clutch FORD FIESTA 2007 Owner's Guide

303-01 B-I17 Engine - 2.OL Duratec-HE (M14) 303-01 B-117
INSTALLATION
37. Using the special tool, connect the steering
Connect the clutch slave cylinder supply
gear to power steering fluid reservoir return
line.
I I line to the power steering fluid reservoir. Install the spring clip.
38.
Attach the steering gear to power steering 41. Connect the reversing lamp switch
fluid reservoir return line support bracket
electrical connector.
to the generator.
42. Lower the vehicle.
39. Connect the A/C low pressure switch
connector. 43. Install the coolant expansion tank.
40a &AUTION:I~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
2006.0 Fiesta 1212006 ~451291 en
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303-01 8-1 20 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 20
INSTALLATION
57. Connect the cooling fan motor and cooling
fan resistor electrical connectors.
58. Install the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
59. Adjust the gearshift cables.
For additional information, refer to:
Gearshift Cable Adjustment (308-00
Manual
Transmission/Transaxle and
Clutch
- General Information, General
Procedures).
60. Bleed the hydraulic clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
61. Install the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and Installation).
62. Install the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (3031 2
Intake Air Distribution and Filtering,
Removal and Installation).
63. Fill and bleed the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 2.OL Duratec-HE
(M14), General Procedures).
2006.0 Fiesta 1212006 G451291 en
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Fuel Charging and Controls - 2.OL
303-048-23 Duratec-HE (M14) 303-04B-23
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
Fuel system leak(s). CHECK the system for fuel
leak(s). REPAIR or INSTALL
new parts as necessary.
I Fuel filter blocked. I INSTALL a new fuel filter. I
Incorrect engine oil.
INSTALL a new oil filter and
engine oil.
I Generator. 1. REFER to WDS. I
EGR valve sticking open. REFER to: Engine Emission
Control (303-08 Engine
Emission Control
- 2.OL
Duratec-HE (M 14), Diagnosis
and Testing).
Slipping
clutch. REFER to: Manual Transaxle
and Clutch (308-00,
Diagnosis and Testing).
ECT 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.
PCM calibration. Using WDS, CHECK for the
availability of a calibration
update.
--
I . Incorrect valve timing. I CHECK the valve timing. I
Engine cuts out during hard
acceleration
Low cylinder compression.
CMP sensor. CHECK
the engine compres-
sion.
Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
CKP sensor. Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
Fuel rail fuel pressure sensor.
REFER to: Fuel System Pres-
sure Check (31
0-OOA,
General Procedures).
Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
Low fuel system pressure.
2006.0 Fiesta 1212006 GI 65371 en
Check the fuel system pres-
sure.
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303-05-1 7 Accessory Drive 303-05-1 7
DIAGNOSIS AND TESTING
REFER to: Accessory Drive Belt Tensioner -
1.6L Duratorq-TDCi (DV) Diesel, Vehicles i With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and lnstallation).
TEST the system for normal operation.
2. Detach the accessory drive belt in the area of
the accessory drive belt tensioner.
3. N0TE:The accessory drive belt tensioner
has a damping feature, which is usually a
friction device, therefore some friction within
the system is normal.
Using the correct tool, move the accessory drive
belt tensioner from its relaxed position through
its full stroke and back to the relaxed position
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley
and check for damage, freedom of rotation and
alignment. INSTALL a new accessory drive belt
tensioner as necessary.
Accessory Drive Belt Tensioner - Dynamic
Check
The accessory drive belt tensioner may be checked
dynamically as follows:
1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the
A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or
A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner -
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and lnstallation).
( :I. REFER to: Accessory Drive Belt Tensioner - TEST the system for normal operation.
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
2. Excessive accessory drive belt rideout (uneven
With: Air Conditioning (303-05, Removal and
depth of grooves in the accessory drive belt)
Installation). may cause excessive accessory drive belt
REFER to: Accessory Drive Belt Tensioner
- tensioner movement. Check the condition by
1.6L Duratorq-TDCi (DV) Diesel (303-05
installing a new accessory drive belt.
Accessory Drive, Removal and
installation). . REFER to: Accessory Drive Belt - 1.3~
TEST the system for normal operation. Duratec-8V (Rocam) (303-05 Accessory
Drive,
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner.
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal operation. Removal and Installation).
REFER to: Accessory Drive Belt
- 1.4L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive, Removal and Installation).
REFER to: Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive, Removal and Installation).
REFER to: Accessory Drive Belt
- 2.OL
Duratec-H E (M 14) (303-05 Accessory Drive,
Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 12/2006 G346263en
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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
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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
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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 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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303-1 4-20 Electronic Engine Controls 303-1 4-20
DIAGNOSIS AND TESTING
1 PO643 1 Transmission sensor power supply 1 high voltage I
MIL Code
PO641
PO642
1 PO646 1 Air conditioning (NC) clutch relay circuit low voltage I
1 PO647 1 NC clutch relay circuit high voltage I
Description
Transmission sensor power supply 1 noisy signal
Transmission sensor power supply
I low voltage
I PO651 I Transmission sensor power supply 2 noisy signal I
i
PO652
PO653
Transmission sensor power supply 2 low voltage
Transmission sensor power supply
2 high voltage
PO654
PO686
1 PO692 1 Cooling fan 1 control circuit high voltage I
Engine run output circuit malfunction
Main relay malfunction low voltage
PO687
PO691
1 PO693 1 Cooling fan 2 control circuit low voltage I
Main relay malfunction high voltage
Cooling fan
1 control circuit low voltage
1 PO694 1 Cooling fan 2 control circuit high voltage I
I PI500 I Vehicle speed sensor (VSS) output circuit malfunction I
PO704
PI 000
Generator command malfunction I
Clutch switch implausible signal
EOBD system readiness test not complete
I P2107 I Safety failure level 3 I
PI 794
P2100
I P2108 I Safety failure level 2 error I
Battery voltage malfunction too high or too low
Engine throttle body H-bridge malfunction
APP sensor circuit 1 high input I
P2119
P2122
1 P2127 1 APP sensor circuit 2 low input I
Engine throttle body throttle flap malfunction
Accelerator pedal position (APP) sensor circuit
1 low input
1 P2128 1 APP sensor circuit 2 high input I
1 P2176 1 Engine throttle body adaptive algorithm failed 1
P2128
P2135
APP sensor circuits I and 2 plausibility error
TP sensor circuits 1 and 2 plausibility error
I UOOOl I Control Area Network (CAN) bus-off or mute I
P2280
P2282
I UOlOl I CAN missing frame from TCU I
Air cleaner obstruction or leakage
Air leakage between throttle and inlet valves
2006.0 Fiesta 1212006 G384566en
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Automatic Transmission/Transaxle .
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
SECTION 307-01 Automatic Transmission/Transaxle
. Vehicles With: 4-Speed Automatic Transmission
(AW81-40)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications
........................................................................\
.............................................. 307-0 1 -3
DESCRIPTION AND OPERATION
Automatic Transaxle
........................................................................\
...................................
Transmission cross-section ........................................................................\
........................
Torque converter with Torque Converter Clutch (TCC) ......................................................
Fluid pump and stator shaft ........................................................................\
........................
........................................................................\
......... Planetary gearset ......................... .:
Clutches and brakes ........................................................................\
...................................
Intermediate gear stage and differential assembly .............................................................
Main control body ........................................................................\
.......................................
Internal' gearshift mechanism ........................................................................\
.....................
Fluid circuit ........................................................................\
.................................................
........................................................................\
....................................... Identification Tags
Type plate
........................................................................\
...................................................
Transmission Ranges and Power Flow ........................................................................\
......
Transmission ratio and power flow route - 1st gear ............................................................
Transmission ratio and power flow route - 2nd gear ..........................................................
Transmission ratio and power flow route . 3rd gear ...........................................................
Transmission ratio and power flow route . 4th gear ...........................................................
Transmission ratio and power flow route . reverse gear ....................................................
Transaxle Electronic Control System ........................................................................\
..........
........................................................................\
..................................................... Overview
Transmission control unit
........................................................................\
............................
........................................................................\
.................................... Gearshift strategies
Selector lever positions
........................................................................\
..............................
Signal transmission on the CAN databus ........................................................................\
...
........................................................................\
...................................................... Sensors
........................................................................\
.................................................... Actuators
DIAGNOSIS AND TESTING
Automatic Transaxle
........................................................................\
................................... 307-01
Inspection and Verification ........................................................................\
.................... 307-01
Diagnostic Trouble Code Chart
........................................................................\
.................. 307-01
........................................................................\
...................................... Line Pressure Test 307-01
Stall Speed Test
........................................................................\
....................................... 307-01
Time Lag Test
........................................................................\
............................................. 307-01
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