DRIVE SHAFT FORD FIESTA 2007 Repair Manual

303-05-26 Accessory Drive 303-05-26
REMOVAL AND INSTALLATION
Accessory Drive Belt - 2.OL Duratec-HE (M14)(21 567 0)
Removal 4. Remove the accessory drive belt.
I. Disconnect the battery ground cable. 1. Rotate the accessory drive belt tensioner
For additional information, refer to: Battery counterclockwise.
Disconnect
(41 4-01 Battery, Mounting and 2. Remove the accessory drive belt.
Cables,
~eneral procedures).
-
2. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
3. Remove the crankshaft pulley splash shield.
2006.0 Fiesta 1212006 G421384en
procarmanuals.com

303-06-3 Starting System 303-06-3
DESCRIPTION AND OPERATION
Starting System
Starting system
1 tern Description
I 1 I lgnitionlstarter switch I
1 2 1 Starter relay I
1 3 1 Electric starter motor I
1 4 1 Powertrain control module (PCM) I
1 5 1 Sensor,- crankshaft position ( CKP) I
The purpose of the starting system is to turn the
engine crankshaft at a speed which enables the
engine to start.
The engine is started as follows:
Ignitionlstarter switch in position
Ill.
The starter relay is activated by the PCM .
The solenoid is supplied with voltage.
The solenoid engages the starter motor pinion
with the flywheel ring gear.
The solenoid applies battery current to the
starter.
The starter turns the crankshaft until the engine
starts. The key can then be released and it
automatically returns to position
I I.
The system incorporates the "Smart
StartingWstrategy. This makes starting faster and
protects the starter.
If the driver fails to release the key immediately
after the engine starts, the PCM interrupts
activation of the starter relay and thus switches off
the electric starter motor.
The speed signal provided by the CKP sensor is
used for monitoring the starting procedure.
2006.0 Fiesta 1212006 GI 63308en
procarmanuals.com

303-1 4-6 Electronic Engine Controls 303-1 4-6
DESCRIPTION
AND OPERATION
Item Descri~tion
1 5 1 Crankshaft Position (CKP) sensor 1
Throttle Control Unit (TCU)
1 6 ( Camshaft Position (CMP) sensor I Components
1 7 1 Heated Oxygen Sensor (H02S) I
1 8 1 Power Steering Pressure (PSP) sensor I
1 10 1 Brake Pedal Position (BPP) switch I
9 Vehicle Speed Sensor (VSS)
(only on
vehicles without Anti-lock Braking System
(ABS))
1 12 1 Clutch Pedal Position (CPP) switch I
11
1 13 1 Generator I
Accelerator Pedal Position (APP) sensor
1 14 1 Current supply relay I
1 15 1 Ignition key I -
16
17
1 20 1 Inertia fuel shut-off switch I
Battery
Powertrain Control Module (PCM)
-
18
19
1 21 1 Fuel Pump Driver Module (FPDM) I
Data Link Connector (DLC)
Fuel Pump (FP) relay
1 22 1 Fuel injectors I
23 Evaporative emissions (EVAP) solenoid
1 lvalve
1 24 1 Idle Air Control (IAC) valve 1
1 25 1 Throttle Control Unit (TCU) I
26 Air Conditioning (AIC) compressor clutch
1 I 1 blower switch
1 27 1 Injector Driver
Module (IDM) I
1 28 1 Start inhibit relay I
1 29 1 Instrument cluster I
Item Descri~tion
I I ITP sensor I
1 2 1 Electric motor I
The electronically controlled throttle control unit
(TCU) consists of the following components:
Housing
Throttle flap
Throttle flap spindle
Gear set
Electric motor with pinion
TP sensor
Stop screw
Throttle flap return spring
2006.0 Fiesta 1212006 G204204en
procarmanuals.com

303-1 4-7 Electronic Engine Controls 303-1 4-7
DESCRIPTION AND OPERATION
Function The throttle flap position is adjusted and monitored
in a closed control loop. The TP sensor provides
I A CAUTI0N:The throttle control unit (TCU)
the PCM with the information on the actual position
must not be dismantled. No adjustments
of the throttle flap.
or repairs can be made to the TCU.
Item Description
I I I stop screw I
1 2 IToothed segment I
1 3 1 Throttle flap spindle I
1 4 1 Throttle flap return spring I
1 5 1 Intermediate shaft with gear I
1 6 1 Electric motor with pinion I
The APP sensor sends the data containing the
driver's acceleration requirement to the PCM. This
information depends directly on the movement of
the accelerator pedal.
The PCM processes this information and converts
it into an output signal for the throttle control unit
(TCU). This output signal is the control for the
electric motor.
The electric motor moves the throttle flap spindle
by means of the gear set.
Standby function
If a fault develops in the throttle control unit (TCU),
a standby function is carried out. This standby
function allows a slight opening of the throttle flap, so that enough air passes through to allow limited
engine operation.
For this purpose, there is an throttle flap adjustment
screw on the throttle housing. The return spring
closes the throttle flap until the stop of the toothed
segment touches the stop screw. In this way a
defined throttle flap gap is formed for limp home
mode.
The stop screw has a spring loaded pin, which
holds the throttle flap open for limp home mode.
In normal operating mode, this spring loaded pin
is pushed in by the force of the electric motor when
the throttle flap must be closed past the limp home
position
(e.g. for idle speed control or overrun
shutoff).
CPP switch
The CPP switch is located directly on the pedal
box.
The engine management recognises gearshifts
through the CPP switch and thus improves engine
running characteristics.
The CPP switch passes a ground signal to the
PCM when the clutch pedal is depressed
(disengaged).
2006.0 Fiesta 1212006 G204204en
procarmanuals.com

303-1 4-1 5 Electronic Engine Controls 303-1 4-1 5
DIAGNOSIS AND TESTING
Monitors
The purpose of the monitors is to continuously
check the operation of the emission related sensors
and actuators. It then establishes if they are
operating within specified tolerances. All monitors
carry out their functions in such a way as to be
unnoticeable by the driver of the vehicle. Each one
is carried out under specific conditions of load,
speed and engine temperature. The Comprehensive Component Monitor, Combustion
Misfire Monitor and
AirIFuel Ratio Monitor operate
continuously. The remaining monitors are only
invoked under certain operating conditions. On
diesel variants, all of the monitors operate under
normal driving conditions: There are no monitors
which intervene and cause special operating
modes to enable the monitors to work. Some diesel
monitors are non-continuous. This means that in
a drive cycle, monitoring is done as and when
suitable driving conditions exist and potential faults
are accumulated and compared with acceptance
criteria. Examples of this type are the turbocharger
boost pressure and exhaust gas recirculation
(EGR) monitors on vehicles with common rail fuel
injection.
( Comprehensive Component Monitor (CCM)
When the CCM detects a component operating out
of tolerance, it sets a Diagnostic Trouble Code
(DTC), which is stored in the EEPROM. If the same
concern is confirmed during the next trip the MIL
will be switched on. The CCM monitors many
components, sub-systems and signals. The
following is a list of those that can effect emissions
depending on application:
Electronic Ignition (El) System.
Crankshaft Position (CKP) Sensor.
Ignition Coil.
Electronic Throttle Control Unit.
Camshaft Position (CMP) Sensor.
Air Conditioning
(AIC) Clutch.
Idle Air Control (IAC) Valve.
Mass Air Flow (MAF) Sensor.
Manifold Absolute Pressure (MAP) Sensor.
Intake Air Temperature (IAT) Sensor.
Engine Coolant Temperature (ECT) Sensor.
Cylinder Head Temperature (CHT) Sensor.
Heated Oxygen Sensor
(H02S).
Catalyst Monitor Sensor.
Charge Air Temperature Sensor.
Knock Sensor (KS).
Throttle Position (TP) Sensor.
Vehicle Speed Sensor (VSS).
Boost Pressure Sensor.
Cam-Crank Phasing Sensor.
EEPROM.
High Pressure Fuel Injection Pump.
Exhaust Gas Recirculation (EGR) Valve Monitor.
Fuel Injectors.
Turbocharger.
Combustion Noise Monitor.
Barometric Pressure (BARO) Sensor.
Combustion Misfire Monitor (All except vehicles
with diesel engine)
The combustion misfire monitor operates independently of the others, and can detect misfires
caused by the ignition system, fuel system or
mechanical engine components. As each cylinder
fires, a characteristic crankshaft acceleration is
produced. The monitor detects irregularities in the
acceleration pattern using the crankshaft position (CKP) sensor, thus detecting the misfire. It can
also detect which cylinder has misfired.
Combustion misfires can be categorized as follows:
Type
A: These can cause catalytic converter
damage due to excessive internal temperatures.
If a certain number of misfires occur over a
pre-determined number of engine revolutions, the
MIL will be switched on to alert the driver of the
concern.
Type B: These can lead to an increase in emissions
to a point above the EOBD threshold. If the misfire
is detected during a second trip, over a,
pre-determined number of engine revolutions, the
MIL will be switched on. If the misfire does not
occur over the next three trips, the MIL will be
extinguished
AirIFuel Ratio (AFR) Monitor (All except vehicles
with diesel engine)
The H02S fitted before the catalytic converter
(upstream) measures the oxygen content of the
exhaust gas and the variations in it. This then
enables the PCM to adjust the opening times of
the fuel injectors to maintain the correct AFR. This
is known as Short Term Fuel Trim (STFT). If the
same variation is registered a pre-determined
number of times, a permanent correction factor is
applied. This is known as Long Term Fuel Trim
(LTFT), which is stored in the EEPROM. When the
correction factors exceed pre-determined limits a
DTC will be set in the EEPROM. If a concern is
2006.0 Fiesta 1212006 G384566en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
DESCRIPTION AND OPERATION
The TCC is engaged depending on the current
driving situation when the selector lever is in
I position "D" and 3rd or 4th gear is engaged. When
4th gear is disabled
(OID Off) the TCC is
engaged in 3rd gear depending on the current
driving situation.
Fluid pump and stator shaft
Item Description It sucks up transmission fluid from the oil pan,
1
2
3
2006.0 Fiesta 1212006 G380521 en
Fluid pump housing
4 builds
up the oil pressure and then supplies it under
high pressure to the main control body.
Inner rotor, fluid pump
Outer rotor, fluid pump The
fluid pump is driven by the crankshaft via the
torque converter housing.
transmission housing.
The fluid pump is a G-rotor oil pump.
The stator shaft is bolted to the fluid pump. It
engages via teeth in the stator of the torque
converter and acts as a support for the latter.
Stator
shaft The
fluid pump housing is bolted to the
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40) 307-01 -8
DESCRIPTION AND OPERATION
Planetary
gearset
Description The following connections exist between the
/ individual components:
small sun gear - short planet gears - long planet
Long planet gear gears- annulus,
3 Small sun gear large sun gear - long planet gears - annulus.
4
5
The output always flows through the annulus.
6
2006.0 Fiesta 1212006 ~380521 en
Short planet gear
Transmission input shaft The different transmission ratios
are selected by
actuating and releasing the individual clutches and
brakes.
shaft via the corresponding clutch either onto the
A Ravigneaux planetary gearset is a two-stage
small sun gear (1st - 3rd gear) or the planet gear gearset with a shared planet gear carrier and one carrier (3rd and 4th gear) or the large sun gear annulus. (reverse gear).
Large sun gear
The drive is transmitted from the transmission input
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -1 2 Transmission (AW81-40) 307-01 -1 2 --
DESCRIPTION AND OPERATION
Item Description The output wheel of the planetary gearset drives
I 1 I Output wheel, planetary gearset
2
I I 1
The annulus of the planetary gearset is fixedly Any differences in rotational speed between the
connected to the output
wheel of the planetary two halfshafts are compensated by the differential.
gearset.
the input wheel of the intermediate gear stage.
3
4
Main control body
Output wheel, intermediate gear stage
Item Descri~tion The hydraulic lines and pressures are electronically
The output
wheel of
the intermediate gear stage [<.
drives the spur gear of the differential assembly.
Differential assembly
Input wheel, intermediate gear stage The
differential assembly transmits the torque
via
the halfshafts to the front wheels.
In addition, the manual selector slide in the main
control body provides a hydraulic emergency
running programme which
allows the vehicle to be
Manual selector lever driven in 3rd aear with the selector lever in position
.
1
Shift timing solenoid valve
5
2006.0 Fiesta 1212006 ~380521 en
regulated by a proportional solenoid valve (main
regulating valve) and four shift solenoid valves.
1 6 1 SSA shift solenoid valve
SSB
shift solenoid valve
transmission control unit-fail. -
"D", "2" or "ll'and in reverse gear with the selector
lever in position "R if key components or the
The hydraulic pressure is distributed to the The
manual selector slide is actuated by the driver
individual clutches and brakes in the main control via the selector lever, the selector lever cable, the
body. selector shaft lever and the internal gearshift
mechanism.
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -1 9 Transmission (AW81-40) 307-01 -1 9
DESCRIPTION AND OPERATION
1 2 I Transmission input shaft I
Item Description The planet gear carrier (6) is held by the I st gear
1 3 1 I st - 3rd gear clutch I
I 1 I From the torque converter
1 4 1 Small sun gear I
one-way clutch (5).
1 5 1 1st gear one-way clutch I
1 6 1 Planet gear carrier I
1 7 Reverse gear brake I
1 8 1Short planet gear I
1 9 1 Long planet gear I
1 0 Annulus
and output wheel of the planetary
1 1 gearset
vllntermediate gear stage I
1 12 1 Differential assembly I
N0TE:ln selector lever position "1 " the planet gear
carrier is also held by the reverse gear brake
(7)
(engine braking).
The short planet gears (8) are driven by the small
sun gear in the opposite direction of rotation to the
output from the engine.
The short planet gears drive the long planet gears
(9) in the same direction of rotation as the output
from the engine.
The long planet gears drive the ring gear (10) in
the same direction of rotation as the output from
the engine.
The annulus is fixedly connected to the output
wheel of the planetary
gearset and drives the
intermediate gear stage (1 1
) in the opposite
direction of rotation to the output from the engine.
I B I Planetary gearset, front I the output from the engine.
A
Drive is transmitted from the torque converter (1)
to the transmission input shaft (2) and via the
/ 1st-3rd gear clutch (3) to the small sun gear (4).
2006.0 Fiesta 1212006 G380528en
Planetary gearset, rear The intermediate gear stage drives
the differential
assembly (12) in the same direction of rotation as
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -21 Transmission
(AW81-40) 307-01 -21
DESCRIPTION AND OPERATION
Item Description
111lst gear clutch I
I
1 4 1 Small sun gear I
--
I
2
1 9 1 Long planet gear I
From the torque converter
Transmission input shaft
6 8
10 Annulus
and output wheel of the planetary
I lgearset
Planet gear carrier
Short planet gear
I 11 I Intermediate gear stage I
1 12 1 Differential assembly I
The large sun gear (15) is held by the 2nd gear
one-way clutch (14) and the 2nd-4th gear brake
(1 3).
N0TE:ln selector lever position "2" the large sun
gear is also held by the 4th gear brake (1 6) (engine
braking).
The short planet gears (8) are driven by the small
sun gear in the opposite direction of rotation to the
output from the engine.
The short planet gears drive the long planet gears
(9) in the same direction of rotation as the output
from the engine.
The long planet gears are supported by the large
sun gear which is being held, and they drive the
planet gear carrier (6) in the same direction of
rotation as the output from the engine.
The long planet gears drive the ring gear (10) in
the same direction of rotation as the output from
the engine.
The annulus is fixedly connected to the output
wheel of the planetary
gearset and drives the
A
1st-3rd gear clutch (3) to the small sun gear (4).
B
2006.0 Fiesta 1212006 G380528en
direction of rotation to the output from the engine.
Planetary gearset, rear intermediate
gear stage (1 1 ) in the opposite
Drive is transmitted from the torque converter (1 ) assembly (12) in the Same direction of rotation as
to the transmission input shaft (2) and via the the
output from the engine.
Planetary
gearset, front
The intermediate gear stage drives the differential I
procarmanuals.com