oil FORD FIESTA 2007 Workshop Manual

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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Engine Emission Control - 2.OL Duratec-HE
303-08B-1 (MI41 303-08B-1
1 SECTION 303-08B Engine Emission Control - 2.OL
Duratec-HE (M14)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................\
.......................................... 303-088-2
DESCRIPTION AND
OPERATION
Engine Emission Control ........................................................................\
............................ 303-088-3
DIAGNOSIS AND TESTING
Engine Emission Control ........................................................................\
...................... 303-088-6
Inspection and Verification
........................................................................\
........................ 303-088-6
Symptom Chart
........................................................................\
.......................................... 303-088-6
REMOVAL AND INSTALLATION
,, Exhaust Gas Recirculation (EGR) Valve ........................................................................\
.... 303-088-8
Crankcase Vent Oil Separator
............................. ........................................................... 303-088-1 0
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Engine Emission Control - 2.OL Duratec-HE
(MI41
SPECIFICATIONS
Toraue Specifications
I Description I Nm I Ib-ft I Ib-in I/
I Exhaust gas recirculation (EGR) valve bolts I 25 I 18 I - I\
2006.0 Fiesta 12/2006 G37567en
EGR valve outlet tube union
Crankcase vent oil separator retaining bolts 55
10
41
-
-
89
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Engine Emission Control - 2.OL Duratec-HE
303-08B-4
(MI41 303-08B-4
DESCRIPTION AND OPERATION
Item Description two hoses. One PCV hose connects the PCV valve
to the intake manifold, the other PCV hose
2
3
The positive crankcase ventilation (PCV) system
consists of a valve mounted in the crankcase vent
oil separator (attached to the cylinder block) and
connects the valve cover to the air cleaner. 1
4
2006.0 Fiesta 1212006 G37563en
Positive crankcase ventilation (PCV) valve
PCV hose
Crankcase vent oil
se~arator
Under idle and part throttle conditions, the
crankcase vapor flows through the intake manifold
Crankcase vent oil separator retaining
bolt into the combustion chambers where the vapor is
burnt during combustion.
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Engine Emission Control - 2.OL Duratec-HE
303-08B-6
(MI41 303-08B-6
DIAGNOSIS AND TESTING
Engine Emission Control
lnspection and Verification
General Equipment Visual Inspection Chart L..
I. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Worldwide Diagnostic System
(WDS)
- Hose(s)/hose joints
- Gasket(s)
- Positive crankcase
ventilation (PCV)
valve
- PCV separator
Mechanical
- Exhaust gas recircu-
lation (EGR) valve
Electrical
- Electrical
con
nector(s)
- Wiring harness
- Fuse(s)
- Relay
- EGRvalve
- Powertain control
module (PCM)
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 concern is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Symptom Possible Sources Action
I
Poor engine performance EGR valve.
Using WDS, CHECK the EGR
Valve Duty Cycle input signal
I to the EGR vacuum regulator
valve. If the result is 0%,
REMOVE the EGR valve.
REFER to Exhaust Gas Recir-
culation (EGR) Valve
- in this
section.
INSPECT the EGR valve and
valve seat for damage. Make
sure that the EGR valve is in
the closed position. If the EGR
valve is not closed. INSTALL
a
new EGR valve. TEST the
system for normal operation. If
the result is not 0% continue
the engine diagnostic using
WDS.
2006.0 Fiesta 1212006 G334290en
Excessive crankcase pressure Blocked or damaged PCV
hose(s).
Blocked crankcase vent oil
separator. CHECK
the PCV system
components for blockages, CLEAN or INSTALL new
components as necessary.
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Engine Emission Control - 2.OL Duratec-HE
303-08B-10 (MI41 303-08B-10
REMOVAL AND INSTALLATION
Crankcase Vent Oil Separator
Removal
I. Remove the intake manifold. For additional Discard the gasket.
information, refer to Section 303-OIA
[Engine
-- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I 6V (Sigma)ll .6L Duratec-I 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)] 1 303-01 E
[Engine
-- 1.6L Duratorq-TDCi (DV) Diesel].
2. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV valve.
Installation
I. N0TE:lnstall a new crankcase vent oil
separator gasket.
To
install, reverse the removal procedure.
3. Remove the PCV
valve from the crankcase
vent
oil separator.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.
4. Remove the crankcase vent oil separator.
- - --
2006.0 Fiesta la2006 G37566en
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303-1 2-8 Intake Air Distribution and Filtering 303-1 2-8
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Oil in the air intake system Blocked or damaged positive
crankcase
ventilation (PCV)
valve.
Blocked or damaged PCV
pipe(s)/hose(s).
Blocked or damaged crankcase
vent
oil separator.
Vehicles with 1.25L Duratec-
16V
(Sigma)/l.3L Duratec-8V (
(Rocam)/l.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) engine.
REFER to: Crankcase Vent
Oil
Separator (303-08 Engine
Emission
Control - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L
Duratec-1
6V (Sigma),
Removal and Installation).
Vehicles with 2.0L Duratec-HE
(M14) engine.
REFER to: Crankcase Vent
Oil
Separator (303-08C Engine
Emission
Control - 2.OL
Duratec-HE (M14), Removal
and Installation).
Turbocharger (Vehicles with
Duratorq-TDCi (DV)
Diesel
engine or 1.6L Duratorq-TDCi
(DV)
Diesel engine).
Vehicles with 1.4L Duratorq-
TDCi (DV)
Diesel engine.
REFER to: Turbocharger (303- 04
Fuel Charging and
Controls - Turbocharger -
1.4L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
Vehicles with I .6L Duratorq-
TDCi (DV)
Diesel engine.
REFER to: Turbocharger
- I .6L
Duratorq-TDCi (DV)
Diesel
(303-04 Fuel Charging and
Controls - Turbocharger -
1.6L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
Water in the air cleaner Detached air cleaner intake
pipe. CHECK
the air cleaner intake
pipe for security. INSTALL new
intake air system components
as necessary. TEST the
system for
normal operation.
Blocked air cleaner drain. CLEAN
the air cleaner drain.
TEST the system for
normal
operation.
Engine lacks power
Air cleaner element blocked. INSPECT the air cleaner for ,.
new air cleaner element as
i signs of blockage. INSTALL a .
necessary. I_
2006.0 Fiesta 1212006 G421937en
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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 4-3 Electronic Engine Controls 303-1 4-3
SPECIFICATIONS
control module (PCM) retaining nuts
and retaining bolts
Torque
Specifications
- vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine
I Camshaft position (cMP) sensor retaining bolt I 5 I - I 44 I
lb-in
Timing belt upper cover retaining bolts
Timing belt lower cover retaining bolts
I Crankshaft position (CKP) sensor retaining bolt I 8 I - I 71 I
Ib-ft Description
I Crankshaft pulley retaining bolt I a I - I - I
Nm
4
6
I For additional information, refer to: Crankshaft Position (CKP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel (303-14 Electronic Engine I
I Controls, Removal and Installation). I
-
-
Torque Specifications - vehicles with 2.OL Duratec-HE (M14) eng 35
53
I Description I Nm
ine
I Powertrain control module
(PCM) retaining bolts I 10 I - I 89 I
I PCM mounting bracket retaining bolts I 25 I 18 I - I
I Knock sensor (KS) retaining bolt I 20 I 15 I - I
I Crankshaft position (CKP) sensor retaining bolt I 7
'1 Camshaft position (CMP) sensor retaining bolt I 6
I Ignition coil pack retaining bolts I 6 I - I 53 I
I Exhaust manifold heatshield retaining bolts I 10 I - I 89 I
2006.0 Fiesta 1212006 GI 48226en
-- -
Heated oxygen sensor (H02S)
Catalyst monitor sensor (CMS) 47
47
35
35
-
-
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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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