Content

General information

• General information
• Identification codes
• Jacking and lifting
• Maintenance schedules

Noise, vibration and harshness

• Noise, vibration and harshness description and operation
• Noise, vibration and harshness diagnosis and testing

Police equipment

• Flasher lighting, siren and speaker system
• Auxiliary steering wheel controls
• Dtc chart: BCM
• Group flash pattern programming
• Individual flash pattern programming
• Flasher module
• Flasher switch pad
• Generic function module
• Grille mounted flashing light emitting diode (led) lamps
• Flasher lighting relay panel
• Headliner mounted front flashing light emitting diode (led) lamps
• High mounted flashing light emitting diode (led) lamps
• Liftgate flashing light emitting diode (led) lamps
• Lighting and siren control module
• Quarter window flashing light emitting diode (led) lamps
• Rear side marker flashing light emitting diode (led)
• Spot lamp
• Exterior mirror flashing light emitting diode (led) lamps
• Siren speaker

Suspension

• Suspension system - general information
• Specifications
• Diagnosis and testing
• Front toe adjustment
• Rear camber adjustment
• Rear toe adjustment
• Ride height measurement
• Front camber adjustment
• Front suspension
• Front stabilizer bar link
• Front stabilizer bar
• Front strut and spring
• Front wheel bearing and wheel hub
• Lower arm bushing
• Lower arm
• Wheel knuckle
• Wheel studs
• Front strut and spring
• Rear shock absorber
• Rear stabilizer bar link

Wheels and tires

• Specifications
• Safety precautions - overview
• Diagnosis and testing
• Wheel to hub runout minimization
• Wheel to tire runout minimization
• Wheel and tire removal and installation
• Disassembly and assembly

Tire pressure monitoring system

• Tire pressure monitoring system
• Tire pressure monitoring system, police interceptor - utility diagnosis and testing
• Tire pressure monitoring system - system operation and component description
• Tire pressure monitoring system sensor activation
• Tire pressure monitoring system sensor location calibration
• Tire pressure monitoring system sensor

Driveline and axles

• Driveshaft
• Specifications
• Diagnosis and testing
• Driveshaft angle measurement
• Driveshaft runout and balancing
• Rear drive axle / differential
• Differential fluid level check
• Differential housing cover
• Drive pinion seal
• Axle assembly
• Rear halfshaft seal
• Front drive halfshafts
• Rear drive halfshafts
• Inner constant velocity joint boot
• Outer constant velocity joint boot
• Rear halfshaft

Brakes

• Brake system - general information
• Specifications
• Symptom chart
• Brake system pressure bleeding
• Component bleeding
• Brake disc machining
• Front disc brake
• Rake caliper anchor plate
• Brake disc shield
• Brake caliper
• Brake disc
• Brake pads
• Front brake flexible hose
• Rear disc brake
• Rear brake flexible hose
• Parking brake and actuation
• Parking brake cable tension release
• Parking brake cable
• Parking brake control
• Parking brake front cable
• Parking brake warning indicator switch
• Hydraulic brake actuation
• Brake pedal control switch
• Brake pedal and bracket
• Power brake actuation
• Brake vacuum sensor
• Anti-lock brake system and stability control
• Anti-lock brake system module
• Front wheel speed sensor
• Hydraulic control unit
• Rear wheel speed sensor

Steering

• Steering column
• Power steering
• Steering column - overview
• Steering column - system operation and component description
• DTC chart: sccm
• Steering wheel cover repair
• Steering column shaft
• Steering column tilt motor
• Steering column
• Steering wheel
• Steering wheel and column electrical components
• Heated steering wheel module
• Ignition lock cylinder housing
• Ignition switch - vehicles with: keyless vehicle system
• Ignition switch
• Steering column control module
• Steering column control switch
• Steering column multifunction switch
• Steering wheel multifunction switch

Engine 3.5l Duratec (209KW/284PS)

• Engine system - general information
• Engine - overview
• Diagnosis and testing
• Bearing inspection
• Cylinder block core plug replacement
• Cylinder block distortion
• Cylinder bore taper
• Cylinder head distortion
• Exhaust manifold cleaning and inspection
• Piston ring end gap
• Piston selection
• Owertrain / drivetrain mount neutralizing
• Sealing surface cleaning and preparation
• Valve guide inner diameter
• Valve stem diameter
• Connecting rod bearing journal clearance
• Crankshaft main bearing journal clearance
• Lower intake manifold
• Valve cover
• Ariable camshaft timing
• Oil cooler
• Oil pan
• Oil pressure switch
• Oil pump
• Timing chain
• Engine front cover
• Engine mount
• Cylinder head
• Crankshaft rear seal with retainer plate
• Cylinder head
• Crankshaft front seal
• Camshafts
• Flexplate
• Upper intake manifold
• Cylinder head
• Piston
• Engine removal
• Engine installation
• Engine assembly
• Engine disassembly

Engine cooling

• Ngine cooling - component location
• Engine cooling - system operation and component description
• Cooling system draining, vacuum filling and bleeding
• Cooling system flushing
• Oolant inlet pipe
• Coolant pump
• Degas bottle
• Cooling fan motor and shroud
• Block heater
• Radiator
• Thermostat housing
• Thermostat

Fuel charging and controls

• Fuel charging and controls
• Fuel injectors
• Fuel pump driver module
• Fuel rail
• Throttle body

Accessory drive

• Accessory drive
• Accessory drive belt tensioner
• Accessory drive belt

Starting system

• Specifications
• Diagnosis and testing
• Starter motor drive gear and flywheel ring gear inspection
• Starter motor

Engine ignition

• Specifications
• Engine ignition - component location
• Engine ignition - system operation and component description
• Diagnosis and testing
• Ignition coil-on-plug
• Spark plugs

Engine emission control

Intake air distribution and filtering

• Intake air distribution and filtering
• Air cleaner outlet pipe
• Air cleaner

Evaporative emissions

• Evaporative emissions
• Evaporative emission system leak
• Evaporative emission canister purge valve
• Evaporative emission canister vent solenoid
• Evaporative emission canister ventilation filter
• Evaporative emission canister
• Fuel tank pressure sensor and tube

Electronic engine controls

• DTC chart: powertrain control module
• Knock sensor
• Manifold absolute pressure and temperature sensor
• Powertrain control module
• Variable camshaft timing oil control
• Heated oxygen sensor
• Crankshaft position sensor
• Cylinder head temperature sensor
• Electronic engine controls
• Camshaft position sensor
• Catalyst monitor sensor

Automatic transmission 6F50

• Automatic transmission - 6-speed automatic transmission - 6F50/6F55
• Specifications
• Differential exploded view
• Direct clutch assembly
• Final drive
• Forward clutch assembly
• Input shaft
• Intermediate clutch assembly
• Low one-way clutch assembly
• Low / reverse clutch assembly
• Main control valve body
• Overdrive clutch assembly
• Parameter identification chart
• Pump assembly
• Transmission description
• Disassembled views
• Planetary assembly description and operation
• DTC chart: pcm
• Direct clutch assembly diagnosis and testing
• Forward clutch assembly diagnosis and testing
• Diagnosis by symptom
• Intermediate clutch assembly diagnosis and testing
• Low one-way clutch assembly diagnosis and testing
• Low/reverse clutch assembly diagnosis and testing
• Transmission line pressure test diagnosis and testing
• Transmission stall speed test diagnosis and testing
• Torque converter clutch diagnosis and testing
• Overdrive clutch assembly diagnosis and testing
• Transmission air pressure test diagnosis and testing
• Transmission case reseal
• Transmission fluid drain and refill
• Transmission fluid exchange
• Transmission identification
• Transmission strategy download
• Halfshaft seal
• Main control cover
• Output shaft speed sensor
• Roll restrictor
• Transmission - removal and installation
• Selector shaft seal
• Transfer shaft
• Differential
• Transmission case
• Transmission range sensor
• Transmission support insulator
• Transmissionassembly
• Transmission disassembly
• Torque converter housing disassembly and assembly of subassemblies
• Transmission overhaul
• Main control valve body overhaul

Transmission cooling

• Transmission fluid cooler - backflushing and cleaning
• Transmission fluid cooler tubes
• Cooler bypass valve

Automatic transmission external controls

• External controls
• Brake shift interlock actuator manual override
• Brake shift interlock actuator
• Downshift paddle switch
• Selector lever assembly
• Selector lever boot
• Selector lever cable
• Selector lever knob
• Selector lever mechanism
• Transmission control switch
• Upshift paddle switch

Transfer unit and four-wheel drive systems

• Four-wheel drive systems
• Four-wheel drive systems
• DTC chart: awd system - PCM
• Active torque coupling configuration
• All-wheel drive module
• All terrain control module
• Power transfer unit
• Power transfer unit diagnosis and testing
• Install idler shaft bearing repair kit
• Power transfer unit draining and filling
• Power transfer unit fluid level check
• Power transfer unit oil life monitor reset
• Power transfer unit cooler
• Power transfer unit input shaft seal
• Power transfer unit rear seal
• Intermediate shaft seal
• Oil pump
• Power transfer unit removal
• Power transfer unit installation
• Power transfer unit overhaul

Exhaust system

• Exhaust system
• Symptom chart(s)
• Catalytic converter
• Exhaust y-pipe
• Muffler and tailpipe

Fuel system

• Fuel system
• Fuel system pressure checkquick release coupling
• Spring lock couplings
• Fuel tank and lines - overview
• Fuel tank filler pipe
• Fuel tank
• Fuel level sender
• Fuel lines
• Fuel pump and sender unit

Acceleration control

• Acceleration controldiagnosis and testing
• Acceleration control - overview
• Accelerator pedal

Climate control system

• Climate control system - general
• Air conditioning clutch air gap adjustment
• Air conditioning compressor leak detection
• Air conditioning odor treatment
• Air conditioning system flushing
• Air conditioning system recovery, evacuation and charging
• Electronic leak detection
• Evaporator core leak check
• Fluorescent dye leak detection
• Refrigerant identification testing
• Refrigerant oil adding
• Refrigerant system tests
• Condenser core leak check
• Heater core leak check
• Air conditioning compressor
• Air conditioning compressor outlet line
• Air conditioning pressure transducer
• Air distribution door actuator
• Air inlet door actuator
• Ambient air temperature sensor
• Driver side register
• Driver side temperature door actuator
• Evaporator temperature sensor
• Evaporator
• Cabin air filter
• Center registers
• Climate control housing
• In-vehicle temperature and humidity sensor
• Passenger side register
• Passenger side temperature door actuator
• Receiver drier element
• Condenser
• Temperature door actuator
• Thermostatic expansion valve
• Thermostatic expansion valve manifold and tube assembly
• Heater core
• Blower motor speed control
• Blower motor
• Heating, ventilation and air conditioning control module
• Sunload sensor

Rear climate control

• Rear climate control
• Rear air distribution door actuator
• Rear blower motor speed control
• Rear blower motor
• Rear evaporator inlet line
• Rear evaporator outlet line
• Rear evaporator
• Rear heater core
• Rear heating, ventilation and air conditioning control module
• Rear temperature door actuator
• Rear thermostatic expansion valve
• Rear evaporator

Instrumentation and warning systems

• Instrument panel and interior switches illumination
• DTC chart: body control module (BCM)

Instrumentation, message center and warning chimes

• Instrument panel cluster
• Instrument panel cluster lens
• Instrument panel cluster
• DTC chart: instrument panel cluster
• Message center
• Warning chimes
• Seatbelt minder deactivating / activating
• Warning chimes - system operation and component description

Horn

• Horn
• DTC chart: horn
• Horn removal and installation

Parking aid

• Specifications
• Azimuth system check
• Parking aid
• DTC chart
• Front active park assist sensors
• Rear active park assist sensors

Battery and charging system

• Charging system

Battery, mounting and cables

• Specifications
• Battery and cables - overview
• Battery diagnosis and testing
• Battery and cables - system operation and component description
• Battery charging
• Battery disconnect and connect
• Battery drain check
• Battery cables
• Battery removal and installation'generator current sensor

Voltage converter / inverter

• Direct current / alternating current inverter
• Alternating current power outlet socket
• Direct current / alternating current inverter

Information and entertainment

• Information and entertainment system
• DTC chart: ACM
• Bezel diagnostics
• Audio front control module
• Audio unit antenna cable
• Audio unit antenna
• Front control / display interface module
• Front controls interface module
• Front door speaker
• Front door tweeter speaker
• Rear door speaker
• Audio input jack
• Global positioning system module
• Satellite radio antenna cable
• Ync module to universal serial bus port cable
• Microphone
• Subwoofer speaker

Lighting

• Exterior lighting
• Diagnosis and testing
• Headlamp adjustment
• Front fog lamp bulb
• Front fog lamp
• Ballast
• Headlamp assembly
• Headlamp bulb
• Headlamp control module
• Headlamp leveling sensor
• Headlamp switch
• High mounted stoplamp
• Light sensor
• Rear lamp assembly
• Rear lamp bulb
• Rear turn signal lamp bulb
• Stoplamp switch
• Interior lighting
• DTC chart: BCM

Electrical distribution

• Module communications network
• Communications network
• DTC chart: gateway module
• Between the integrated diagnostic system and the vehicle
• Module configuration
• Module programming

Electronic feature group

• A perimeter anti-theft alarm
• Perimeter anti-theft alarm
• DTC chart

Passive anti-theft system

• DTC charts
• Anti-theft security access
• Key programming using two programmed keys
• Passive anti-theft system transceiver
• Passive anti-theft system
• Anti-theft security access
• Key programming using two programmed keys
• Passive anti-theft system center antenna

Remote convenience

• Universal transmitter

Cruise control

• Cruise control - system operation and component description
• Cruise control - overview
• DTC charts
• Collision warning and collision avoidance system
• Head up display module
• Side and rear vision
• Lane keeping system
• Multifunction electronic modules
• Module controlled functions
• DTC chart: body control module
• Factory mode deactivation
• Transport mode deactivation
• Body control module
• Driver door module
• Passenger door module
• Radio transceiver module

Body

• Rear door check arm
• Power liftgate motor
• Liftgate
• Liftgate anti-pinch switch
• Hood alignment
• Front door alignment
• Rear door alignment
• Power liftgate initialization
• Liftgate alignment
• Body closures
• Hood
• Fender
• Fender splash shield
• Engine undershield
• Engine undershield - police
• Cowl panel
• Cowl panel grille
• Active grille shutter
• Active grille shutter actuator
• DTC chart: powertrain control module
• Active grille shutter
• Front end body panels
• Symptom chart
• Body - overview
• Specifications
• Body system - general information
• Roof rail
• Rocker panel moulding
• Front fender moulding
• Front door upper moulding
• Rear spoiler
• Rear door upper moulding
• Rear door moulding
• Liftgate moulding
• Finish panel repair
• Steering column shrouds
• Loadspace trim panel
• Headliner
• Headliner - lowering
• Rear door trim panel
• Liftgate trim panel
• Fuel filler door
• Fuel filler door spring
• Rear gate trunk module
• Hands-free liftgate actuation upper sensor
• Hands-free liftgate actuation module
• Hands-free liftgate actuation lower sensor
• Front door
• Front door check arm
• Rear door
• Windshield moulding
• Front door moulding
• Rear quarter panel moulding
• Rear view mirrors
• Power mirrors synchronization
• Exterior mirror
• Interior rear view mirror
• Front seats
• Driver front seat module
• Driver multi-contour seat module
• Front head restraint guide sleeve
• Front seat backrest blower motor
• Front seat control switch
• Front seat power lumbar assembly
• Front seat track
• Second row seats
• Power fold seat control
• Second row double seat
• Third row seats
• Glass, frames and mechanisms
• Lead terminal repair
• Power door window initialization
• Fixed glass
• Instrument panel and console
• Handles, locks, latches and entry systems
• Wipers and washers
• Roof opening panel
• Bumpers
• Seatbelt systems
• Frame and mounting

Wiring diagrams