charging FORD FIESTA 2007 Service Manual

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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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-25 Duratec-HE (M14) 303-04B-25
REMOVAL AND INSTALLATION
Item 5 Air cleaner outlet pipe and resonator from
the air cleaner and remove the air
1. Detach the air cleaner outlet pipe resonator cleaner
outlet pipe.
Installation Details
Ifem 7 Throttle body
N0TE:Do not fully tighten the throttle body
retaining bolts at this stage.
I. Install each throttle body retaining bolt three
full turns by hand.
Item 7 Throttle body
1. Tighten the throttle body retaining bolts in
the sequence shown.
2006.0 Fiesta 1212006 G421320en
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Fuel Charging and Controls - 2.OL
Duratec-HE (M14)
REMOVAL AND INSTALLATION
Fuel Injectors(23 455 0)
1. Remove the fuel injection supply manifold.
For additional information, refer to Fuel
Injection Supply Manifold
- in this section.
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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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Fuel Charging and Controls - 2.OL
Duratec-HE (M14)
REMOVAL AND INSTALLATION
Description Item Description
See Removal Detail
See Removal Detail
Fuel charging wiring harness retaining clip
Item Description I . WARNINGS:
or near any fuel related components.
Highly flammable vapors are always
present and may ignite. Failure to follow
these instructions may result in personal
7
8
I I iniurv.
Fuel rail retaining bolts
Fuel rail A Do not smoke or carry lighted tobacco or
open flame of any type when working on
11
Removal Details
1 12 1 Fuel injectors
Item 1 Fuel charging wiring harness retaining
clip
Fuel injector O-ring seals
See Installation Detail
always observe fuel handling precautions.
1. Detach the fuel charging wiring harness
retaining clip from the intake manifold.
I w
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
Failure to follow these instructions may
5. To install, reverse the removal procedure.
result in personal injury.
2006.0 Fiesta 1212006 G421322en
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Fuel Charging and Controls - 2.OL
303-04B-29 Duratec-HE (M14) 303-04B-29
REMOVAL AND INSTALLATION
Item 5 Fuel rail fuel supply line
, 1. Disconnect the fuel supply line from the fuel rail.
For additional information, refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
Item 6 Fuel charging wiring harness retaining
clip
1. Detach the fuel charging wiring harness
retaining clip from the fuel rail retaining bolt.
Item 10 Fuel injector retaining clips
1. Remove the fuel injector retaining clips.
Installation Details
item 11 Fuel injector O-ring seals
1. Lubricate the fuel injector O-ring seals with
clean engine oil.
Discard the fuel injector retaining clips.
- --
2006.0 Fiesta 1212006 G421322en
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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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303-06-5 Starting System 303-06-5
DIAGNOSIS AND TESTING
Symptom
The engine cranks slowly
Unusual starter noise
The starter spins but the engine
does not crank
Possible Sources Action
Relay.
Battery.
Starter motor.
Starter motor.
Flywheel ring gear.
Starter motor.
Flywheel ring gear.
CARRY OUT the relay
Component Test. REFER to
the wiring diagrams.
GO to Pinpoint Test B.
REFER to: Charging System
(414-00 Charging System
-
General Information,
Diagnosis and Testing).
CARRY OUT the starter motor
Component Test using WDS.
GO to Pinpoint Test C.
REMOVE the starter motor.
REFER to: (303-06 Starting
System)
Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-I 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) (Removal and
Installation),
Starter Motor - 1.4L Duratorq-
TDCi (DV)
Diesel (Removal
and Installation).
INSPECT the starter motor
gear for damage. INSTALL a
new starter motor as neces-
sary.
INSPECT the flywheel for
damage.
REMOVE the starter
motor.REFER to: (303-06
Starting System)
Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma) (Removal and
Installation),
Starter Motor - 1.4L Duratorq-
TDCi (DV)
Diesel (Removal
and Installation).
INSPECT the starter motor
gear for damage. INSTALL a
new starter motor as neces-
sary.
INSPECT the flywheel for
damage.
2006.0 Fiesta 1212006 Gl51301en
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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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