battery FORD FIESTA 2007 Repair Manual

303-06-7 Starting System 303-06-7
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I A3: CHECK CIRCUIT 29-BB17 (OGIBK) FOR OPEN I
I Ignition switch in position 0. I
I rn Disconnect Starter Relay C423. I
Measure the voltage between starter relay C423
pin 3, circuit
29-8817 (OGIBK), harness side
Is the voltage greater than 10 volts?
+ Yes
REPAIR circuit 50-BB10 (GYIBK). TEST the
system for normal operation.
+ No
REPAIR circuit 29-BB17 (OGIBK). TEST the
system for normal operation.
I A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN I - - --
Measure the resistance between the starter
motor casing and battery
1 ground terminal.
Is the resistance less than 0.5 ohms?
+ Yes
INSTALL a new starter motor.
REFER to: Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-06 Starting System, Removal
and Installation)
I Starter Motor - 1.4L Duratorq-TDCi (DV)
Diesel (303-06 Starting System, Removal
and
Installation).
INSPECT the starter motor gear for damage.
INSTALL a new starter motor as necessary.
+ No
CLEAN and TIGHTEN all battery and engine
ground cable connections. TEST the system
for normal operation.
PINPOINT TEST B : THE ENGINE DOES NOT CRANKIRELAY DOES NOT CLICK
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
B1: CHECK THE SWITCHED POWER TO THE STARTER RELAY
Disconnect Starter Relay C423.
rn lgnition switch in position Ill.
2006.0 Fiesta 1212006 GI 51 301 en
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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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303-06-1 I Starting System 303-06-1 1
REMOVAL AND INSTALLATION
Starter Motor - 1.3L Duratec-8V (Rocam)/l.25L Duratec-I 6V
I \, (Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma)(26 204 0)
Removal
I. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and
Cables].
2. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
3. Disconnect the ignition switch to starter
motor solenoid and battery to starter motor
solenoid cables (oil filter shown removed for
clarity).
4. Remove the starter motor retaining bolts and
remove the starter motor.
, Installation
I. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G210046en
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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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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 4-9 Electronic Engine Controls 303-1 4-9
DESCRIPTION AND OPERATION
If one potentiometer fails, the engine will run with
reduced power (maximum torque
80 Nm), if both
potentiometers fail, the engine will run with reduced
power (maximum torque
55 Nm).
This warning may also be indicated if the engine
does not start. The cause may be a poor state of
charge of the battery.
The warning indication normally disappears once
the battery is re-charged.
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 2 Electronic Engine Controls 303-1 4-1 2
DESCRIPTION AND OPERATION
Powertrain control module (PCM) The KS detects engine vibrations caused by knock
and produces an output voltage signal in proportion
, to the knock. The PCM uses the voltage signal to(
control knock by retarding the ignition timing.
The powertrain control module is located within the
engine compartment below the battery and is
secured to the left-hand chassis rail by means of
a mounting bracket. On right-hand drive vehicles
the PCM is protected by a security shield which is
secured to the retaining bracket by a shear-head
bolt. In order to disconnect the PCM electrical
connectors it is necessary to remove the security
shield.
The PCM monitors and processes the signals from
the sensors and compares these with stored
parameters. The PCM uses this information to
calculate the output signals to the actuators.
Communications between the PCM and other
control units (for example, the stability assist and
the instrument cluster) including the DLC for
diagnosis of the system, take place on the
controller area network (CAN).
Intake manifold tuning valve solenoid
The solenoid for the intake manifold tuning system
is located on the transmission side of the cylinder
head.
Vacuum is supplied by a central vacuum
connection from the intake manifold.
The solenoid for the intake manifold tuning system
is supplied with either the maximum voltage or zero
voltage,
i.e. the valves are either fully open or fully
closed.
Actuation depends on the engine speed and the
engine load.
Diagnosis can be carried out through the DLC
using the Worldwide Diagnostic System (WDS)
BPP switch
diagnostic equipment.
Knock sensor (KS)
The BPP switch and the stoplamp switch are tt(r located on the pedal box and provide the PCM with
the information that the brake pedal has been
pressed and that the vehicle is therefore being
The knock sensor is located on the cylinder block decelerated.
between cylinders
2 and 3.
2006.0 Fiesta 1212006 G422229en
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Electronic Engine Controls
DIAGNOSIS AND TESTING
I PO304 I Cylinder No. 4 misfire detected I
/ I
KS implausible signal I
MIL Code
PO303
PO31 5
PO324
1 PO335 1 Crankshaft position (CKP) sensor implausible signal I
Description
Cylinder No. 3 misfire detected
Flywheel segment adaptation at the Limit
Knock sensor (KS) communication error or implausible signal
1 PO336 1 CKP sensor missing teeth I
1 PO336 1 CKP sensor loss of synchronization I
1 PO336 1 CKP sensor no signal I
I PO340 I Camshaft position (CMP) sensor no signal I
I PO341 I CMP sensor implausible signal I
I PO351 I Ignition coil A primary malfunction I
1 PO352 1 Ignition coil B primary malfunction I
I PO420 I Catalyst system efficiency below threshold I
1 PO444 1 Evaporative mission canister purge valve open circuit I
1 PO458 1 Evaporative mission canister purge valve low voltage I
I '1 PO459 1 Evaporative mission canister purge valve high voltage I
I PO460 I Fuel tank level malfunction from instrument cluster I
-3 I VSS signal too high I
PO500
PO500
Vehicle speed sensor (VSS) signal malfunction
Vehicle speed via CAN (VS CAN) implausible signal
PO51 1
PO560
I PO603 I Powertrain control module (PCM) error NVMY or EEPROM error 1
Idle air control (IAC) valve circuit malfunction
Battery system voltage malfunction high voltage
PO562
PO571
I PO604 I PCM error RAM error I
Battery system voltage malfunction open circuit
Brake switch plausibility error
PO605 I PCM error checksum error I
I PO610 I VID block checksum not correct or not programmed I
I PO617 I Starter relay malfunction I
I PO620 I Generator circuit malfunction I
1 PO628 1 Fuel pump primary circuit low voltage I
I
7 1 Fuel pump primary circuit high voltage I
2006.0 Fiesta 1212006 G384566en
PO625
PO626
Generator low voltage
Generator high voltage
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