cam FORD FIESTA 2007 Workshop Manual

303-06-7 Starting System 303-06-7
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I A3: CHECK CIRCUIT 29-BB17 (OGIBK) FOR OPEN I
I Ignition switch in position 0. I
I rn Disconnect Starter Relay C423. I
Measure the voltage between starter relay C423
pin 3, circuit
29-8817 (OGIBK), harness side
Is the voltage greater than 10 volts?
+ Yes
REPAIR circuit 50-BB10 (GYIBK). TEST the
system for normal operation.
+ No
REPAIR circuit 29-BB17 (OGIBK). TEST the
system for normal operation.
I A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN I - - --
Measure the resistance between the starter
motor casing and battery
1 ground terminal.
Is the resistance less than 0.5 ohms?
+ Yes
INSTALL a new starter motor.
REFER to: Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-06 Starting System, Removal
and Installation)
I Starter Motor - 1.4L Duratorq-TDCi (DV)
Diesel (303-06 Starting System, Removal
and
Installation).
INSPECT the starter motor gear for damage.
INSTALL a new starter motor as necessary.
+ No
CLEAN and TIGHTEN all battery and engine
ground cable connections. TEST the system
for normal operation.
PINPOINT TEST B : THE ENGINE DOES NOT CRANKIRELAY DOES NOT CLICK
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
B1: CHECK THE SWITCHED POWER TO THE STARTER RELAY
Disconnect Starter Relay C423.
rn lgnition switch in position Ill.
2006.0 Fiesta 1212006 GI 51 301 en
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303-06-1 0 Starting System 303-06-1 0
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
Measure the voltage between the starter motor
terminal 30, component side and the battery
positive
terminal.
Is the voltage less than 0.5 volts?
+ Yes
GO to C2.
+ No
CLEAN and TIGHTEN all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery to starter motor
solenoid cable.
REFER to: Battery to Starter Motor Solenoid
Cable - 1.3L Duratec-8V (Rocam) (41 4-01
Battery, Mounting and
Cables, Removal and
Installation)
1 Battery to Starter Motor Solenoid Cable -
1.25L Duratec-1 6V (Sigma)/l.4L Duratec-
16V (Sigma)/l.6L Duratec-1 6V (Sigma)
(414-01 Battery, Mounting and
Cables,
Removal and Installation).
Test the system for normal operation. - - ---
I C2: CHECK FOR GROUND CONNECTION
-
I f
Ignition switch in position Ill.
Is the voltage less than 0.5 volts?
-, Yes
CHECK the battery.
REFER to: Charging System (414-00 Char-
ging System
- General Information,
Diagnosis and Testing).
TEST the system for
normal operation.
+ No
CLEAN and TIGHTEN all battery ground cable
connections, starter motor mounting and body
to ground straps. TEST the system for
normal
operation. If the concern persists, INSTALL a
new battery ground
cable. Testlhe system for
normal operation.
2006.0 Fiesta 1212006 GI 51 301 en
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303-06-1 I Starting System 303-06-1 1
REMOVAL AND INSTALLATION
Starter Motor - 1.3L Duratec-8V (Rocam)/l.25L Duratec-I 6V
I \, (Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma)(26 204 0)
Removal
I. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and
Cables].
2. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
3. Disconnect the ignition switch to starter
motor solenoid and battery to starter motor
solenoid cables (oil filter shown removed for
clarity).
4. Remove the starter motor retaining bolts and
remove the starter motor.
, Installation
I. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G210046en
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-08A-1 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-08A-1
SECTION 303-08A Engine Emission Control - 1.3L
Duratec-8V (Rocam)/lm25L Duratec-I 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V (Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................\
............................................. 303-08A-2
DESCRIPTION AND OPERATION
Engine Emission Control ........................................................................\
............................ 303-08A-3
Positive Crankcase Ventilation (PCV)
- 1.3L Duratec 8V .................................................. 303-08A-3
PCV
- 1.4Ll1.6L Duratec 16V ................................. ...................... .............................. 303-08A-5
DIAGNOSIS AND TESTING
Engine Emission Control.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-08A-6
Inspection and Verification
........................................................................\
.......................... 303-08A-6
i Symptom Chart.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-08A-6
REMOVAL AND INSTALLATION
Crankcase Vent Oil Separator ........................................................................\
.................... 303-08A-7
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
SPECIFICATIONS
Torque Specifications
Description
Crankcase vent oil separator retaining bolts
2006.0 Fiesta 1212006 GI 4821 9en
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
DESCRIPTION AND OPERATION
Engine Emission Control
Positive Crankcase Ventilation (PCV) - 1.3L Duratec 8V
Overview
Side view Item Description
2006.0 Fiesta 1212006 GI 67099en
Item Description From Evaporative Emission (EVAP)
solenoid valve
1
2
Cylinder head cover with integrated oil
separator
From PCV valve
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-08A-4 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-08A-4
DESCRIPTION AND OPERATION
PCV valve
Sectional view
Item Description
Deflection panel
Side view
item Description
I I 1 Spring I I 1 I Deflection plate I
1 2 1 pistons I
The PCV valve is located on the upper side of the
cylinder head cover.
The crankcase gases are sucked by the PCV valve
into the intake manifold.
The PCV valve is opened by the vacuum in the
intake manifold.
The amount of crankcase gases depends on the
engine speed. The quantity sucked in is determined
by the spring and the shape of the piston. The deflection plate
is integrated into the cylinder
head cover.
It prevents oil from being sucked in and burned in
the combustion process.
The oil drops condense on the deflection plate and
are then returned to the oil circuit.
2006.0 Fiesta 1212006 GI 67099en
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-08A-5 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-08A-5
DESCRIPTION AND OPERATION
PCV
- 1.4Ll1.6L Duratec 16V
Description The crankcase gases are freed of oil in the valve
cover and in the PCV oil separator in order to
prevent the oil from being sucked in and burned.
housing The
PCV valve is located in the PCV oil separator.
The amount of crankcase gases depends on the
engine speed.
The crankcase gases
are sucked
by the PCV valve
into the intake manifold. 3
4
2006.0 Fiesta 1212006 GI 67099en
Hose from PCV oil separator to intake
manifold
intake manifold.
PCV
oil separator with integral PCV valve The
PCV valve is opened by the vacuum in the
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-I 6V (Sigma)
DIAGNOSIS AND TESTING
Engine Emission Control
lnspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
damage.
3. If an obvious cause for an observed or reported
Visual lnspection Chart
I 1 concern is found, correct the cause (if possible)
I Mechanical I before proceeding to the next step.
. -
Symptom Chart
Positive crankcase ventilation (PCV) valve
PCV separator
Symptom Chart
Symptom
Excessive crankcase pressure
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Oil in the air intake system Possible
Sources
Blocked PCV valve.
Blocked PCV separator.
Blocked PCV hose.
Restriction in PCV separator.
PCV valve permanently open. Action
CLEAN
or INSTALL new PCV
components as necessary.
TEST the system for normal
operation. If the concern
persists, REFER to
Section 303-00 [Engine
System
- General Information].
CLEAN or INSTALL a new
PCV separator. TEST the
system for normal operation.
-
INSTALL a new PCV valve.
TEST the system for normal
operation.
2006.0 Fiesta 1212006 Gl48220en
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Engine Emission Control - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llm4L
303-O8A-7 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-0844-7
REMOVAL AND INSTALLATION
Crankcase Vent Oil Separator
i
Removal
1. Remove the air cleaner. For additional
information, refer to Section
303-1 2 [Intake
Air Distribution and Filtering].
2. Remove the intake manifold. For additional
information, refer to Section 303-01A
[Engine
-- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)llm6L Duratec-1 6V
(Sigma)] I 303-01 B [Engine -- 1.4L
Duratorq-TDCi (DV) Diesel] I 303-01 C [Engine
-- 1.3L Duratec-8V (Rocam)] I 303-01 D
[Engine
-- 2.OL Duratec-HE (M14)I 1 303-01 E
[Engine
-- 1.6L Duratorq-TDCi (DV) Diesel].
3. Remove the crankcase vent oil separater.
Discard the gasket.
Installation
I. N0TE:lnstall a new crankcase vent oil
separator gasket.
To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G210048en
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