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Lincoln Aviator 2020-2026 Service Manual / Body and Paint / Body and Paint / Body Repairs - General Information / General Procedures - Welding Precautions

Lincoln Aviator: Body Repairs - General Information / General Procedures - Welding Precautions

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  WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

  WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

NOTICE: SRS components should always be depowered and disconnected before beginning any welding procedure.

NOTICE: Electronic modules and related wiring can be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.

NOTICE: EV (Electric Vehicle), HEV and PHEVcontain a HVTB (High Voltage Traction Battery). Before welding near the HVTB, the HVTB must be removed to avoid heat damage.

  1. A test weld should always be carried out on a test sample.
  1. The correct protective clothing should always be worn.
  1. Always work in a well ventilated area to avoid accumulation of noxious and oxygen displacing gases.
  1. Place protective covers around components and wiring harnesses to protect from welding spatter.
  1. Use grinding discs and wire brushes dedicated to the type of material being welded.
  1. Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used. ER70S-3 or ER70S-6 wire is typically used for MIG welding on steel.
  1. Disconnect and isolate battery ground cable.
  1. Components made of Boron, Martensitic, HSS (high-strength steel) and UHSS (ultra high-strength) steel should not be heated to straighten or repair. Severely bent or kinked components should be replaced with new ones.
  1. Factory welds may be substituted with either STRW (squeeze-type resistance welding) spot welds or MIG plug welds.
  1. MIG plug welds must equal factory welds in both location and quantity.
  1. MIG plug weld holes should equal 8 mm (0.31 in) diameter.
  1. Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld location.
  1. Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
  1. Use of a weld-through primer is recommended where applicable.
  1. When welding, always place the ground clamp as close as possible to the weld area.
  1. Never connect the welder ground clamp to the vehicle subframe.
  1. Never weld a vehicle subframe, steering or suspension component. Service is through replacement only.

    General Procedures - Plastic Repairs

    Materials Name Specification Plastic Bonding AdhesiveTA-9 -  Inspection NOTE: Plastics Identification   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information...

    Body Repairs - Vehicle Specific Information and Tolerance Checks

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    Lincoln Aviator 2020-2026 Service Manual: Diagnosis and Testing - Evaporative Emissions


    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).   Diagnostic Trouble Code Chart Module   DTC Description Action   PCM P00FE:00 EVAP System Tank Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P043E:00 EVAP System Leak Detection Reference Orifice Low Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P043F:00 EVAP System Leak Detection Reference Orifice High Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P0442:00 EVAP System Leak Detected (Small Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0443:00 EVAP System Purge Control Valve A Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0446:00 EVAP System Vent Control Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0451:00 EVAP System Pressure Sensor / Switch A Circuit Range / Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P0452:00 EVAP System Pressure Sensor / Switch A Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P0453:00 EVAP System Pressure Sensor / Switch A Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P0454:00 EVAP System Pressure Sensor / Switch A Circuit Intermittent: No Sub Type Information   GO to Pinpoint Test HX   PCM P0455:00 EVAP System Leak Detected (Large Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0456:00 EVAP System Leak Detected (Very Small Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0457:00 EVAP System Leak Detected (Fuel Cap Loose / Off): No Sub Type Information   GO to Pinpoint Test HX   PCM P0460:00 Fuel Level Sensor A Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0461:00 Fuel Level Sensor A Circuit Range/Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P0462:00 Fuel Level Sensor A Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P0463:00 Fuel Level Sensor A Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P0496:00 EVAP System High Purge Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EA:00 EVAP System Small Leak Detected - Fuel Tank Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EB:00 EVAP System Small Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04ED:00 EVAP System Large Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EE:00 EVAP System Very Small Leak Detected - Fuel Tank Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EF:00 EVAP System Very Small Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04F0:00 EVAP System High Load Purge Line A Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P144A:00 EVAP System Purge Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P144B:00 EVAP System Secondary Purge Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P144C:00 EVAP System Purge Flow Performance During Boost: No Sub Type Information   GO to Pinpoint Test HX   PCM P1450:00 Unable To Bleed Up Fuel Tank Vacuum: No Sub Type Information   GO to Pinpoint Test HX   PCM P2401:00 EVAP System Leak Detection Pump Control Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P2402:00 EVAP System Leak Detection Pump Control Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P2418:00 EVAP System Switching Valve Control Circuit/Open: No Sub Type Information   GO to Pinpoint Test HX   PCM P2450:00 EVAP System Switching Valve Performance/Stuck Open: No Sub Type Information   GO to Pinpoint Test HX   PCM P2451:00 EVAP System Switching Valve Stuck Closed: No Sub Type Information   GO to Pinpoint Test HX   PCM P24B9:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Range/Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BA:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BB:00 EVAP System Leak Detection Pump Pressure Sensor Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BC:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Intermittent: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BE:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BF:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P24C0:00 EVAP System Leak Detection Pump Vacuum Switching Valve Stuck On: No Sub Type Information   GO to Pinpoint Test HX   PCM P24C1:00 EVAP System Leak Detection Pump Vacuum Switching Valve Performance/Stuck Off: No Sub Type Information   GO to Pinpoint Test HX   PCM P260F:00 EVAP System Monitoring Processor Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P2DDA:00 EVAP System Leak Detection Pump Performance/Stuck Off: No Sub Type Information   GO to Pinpoint Test HX   PCM P2DDB:00 EVAP System Leak Detection Pump Stuck On: No Sub Type Information   GO to Pinpoint Test HX Global Customer Symptom Code (GCSC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

    Lincoln Aviator 2020-2026 Service Manual: General Procedures - Cylinder Bore Taper


    Check NOTE: Refer to the appropriate Section 303-01 for the specification. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper...

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    Child Seats

    Lincoln Aviator. Child Seats

    Use a child restraint (sometimes called an infant carrier, convertible seat, or toddler seat) for infants, toddlers and children weighing 40 lb (18 kg) or less (generally four-years-old or younger).

    Using Lap and Shoulder Belts

    WARNING: Do not place a rearward facing child restraint in front of an active airbag. Failure to follow this instruction could result in personal injury or death.

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