2007 FORD FIESTA Electrical

303-004 Engine System - General Information 303-00-4
DIAGNOSIS AND TESTING
Engine
Special Tool(s)
Socket, Spark Plug
303-499
I Adhesive - Loctite 243 I WSK-M2G349A7 I
Materials
1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
k.
Name S~ecification
Leaks from oil carrying
components or basic engine.
E47332
&
21211
CHECK for cracks in oil
carrying components of the
basic engine by means of a
leak test. INSTALL new
components or seals as
necessary.
2006.0 Fiesta 1212006 GI 52554en
Compression Test Adapter
303-1 052
Pliers, Valve Stem Seal
303-508
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart Symptom Possible Sources Action
Visual
Inspection Chart
Loss of oil Mechanical
- Coolant
leaks
- Oil leaks
- Fuel system leaks
- Visibly damaged or
worn parts
- Loose or missing
nuts or bolts Electrical
- Fuse(s)
- Loose
or corroded
connector(s)
- Powertrain control
module
- Damaged or worn
switch(es)
Oil leaks on components that
are
eithei coated in oil them-
selves or on components local
to them.
Internal or external leak at the
oil cooler.
Leak at the crankshaft seal.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
CHECK for evidence of oil
leaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident, INSTALL
new gaskets or components as
required.
CHECK the coolant expansion
tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
INSTALL a new crankshaft
seal.
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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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303-00-1 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.
2006.0 Fiesta 1212006 GI 52554en
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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.
2006.0 Fiesta 1212006 GI 52554en
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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).
2006.0 Fiesta 1212006 GI 52554en
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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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303-00-1 9 Engine System - General Information 303-00-1 9
DIAGNOSIS AND TESTING
11. Remove the glow plugs. 16 Install the glow plug power supply.
I ' I2 Install the special tool and a suitable IT Attach the EGR cooler (if equipped).
compression tester into the glow plug bore.
N0TE:Crank the engine with the starter motor until
the reading on the compression tester stops rising.
13 Carry out the measurement on all cylinders,
following the measuring equipment
manufacturer's instructions.
$4 Detach the compression tester and the special
tool.
15 Install the glow plugs.
18. Connect the fuel injector electrical connectors.
I
2006.0 Fiesta 1212006 GI 52554en
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303-00-21 Engine System - General Information 303-00-21
DIAGNOSIS AND TESTING
N0TE:Twist the spark plug connectors slightly 8. Using the special tool, install the spark plugs.
before disconnecting them. Pull on the connector
and not on the cable.
5. Disconnect the spark plug connectors.
6. Using the special tool, remove the spark plugs.
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
compression pressure recorder with the suitable
adapter.
9. Connect the spark plug connectors.
10 Connect the El coil electrical connector to the
El coil.
2006.0 Fiesta 1212006 GI 52554en
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