engine coolant FORD FIESTA 2007 Workshop Manual

Fuel Charging and Controls - 2.OL
303-048-1 0 Duratec-HE (M14) 303-04B-10
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Fuel rail fuel pressure sensor. Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
Fuel injectors. INSPECT
the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
I Incorrect valve timing. I CHECK the valve timing. I
Poor starting
Low cylinder compression.
Low fuel system pressure.
TEST the cylinder compres-
sion.
Check the fuel system pres-
sure.
REFER to: Fuel System Pres-
sure Check (31
0-OOA,
General Procedures).
Fuel system leak. CHECK the system for fuel
leak(s). REPAIR the system as
necessary.
Fuel system restriction. INSPECT the
fuel system.
INSTALL new components as
necessary. TEST the system
for normal operation.
I Fuel filter blocked. I INSTALL a new fuel filter. I
lncorrect engine oil.
Air
cleaner element blocked.
INSTALL a new engine oil filter
and engine oil.
INSTALL a new air cleaner
element.
lncorrect power steering fluid. DRAIN and REFILL the
power
steering system with the correct
fluid.
REFER to: Power Steering
System Flushing
- Vehicles
With: Electro-Hydraulic Power
Steering (EHPS) (21 1-00,
General Procedures).
2006.0 Fiesta 1212006 GI 65371 en
CKP sensor.
Engine coolant temperature
(ECT) sensor. Carry out a
full engine
diagnosis using the guided
diagnostic menu in WDS.
Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
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Fuel Charging and Controls - 2.OL
303-04B-19 Duratec-HE (M14) 303-04B-19
DIAGNOSIS AND TESTING
White smoke
Possible Sources Action
Incorrect or contaminated fuel. CHECK for signs of contamina-
tion such as strange odors from
the fuel tank.
If contaminated fuel is found,
DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(31
0-OOA, General Proced-
u res).
INSTALL a new fuel filter.
INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
INSTALL a new fuel injection
supply manifold.
REFER to: Fuel Injection
Supply Manifold
(303-04C,
Removal and Installation).
Coolant in the combustion
chamber. CARRY OUT a cooling system
pressure test.
REFER to: Engine Cooling
(303-03C, Diagnosis and
Testing).
REMOVE the cylinder head.
INSPECT the cylinder head,
cylinder head gasket and
cylinder bores for wear or
damage. REFER to: Cylinder Head (303-
01
C, In-vehicle Repair).
2006.0 Fiesta 1212006 GI 65371 en
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303-0514 Accessory Drive . 303-05-4
DESCRIPTION AND OPERATION
Accessory Drive - 2.OL Duratec-HE (M14)
2.OL Duratec HE (M14) engine
,
Item Description
I 1 I Accessory drive belt 1
1 2 1 Power steering pump pulley I
1 3 1 Coolant pump pulley I
1 4 1 Air conditioning (AIC) compressor pulley I
1 5 1 Crankshaft pulley I
1 6 1 Accessory drive belt tensioner pulley I
1 7 1 Generator pulley I
2006.0 Fiesta 1212006 G421383en
8
---
Accessorydrivebeltidlerpulley
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Engine Emission Control - 2.OL Duratec-HE
(MI41
REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve
1. Drain the cooling system.
For additional information, refer to: Cooling
Special
Tool(s) 3.
Remove the air cleaner intake tube.
System Draining, Filling and Bleeding
24003
(303-03 Engine cooling - 2.01 Duratec-HE
(M14), General Procedures).
4. Using the special tool, disconnect the
2. Remove the air cleaner outlet pipe.
radiator upper coolant hose from the coolant
outlet connector.
Removerllnstaller, Coolant
Hose Clamp
303-397
5. Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G421887en
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Engine Emission Control - 2.OL Duratec-HE
(MI41
REMOVAL AND INSTALLATION
I
' Item Description
I 1 I EGR valve electrical connector I
I * 1
EGR valve coolant hose
See Removal Detail
6. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G421887en
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303-1 4-2 Electronic Engine Controls 303-1 4-2
SPECIFICATIONS
I Powertrain control module (PCM) retaining bolts I 3 I - I 27 I
Torque Specifications - vehicles with 1.3L Duratec-8V (Rocam) engine
I Knock sensor (KS) retaining bolt I 20 I 15 I - I
Description
I Crankshaft position (CKP) sensor retaining bolt I 10 I - I 89 I
I Camshaft position (CMP) sensor retaining bolt I
I Throttle position (TP) sensor screws I 5 I - I 44 I
Ib-in I/ Nm
I Idle air control (IAC) valve retaining bolts I 10 I - I 89 I
I b-ft
Ignition coil pack retaining bolts
Exhaust manifold heatshield retaining
bolts
Torque Specifications - vehicles with 1.25L Duratec-1 6V (Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-I 6V (Sigma) engine
Heated oxygen sensor (H02S)
Catalyst monitor sensor (CMS)
I Powertrain control module (PCM) retaining bolts I 3 I - I 27 I
6
10
I Knock sensor (KS) retaining bolt I 20 I 15 I - I
47
47
-
-
I Camshaft position (CMP) sensor retaining bolt I 10 I - I 89 I
53
89
35
35
Cylinder head temperature (CHT) sensor
Crankshaft position (CKP) sensor retaining bolt
I Engine coolant temperature (ECT) sensor I 20 I 15 I - I
-
-
I Idle air control (IAC) valve I 10 I - I 89 I
25
10
I Heated oxygen sensor (H02S) I 47 I 35 I - I -- --
I Catalyst monitor sensor (CMS) 47 I 35 1 - I
18
-
-
89
Powertrain control module (PCM) retaining nuts
and retaining bolts
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine
1 Timing belt upper cover retaining bolts I 4 I - I 35 I
I Timing belt lower cover retaining bolts I 6 I - I 53 I
l b-in
Description
I Camshaft position (CMP) sensor retaining bolt I 5 I - I 44 I
I Crankshaft position (CKP) sensor retaining bolt I 8 I - I 71 I
Nm
I Crankshaft pulley retaining bolt I a I - I - I
I b-ft
I- .
For additional information, refer to: Crankshaft Position (CKP) Sensor - 1.4L Duratorq-Ci D) Diesel (303-14 Electronic Engine ''
I Controls, Removal and Installation).
2006.0 Fiesta 1212006 Gl48226en
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303-1 4-5 Electronic Engine Controls 303-1 4-5
DESCRIPTION AND OPERATION
Item Description Item Description
2006.0 Fiesta 1212006 G204204en
I 1 I Temperature and Manifold Absolute
2 3 1 Knock Sensor (KS)
pressure (T-MAP) sensor
Throttle Position (TP) sensor
4 Sensor - Engine Coolant Temperature
(ECT)
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303-1 4-1 1 Electronic Engine Controls 303-1 4-1 I
DESCRIPTION AND OPERATION
Item Description Components
MAPT sensor
Manifold absolute pressure and
temperature (MAPT) sensor
1 2 1 Camshaft position (CMP) sensor I
1 3 1 Knock sensor (KS) I
vl~Ame%air temperature sensor I
1 5 1 Instrument cluster I
1 6 1 Battery I
1 7 1 Spark plug wires I
1 8 1 Exhaust gas recirculation (EGR) valve I
1 9 1 Fuel pump module I
1 10 1 Fuel rail and fuel injectors I
I 11 I Intake manifold tuning valve solenoid The
MAPT sensor is attached to the housing of the
intake manifold valve behind the throttle body. The
signal from the MAPT sensor is used to modify the
ignition and fuel delivery.
1 12 1 Accelerator pedal position (APP) sensor
1 13 1 Clutch pedal position (CPP) switch
1 14 1 Brake pedal position (BPP) switch
CMP sensor 1 15 1 Stoplamp switch
1 16 1 Power steering pressure (PSP) switch I
1 17 1 Catalyst monitor sensor I
FIGted oxygen sensor (H02S) I
1 19 1 Generator (input signal) I
1 20 1 Crankshaft position (CKP) sensor I
1 21 1 Engine coolant temperature (ECT) sensor I
22 Throttle position
(TP) sensor (part of
I I throttle body)
1 23 1 Powertrain control module (PCM) I The CMP sensor is located on the right-hand side
of the valve cover above the intake camshaft. The
CMP sensors send signals to the PCM which are
then used by the PCM to calculate the position of
the camshaft.
2006.0 Fiesta 1212006 G422229en
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303-1 4-1 4 Electronic Engine Controls 303-1 4-1 4
DIAGNOSIS AND TESTING
Electronic Engine Controls
General Equipment
I Worldwide Diagnostic system (WDS)
Principles of Operation
For Principles of Operation on the electronic
accelerator control system
REFER to: Acceleration Control (31
0-02A,
Diagnosis and Testing).
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the
powertrain control module (PCM). This system
continuously monitors vehicle emission
components. The system includes a malfunction
indicator lamp (MIL) which indicates when there is
a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC
memory can be accessed using a generic scan
tool or WDS.
EOBD is mandated within European Union
regulations from the year 2000 for passenger
vehicles with petrol engines and from 2003 onwards for passenger vehicles with diesel
engines.
EOBD Functions:
Establishes when and how emissions control
faults must be indicated.
Actuates emission control malfunction indicator
lamp (MIL) and fault memory.
Indicates operating conditions in which the
concern occurred (freeze frame data).
Standardized output of operating data such as
engine speed, engine coolant temperature etc.
Standardized names and abbreviations for
components and systems.
Standardized
DTCs for all manufacturers.
Standardized communication with the diagnostic
equipment.
Standardized 16-pin data link connector (DLC)
in area of the instrument panel.
Concern display must be possible using a
generic scan tool.
EOBD consists of the following elements:
Warm-up Cycle C'
The warm-up cycle is an operation that consists of
key on, engine start and a coolant temperature
increase of
22"C, exceeding 71 OC on completion.
Drive Cycle
A drive cycle commences when the engine is
started (cold or warm) and ends when the engine
is switched off.
Trip
A trip begins when the engine is started and is
complete when all the EOBD monitors have
completed a self-test. This may take place over a
number of drive cycles. On diesel variants, the
information gathered from one drive cycle is not
carried over to a subsequent cycle or cycles.
When a concern has been rectified, particularly
after electronic engine control components have
been changed, the DTC memory, which is part of
the EEPROM must be cleared of all trouble codes.
When the DTC memory has been cleared, the code
.
PI000 (known as the readiness code) is set in the
PCM memory, which indicates that since the
EEPROM has been cleared, not all of the
monitoring systems have completed their tests.
PI000 can only be cleared by carrying out a trip,
which includes driving the vehicle under variable
conditions of speed, load and time so that all of the
monitors are completed. As
PI000 will not
illuminate the MIL it is not necessary to carry out
the trip before returning the vehicle to the customer.
Freeze Frame Data
When a concern is detected, various data is stored
depending on application including:
Diagnostic trouble code.
Vehicle speed.
Engine coolant temperature.
Engine speed.
Engine load.
Mixture formation trim value (trim value for
engine wear) (All except vehicles with diesel
engine).
State of oxygen sensor control (open and closed
loop) (All except vehicles with diesel engine).
Distance covered since the concern was first
registered.
2006.0 Fiesta 1212006 G384566en
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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
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