2007 FORD FIESTA cam

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).
2006.0 Fiesta 1212006 GI 52554en
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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).
2006.0 Fiesta 1212006 GI 52554en
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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).
2006.0 Fiesta 1212006 f GI 52554en
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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.
2006.0 Fiesta 1212006 GI 52554en
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303-00-22 Engine System - General Information 303-00-22
DIAGNOSIS AND TESTING
11. Install the fuel pump relay.
I2 Install the air cleaner.
REFER to: Air Cleaner - 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-16V (Sigma)/l .6L
Duratec-I 6V (Sigma) (303-1 2 Intake Air
Distribution and
Filtering, Removal and
Installation).
13 Using worldwide diagnostic system (WDS), clear
the fault codes from the PCM.
Measure the compression ressure
(Engine
- 1 .3L Duratec-8V P Rocam)) N0TE:Twist the spark plug connectors slightly
1. Open the
central junction box (CJB) and remove
the
fuel pump relay.
before disconnecting them. Pull on the connector
and not on the
cable.
5. Disconnect the spark plug connectors.
N0TE:The engine will start, run for a few seconds
and then stop. 6. Remove the spark plugs.
2. Start the engine.
3. Remove the air
cleaner.
REFER to: Air Cleaner - 1.3L Duratec-8V
(Rocam) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
N0TE:Operate the starter motor with wide open
throttle until the reading on the compression tester
stops rising.
7. Carry out the measurement in accordance with
the instructions
supplied with the measuring
device on every
cylinder using a suitable
4. Disconnect the electronic ignition (El) coil compression pressure recorder
with the suitable (:
electrical connector from the El coil. adapter.
2006.0 Fiesta 1212006 GI 52554en
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303-00-23 Engine System - General Information 303-00-23
DIAGNOSIS AND TESTING
8. Install the spark plugs.
9. Connect the spark plug connectors.
1Q Connect the El coil electrical connector to the
El coil. 11.
Install the fuel pump relay.
I2 Install the air cleaner.
REFER to: Air Cleaner
- 1.3L Duratec-8V
(Rocam) (303-1 2 Intake Air Distribution and
Filtering, Removal and Installation).
13 Using worldwide diagnostic system (WDS), clear
the fault codes from the PCM.
Measure the compression ressure
(Engine
- 2.OL Duratec-HE PMI~))
1. Open the central junction box (CJB) and remove
the fuel pump relay.
N0TE:The engine will start, run for a few seconds
and then stop.
2. Start the engine.
3. Remove the air cleaner.
REFER to: Air Cleaner
- 2.OL Duratec-HE (M14)
(303-1 2 Intake Air Distribution and Filtering,
Removal and Installation).
4. Disconnect
the electronic ignition (El) coil
electrical connector from the El coil.
2006.0 Fiesta 1212006 GI 52554en
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303-00-28 Engine System - General Information 303-00-28
DIAGNOSIS AND TESTING
6. N0TE:Measure the oil pressure at an oil
temperature of 80°C.
N0TE:Oil pressure at 2000 rpm: 3.5 bar.
Measure the oil pressure.
7. Raise and support the vehicle. REFER to:
(I 00-02 Jacking and Lifting)
Jacking (Description and Operation), Lifting (Description and Operation).
8. Detach the oil pressure gauge and connector
from the oil pressure switch bore.
9. Coat the oil pressure switch with adhesive.
IQ Install the oil pressure switch. 11.
Connect the oil pressure switch electrical
connector to the oil pressure switch.
I2 Lower the vehicle.
Measure the oil pressure (Engine - 1.3L
Duratec-8V (Rocam))
N0TE:The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity, extent
of oil filter contamination).
N0TE:Measure the oil pressure at the specified
engine speed.
1. Raise and support the vehicle. REFER to:
( I (1 00-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
2. Disconnect the oil pressure switch electrical
connector from the oil pressure switch.
2006.0 Fiesta 1uzoo6 GI 52554en
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