Brakes/Engine Controls - High Pedal Effort at High Alt.
TSB 06-18-509/18/06
INCREASED BRAKE PEDAL EFFORTS REQUIRED ON
INITIAL STOPPING AFTER COLD START AT HIGH
ALTITUDE
FORD:
2005-2007 Focus
This article supersedes TSB 05-16-13 to update the vehicle model years.
ISSUE
Some 2005-2007 Focus vehicles, equipped with the 2.0L 4V (non PZEV) engine, may require increased brake pedal efforts during initial stopping after cold starts at high altitude (5,000 feet and above). This may be caused by reduced engine vacuum supply at the brake booster.
ACTION
DO NOT PERFORM THIS TSB FOR BRAKE CONCERNS OTHER THAN INCREASED BRAKE PEDAL EFFORTS AT HIGH ALTITUDES (5,000 FEET AND ABOVE). Install an aspirator assembly and reprogram the powertrain control module (PCM) to the latest calibration using IDS release B43.16 and higher, or B44.8 and higher. This new calibration is not included in the B44 CD. Calibration files may also be obtained at the website. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE BRAKE ASPIRATOR SERVICE FIX WAS ONLY DESIGNED FOR THE 2.0L NON PZEV ENGINE.
1. Disconnect the brake booster vacuum hose and check valve at the brake booster.
2. Disconnect the brake booster vacuum hose at the intake manifold. Refer to Workshop Manual (WSM), Section 303-01.
3. Disconnect the brake booster vacuum hose retainer clip from the valve cover stud.
4. Remove the brake booster vacuum hose and check valve assembly and discard.
5. Disconnect the vent tube from the air cleaner outlet pipe. Refer to WSM, Section 303-01.
6. Remove the two (2) clamps on both ends of the air cleaner outlet pipe and remove the air cleaner outlet pipe and discard.
NOTE
DO NOT DISCARD THE AIR CLEANER OUTLET PIPE CLAMPS AS THEY WILL BE REUSED IN STEP 7.
7. Install the new air cleaner outlet pipe included with the aspirator assembly, Part Number 554Z-9C490-AA, and insert the vent pipe. Refer to WSM, Section 303-01 (Figure 1).
8. Insert the aspirator assembly brake booster vacuum line into the intake manifold. Refer to WSM, Section 303-01 (Figure 1).
9. Insert the aspirator assembly brake booster vacuum line into the brake booster (Figure 1).
NOTE
THE NEW ASPIRATOR ASSEMBLY DOES NOT INCLUDE A CHECK VALVE AT THE BRAKE BOOSTER END OF THE VACUUM LINE. THE CHECK VALVE IS NOW LOCATED INTERNALLY IN THE ASPIRATOR ASSEMBLY AND IS NO LONGER NEEDED AT THE BRAKE BOOSTER END OF THE VACUUM LINE. BE CAREFUL NOT TO PUSH THE GROMMET INTO THE BRAKE BOOSTER WHEN INSTALLING THE VACUUM LINE.
10. Insert the aspirator assembly retaining clip onto valve cover stud (Figure 1).
11. Reprogram the PCM to the latest calibration using IDS release B43.16 and higher, or B44.8 and higher. This new calibration is not included in the B44 CD. Calibration files may also be obtained at the website.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061805A 2005-2007 Focus 2.0L 4V: 0.6 Hr.
Replace The Aspirator
Assembly And Reprogram
The Powertrain Control
Module (Do Not Use With
12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9C482 42
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