2007 FORD FIESTA cam

303-05-1 4 Accessory Drive 303-05-1 4
DIAGNOSIS AND TESTING
Symptom
N0TE:Squeal is defined as a
continuous shriek, most noticeable
when the engine is being acceler-
ated or with electrical load.
Accessory drive belt squeal
N0TE:Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt whine
Possible Sources Action
Accessory drive belt tensioner
worn, damaged or contamin-
ated with oil.
Poor surface finish on
accessory drive belt idler pulley
flat
surface(s).
CHECK the accessory drive
belt tensioner for correct opera
tion, damage or contamination.
REFER to the Accessory Drive
Belt Tensioner Component
Test in this procedure.
INSTALL a new accessory
drive belt tensioner as neces-
sary.
REFER to: Accessory Drive
Belt Tensioner
- 1.6L
Duratorq-TDCi (DV) Diesel,
Vehicles With: Air Condi-
tioning (303-05, Removal and
Installation)
1 Accessory Drive Belt
Tensioner
- I .6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal
operation.
REMOVE the accessory drive
belt.
REFER to: Accessory Drive
Belt
- 1.3L Duratec-8V
(Rocam) (303-05 Accessory
Drive, Removal and Installa-
tion)
1 Accessory Drive Belt - 1.4L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt Tensioner
- 1.6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal
and Installation)
I Accessory Drive Belt - 2.OL
Duratec-H E (M14) (303-05
Accessory Drive, Removal
and Installation).
INSPECT the idler
pulley(s) for
surface finish. INSTALL a new
idler
pulley(s) as necessary.
TEST the system for normal
operation.
2006.0 Fiesta 1212006 G346263en
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303-05-1 5 Accessory Drive 303-05-1 5
DIAGNOSIS AND TESTING
Symptom
N0TE:Chirp is defined as a twit-
tering noise, often intermittent
Accessory drive belt chirp Possible
Sources Action
Accessory drive belt idler pulley
bearing failure.
Pulley misalignment (usually
evident at idle). REMOVE
the accessory drive
belt.
REFER to: Accessory Drive
Belt
- 1.3L Duratec-8V
(Rocam) (303-05 Accessory
Drive, Removal and Installa-
tion)
I Accessory Drive Belt - 1.4L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - I .6L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 2.OL
Duratec-HE (M14) (303-05
Accessory Drive, Removal
and Installation).
INSPECT the idler
pulley(s) for
smooth rotation. INSTALL a
new idler
pulley(s) as neces-
sary. TEST the system for
normal operation.
CHECK that the accessory
drive belt is running centrally
on the flat pulleys. TEST the
system for normal operation.
CHECK the pulleys for
excessive end float and bent
flanges.
With the engine running at idle,
use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
2006.0 Fiesta 121~oo6 G346263en
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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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303-06-1 Starting System 303-06-1
SECTION 303-06 Starting System
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications - vehicles with 1.25L Duratec-1 6V (Sigma)ll.3L Duratec-8V
(Rocam)/l.4L Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma) engines ...... . . . . .. . . .. .. .. .
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV)/1.6L Duratorq-TDCi (DV)
Diesel engines ........................................................................\
......................................
Torque Specifications - vehicles with 2.OL Duratec-HE (M14) engine .............................
DESCRIPTION AND OPERATION
Starting System ........................................................................\
..........................................
Starting system ........................................................................\
...........................................
DIAGNOSIS AND TESTING
Starting System ........................................................................\
..........................................
Inspection and Verification ........................................................................\
..........................
Symptom Chart ........................................................................\
...........................................
Pinpoint Tests ........................................................................\
.............................................
REMOVAL AND INSTALLATION
PAGE
Starter Motor - 1.3L Duratec-8V (Rocam)/l.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (26 204 0) 303-06-1 1
Starter
Motor - 2.OL Duratec-HE (M14) ............................. ................................................ 303-06-1 2
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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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303-06-6 Starting System 303-06-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Pinpoint Tests
The starter stops cranking the
engine before the engine starts
N0TE:Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A
: THE ENGINE DOES NOT CRANKITHE REWY DOES CLICK
PCM.
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
I A1 : CHECK VOLTAGE TO STARTER SOLENOID I
I I Ignition switch in position Ill. I
Measure the voltage between starter motor
terminal 50, harness side and ground.
Is the voltage greater than I0 volts?
+ Yes
GO to
A2.
+ No
GO to A3.
1~2: CHECK THE VOLTAGE DROP I
Measure the voltage between starter motor
terminal 30, component side and the battery
positive
terminal.
Is the voltage less than 0.5 volts?
+ Yes
GO to A4.
+ No
CLEAN and TIGHTEN
all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery starter motor
solenoic
cable.
REFER to: Battery to Starter Motor Solenoid
Cable - 1.3L Duratec-8V (Rocam) (41 4-0 1
Battery, Mounting and
Cables, Removal and
Installation)
I Battery to Starter Motor Solenoid Cable -
1.25L Duratec-I 6V (Sigma)ll.4L Duratec-
1
6V (Sigma)ll .6L Duratec-1 6V (Sigma)
(414-01 Battery, Mounting and
Cables,
Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 GI 51 301 en
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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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