FORD FIESTA 2007 Workshop Manual

303-00-9 Engine System - General Information 303-00-9
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
lgnition system (petrol engines
only).
CHECK the ignition system.
REFER to:
Engine
lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine
lgnition (303-07 Engine
lgnition - 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
Incorrect valve timing. CHECK and adjust the valve
timing. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), I n-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Broken or damaged timing
beltltiming chain or
pulleylsprocket.
CHECK the timing beltltiming
chain and sprocketslpulleys.
INSTALL new components as
necessary. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
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303-00-1 0 Engine System - General Information 303-00-1 0
DIAGNOSIS AND TESTING
Symptom
Very poor power output or fuel
consumption too high or engine
running rough
Possible Sources Action
Fuel system. CHECK the fuel system.
REFER to:
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Diagnosis and
I Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.3L Duratec-8V
(Rocam), Diagnosis and
Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- I .4L Duratorq-
TDCi (DV) Diesel, Diagnosis and Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.6L Duratorq-
TDCi (DV) Diesel, Diagnosis
and Testing).
Engine intake air system. CHECK the intake air system.
REFER to: lntake Air Distribu-
tion and Filtering
(303-12
lntake Air Distribution and
Filtering, Diagnosis and
Testing).
Exhaust system blocked. I CHECK the exhaust system.
REFER to: Exhaust System
(309-00 Exhaust System,
Description and Operation).
Engine management system.
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
Fault in ignition system (petrol
engines only). CHECK the ignition system.
REFER to:
Engine lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine lgnition (303-07 Engine
lgnition
- 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
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303-00-1 I Engine System - General Information 303-00-1 I
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action --
Turbocharger (diesel engine
only).
CHECK the turbocharger.
REFER to:
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.6L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
Incorrect valve timing. Timing
beltltiming sprocket or
pulleylsprocket damaged. CHECK
and adjust the
valve
timing. REFER to:
Timing
Belt (303101 Engine -
I .25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Ignition timing incorrect (petrol
engines only).
CHECK the electronic engine
controls.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
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303-00-1 2 Engine System - General Information 303-00-1 2
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Noisy running Engine auxiliary components
loose or damaged. CHECK
engine auxiliary
components for damage or
looseness. REFER to:
Timing Belt
(303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Timing Chain
(303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain
(303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing Belt
(303-01 Engine -
I .4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Noisy running, misfiring, back-
firing or knocking
Incorrect fuel DETERMINE which type of fuel
was last put in the tank (note
the country specific fuel
specifications).
Valve timing incorrect, timing
beltlchain or pulleylsprocket
damaged.
Water in fuel or fuel contamin-
ated.
CHECK and adjust the valve
timing. REFER to:
CHECK the fuel system for
water or other contamination.
Timing Belt
(303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
I n-vehicle Repair),
Crankshaft Pulley
(303-01
Engine - 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
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303-00-1 3 Engine System - General Information 303-00-1 3
DIAGNOSIS AND TESTING
Symptom
Noisy running or valve train
noise
Possible Sources Action
Valve clearance too large due
to
faulty valve tappets or worn
valve train components.
Timing
belt or timing chain
damaged.
INSTALL new hydraulic lash
adjusters or adjust the valve
clearance. REFER to:
Valve Clearance Adjustment
(303-01 Engine
- 1.25L
Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
General Procedures),
Camshaft
Followers (303-01
Engine - 1.3L Duratec-8V
(Rocam), In-vehicle Repair),
Valve Clearance Adjustment
(303-01 Engine
- 2.OL
Duratec-H E (M 14), General
Procedures),
Hydraulic Lash Adjuster (303-
01 Engine
- I .4L Duratorq-
TDCi (DV) Diesel, In-vehicle
Repair),
Camshaft (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
INSTALL a new timing belt or
timing chain. REFER to:
Timing Belt (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel,
In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 4 Engine System - General Information 303-00-1 4
DIAGNOSIS AND TESTING
Symptom
Possible Sources
Action
Timing belt or timing chain
incorrectly tensioned.
CHECK the timing belt or
timing chain tension. INSTALL
a new timing belt or timing
chain as necessary. REFER to:
Timing Belt (303-01 Engine
-
I .25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing Belt
(303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt (303-01 Engine
-
I .6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Noisy running or engine noise
Engine components
- Pistons
- Piston rings
- Connecting rod big end,
main bearing or thrust
bearing journals
- Connecting rods bent or
damaged.
CHECK the engine compon-
ents for wear or damage. Make
sure all components are within
specification. INSTALL new
components as necessary.
Engine - Oil Leaks
NOTE: Before installing new gaskets or seals, make
sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet
(UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a
suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
A WARN1NG:Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five
minutes. 4.
Switch off the engine.
N0TE:lf no leak can be found, road test the vehicle
under various loads and check the engine for leaks
again.
5. Check the engine for oil leaks using a suitable
UV lamp.
'
6. Rectify any leaks found and check the engine
for oil leaks.
Measure the compression pressure
N0TE:The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
disconnected. This error message must be deleted
from the fault memory using WDS after completing
the compression test.
(' ,
'I N0TE:Valve clearance must be set correctly before
performing a compression test. Make sure the
engine is at the normal operating temperature.
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303-00-1 5 Engine System - General Information 303-00-1 5
DIAGNOSIS AND TESTING
N0TE:The varying design of compression checking
% devices and fluctuating starter motor speeds
normally only allows for a comparison to be made
of the compression pressures in all cylinders.
Measure the compression pressure
Engine
- 1.4L Duratorq-TDCi (DV)
biesel)
1. Remove the air cleaner.
REFER to: Air Cleaner
- 1.4L Duratorq-TDCi
(DV) Diesel (303-12 Intake Air Distribution and
Filtering, Removal and
Installation). 4. Detach the exhaust gas recirculation (EGR) tube
from the cylinder block and from the EGR valve
(if equipped).
I I 2. Disconnect the fuel injector wiring harness main
connector. 5. Detach the EGR tube from the EGR cooler (if
equipped).
3. Disconnect the glow plug relay electrical
connector.
6. Remove the EGR tube from the intake manifold
assembly.
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303-00-1 6 Engine System - General Information 303-00-1 6
DIAGNOSIS AND TESTING
7. Disconnect the glow plug electrical connectors.
8. Remove the glow plugs.
9, Install a suitable compression pressure recorder
with a suitable adapter into the glow plug bore.
N0TE:Operate the starter motor until the reading
on the compression tester stops rising.
1Q Carry out the measurement in accordance with
the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter. 11.
Detach the compression tester and adapter.
I2 Install the glow plugs.
13 Connect the glow plug electrical connectors.
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303-00-1 7 Engine System - General Information 303-00-1 7
DIAGNOSIS AND TESTING
14. N0TE:Check the EGR tube O-ring seal.
Install a new seal
if necessary. I
, Install the EGR tube to the intake manifold
assembly.
18 Connect the fuel injector wiring harness main
connector.
19 Install the air cleaner.
REFER to: Air Cleaner
- 1.4L Duratorq-TDCi
15 Attach the EGR tube to the cylinder block and (DV) Diesel (303-12 Intake Air Distribution
and
to the EGR valve (if equipped). Filtering, Removal
and Installation).
Using worldwide diagnostic system (WDS), clear
the fault codes from the PCM.
Measure the compression pressure
Engine
- 1.6L Duratorq-TDCi (DV)
biesel)
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 mixtures are always
16 Attach the EGR tube to the EGR cooler (if present and can ignite. Failure to follow
equipped). these instructions may result in personal
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below
30' C,
whichever is the greater. Failure to follow
these instructions may result in personal
injury.
I. Using datalogger in world wide diagnostic
system (WDS), check that the fuel pressure has
dropped to zero and that the fuel temperature
17. Connect the glow plug relay electrical connector. has
either reached ambient temperature or is
below 30°C, whichever is the greater.
2. Raise and support the vehicle. REFER to:
(1 00-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
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303-00-1 8 Engine System - General Information 303=00-18
DIAGNOSIS AND TESTING
3. Remove the engine undershield.
4. Remove the radiator undershield.
7. Remove the engine upper cover.
<
8m ~CAUTION:DO not disconnect the fuel
injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical
connectors.
9. Detach the exhaust gas recirculation (EGR)
cooler (if equipped) and position it to one side.
5. Remove the glow plug relay.
6. Lower the vehicle.
1Q Remove the glow plug power supply.
2006.0 Fiesta 1212006 GI 52554en
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