Electrical FORD FIESTA 2007 Workshop Manual

Fuel Charging and Controls - 1.25L
Duratec-1 6V (Sigma)llI4L Duratec-1 6V
303-04A-7 (Sigma)llI6L Duratec-1 6V (Sigma) 303-04A-7
REMOVAL AND INSTALLATION
Fuel Injection Supply Manifold(23 450 0)
Removal
WARNINGS:
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury.
5. Disconnect the fuel injector electrical
connectors and position the wiring harness
to one side.
1. Release the fuei system pressure. For
additional information, refer to 6. Disconnect the vacuum line from the fuel
Section
31 0-00 [Fuel System - General pressure
regulator.
Information].
2. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and
Cables].
3. Remove the air cleaner. For additional
information, refer to Section
303-12 [Intake
Air Distribution and Filtering].
4. Remove the positive crankcase ventilation
(PCV) hose.
7. N0TE:Fuel supply line connectors are white
or are identified by a white band. Fuel return
line connectors are red or are identified by
a red band.
2006.0 Fiesta 1212006 GI 89083en
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Fuel Charging and Controls - 2.OL
303-04B-6 Duratec-HE (M14) 303-04B-6
DIAGNOSIS AND TESTING
1 6 1 Heated Oxygen sensor (H02s) I
Item Description Fuel supply
1 7 1 Intake manifold I
5
Fuel injectors
Throttle body
The fuel supply for all petrol fueled variants is
equipped with a return-less fuel system. This
means that the fuel delivery pressure at the fuel
injectors, is monitored and controlled by the fuel
tank module. This control is achived by switching
the fuel pump on and off.
The fuel pump module for both the Ethanol E85
TO maintain the same or similar power output to variant vehicle and the unleaded fueled vehicle are
that of the unleaded fuel vehicle, the fuel injectors
very similar, visual^ the only difference is the fuel
have been replaced with high flow fuel injectors. pump electrical connections which on the Ethanol
E85 variant is sealed. This is not the only
differance, both fuel pump modules have different
(
Fuel composition monitoring fuel level sensor resistor card values.
The quantity of Ethanol E85 in relation to the
quantity of unleaded fuel contained in the fuel tank
at any one time is not monitored at the fuel tank.
The Ethanol percentage volume can only decrease
from its maximum 85% (pure Ethanol
E85), to zero
(1 00% unleaded fuel).
The fuel charging system compensates for the
changes in fuel composition using the signal
received by the power train control module (PCM)
from the
H02s. The PCM adapts the fueling and
ignition calibrations to suit the current fuel tank
content composition.
Cold start
To overcome the problems relating to cold start
inherent with Ethanol E85 vehicles (temperatures
down to -29 degrees centigrade), a block heater
has been installed into the engine coolant system.
The block heater is located to the rear of the engine
under the exhaust manifold. The block heater is
fitted with a dedicated harness which terminates at an external plug connector fitted into the radiator
grill.
2006.0 Fiesta 1212006
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Fuel Charging and Controls - 2.OL
303-04B-8 Duratec-HE (M14) 303-04B-8
DIAGNOSIS AND TESTING
lntake manifold
item Description
I 1 I Intake manifold tuning (IMT) swirl plates I Inspection and Verification
121
lntake manifold runner control (IMRC)
throttle plates
The intake manifold for both Ethanol
E85 and
standard unleaded fueled vehicles is the same
construction.
Built into the intake manifold, are the
IMRC throttle
plates and IMT swirl plates.
Under low demand throttle conditions, the air
charge is delivered to the cylinder head intake ports
through the primary air intake chambers. The clean
flow of the air charge is disturbed by the IMT swirl
plates to assist in the mixing of the air fuel mixture
at the fuel injectors.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual lnspection Chart
I Mechanical I Electrical I
- Fuel leak(s)
- Vacuum line(s)
- Gasket(s)
- Seal(s)
- Fuel injector(s)
- Throttle body
- Fuel rail
- Powertrain control
module (PCM)
- Wiring harness
- Electrical
connector(s)
- Throttle body
- Fuel injector(s)
2006.0 Fiesta 1212006 GI 65371en
During high demand throttle conditions, the IMRC
throttle plates are opened and the air charge is - Fuel supply line
allowed to use both primary and secondary intake
chambers. This means a higher volume of air 3. If an obvious cause for an observed or reported
charge can be accommodated by the intake concern
is found, correct the cause (if
possible) (
before proceeding to the next step. \. . manifold. During this high demand throttle
condition, the IMT swirl plates are fully open so as
4. If the cause is not visually evident, verify the
not to restrict the air charge flow.
symptom and refer to the Symptom Chart.
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Fuel Charging and Controls - 2.OL
303-04B-24 Duratec-HE (M14) 303-04B-24
REMOVAL AND INSTALLATION
Throttle Body
1. Remove the components in the order
indicated in the following
illustration(s) and
tablelsl.
Item Description Item Description
See Removal ~etaii-
1 7 I Throttle body 1 4. Turn the ignition key to the OFF position.
1
2 I I
2. To install, reverse the removal procedure.
3
4
5
6
Removal Details
8
Air cleaner intake pipe retaining clip
Air cleaner intake pipe
Item 2 Air cleaner intake pipe
See Installation Detail
Throttle body gasket
Air cleaner outlet pipe retaining clip
Air cleaner outlet pipe retaining clip
Air cleaner outlet pipe and resonator
See Removal Detail
Throttle body electrical connector
1. Detach the air cleaner intake pipe from the
air cleaner intake pipe duct.
3. N0TE:Do not press the accelerator pedal
during the initialization period as this will
prevent the complete initialization of the
throttle body.
Turn the ignition key to position
II and wait
for one minute to initialize the throttle body.
2006.0 Fiesta 1212006 G421320en
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Fuel Charging and Controls - 2.OL
303-04B-27 Duratec-HE (M14) 303-04B-27
REMOVAL AND INSTALLATION
Fuel Rail
Materials Name Specification
I Engine Oil - 5W-30 I WSS-~2~91 3-B I
WARNINGS:
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapors are always
present and may ignite. Failure to follow
these instructions may result in personal
injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury.
1. Release the fuel system pressure.
For additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System
- General Information, General
Procedures).
2. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
3. Remove the air cleaner assembly.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (303-1 2
intake Air Distribution and Filtering,
Removal and Installation).
4. Remove the components in the order
indicated in the following
illustration(s) and
table(s).
Item Description Item Description
Fuel charging wiring harness retaining clip
See Removal Detail
Fuel charging wiring harness electrical
connector
2006.0 Fiesta 1212006 G421322en
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303-05-1 4 Accessory Drive 303-05-1 4
DIAGNOSIS AND TESTING
Symptom
N0TE:Squeal is defined as a
continuous shriek, most noticeable
when the engine is being acceler-
ated or with electrical load.
Accessory drive belt squeal
N0TE:Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt whine
Possible Sources Action
Accessory drive belt tensioner
worn, damaged or contamin-
ated with oil.
Poor surface finish on
accessory drive belt idler pulley
flat
surface(s).
CHECK the accessory drive
belt tensioner for correct opera
tion, damage or contamination.
REFER to the Accessory Drive
Belt Tensioner Component
Test in this procedure.
INSTALL a new accessory
drive belt tensioner as neces-
sary.
REFER to: Accessory Drive
Belt Tensioner
- 1.6L
Duratorq-TDCi (DV) Diesel,
Vehicles With: Air Condi-
tioning (303-05, Removal and
Installation)
1 Accessory Drive Belt
Tensioner
- I .6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal
operation.
REMOVE the accessory drive
belt.
REFER to: Accessory Drive
Belt
- 1.3L Duratec-8V
(Rocam) (303-05 Accessory
Drive, Removal and Installa-
tion)
1 Accessory Drive Belt - 1.4L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt Tensioner
- 1.6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal
and Installation)
I Accessory Drive Belt - 2.OL
Duratec-H E (M14) (303-05
Accessory Drive, Removal
and Installation).
INSPECT the idler
pulley(s) for
surface finish. INSTALL a new
idler
pulley(s) as necessary.
TEST the system for normal
operation.
2006.0 Fiesta 1212006 G346263en
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303-06-4 Starting System 303-06-4
DIAGNOSIS AND TESTING
Starting System
Refer to Wiring Diagrams Section 303-06, for
schematic and connector information.
General Eaui~ment
I Worldwide Diagnostic System (WDS) I
Electrical
Electrical connector(s)
Relay
Central junction box (CJB)
Switch(es)
Battery
Starter motor
Powertrain Control Module (PCM)
lnspection and Verification
I. Verify the customer concern.
2. Visually inspect for obvious signs of electrical
damage.
Visual lnspection Chart
Symptom Chart
Electrical
Fuse(s)
Wiring harness
Symptom
The engine does not crank/the
relay does click 3.
If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the
The engine does not crank/the
relay does not click symptom
and refer to the Symptom Chart.
Possible Sources Action
Battery. REFER to: Charging System
(414-00 Charging System
-
General Information,
Diagnosis and Testing).
1
Starter motor. CARRY OUT the starter motor
I Component Test using WDS.
Relay. CARRY OUT the relay
Component Test. REFER to
the wiring diagrams.
I Circuit(s). I GO to Pinpoint Test A. I
I PCM. I REFER to WDS. I
Battery. REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
Fuse. INSTALL a new fuse as
necessary. If the fuse fails
again check for short to ground.
Passive anti-theft system
(PATS). REFER to: Anti-Theft - Passive
(41 9-01 Anti-Theft
- Passive,
Diagnosis and Testing).
I
Starter motor. CARRY OUT the starter motor(
I Component Test using WDS.
I Ignition switch. I GO to Pinpoint Test B. I
2006.0 Fiesta la2006 GI 51 301 en
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303-06-6 Starting System 303-06-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Pinpoint Tests
The starter stops cranking the
engine before the engine starts
N0TE:Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A
: THE ENGINE DOES NOT CRANKITHE REWY DOES CLICK
PCM.
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
I A1 : CHECK VOLTAGE TO STARTER SOLENOID I
I I Ignition switch in position Ill. I
Measure the voltage between starter motor
terminal 50, harness side and ground.
Is the voltage greater than I0 volts?
+ Yes
GO to
A2.
+ No
GO to A3.
1~2: CHECK THE VOLTAGE DROP I
Measure the voltage between starter motor
terminal 30, component side and the battery
positive
terminal.
Is the voltage less than 0.5 volts?
+ Yes
GO to A4.
+ No
CLEAN and TIGHTEN
all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery starter motor
solenoic
cable.
REFER to: Battery to Starter Motor Solenoid
Cable - 1.3L Duratec-8V (Rocam) (41 4-0 1
Battery, Mounting and
Cables, Removal and
Installation)
I Battery to Starter Motor Solenoid Cable -
1.25L Duratec-I 6V (Sigma)ll.4L Duratec-
1
6V (Sigma)ll .6L Duratec-1 6V (Sigma)
(414-01 Battery, Mounting and
Cables,
Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 GI 51 301 en
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303-06-1 2 Starting System 303-06-1 2
REMOVAL AND INSTALLATION
Starter Motor - 2.OL Duratec-HE (M14)
/'
I. Disconnect the battery ground cable. 2. Raise and support the vehicle. (.. . ,,
For additional information, refer to: Battery For additional
information, refer to: Lifting
Disconnect
(414-01 Battery, Mounting and (1 00-02 Jacking and Lifting, Description
Cables, General Procedures). and
Operation).
3. Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G421390en
Item Description Item Description I I I 1 Starter motor electrical connectors
See Removal Detail
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303-06-1 3 Starting System 303-06-1 3
REMOVAL AND INSTALLATION
Item Description Item Description
I I 4. To install, reverse the removal procedure.
I See Installation Detail
2
Removal Details
1 3 1 Starter motor
Item 1 starter motor electrical connectors Item 3 Starter motor
Starter motor wiring harness support
bracket
1. Disconnect the ignition switch and battery 1. Discard the starter motor gasket.
to starter motor solenoid cables.
See Removal Detail
See Installation Detail
Installation Details
Item 1 Starter motor electrical connectors Item 3 Starter motor
1. N0TE:Clean the electrical connectors before 1. N0TE:Clean the mating surfaces before
connecting the cables. Failure to follow this
installing the new starter motor
gasket. - - instruction may cause a high resistance
between the electrical connectors and the Install
a new starter motor gasket into the
starter motor solenoid. transaxle
housing prior to installing the
starter motor.
Connect the ignition switch and battery to
starter motor solenoid cables.
2006.0 Fiesta 1212006 G421390en
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