Ford FCSD TECHNICAL TRAINING FCS-14000-DL Manuel d'utilisateur

FCSDTechnical TrainingINTERACTIVE STUDY GUIDE2005EXPEDITION/NAVIGATORNEW MODEL TECHNICIANTRAININGFCS-14000-DL2005 EXPEDITION/NAVIGATOR NEW MODEL TECHN

INTRODUCTIONIN-DEALERSHIP TRAINING MAP2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-4

LESSON 3: POWERTRAINNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-043-64

LESSON 4: ELECTRICALOBJECTIVES•Identify ETC warning features.•Identify climate control features.•Identify charging system features.•Identify Vehicle S

LESSON 4: ELECTRICALClimate Controlled Seats Climate Controlled Seats Control HeadItem Description Item Description1 Driver’s Side Intensity Level LED

LESSON 4: ELECTRICALWarning Devices ETC Warning•New Electronic Throttle Control (ETC) warning message.•When an ETC system fault occurs, a message is d

LESSON 4: ELECTRICALInstrument Cluster Lighting •In 2004 the Navigator had a seperate dimming module that could be serviced seperately. For 2005, thed

LESSON 4: ELECTRICALCharging System Smart Charge Generator•The 2005 Expedition and Navigator are both equipped with a PCM-controlled charging system k

LESSON 4: ELECTRICALVehicle Security Module For the 2005 Expedition/Navigator, the Vehicle Security Module (VSM) strategy has been revised to allowRem

LESSON 4: ELECTRICALModule Communication Network Module Communication NetworkThe diagnostic tool connects to each network through the Data Link Connec

LESSON 4: ELECTRICALCommunication Protocols The 2005 Expedition and Navigator feature the following comunication protocols: •Medium Speed Controller A

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLSESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-1

INTRODUCTIONPURPOSEThe purpose of this FORDSTAR course is to provide Ford and Lincoln/Mercury service technicians with theknowledge needed to understa

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-2

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-3

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-4

APPENDIX: GLOSSARY OF TERMSGLOSSARY OF TERMS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-5

APPENDIX: GLOSSARY OF TERMSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-6

INTRODUCTIONNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-6

LESSON 1: OVERVIEWOBJECTIVES•Identify the new powertrain applications for Expedition and Navigator.•Identify exterior features.•Identify interior feat

LESSON 1: OVERVIEWMechanical and Chassis Features Mechanical and Chassis Features•5.4L 3-Valve Triton Engine w/Variable Cam Timing.•6HP26 Automatic Tr

LESSON 1: OVERVIEWEngine - 5.4L 5.4L 3-Valve Triton PhaserThe 2005 Expedition and Navigator are available with one engine:•New for 2005, the 5.4L 3-v

LESSON 1: OVERVIEW•Variable Cam Timing (VCT) varies cam timing to match performance demands.•Charge Motion Control Valves (CMCV) manage the flow of ai

LESSON 1: OVERVIEWAutomatic Transmission 6HP26 TransmissionThe 2005 Expedition will use the 4R75E automatic transmission like the 2004 and 2005 F-150,

LESSON 1: OVERVIEWExterior Features 2005 Navigator Exterior•New body side cladding– Bold new body side cladding is added to the 2005 Lincoln Navigator

LESSON 1: OVERVIEW2005 Expedition Exterior•New badging for Limited and FX4 (mid 4th quarter availability).– Expedition for 2005 comes with new badging

LESSON 1: OVERVIEWInterior Features 2005 Navigator Interior•New 6HP26 automatic transmission gear selector.– Lincoln Navigators are equipped with a ne

LESSON 1: OVERVIEW2005 Expedition InteriorThe 2005 Expedition receives minor trim and finish updates as:•Power fold side view miror switch (Limited on

LESSON 1: OVERVIEWLifting and Jacking Lifting and Jacking PointsThe front and rear lifting and jacking locations are as indicated.2005 Expedition/Navi

LESSON 1: OVERVIEWMaintenance Check Points Maintenance Check Points (Navigator Shown)Item Description Item Description1 Cabin Air Filter 6 Engine Cool

LESSON 1: OVERVIEWNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-041-12

LESSON 2: CHASSISOBJECTIVES•Identify changes to the TPMS.•Identify new suspension system features.•Identify new drive axle/differential driveline feat

LESSON 2: CHASSISWheels and Tires Tire Pressure Monitor•TPMS functionality is integrated into Vehicle Security Module (VSM) located in the right kick

LESSON 2: CHASSISTPMS General Information Temperature fluctuation changes tire inflation pressure 7KPa per 12 degrees Celsius (1 psi per 10 degrees F)

LESSON 2: CHASSISFunctionality - 2005 Model Year Sensor Wheel PackageItem Description Item Description1 Blue, 315 Mhz Tire Pressure Sensor•4-sensor sy

LESSON 2: CHASSISSensor Description TPMS SensorItem Description Item Description1 Transmitter Case 5 Aluminum Valve2 Air Hole: Top 6 Inside: Core3 Pot

IMPORTANT SAFETY NOTICEAppropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,

LESSON 2: CHASSISModule Description •TPM System integrated into Vehicle Security Module (VSM).•Module designed to:– Receive tire pressure and sensor i

LESSON 2: CHASSISCluster Messages The following are messages that can be displayed on the message center (if equipped on Expedition models,standard on

LESSON 2: CHASSISDTCs DTC DescriptionB1342 ECU DefectiveB2477 Module Configuration FailureB2868 Left Front Sensor FaultB2869 Right Front Sensor FaultB

LESSON 2: CHASSISTPMS PIDs NGS Name WDS Name DescriptionLF_ID LF_ID_VSM LEFT FRONT TIRE SENSORIDRF_ID RF_ID_VSM RIGHT FRONT TIRE SENSORIDRR_ID RR_ID_V

LESSON 2: CHASSISPossible Failure Modes and Root Causes •TPMS indicator light stays ON continuously. Message center (if equipped) Displays: ‘‘Low Tire

LESSON 2: CHASSISDriveshaft Driveshaft•Navigator 4x2 models use a unique 2-piece driveshaft.•Staked U-Joint Service.– The original u-joints are staked

LESSON 2: CHASSISFront Drive Axle/Differential Front Drive Axle/Differential•New companion flange– The design of the front axle companion flange is un

LESSON 3: POWERTRAINOBJECTIVES•Identify new 5.4L 3-valve engine features.•Explain the operation of the VCT system.•Explain the revised procedure for c

LESSON 3: POWERTRAINEngine - 5.4L 5.4L 3-Valve Triton PhaserThe 2005 Expedition and Navigator are available with one engine:•New for 2005, the 5.4L 3

LESSON 3: POWERTRAIN•Charge Motion Control Valves (CMCV) manage the flow of air into the cylinders.•Vibration-resistant ribbing and reinforcement in t

CUSTOMER EXPECTATIONSCustomer Expectations: Service1. Make it convenient to have my vehicle 5. Provide me with a clear and thoroughserviced at your de

LESSON 3: POWERTRAIN5.4L Three-Valve HeadThe three-valve head has two smaller intake valves and one larger exhaust valve. •The three-valve head includ

LESSON 3: POWERTRAINAir Filter Intake Air Filter Module (IAFM)The intake air distribution and filtering design has been replaced with:•New split line

LESSON 3: POWERTRAINMass Air Flow (MAF) SensorThe compact Mass Air Flow (MAF) sensor is located on the IAFM.•This sensor combines the Intake Air Tempe

LESSON 3: POWERTRAINElectronic Throttle Control (ETC) ETC Throttle Body•The 5.4L 3V engine used in both the Expedition and Navigator utilizes Electron

LESSON 3: POWERTRAINCharge Motion Control Valves (CMCV)The Charge Motion Control Valves (CMCV) are electronically controlled metal flaps at the end of

LESSON 3: POWERTRAINCMCV MotorThe CMCVs use one electronically controlled motor to operate the CMCVs for both sides of the intake manifold.2005 Expedi

LESSON 3: POWERTRAINCMCV Block DiagramThe CMCVs are controlled electronically by the PCM.•The inputs used by the PCM for the CMCV operation are:– Engi

LESSON 3: POWERTRAINVCT System 5.4L Variable Cam Timing Solenoid Electrical ConnectorConventional camshafts are permanently synchronized with the engi

LESSON 3: POWERTRAINVCT Operation VCTThe theory of operation for the 5.4L VCT is similar to the 3.9L VCT used on the Lincoln LS and 2004 FordF-150 w/5

LESSON 3: POWERTRAINThe basics of VCT operation are: •A hydraulic timing mechanism (VCT phaser) rotates the camshafts in relation to their drive sproc

TABLE OF CONTENTSINTRODUCTION... Intro-1Te

LESSON 3: POWERTRAIN5.4L 3-Valve Camshaft Position SensorThe VCT system requires a cam position sensor for each camshaft. •The PCM can then monitor th

LESSON 3: POWERTRAINOil Temperature SensorThe VCT system uses a replaceable oil temperature sensor, located on the oil pan. •Engine oil temperature ha

LESSON 3: POWERTRAINPhaser Components VCT PhaserThe VCT components include: •Camshaft phaser sprockets.•Right and left camshaft phaser sprocket assemb

LESSON 3: POWERTRAINPhaser Oil VanesThe oil vanes create oil cavities for valve-directed oil to rotate the camshaft in relation to the crankshaft. •Oi

LESSON 3: POWERTRAINVCT Phaser DisassembledThe VCT phaser varies camshaft timing in response to oil pressure exerted on either side of the vanes. CAUT

LESSON 3: POWERTRAINVCT Solenoid RemovalThe VCT solenoid is serviced separately from the VCT valve body. No special tools are needed to remove thesole

LESSON 3: POWERTRAINVCT Valve Body Oil PassagesItem Description Item Description1 Solenoid filter 5 Oil passage back into head2 Oil passage to advance

LESSON 3: POWERTRAINLocking PinThe locking pin locks the camshaft in a fully advanced position when the engine is off. •The pin locks the phaser to th

LESSON 3: POWERTRAINPhaser/Camshaft Removal Procedure Remove Valve CoverThe phaser replacement procedure has been revised for the 5.4L 3V engine. This

LESSON 3: POWERTRAINSet Crankshaft Damper Notch to 1 o’clock PositionSet the crankshaft keyway to 12 o’clock. The machined notch on the back face of t

TABLE OF CONTENTSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04ii

LESSON 3: POWERTRAINCam Lobe PositioningItem Description Item Description1 Intake Lobe 2 Exhaust Lobe Pointing InwardThe camshaft must be positioned w

LESSON 3: POWERTRAINMark Crankshaft DamperThe damper spoke pointing upwards just to the left of the machined notch is the one with the keyway cut in i

LESSON 3: POWERTRAINLoosen One TurnLoosen the camshaft phaser bolt one turn. Do not remove the bolt. CAUTION: DO NOT use an impact wrench when looseni

LESSON 3: POWERTRAINRemove Only the Indicated FollowersWhen removing the followers, remove the exhaust followers from the exhaust manifold side of the

LESSON 3: POWERTRAINSet Crankshaft Damper Spoke to 6 o’clock PositionRotate the marked damper spoke clockwise to the 6 o’clock position. CAUTION: It i

LESSON 3: POWERTRAINInset Timing Chain Wedge ToolAssemble the ESST 303-636 Timing Chain Wedge to the ESST 303-637 Handle. Insert the timing chain wedg

LESSON 3: POWERTRAINLoosen #1 Camshaft Bearing Cap BoltsMark the cam caps for proper reinstallation.NOTE: The camshaft bearing caps must be installed

LESSON 3: POWERTRAINRemove the Phaser BoltThe remaining followers will be loose on the lifters. Be sure to keep them in place so that the camshaft can

LESSON 3: POWERTRAINRemove the PhaserUsing extreme care, withdraw the phaser from the nose of the camshaft. It may be necessary to slightly tip up the

LESSON 3: POWERTRAINCam and Phaser Reassembly Seating Cam FollowersCare should be taken to ensure that the remaining followers are properly seated pri

INTRODUCTIONFCSDTechnical TrainingThe distance learning course you are about to take is intended to give you new knowledge and information aboutdiagno

LESSON 3: POWERTRAINPhaser Pin and Cam NotchItem Description Item Description1 Phaser Pin 2 Cam NotchIt is extremely important to align the phaser pin

LESSON 3: POWERTRAINInstalling the Bearing CapsInstall the camshaft bearing caps in the reverse order of removal. NOTE: The camshaft bearing caps must

LESSON 3: POWERTRAINElectronic Engine Controls Electronic Engine Controls•New integrated 4x4 strategy.– 4x4 operational strategy is now incorporated i

LESSON 3: POWERTRAIN•New premium fuel calibration (Navigator).– The aggressive spark and fuel programming requires 91 octane (or higher) fuel for maxi

LESSON 3: POWERTRAINFuel Tank and Lines Fuel Tank and Lines•New fuel filter– The fuel filter is located on the front side of the fuel tank. It can be

LESSON 3: POWERTRAINEngine Special Service Tools Engine Special Service ToolsItem Description Item Description1 ESST 307-516/1 Installer, Teflon Seal

LESSON 3: POWERTRAINAutomatic Transmission Description 6HP26 TransmissionThe 6HP26 transmission uses planetary gears with multiple clutches and electr

LESSON 3: POWERTRAIN•shift feel.•shift scheduling.•modulated Torque Converter Clutch (TCC) applications.•engine braking.This transmission has a mechat

LESSON 3: POWERTRAINOperation 6HP26 CutawayEngine power reaches the transmission by a torque converter with an integral converter clutch. The six forw

LESSON 3: POWERTRAINIdentification Tag Identification TagThe identification tag is located on the left side of the case just rearward of the manual co

INTRODUCTIONLOGGING ONYour response keypad transmits data and voice between you and the host site via telephone lines and satellite. It isyour ‘‘lifel

LESSON 3: POWERTRAINRange Selection Shifter PatternThe transmission has eight range positions: P, R, N, D6, D4, 3, 2 and 1.In the Park position:•There

LESSON 3: POWERTRAINThe D6 position is the normal position for most driving conditions. It provides:•Automatic shifts 1-6 and 6-1•Apply and release of

LESSON 3: POWERTRAINShift Patterns •Under certain conditions the transmission automatically downshifts to a lower gear range (without moving therange

LESSON 3: POWERTRAINShift Elements Shift ElementsItem Description Item Description1 Double Planetary Gearset 6 Overdrive Clutch2 Forward Clutch 7 Low/

LESSON 3: POWERTRAINThe shift elements are engaged hydraulically. The transmission fluid pressure builds up between the cylinder andthe piston, pressi

LESSON 3: POWERTRAINMulti Plate Clutch Multi Plate ClutchItem Description Item Description1 Clutch Pack Cluster 6 Turbine Shaft2 Piston 7 Lubricating

LESSON 3: POWERTRAINFluid Pan, Gasket and Filter Fluid Pan, Gasket and FilterThe transmission fluid pan, gasket and filter is a one-piece assembly. Al

LESSON 3: POWERTRAIN5. Start the engine. Move the transmission range selector lever through all the gear ranges, checking forengagements.6. With the e

LESSON 3: POWERTRAINTransmission Control Module (TCM) and Main Control Valve Body Transmission Control Module (TCM) and Main Control Valve BodyThe Mai

LESSON 3: POWERTRAINTransmission Electronic System The TCM receives input signals from certain transmission-related sensors and switches. The TCM uses

INTRODUCTIONKEYPAD OPERATIONCALL Key •Press the CALL key if you have a question or comment. This places you in the call queue. The system indicatesyou

LESSON 3: POWERTRAINTransmission Control Module (TCM) Transmission Control Module (TCM)The TCM is mounted on top of the main control valve body. The c

LESSON 3: POWERTRAINSolenoids SolenoidsItem Description Item Description1 SSA (EDS1) 5 SSD (EDS4)2 SSB (EDS2) 6 SSE (MV1)3 SSC (EDS3) 7 TCC (EDS6)4 PC

LESSON 3: POWERTRAINController Area Network (CAN) Interface Controller Area Network (CAN) InterfaceFor the TCM to carry out shift point and shift qual

LESSON 3: POWERTRAINSensors Integrated With TCM Sensors Integrated With TCMItem Description Item Description1 Output Shaft Speed (OSS) Sensor 3 Turbin

LESSON 3: POWERTRAINTransmission Range Position Sensor Transmission Range Position SensorThe TCM uses the position of this switch, housed on the TCM a

LESSON 3: POWERTRAINTransmission Operational Strategies Adaptive shift strategy is comprised of the following functions:•Shift Energy Management - Red

LESSON 3: POWERTRAINTCM Monitoring Functions The TCM monitors all transmission inputs and outputs to identify possible transmission failures. If a fau

LESSON 3: POWERTRAINMonitoring The Substrate Temperature Sensor Substrate Temperature SensorThe TCM controls a number of high power solenoids and is s

LESSON 3: POWERTRAINTransmission Cooling Transmission Cooling•New quick connect transmission oil cooler lines.– Quick connect fittings are used at the

LESSON 3: POWERTRAIN6HP26 Transmission Special Service Tools Item Description307-552 Direct Clutch Service Fixture307-553 Front Pump Removal Tool307-5