFT). If the
• Engine Coolant Temperature (ECT) Sensor.
same variation is registered a pre-determined
• Cylinder Head Temperature (CHT) Sensor. number of times, a permanent correction factor is
• Heated Oxygen Sensor (HO2S). applied. This is known as Long Term Fuel Trim
• Catalyst Monitor Sensor. (LTFT), which is stored in the EEPROM. When the
• Charge Air Temperature Sensor. correction factors exceed pre-determined limits a
DTC will be set in the EEPROM. If a concern is
• Knock Sensor (KS). detected in either the STFT or LTFT, and it is still
• Throttle Position (TP) Sensor. present on a second trip, the MIL will be switched
• Vehicle Speed Sensor (VSS). on.
• Boost Pressure Sensor.
• Cam-Crank Phasing Sensor.
• EEPROM.

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303-14-11 Electronic Engine Controls 303-14-11
DIAGNOSIS AND TESTING
Heated Oxygen Sensor (HO2S) Monitor (All except Combustion Noise Monitor (Vehicles with common
vehicles with diesel engine) rail fuel injection)
This monitors the operation of the pre (upstream) In diesel variants, the Combustion Noise Monitor
and post (downstream) catalytic converter HO2S is used to trim the fuel injection pulse lengths. Each
sensors. It will detect deviations in air/fuel ratios fuel injector has an associated set of correction
(AFR) and sensor faults. data that is determined during a production end of
The HO2S will cause emission increase when its line test. The Combustion Noise Monitor is used
response time increases too much. To diagnose to determine how the fuel injector characteristic
a sensor a period is measured and the number of changes from this initial calibration over the life of
lean/rich transitions are counted. The sum of valid the fuel injector.
periods is then calculated. To avoid EGR Monitor (Vehicles with diesel engine)
non-representative measurements, the period is
valid only if the HO2S has been below a low The functionality of the EGR system is checked by
threshold and above a high threshold between 2 comparing either the MAP sensor output or EGR
consecutive lean/rich transitions. A failure is valve lift potentiometer output (depending upon
declared when the sum of the measured periods application) with expected values.
exceeds the sum of the corresponding limit (held
Diagnostic Requirements
within the PCM) and the MIL is illuminated.

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Vehicles equipped with EOBD, can be diagnosed
Catalytic Converter Efficiency Monitor (All except using the WDS. In order for the EOBD system to
vehicles with diesel engine) be invoked, a number of criteria must be met. After
The efficiency of a catalytic converter is measured any repair, which could affect emissions, a trip must
by its ability to store and later release oxygen to be carried out on the vehicle, to make sure that
convert harmful gases. The efficiency is reduced engine management system operates correctly.
if the converter becomes contaminated as it ages,
Malfunction Indicator Lamp (MIL)
and at high gas flow rates, because the exhaust
gas does not remain in the converter long enough The MIL is located in the instrument cluster and is
to complete the conversion process. fitted to alert the driver to the fact that an abnormal
This monitor checks for the oxygen storage condition has developed in the engine management
capacity (OSC) of the catalytic converter. During system, that is having an adverse effect on
a controlled period, the catalyst monitor sensor emissions. In cases of misfires which are likely to
signal is analyzed to evaluate the OSC of the cause catalytic converter damage, it is switched
catalyst. It represents the quantity of oxygen that on immediately. With all other faults it will illuminate
is really used for the oxidation-reduction reaction continuously from the second trip after the condition
by the catalytic converter If a fault has occurred occurred. Under normal operation it should
with the catalyst monitor sensor during the catalyst illuminate at key-on and go out almost as soon as
diagnosis, a sensor diagnosis is carried out. During the engine is started.
the controlled diagnosis phase, the catalyst monitor Diagnostic Trouble Codes (DTCs)
sensor activity is measured and is compared to the
OSC of the catalyst. If this activity is high (low The DTCs given by the PCM are standardized,
OSC) the MIL will be illuminated. If throughout the which means that generic scan tools can read
controlled phase, repeated several times, the results from all vehicles.
downstream sensor output has not moved, the • The DTC is always a 5 digit alphanumerical
closed loop mode is delayed in order to test the code, for example ”P0100".
sensor. If the catalyst monitor sensor is set to rich,
• The first digit of a code (letter) identifies the
the injection time is forced to lean and conversely
system which has set the code. Provision has
if the downstream sensor is set to lean, the
been made for a total of four systems to be
injection time is forced to rich until the sensor
identified although only the 'P' code is required
switches over or until the end of a delay. If this
for EOBD.
delay expires or the sensor does not switch, the
sensor is treated as failed. – 'B' for the body
– 'C' for the chassis
– 'P' for the powertrain
– 'U' for the network communications systems

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303-14-12 Electronic Engine Controls 303-14-12
DIAGNOSIS AND TESTING
• All of the ”x0xxx" codes are standardized codes. • The third digit of a code (numeric) identifies the
However, any manufacturer can use additional sub-system which has set the code.
codes over and above the standardized codes. – 'Px1xx' for metering of fuel and air supply
These will be labelled ”x1xxx"
– 'Px2xx' for metering of fuel and air supply
– 'Px3xx' for ignition system – combustion
misfires
– 'Px4xx' for auxiliary emission control
equipment
– 'Px5xx' for vehicle speed, idle setting and
other related inputs
– 'Px6xx' for trip computer and other related
outputs
– 'Px7xx' for transmission.
– 'Px8xx' for transmission.
– 'Px9xx' category to be determined
– 'Px0xx' category to be determined
• When a concern occurs, the actions taken

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include storage of the relevant information and
actuation of the MIL occurs in line with the
relevant legislation.

MIL Code List

MIL Code Description

P0030 Heated oxygen sensor (HO2S) heater open circuit
P0031 HO2S heater low voltage
P0032 HO2S heater high voltage
P0036 Catalyst monitor sensor heater open circuit
P0037 Catalyst monitor sensor heater low voltage
P0038 Catalyst monitor sensor heater high voltage
P0053 HO2S heater resistance out of limits
P0054 Catalyst monitor sensor heater resistance out of limits
P0106 Manifold absolute pressure (MAP) sensor plausibility malfunction
P0107 MAP sensor circuit low input
P0108 MAP sensor circuit high input
P0109 MAP sensor temporary malfunction
P0112 Intake air temperature (IAT) circuit low input
P0113 IAT circuit high input
P0114 IAT intermittent failure
P0116 Engine coolant temperature (ECT) signal stuck at low level
P0117 ECT circuit low input
P0118 ECT circuit high input

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303-14-13 Electronic Engine Controls 303-14-13
DIAGNOSIS AND TESTING

MIL Code Description

P0119 ECT intermittent failure
P0122 Throttle position (TP) sensor circuit 1 low input
P0123 TP sensor circuit 1 high input
P0130 HO2S circuit open circuit
P0131 HO2S circuit low voltage
P0132 HO2S circuit high voltage
P0133 HO2S circuit slow response
P0134 HO2S low amplitude
P0136 Catalyst monitor sensor circuit open circuit
P0137 Catalyst monitor sensor circuit low voltage
P0138 Catalyst monitor sensor circuit high voltage

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P0139 Catalyst monitor sensor circuit slow response
P0171 Fuel system error, lean limit
P0171 Fuel system error , NOx emissions
P0172 Fuel system error , rich limit
P0172 Fuel system error, HC/CO emissions
P0201 Cylinder No. 1 - injector circuit open circuit
P0202 Cylinder No. 2 - injector circuit open circuit
P0203 Cylinder No. 3 - injector circuit open circuit
P0204 Cylinder No. 4 - injector circuit open circuit
P0222 TP sensor circuit 2 low input
P0223 TP sensor circuit 2 high input
P0231 Fuel pump input low voltage
P0232 Fuel pump input high voltage
P0261 Cylinder No. 1 - injector circuit low voltage
P0262 Cylinder No. 1 - injector circuit high voltage
P0264 Cylinder No. 2 - injector circuit low voltage
P0265 Cylinder No. 2 - injector circuit high voltage
P0267 Cylinder No. 3 - injector circuit low voltage
P0268 Cylinder No. 3 - injector circuit high voltage
P0270 Cylinder No. 4 - injector circuit low voltage
P0271 Cylinder No. 4 - injector circuit high voltage
P0300 Random misfire detected
P0301 Cylinder No. 1 misfire detected
P0302 Cylinder No. 2 misfire detected

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303-14-14 Electronic Engine Controls 303-14-14
DIAGNOSIS AND TESTING

MIL Code Description

P0303 Cylinder No. 3 misfire detected
P0304 Cylinder No. 4 misfire detected
P0315 Flywheel segment adaptation at the Limit
P0324 Knock sensor (KS) communication error or implausible signal
P0325 KS implausible signal
P0335 Crankshaft position (CKP) sensor implausible signal
P0336 CKP sensor missing teeth
P0336 CKP sensor loss of synchronization
P0336 CKP sensor no signal
P0340 Camshaft position (CMP) sensor no signal
P0341 CMP sensor implausible signal

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P0351 Ignition coil A primary malfunction
P0352 Ignition coil B primary malfunction
P0420 Catalyst system efficiency below threshold
P0444 Evaporative mission canister purge valve open circuit
P0458 Evaporative mission canister purge valve low voltage
P0459 Evaporative mission canister purge valve high voltage
P0460 Fuel tank level malfunction from instrument cluster
P0500 Vehicle speed sensor (VSS) signal malfunction
P0500 Vehicle speed via CAN (VS CAN) implausible signal
P0503 VSS signal too high
P0511 Idle air control (IAC) valve circuit malfunction
P0560 Battery system voltage malfunction high voltage
P0562 Battery system voltage malfunction open circuit
P0571 Brake switch plausibility error
P0603 Powertrain control module (PCM) error NVMY or EEPROM error
P0604 PCM error RAM error
P0605 PCM error checksum error
P0610 VID block checksum not correct or not programmed
P0617 Starter relay malfunction
P0620 Generator circuit malfunction
P0625 Generator low voltage
P0626 Generator high voltage
P0628 Fuel pump primary circuit low voltage
P0629 Fuel pump primary circuit high voltage

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303-14-15 Electronic Engine Controls 303-14-15
DIAGNOSIS AND TESTING

MIL Code Description

P0641 Transmission sensor power supply 1 noisy signal
P0642 Transmission sensor power supply 1 low voltage
P0643 Transmission sensor power supply 1 high voltage
P0646 Air conditioning (A/C) clutch relay circuit low voltage
P0647 A/C clutch relay circuit high voltage
P0651 Transmission sensor power supply 2 noisy signal
P0652 Transmission sensor power supply 2 low voltage
P0653 Transmission sensor power supply 2 high voltage
P0654 Engine run output circuit malfunction
P0686 Main relay malfunction low voltage
P0687 Main relay malfunction high voltage

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P0691 Cooling fan 1 control circuit low voltage
P0692 Cooling fan 1 control circuit high voltage
P0693 Cooling fan 2 control circuit low voltage
P0694 Cooling fan 2 control circuit high voltage
P0704 Clutch switch implausible signal
P1000 EOBD system readiness test not complete
P1500 Vehicle speed sensor (VSS) output circuit malfunction
P1632 Generator command malfunction
P1794 Battery voltage malfunction too high or too low
P2100 Engine throttle body H-bridge malfunction
P2107 Safety failure level 3
P2108 Safety failure level 2 error
P2119 Engine throttle body throttle flap malfunction
P2122 Accelerator pedal position (APP) sensor circuit 1 low input
P2123 APP sensor circuit 1 high input
P2127 APP sensor circuit 2 low input
P2128 APP sensor circuit 2 high input
P2128 APP sensor circuits 1 and 2 plausibility error
P2135 TP sensor circuits 1 and 2 plausibility error
P2176 Engine throttle body adaptive algorithm failed
P2280 Air cleaner obstruction or leakage
P2282 Air leakage between throttle and inlet valves
U0001 Control Area Network (CAN) bus-off or mute
U0101 CAN missing frame from TCU

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303-14-16 Electronic Engine Controls 303-14-16
DIAGNOSIS AND TESTING

MIL Code Description

U0121 CAN missing frame from ABS
U0122 CAN missing frame from ESP
U0155 CAN missing frame from HEC
B1213 Number of Passive Anti-Theft System (PATS) programmed keys is below minimum
B1600 PATS ignition key transponder signal is not received
B1601 PATS received incorrect key-code from ignition key transponder
B1602 PATS received invalid format of key-code from ignition key transponder
B1681 PATS transceiver module signal is not received
B2103 PATS immobilizer antenna not connected
B2139 PATS immobilizer challenge response doesn't match
B2141 PATS immobilizer no PCM-ID transferred

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B2431 PATS immobilizer transponder programming failure
U2510 PATS immobilizer problem with messages on data link

Inspection and Verification

1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart
Mechanical Electrical
– Sensors – Fuse(s)
– Actuators – Wiring harness
– Electrical
connector(s)
– Powertrain control
module (PCM)

3. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom and refer to the WDS or equivalent
scan tool to diagnose the system.

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303-14-17 Electronic Engine Controls 303-14-17
REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) — Vehicles Without: PCM

Security Shield
General Equipment
Worldwide Diagnostic System (WDS)

Removal

1. If a new PCM is to be installed, connect the

WDS and upload the PCM configuration
information using the Programmable Modules
Installation Routine, prior to commencing the
removal of the PCM.
General Equipment: Worldwide Diagnostic
System (WDS)

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2. Disconnect the battery the ground cable.
Refer to:Battery Disconnect (414-01 Battery,
Mounting and Cables, General Procedures).
3. Torque: 10 Nm

1
2

x4

E73653

Installation
1. To install reverse the removal procedure.
2. If a new PCM is to be installed, connect the
WDS and download the PCM configuration
information using the Programmable Modules
Installation Routine, after the installation of the
PCM.
General Equipment: Worldwide Diagnostic
System (WDS)
3. Change the engine oil and oil filter.
4. Carry out the oil reset procedure.
Refer to:Oil Change Reminder Indicator Reset
(413-09 Warning Devices, General
Procedures).

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REMOVAL AND INSTALLATION

Cylinder Head Temperature (CHT) Sensor — 2.4L Duratorq-TDCi

(Puma) Diesel
Special Tool(s) Special Tool(s)
Socket, Cylinder Head
Temperature Sensor
303-680

303680

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

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1. Remove the intake manifold.
Refer to:Intake Manifold (303-01 Engine - 2.4L
Duratorq-TDCi (Puma) Diesel, In-vehicle
Repair).
2. Special Tool(s): 303-680
Torque: 10 Nm

303-680

E73652

Installation
NOTE:Make sure that a new component is
installed.
1. To install, reverse the removal procedure

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303-14-19 Electronic Engine Controls 303-14-19
REMOVAL AND INSTALLATION

Camshaft Position (CMP) Sensor — 2.4L Duratorq-TDCi (Puma)

Diesel

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the intake manifold.
Refer to:Intake Manifold (303-01 Engine - 2.4L
Duratorq-TDCi (Puma) Diesel, In-vehicle
Repair).
2. CAUTION:Make sure that all openings
are sealed.
Torque: 3 Nm

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E71153

3. Torque: 9 Nm

E71154

Installation
1. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Knock Sensor (KS) — 2.3L Duratec-HE (MI4)

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

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2
E66333

2. NOTE:Make sure that the mating faces are

clean and free of foreign material.
NOTE:Make sure that the sensor is installed in
the same location as when removed.
Torque: 22 Nm

E66334

Installation
1. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Camshaft Position (CMP) Sensor

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Torque: 8 Nm

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E65228

Installation
1. Lubricate the O-ring seal with clean engine oil.
2. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Heated Oxygen Sensor (HO2S)

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. NOTE:A new component may be supplied with
a longer cable than the one removed. Make sure
that the cable is routed and secured in such a
way that it cannot be damaged and cause a
noise, vibration or harshness (NVH) concern.
Torque: 42 Nm

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E66338

Installation
1. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Engine Coolant Temperature (ECT) Sensor — 2.3L Duratec-HE

(MI4)

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the coolant outlet connector.
Refer to:Coolant Outlet Connector - 2.3L
Duratec-HE (MI4) (303-03 Engine Cooling,
Removal and Installation).
2. Torque: 13 Nm

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E65227

Installation
1. To install, reverse the removal procedure.

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303-14-24 Electronic Engine Controls 303-14-24
REMOVAL AND INSTALLATION

Catalyst Monitor Sensor

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Raise and support the vehicle.
Refer to:Lifting (100-02 Jacking and Lifting,
Description and Operation).
2. NOTE:A new component may be supplied with
a longer cable than the one removed. Make sure
that the cable is routed and secured in such a
way that it cannot be damaged and cause a
noise, vibration or harshness (NVH) concern.
Torque: 42 Nm

cardiagn.com
E65229

Installation
1. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Manifold Absolute Pressure (MAP) Sensor

Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Torque: 3 Nm

cardiagn.com
E67661

Installation
1. Lubricate the O-ring seal with clean engine oil.
2. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Crankshaft Position (CKP) Sensor — 2.3L Duratec-HE (MI4)

General Equipment Rotate the crankshaft pulley clockwise until
Bolt, M6 x 18 mm the crankshaft pulley timing bolt, M6 x 18
mm can be installed through the crankshaft
CKP alignment tool pulley timing hole into the engine front cover.
1. Raise and support the vehicle.
For additional information, refer to:Lifting
(100-02 Jacking and Lifting, Description
and Operation).
2. CAUTIONS:
Only turn the crankshaft pulley in the
normal direction of rotation.

Tighten the M6 x 18 mm bolt finger-tight

only.

cardiagn.com
E54437

3. Remove the components in the order

indicated in the following illustration(s) and
table(s).

7 Nm 2
3

E54421

Item Description Item Description

1 CKP sensor electrical connector See Installation Detail

2 CKP sensor retaining bolts 3 CKP sensor

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REMOVAL AND INSTALLATION
Item Description 4. To install, reverse the removal procedure.
See Installation Detail

Installation Details
Item 3 CKP sensor
1. Install the CKP sensor alignment tool to the
CKP sensor.

cardiagn.com
E54422

2. Align the CKP sensor with the crankshaft

pulley sensor ring.

E54423

Item 2 CKP sensor retaining bolts

1. Install the CKP sensor retaining bolts.
2. Remove the CKP sensor alignment tool.

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REMOVAL AND INSTALLATION

Crankshaft Position (CKP) Sensor — 2.4L Duratorq-TDCi (Puma)

Diesel

Removal
NOTE:Removal steps in this procedure may Rotate the crankshaft until a flywheel tooth is
contain installation details. visible through the CKP sensor housing.
1. Raise and support the vehicle.
Refer to:Lifting (100-02 Jacking and Lifting,
Description and Operation).
2.

cardiagn.com
E71692

2. CAUTION:The tip of the sensor must

rest on a flywheel tooth.
NOTE:Make sure that a new component is
E73642 installed.
Torque: 7 Nm
3. Discard the CKP sensor.

E71691
E71691

3.
Installation
1. CAUTION:Only rotate the crankshaft
clockwise.

E73642

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REMOVAL AND INSTALLATION
4. Lower the vehicle.

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