Ford Taurus Service Manual: Front End Body Panels

SPECIFICATIONS

Torque Specifications

Ford Taurus. Body

DESCRIPTION AND OPERATION

Active Grille Shutter System

Overview

The grille shutter system (when equipped) is comprised of the grille shutter assembly and the grille shutter actuator. The grille shutter system is primarily used to maximize fuel economy by reducing aerodynamic drag on the vehicle. The grille shutter system is also used to shorten engine warm-up time, increasing engine efficiency and providing heat to the vehicle occupants in a timely manner. The grille shutter actuator receives position commands from the PCM. The grille shutter system carries out a calibration sequence whenever the engine is started, fully opening and closing the shutters before being positioned in the programmed position as requested by the PCM.

PCM inputs/outputs used for controlling of grille shutters are the:

  • ECT sensor
  • IAT sensor
  • A/C pressure transducer
  • APP sensor
  • ABS module (through the HS-CAN )
  • Engine cooling fan motor
  • Engine oil temperature

System Operation

System Diagram

Ford Taurus. Body

Network Message Chart

 Module Network Input Messages - PCM

Ford Taurus. Body

Grille Shutter

The grille shutter actuator positions the grille shutters based on commands from the PCM. The grille shutter moves 90 degrees from fully closed to fully open and, based on the position commanded by the PCM, is set in 1 of 16 positions (approximately 6 degrees between positions).

During normal operation, the grille shutter may be partially to fully open when the engine is off. When the engine is started and ambient temperature is above 1º C (34º F), a calibration of the grille shutter system occurs, which typically takes 15-20 seconds. The grille shutter system performs the calibration sequence by detecting the end positions, open and closed. The calibration sequence can begin in either direction, open or closed, and continues until it is successful or a fault is sensed. A long pause may occur between the 2 portions (open/close) of the calibration sequence. Calibration of the grille shutter system cannot be manually requested, it only occurs as determined by the grille shutter actuator. If certain faults are present (shutter blocked or actuator error), a recalibration is initiated in an attempt to resolve the problem. If the problem is not resolved after a calibrated number of attempts (usually 3 or 4), a timer starts and sets a DTC when the timer reaches a predetermined limit. Other faults also trigger a recalibration request, but not until a grille shutter DTC is set in the PCM.

The PCM communicates the desired position (open or closed) of the grille shutter based on various PCM inputs (vehicle speed, coolant temperature, ambient temperature, A/C system pressure, etc.). The PCM communicates to the grille shutter actuator via a LIN. The LIN supports bi-directional communication between the grille shutter actuator and PCM, allowing the grille shutter actuator to communicate position and fault information to the PCM.

The PCM sets grille shutter DTCs when the fault information is communicated by the grille shutter actuator for a predetermined amount of time. Any failures of the LIN for over 10 seconds continuously results in the grille shutter actuator positioning the grille shutter fully open. There is no indication to the driver of the vehicle when a fault with the grilled shutter system is present or a grille shutter DTC is set in the PCM.

Component Description

Grille Shutter Actuator

The grille shutter actuator is a smart motor which receives position requests from the PCM via the LIN. One of the grille shutter blinds connects to the grille shutter actuator using a retainer. The grille shutter actuator can be serviced individually or as an entire assembly, which includes the grille shutter, grille shutter actuator, retainer, housing and jumper harness.

Grille Shutter

The grille shutter is comprised of shutter blinds which are linked to each other. One of the individual shutter blinds is fixed to the grille shutter actuator. When the grille shutter actuator moves, it moves the attached shutter which causes the other linked shutters to move. The grille shutter is serviced as an assembly (individual shutter blinds are not serviceable) or as an entire assembly, which includes the grille shutter, grille shutter actuator, retainer, housing and jumper harness.

DIAGNOSIS AND TESTING

Active Grille Shutter System

Special Tool(s)

Ford Taurus. Body

DTC Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

PCM DTC Chart

Ford Taurus. Body

Preliminary Inspection

Before diagnosing or repairing the active grille shutter system, inspect the grille opening for any obstructions that can prohibit operation of the grille shutter.

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Symptom Chart

Ford Taurus. Body

Pinpoint Tests

Pinpoint Test A: The Grille Shutter Is Inoperative Or Does Not Operate Correctly

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Refer to Wiring Diagrams Cell 33, Cooling Fan for schematic and connector information.

Normal Operation and Fault Conditions

Refer to Active Grille Shutter System for a description of the normal operation.

DTC Fault Trigger Conditions

Ford Taurus. Body

    Possible Sources
  • Wiring, terminals or connectors
  • Grille shutter actuator
  • Grille shutter linkage
  • Grille shutters
  • PCM

Visual Inspection and Diagnostic Pre-checks

Make sure the grille opening does not have any debris or other obstructions that prohibit operation of the grille shutter.

Make sure the grille shutter actuator electrical connector is not disconnected.

PINPOINT TEST A: THE GRILLE SHUTTER IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY

NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Ford Taurus. Body

Ford Taurus. Body

Ford Taurus. Body

Ford Taurus. Body

Ford Taurus. Body

Ford Taurus. Body

GENERAL PROCEDURES

Hood Alignment

  1. Open the hood.
  1. Loosen the 4 upper hood hinge bolts to the point where the hood slightly moves.

    Ford Taurus. Body

  1. Adjust the hood to align the hood-to-fender gaps. For additional information, refer to Section 501-35.
  1. Tighten the 4 upper hood hinge bolts.
    • Tighten to 20 Nm (177 lb-in).
  1. NOTE: The adjustable hood bumpers are located in the hood.

    Adjust the hood bumpers so that the hood fits flush to the fenders.

    Ford Taurus. Body

REMOVAL AND INSTALLATION

Front End Body Panels - Exploded View

Ford Taurus. Body

Ford Taurus. Body

  1. For additional information, refer to the procedures in this section.

Fender Splash Shield

Removal and Installation

Both sides

  1. Remove the front wheel and tire. For additional information, refer to Section 204-04.
  1. Remove the 3 fender splash shield screws.
  1. Remove the 2 fender splash shield bolts.
  1. Remove the 10 fender splash shield pin-type retainers.

Right side

  1. Remove the 3 engine splash shield pin-type retainers.

Both sides

  1. Remove the fender splash shield.
  1. To install, reverse the removal procedure.

Fender

Removal and Installation

  1. Remove the front bumper cover. For additional information, refer to Section 501-19.
  1. Remove the front wheel and tire. For additional information, refer to Section 204-04.
  1. Remove the fender splash shield. For additional information, refer to Fender Splash Shield in this section.
  1. Remove the headlamp bolts.
  1. Remove the bumper cover mounting bracket bolt.
    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the bumper cover mounting bracket screw.
  1. NOTE: The rocker cover trim panel retainers are one-time use.

    Release the rocker cover trim panel retainers, position rocker cover trim panel aside to gain access to the lower fender mounting bolts.

  1. NOTE: If shims are present during removal, be sure to reinstall shims and check fender alignment.

    Remove the 2 front fender lower rear bolts.

    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the 2 front fender reinforcement bracket-to-fender bolts.
    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the front fender rear inner wheel well bolt.
    • To install, tighten to 12 Nm (106 lb-in).

    Ford Taurus. Body

  1. NOTE: The door must be open to remove the fender-to-fender bracket bolt.

    Remove the front fender upper rear bolt.

    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the front fender upper inner bolt.
    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the front fender upper bolts.
    • To install, tighten to 12 Nm (106 lb-in).
  1. Remove the front fender.
  1. To install, reverse the removal procedure.

Cowl Panel Grille

Ford Taurus. Body

Ford Taurus. Body

  1. Remove the wiper pivot arms. For additional information, refer to Section 501-16.
  1. Remove the cowl panel grille side pin-type retainers.
  1. Disconnect the windshield washer hose connector.
  1. Remove the 2 cowl panel grille retainer clips.
  1. Release the 2 cowl panel grille pin-type retainers.
  1. NOTICE: Failure to follow the removal instruction may result in damaged retaining tabs and would require removal of the windshield glass.

    Disconnect the cowl panel grille from the retaining strip on the cowl.

    • Spread the retaining tabs.
    • Start from the driver side and work the cowl trim panel off, moving across the panel from the LH to the RH side to remove.
  1. Remove the cowl panel grille.
  1. To install, reverse the removal procedure.

Radiator Grille Support

Ford Taurus. Body

Ford Taurus. Body

Removal and Installation

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02.
  1. Remove the 2 air cleaner box intake bolts.
    • To install, tighten to 5 Nm (44 lb-in).

    Ford Taurus. Body

  1. Disconnect the hood security switch electrical connector.
  1. Release the 3 engine wiring harness pushpin clips (2 shown) from the radiator support.

    Ford Taurus. Body

  1. Remove both headlamp assemblies. Refer to Section 417-01.
  1. If equipped, remove the grille shutter assembly. Refer to Grille Shutter Assembly in this section.
  1. Remove the front bumper. Refer to Section 501-19.
  1. Remove the LH and RH radiator side air deflector pushpins and remove the side air deflectors.
  1. Remove the front impact severity sensor and release the harness pushpin clips. Refer to Section 501-20B.
  1. Remove the hood latch bolts and place the latch and cable aside.
    • To install, tighten to 12 Nm (106 lb-in).
  1. If equipped, remove the 2 power steering cooler bolts.
    • To install, tighten to 5 Nm (44 lb-in).

    Ford Taurus. Body

  1. Release the power steering cooler hose pushpin clips from the radiator support. Position and support the power steering cooler under the radiator support.
  1. Remove the 4 radiator bracket-to-frame outboard bolts and the 4 radiator bracket-to-radiator support inboard bolts (4 each side).
    • To install, tighten to 20 Nm (177 lb-in).
  1. NOTICE: When installing the cooling module retaining clips, push the cooling module retaining clips toward the radiator grille support until the clips are properly secured and a snap is heard. Failure to properly secure the cooling module retaining clips may cause damage to the radiator or the cooling module assembly.

    Release the cooling module retaining clips.

    Ford Taurus. Body

  1. Remove the 2 upper radiator grille support bolts.
    • To install, tighten to 20 Nm (177 lb-in).
  1. Remove the radiator support.
  1. To install, reverse the removal procedure.
    • Transfer all necessary components.

Grille Shutter Actuator

Removal and Installation

  1. Remove the grille shutter assembly. Refer to Grille Shutter Assembly.

    Ford Taurus. Body

    Ford Taurus. Body

    Ford Taurus. Body

    Ford Taurus. Body

    Ford Taurus. Body

  1. To install, reverse the removal procedure.

Grille Shutter Assembly

Removal and Installation

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

  1. Remove the front bumper cover. Refer to Section 501-19.

    Ford Taurus. Body

    Ford Taurus. Body

    Ford Taurus. Body

    • To install, tighten to 6 Nm (53 lb-in).

    Ford Taurus. Body

    Ford Taurus. Body

  1. To install, reverse the removal procedure.

Grille Shutter Linkage

Removal and Installation

  1. Remove the grille shutter assembly. Refer to Grille Shutter Assembly.

    Ford Taurus. Body

  1. To install, reverse the removal procedure.
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