2009 ford flex service repair manual by 1639701yu

2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

SPECIFICATIONS TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Description

Nm 6 6 10 25 40 25 5 9 7 25 30 8

Front floor console lower bolts Front floor console rear lower bolts Ground wire bolts Instrument panel center support bracket bolts Instrument panel side bolts Instrument panel upper cowl bolts PCM nuts Passenger side air bag-to-cross beam bolts Rear floor console bolts Steering column shaft-to-steering column bolt Strut upper mount nuts Thermostatic Expansion Valve (TXV) manifold bolt

lb-ft 18 30 18 18 22 -

lb-in 53 53 89 44 80 62 71

DESCRIPTION AND OPERATION REFRIGERATOR The rear floor console may be equipped with a refrigerator feature. The refrigerator operates only when the ignition is in the ON position. The refrigerator should only be used when the engine is running. If there is a need to use the unit when the engine is off, limit the time the refrigerator is running to avoid draining the battery. If the refrigerator is active and the ignition is turned to the OFF position, the refrigerator will also turn off. The last known state of the refrigerator will be stored into the refrigerator module memory. When the ignition is turned back to the ON position, the refrigerator/freezer will automatically activate to the last known state that is stored in the refrigerator module memory. The refrigerator/freezer is equipped with the following:    

Refrigerator switch (located on rear floor console) Compressor/motor assembly (not serviceable) Refrigerant (not serviceable) Refrigerator module (not serviceable)

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Cool Mode

To activate the refrigerator, depress the refrigerator switch to the COOL position for approximately 1 second until the COOL LED illuminates. When the refrigerator is in cool mode, the temperature will cool to approximately 41°F (5°C). In order to turn the refrigerator off when the refrigerator is in cool mode, depress the refrigerator switch to the COOL position for approximately 1 second, until the COOL LED turns off. When the refrigerator is in the cool mode, the refrigerator can be switched to freeze mode by depressing the refrigerator switch to the FREEZE position for approximately 1 second, until the COOL LED turns off and the FREEZE LED illuminates. Freeze Mode

To activate the freezer, depress the refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE LED illuminates. When the refrigerator is in freeze mode, the temperature will cool to approximately 23°F (-5°C). In order to turn the freezer off when the refrigerator is in freezer mode, depress the refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE LED turns off. When the refrigerator is in the freeze mode, the refrigerator can be switched to cool mode by depressing the refrigerator switch to the COOL position for approximately 1 second, until the FREEZE LED turns off and the COOL LED illuminates. Diagnostic Mode

In the event of a system concern, the refrigerator is equipped with the capabilities to provide self diagnostics. For information on the diagnostic mode, refer to the Principles of Operation located in REFRIGERATOR.

DIAGNOSIS AND TESTING REFRIGERATOR Special Tool(s)

SPECIAL TOOL REFERENCE CHART

73III Automotive Meter 105-R0057 or equivalent

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Principles of Operation Refrigerator

The refrigerator consists of a switch, module and motor assembly, which contains a cooling fan, refrigerant, a condenser and a compressor. The refrigerator relay, located in the Battery Junction Box (BJB), controls voltage to the refrigerator. The refrigerator relay coil is grounded at all times. When the ignition switch is in the RUN or ACCESSORY position, voltage is supplied to the refrigerator relay coil from Smart Junction Box (SJB) fuse 34 (5A) and the relay closes. When the refrigerator relay is closed, voltage is sent to the refrigerator from BJB fuse 15 (15A). The temperature of the refrigerator is controlled by a sensor located in the refrigerator module. When a refrigerator mode is selected and the refrigerator temperature is above the target temperature, the compressor will activate. If the temperature is below the target temperature, there is no need for cooling and the compressor will stop. The compressor start up has a predetermined time delay to avoid a potential rapid changing compressor on and off situation. The heat from the compressor and condenser is pushed out of the vents of the refrigerator by means of a fan. This fan runs continuously, as soon as a refrigerator mode is selected. The fan will not stop with the compressor if the target temperature is reached. Diagnostic Mode

The refrigerator can be switched into a diagnostic mode to read the potential error codes of the compressor. When the refrigerator is in diagnostic mode, the COOL LED on the refrigerator switch will flash 1-5 times, Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

depending on the error. Perform the following steps in order to access the refrigerator diagnostic mode: 1. Turn the ignition switch to the ON position. 2. Depress the refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE LED illuminates. 3. Depress the refrigerator switch again to the FREEZE position for approximately 5 seconds, until the FREEZE LED flashes quickly and repeatedly. 4.

NOTE:

Use the Diagnostic Mode Error Code Chart to determine the error.

When the FREEZE LED is quickly flashing, the COOL LED will display the error code by flashing 1-5 times, depending on the error. NOTE: 5.

If the refrigerator is in diagnostic mode and the ignition is turned OFF, the refrigerator will restart in FREEZE mode when the ignition is turned back to the ON position.

To turn the diagnostic mode off, depress the refrigerator switch to the FREEZE position for approximately 1 second. The FREEZE LED will stop flashing, but it will remain illuminated and the refrigerator will be in freeze mode. DIAGNOSTIC ERROR CODE DESCRIPTION CHART Number Diagnostic Diagnostic Error Code Description of Flashes Error Code Battery The voltage level at the refrigerator 12 volt connector is below the parameter 1 protection settings. This code may set when the refrigerator has been active with the cutout engine off. Fan overThe fan loads the electronic unit with more than 1 amp peak. Refer to 2 current cut-out INSPECTION AND VERIFICATION. The rotor is blocked or the differential pressure in the unit is too high. This may occur in high ambient temperature situations or if the refrigerator was Motor start 3 stopped and restarted within a short period at a high load and/or a high error ambient temperature condition. Let the differential pressure lower, before attempting to restart the refrigerator. Minimum The refrigeration system is so heavily loaded by ambient temperatures that the motor speed motor cannot maintain a minimum speed of 1,850 rpm. Let the refrigerator 4 error system cool down before attempting to restart the refrigerator. The refrigerator is so heavily loaded by ambient temperatures that the Thermal cutrefrigerator module gets too hot. Check the vents and the area of the 5 out of compressor, condenser for a blockage, possibly from dust. Check the fan for electrical unit correct operation. Inspection and Verification

1. Verify the customer concern. Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

2. Visually inspect for obvious signs of mechanical or electrical damage: VISUAL INSPECTION CHART Mechanical    

Refrigerator

   

Electrical

Battery Junction Box (BJB) fuse 15 (15A) Smart Junction Box (SJB) fuse 34 (5A) Refrigerator Refrigerator relay Refrigerator switch Loose or corroded connections Wiring harness

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 concern is not visually evident, verify the symptom and GO to SYMPTOM CHART. Symptom Chart

SYMPTOM CHART Condition

Possible Sources  



The refrigerator does not operate correctly



 

Fuse(s) Refrigerator relay Refrigerator switch Refrigerator Circuitry

Action



Go To PINPOINT TEST A.

Pinpoint Tests Pinpoint Test A: The Refrigerator Does Not Operate Correctly

Refer to SYSTEM WIRING DIAGRAMS , Refrigerated Console for schematic and connector information. Normal Operation

When the ignition switch is in the RUN or ACCESSORY position, voltage is supplied to the refrigerator relay coil from Smart Junction Box (SJB) fuse 34 (5A), through circuit CBP34 (VT/BN). The refrigerator relay coil is grounded at all times through circuit GD120 (BK/GN). High current voltage is supplied to the refrigerator relay from Battery Junction Box (BJB) fuse 15 (15A), through circuit SBB15 (WH/RD). When the refrigerator relay is activated, voltage is supplied to the refrigerator through circuit CBB15 (BN/BU). The refrigerator is grounded through circuit GD149 (BK/GY). This pinpoint test is intended to diagnose the following: Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

    

Fuse(s) Refrigerator relay Refrigerator switch Refrigerator Wiring, terminals or connectors

PINPOINT TEST A: THE REFRIGERATOR DOES NOT OPERATE CORRECTLY

A1 CHECK CIRCUIT CBB15 (BN/BU) FOR VOLTAGE  Disconnect: Refrigerator C3415.  Ignition ON.  Measure the voltage between refrigerator C3415-1, circuit CBB15 (BN/BU), harness side and ground.

Fig. 1: Measuring Voltage Between Refrigerator C3415-1, Circuit CBB15 (BN/BU), Harness Side And Ground Courtesy of FORD MOTOR CO. Is the voltage greater than 10 volts? Yes : GO to A6. No : GO to A2. A2 CHECK THE REFRIGERATOR RELAY  Ignition OFF.  Disconnect: Refrigerator Relay.  Carry out the Relay component test for the BJB refrigerator relay. 

Refer to SYSTEM WIRING DIAGRAMS for component testing. Did the refrigerator relay pass the component test? Yes : GO to A3. No : INSTALL a new refrigerator relay. TEST the system for normal operation. A3 CHECK CIRCUIT CBP34 (VT/BN) FOR VOLTAGE  Ignition ON. 

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex



Measure the voltage between BJB refrigerator relay pin 1, circuit CBP34 (VT/BN), harness side and ground.

Fig. 2: Measuring Voltage Between BJB Refrigerator Relay Pin 1, Circuit CBP34 (VT/BN), Harness Side And Ground Courtesy of FORD MOTOR CO. Is the voltage greater than 10 volts? Yes : GO to A4. No : VERIFY SJB fuse 34 (5A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the appropriate SystemWiring Diagrams to identify the possible causes of the circuit short. TEST the system for normal operation. A4 CHECK CIRCUIT SBB15 (WH/RD) FOR VOLTAGE  Measure the voltage between BJB refrigerator relay pin 3, circuit SBB15 (WH/RD), harness side and ground. 

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 3: Measuring Voltage Between BJB Refrigerator Relay Pin 3, Circuit SBB15 (WH/RD), Harness Side And Ground Courtesy of FORD MOTOR CO. Is the voltage greater than 10 volts? Yes : GO to A5. No : VERIFY BJB fuse 15 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the appropriate System Wiring Diagrams to identify the possible causes of the circuit short. TEST the system for normal operation. A5 CHECK FRONT WIPER RELAY CIRCUIT GD120 (BK/GN) FOR GROUND  Measure the resistance between BJB refrigerator relay pin 2, circuit GD120 (BK/GN) and ground. 

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 4: Measuring Resistance Between BJB Refrigerator Relay Pin 2, Circuit GD120 (BK/GN) And Ground Courtesy of FORD MOTOR CO. Is the resistance less than 5 ohms? Yes : REPAIR open in circuit CBB15 (BN/BU). TEST the system for normal operation. No : REPAIR open in circuit GD120 (BK/GN). TEST the system for normal operation. A6 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN  Ignition OFF.  Measure the resistance between refrigerator C3415-3, circuit GD149 (BK/GY), harness side and ground. 

Fig. 5: Measuring Resistance Between Refrigerator C3415-3, Circuit GD149 (BK/GY), Harness Side And Ground Courtesy of FORD MOTOR CO. Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Is the resistance less than 5 ohms? Yes : GO to A7. No : REPAIR the circuit(s). TEST the system for normal operation. A7 CHECK THE REFRIGERATOR SWITCH  Remove the refrigerator switch. Refer to REFRIGERATOR SWITCH.  Carry out the Refrigerator Switch Component Test.  Did the refrigerator switch pass the component test? Yes : GO to A8. No : INSTALL a new refrigerator switch. A8 CHECK FOR CORRECT REFRIGERATOR OPERATION  Disconnect all refrigerator connectors.  Check for:  corrosion.  pushed-out pins.  Connect all the refrigerator connectors and make sure they seat correctly.  Operate the system and verify the concern is still present.  Is the concern still present? Yes : INSTALL a new refrigerated rear floor console. REFER to CONSOLE - REAR, FLOOR. No : The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. TEST the system for normal operation. 

Component Test Refrigerator Switch

Fig. 6: Identifying Refrigerator Switch Courtesy of FORD MOTOR CO. REFRIGERATOR SWITCH REFERENCE CHART Connect Self-Powered Test Light or Ohmmeter to Move Switch to this Terminals Position 1 and 2 COOL

A Good Switch will Indicate Closed

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

1 and 3 1 and 4 1 and 5 1 and 6 2 and 3 2 and 4 2 and 5 2 and 6 3 and 4 3 and 5 3 and 6 4 and 5 4 and 6 5 and 6

FREEZE -

Open Open Open Closed Open Open Open Open Open Open Open Open Open Open

REMOVAL AND INSTALLATION INSTRUMENT PANEL - EXPLODED VIEW Instrument Panel Finish Panels and Fasteners

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 7: Exploded View Of Instrument Panel With Torque Specifications Courtesy of FORD MOTOR CO. WINDOW MOULDING - REAR QUARTER Item Part Number Description 1 W709178 Instrument panel upper cowl bolt (3 required) 2 04480 RH/ 04481 LH Instrument panel side trim panel 3 W712210 Instrument panel side finish panel retaining clip (5 required per side) 4 W712961 Steering column shaft-to-steering column bolt 5 W710259 Instrument panel side bolt (6 required) 6 W709268 Instrument panel center support bracket bolt (4 required) Instrument Panel Trim Panels, Finish Panels and Electrical Connectors

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 8: Identifying Instrument Panel Trim Panels, Finish Panels And Electrical Connectors Courtesy of FORD MOTOR CO. WINDOW MOULDING - REAR QUARTER Item Part Number Description 1 N808453 Steering column opening trim panel screw (3 required) 2 04459 Steering column opening trim panel 3 W712210 Steering column opening trim panel retaining clip (3 required) 4 LH instrument panel electrical connector (part of 14401) 5 Lower LH instrument panel electrical connectors (part of 14401) 6 Small RCM electrical connector (part of 14401) 7 RH instrument panel electrical connector (part of 14401) 8 18812A Antenna cable 9 04338 RH Instrument panel finish panel Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

10 11 12

W712210 04339 W712210

RH Instrument panel finish panel retaining clip (8 required) LH Instrument panel finish panel LH Instrument panel finish panel retaining clip (2 required)

Instrument Panel and Instrument Cluster Finish Panels

Fig. 9: Identifying Instrument Panel And Instrument Cluster Finish Panels Courtesy of FORD MOTOR CO. REMOVAL AND INSTALLATION Item Part Number Description 1 W707628 Center instrument panel finish panel screw (6 required) 2 04302 Center instrument panel finish panel 3 W712210 Center instrument panel finish panel retaining clip (7 required) 4 Instrument cluster finish panel screw covers (part of 044D70) 5 W707628 Instrument cluster finish panel screw (3 required) 6 044D70 Instrument cluster finish panel 7 W712210 Instrument cluster finish panel retaining clip (3 required) 8 13A018 Light sensor 9 Light sensor electrical connector (part of 14401) 10 044E82 Instrument panel defroster grille 11 W712210 Instrument panel defroster grille retaining clip (14 required) Instrument Panel Upper Section Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 10: Identifying Instrument Panel Upper Section Courtesy of FORD MOTOR CO. TIGHTENING TORQUE SPECIFICATIONS Item Part Number Description 1 W505424 Hood release handle bolt 2 16916 Hood release handle 3 W707628 Instrument panel upper section screw (13 required) 4 04320 Instrument panel upper section 5 04545 In-vehicle crossbeam 1. For additional information, refer to the appropriate procedures. INSTRUMENT PANEL Removal

1. Rotate the steering wheel until the front wheels are in the straight-ahead position. 2. Drain the coolant. For additional information, refer to ENGINE COOLING . 3. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM GENERAL INFORMATION AND DIAGNOSTICS . 4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS AND WASHERS . 5. Disconnect the 3 PCM electrical connectors. Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

6. Remove the wire harness retainer from the PCM bracket stud.

Fig. 11: Locating Wire Harness Retainer Of PCM Bracket Stud Courtesy of FORD MOTOR CO. 7. Remove the 2 nuts and the PCM.

Fig. 12: Locating PCM Nuts Courtesy of FORD MOTOR CO. 8. Remove the 3 nuts and the PCM bracket.

Fig. 13: Locating PCM Bracket Nuts Courtesy of FORD MOTOR CO. 9. Remove the vacuum hose clip from the strut tower cross brace. Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 14: Locating Vacuum Hose Clip Courtesy of FORD MOTOR CO. 10.

NOTE:

LH side shown in illustration, RH side similar.

Remove the strut tower cross brace. 

Remove the LH and RH strut upper mount inboard nuts.

Fig. 15: Locating Strut Upper Mount Inboard Nuts Courtesy of FORD MOTOR CO. 11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and position aside.

Fig. 16: Locating Vacuum Hose And Evaporator Purge Solenoid Hose Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Courtesy of FORD MOTOR CO. 12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.

Fig. 17: Locating Crankcase Vent Tube And Vacuum Tube Courtesy of FORD MOTOR CO. 13. Loosen the ACL outlet pipe-to-Throttle Body (TB) clamp and the ACL outlet pipe-to- ACL cover clamp.

Fig. 18: Locating ACL Outlet Pipe-To-Throttle Body Clamp And ACL Outlet Pipe-To- ACL Cover Clamp Courtesy of FORD MOTOR CO. 14. Remove the ACL outlet pipe. 15. Remove the heater hoses from the heater hose separator.

Fig. 19: Locating Heater Hoses Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Courtesy of FORD MOTOR CO. 16. Remove the heater hoses from the heater hose tubes and position aside.

Fig. 20: Locating Heater Hoses Clamp Courtesy of FORD MOTOR CO. 17. Remove the heater hoses from the heater core and position aside.

Fig. 21: Locating Heater Hoses Clamp Courtesy of FORD MOTOR CO. 18. Remove the Thermostatic Expansion Valve (TXV) manifold bolt and the TXV manifold.  Discard the O-ring seals.

Fig. 22: Locating Thermostatic Expansion Valve Manifold Bolt Courtesy of FORD MOTOR CO. Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Remove the RH and LH instrument panel upper cowl bolts. Remove the steering wheel. For additional information, refer to STEERING COLUMN . Remove the front seats. For additional information, refer to SEATING . Remove the front floor console. For additional information, refer to CONSOLE - FRONT, FLOOR. Remove the LH and RH front door scuff plate trim panels.  Lift the scuff plate trim panels upward to release the retaining clips. Remove the LH and RH front door opening weatherstrips. Remove the LH and RH A-pillar trim panels. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION . Remove the LH and RH instrument panel side trim panels.  Pull the instrument panel side trim panels outward to release the retaining clips. Remove the LH and RH lower cowl trim panels.  Pull the lower cowl trim panels rearward to release the retaining clips. Remove the hood release handle bolt and position aside the hood release handle.

Fig. 23: Locating Hood Release Handle Bolt Courtesy of FORD MOTOR CO. 29. Disconnect the LH instrument panel bulkhead electrical connector.

Fig. 24: Locating LH Instrument Panel Bulkhead Electrical Connector Courtesy of FORD MOTOR CO. 30. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical Microsoft Thursday, April 22, 2010 8:42:11 AM

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2009 Ford Flex SE 2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

connector.

Fig. 25: Locating Smart Junction Box Lower Electrical Connectors And Lower Bulkhead Electrical Connector Courtesy of FORD MOTOR CO. 31. Remove and discard the steering column shaft-to-steering column bolt.

Fig. 26: Locating Steering Column Shaft-To-Steering Column Bolt Courtesy of FORD MOTOR CO. 32. Detach the steering column shaft from the steering column. 33. Remove the driver footrest pad.  Remove the 2 pin-type retainers.

Fig. 27: Locating Pin-Type Retainers Microsoft Thursday, April 22, 2010 8:42:11 AM

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