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TECHNICAL SERVICE BULLETIN No.130/1994
Car and Light/Medium Commercial 15.03.1995

Section: 29

Model: Fiesta and Escort/Orion with 1,4 CVH CFI engine and manual transmission

Markets: All

Subject: Running concerns

Summary

Should a customer express concern regarding poor running (poor pulling away when cold, engine stalling after cold start) on a Fiesta or Escort/Orion with a 1,4 CVH CFI engine, it is recommended that the vehicle is checked and reworked as detailed in this bulletin. All of the checks must be carried out, and in the correct order, and revised parts fitted as necessary.

Attached you will find a checklist which should be kept together with the workshop job sheet.

Please tick the completed boxes and fill in the readings taken. Keep it together with the workshop job sheet, so that in the case of further concerns the level of rework can be checked against the checklist.

NOTE:
The new EEC IV-module (93AB 12A650 CC) is not released for Switzerland and Sweden. The release of the new module will be announced when homologated for these markets.


This bulletin replaces TSBs 68/1993.

Please replace page 1 of TSB 130/1994 dated 30.11.94 with this new edition. Please note that the repair codes have changed.

PARTS REQUIRED


LABOUR TIME

For other labour times please refer to the labour times schedule

REPAIR CODES


Cold Engine (cooling time:min. 8 hours)


1. Carry out a STAR test

-- Connect the FDS 2000 or the STAR tester.

-- Carry out the Engine Off Test.

-- Read and make a note of the fault codes displayed.

-- Identify existing faults (displayed before the separator code 20) using FDS 2000 and rectify them.


Disconnect the EEC IV module from the 60-pin plug


2. Check the EEC IV module

NOTE:
Modules for vehicles with the EDIS ignition system must not be fitted to vehicles with a distributor (or vice versa).


-- Ensure that the correct EEC IV module (identifiable by the part number) has been installed for each build period, as follows:

-- Vehicles with distributor:from 8/87: 88FB 12A650 ACfrom 4/90: 88FB 12A650 ADIn the event poor cold drivabilty in ambient temperatures of +10º C to +20º C, the two EEC IV modules detailed above may be replaced with EEC IV module 88FB 12A650 AF (see Parts Required).

-- Vehicles with EDIS ignition systemfrom 7/90: 91AB 12A650 HAfrom 6/91: 92AB 12A650 GAVehicles with power steering (from 10/92) are fitted with module 93AB 12A650 CA or 93AB 12A650 CB.In the event of "poor pulling away when cold, engine stalling after cold start", the modules detailed for EDIS (vehicles with and without power steering) should be replaced with module 93AB 12A650 CC (see Parts Required).

NOTE:
The new EEC IV-module (93AB 12A650 CC) is not released for Switzerland and Sweden. The release of the new module will be announced when available.



3. Check the power-steering pressure switch

-- Check the power-steering pressure switch. If a pressure switch with a brown plastic cap has been fitted, replace this with a pressure switch with a red plastic cap (see Parts Required).


EEC IV module remains disconnected; Disconnect the EDIS module multiplug


4. Check the exhaust system for leaks

NOTE:
Remove the exhaust manifold heatshield to allow a complete inspection of the exhaust manifold.


-- Check the exhaust manifold for cracks.

-- Spray leak-testing spray or soap solution to the exhaust system, from the cylinder head to the HEGO sensor (refer to «TSB 115/1994»).

-- Close the tail pipe with a cloth and crank the engine.

-- Any leaks are shown by formation of foam.

-- Repair any leaks.

NOTE:
Always use new gaskets (see Parts Required). The flange mating surfaces must be flat and should be reworked as necessary to ensure this. If they are over-distorted, replace components as necessary.



5. Check the Crankshaft Position / Speed Sensor (CPS)

-- On vehicles with the EDIS ignition system, check the operation of the CPS as follows:Connect the 12-terminal Breakout box (29-007) to the plug of the EDIS module.Set the multimeter to an AC voltage of 20V.When the engine is cranked, the voltage betwen pins 5 and 6 should measure at least 1,2V.

-- If the voltage is too low, check whether the multiplug and the CPS sensor have gold-plated terminals (visual inspection, see also «TSB 63/1993»). If necessary, modify the multiplug and the CPS sensor according to the instructions in «TSB 63/1993.» If the voltage reading is still below 1,2V, measure the resistance between pins 5 and 7, and 6 and 7. There should be no continuity between the wires from pins 5 and 6 (CPS sensor) and the wire from pin 7 (shield). If there is continuity, rectify the fault. If there is no continuity, adjust the gap between the CPS sensor and the flywheel: the gap should be 0,5 to 0,8 mm. Please note to measure upon a tooth edge on the flywheel.After adjusting the gap, measure the voltage between EDIS pins 5 and 6 again during cranking. If the reading is still below 1,2 V, fit a new CPS sensor (see Parts Required).


6. Check the compression and spark plugs

-- Variations between the individual cylinders should not exceed 3 bar. If they are greater, carry out a liquid decoke.Make sure that the mechanical engine parts are functioning properly.

-- Check spark plug condition, renew if necessary. Check that the correct spark plugs (AGPR32C1) are installed.


7. Check the connectors for ingress of moisture

-- Dismantle the air cleaner and close the vacuum connection.Disconnect all of the engine management connectors (apart from the HEGO sensor multiplug) and test for moisture. If moisture is detected, dismantle the multiplugs as far as possible (sealing caps, locking protection etc.) and spray them thoroughly with brake cleaner.

-- Allow the plugs to dry in the air, pack with Nyo gel grease (see Parts Required) and reassemble.

NOTE:
Particular attention must be paid to the connections of the engine coolant temperature (ECT) sensor and air charge temperature (ACT) sensor.

Do not connect the multiplugs of the ACT and ECT sensors yet.



Connect the EDIS module multiplug, and connect the Breakout box (29-001) with the Y-lead (29-009 A). Do not connect the EEC IV module


8. Check the ECT / ACT wiring

-- Measure the resistance between EEC IV pins 7 (ECT) and 46 (sensor earth), and between pins 25 (ACT) and 46. There should be no continuity. If there is, rectify the wiring fault or remove the soldered parallel resistors. Connect the multiplug of the ACT sensor. If the ECT sensor has already been repositioned into the heater supply line, also connect the multiplug of the ECT sensor as per check 11.


9. Check the HEGO sensor earth

If the HEGO sensor has gold plated terminals the connector of the wirng loom must have also gold plated terminals (See «TSB 63/1993»).


9. a. Check the HEGO sensor earth(Vehicles manufactured before 12/92)

NOTE:
All electrical loads must be switched off.

The EEC IV module must not be connected.

The Breakout Box with the Y-lead must be connected.


-- Measure the resistance between pins 40 and 49:

-- Measure the resistance between pins 40 and 49:

-- If the resistance is infinite (open circuit), go to step 9.b.

-- If the resistance is greater than 1,5 Ohms, solder in a bridge (wire with ø 1,5 mm) approx. 10 cm behind the 60-pin multiplug between the wires of pins 49 and 40 (see Fig. 1). Insulate the soldered areas.



Fig. 1

9. b. Check the HEGO sensor earth(Vehicles manufactured from 12/92)

NOTE:
All electrical loads must be switched off.

The EEC IV module must not be connected.

The Breakout Box with the Y-lead must be connected.


-- Measure the resistance between the pins 46 and 49:

-- If the resistance is infinite (open circuit), check the wire from pin 49 to the HEGO sensor multiplugfor contact.

-- If the wire is functioning correctly, solder in a wiring bridge, as described in step 9.a. (between pins 49 and 40).If the resistance is smaller than 1,5 Ohms, the HEGO sensor is functioning correctly.



Fig. 2


10. Check the vacuum line of the MAP sensor

-- Check if the new MAP sensor (fuel resistant), part number E7DF 9F479 A2A is fitted. If not replace MAP sensor (see Parts Required) to the above mentioned level.

-- Rework the vacuum line from the inlet manifold to the MAP sensor as shown in Fig. 3.

-- Fit the breather valve into the vacuum line approx. 100 mm in front of the MAP sensor.

NOTE:
The existing fuel trap is eliminated by this action.

Fig. 3


11. Relocate the engine coolant temperature (ECT) sensor (improves the fuel consumption mainly on short journeys)


11. a. Escort/Orion '91:

-- Relocate the ECT sensor refering to «TSB 108/1994» or to step 11.b. as detailed below.


11. b. Fiesta and Escort/Orion '86:

-- Relocate the ECT sensor by means of the T-piece, as shown in Fig. 4 (see Parts Required).The coolant hose leading to the heater must be cut approx. 50 mm before the enlarged section, otherwise the T-piece cannot be secured and the hose would have to be replaced.

NOTE:
With the ECT sensor inserted into the heater supply line, the operating temperature is signaled faster to the EEC module.


-- Connect the ECT plug.



Fig. 4


12. Check engine ventilation

-- Remove all hoses and check for blockage.

-- Clean the membrane vent housed within the air cleaner.

-- Remove the throttle by-pass valve if fitted.

-- The vaccuum connection of the engine breather valve (to intake manifold) must have a throttle valve with an internal Ø 1,5 mm. If the throttle valve is not present renew the engine breather valve (see Parts Required).


Connect the EEC IV module, Breakout Box with Y-lead remains connected


13. Check the function of the intake-air heater(vehicles with EDIS only)

-- Switch on the ignition.

-- Check the function of the intake-air heater.

WARNING:
Care must be taken not to burn your fingers! The intake air heater heats up very quick.



14. Check the voltage of the ACT and ECT sensors

-- Set the multimeter to a DC voltage of 20V.

-- Measure and compare the voltage (DC) between EEC IV pins 7 (ECT (+)) and 46 (sensor earth (-)) and the voltage between EEC IV pins 25 (ACT (+)) and 46 (sensor earth (-)). The voltage measurements should not differ by more than 0,2V. If the tolerance is greater, the faulty sensor should be replaced or a soldered series resistor should be removed (if present). See TSB 28/1991 or the Vehicle System Test Manual - Engine Management for the correct voltages.

-- Switch off the ignition.


Connect the fuel pressure gauge

WARNING:
Observe all fuel-handling precautions.


CAUTION:
The fuel shut-off valve must remain open so as to avoid damage to the fuel pump.



15. Check the fuel pressure

-- Start the engine and let it idle.

NOTE:
If there is still a non start condition (no ignition spark), the vehicle can be fitted with a revised EDIS module (see Parts Required).

Check the EDIS circuit using FDS 2000. Starter interference is rarely the cause of starting difficulties, but in cases such as this, replace the starter motor as an experiment.


-- Read off the fuel pressure:this should read 1,0 ± 0,1 bar.

-- If the fuel pressure is outside the tolerance range, it may be adjusted by means of the pressure regulator.

NOTE:
Do not remove the fuel pressure gauge: It will be needed again to check the fuel pressure during a cold start.



16. Check the intake system for leaks

-- Check the intake system for leaks with a suitable leak-testing spray in conjunction with the exhaust gas analyser, or by means of an ultrasonic sensor.

-- Check the vacuum lines for leaks.

-- Eliminate any leaks and replace any faulty vacuum lines (see Parts Required).


Connect the tachometer - Bring the engine to operating temperature (Fan running)


17. Check the base idle speed

-- After it has been actuated, push back the throttle control motor plunger manually. When the plunger is pushed back completely, disconnect the control motor multiplug. Let the engine run at 3000 rev/min for approx. 30 sec. Shut the throttle and check the engine speed. The base idle speed should read 750-800 rev/min. If it is outside the tolerance range, adjust it at the throttle stop bolt. Use a 2,5 mm Allen key or a screwdriver.

NOTE:
Do not make any adjustments to the throttle control motor stop.


-- Turn the engine off and connect the control motor multiplug.


18. Check the voltage of the throttle position sensor (TPS)

-- Start the engine and let it idle for approx. 1 minute.

-- Set the multimeter to a DC voltage of 20V.

-- While the engine is running at a steady idle speed, disconnect the plug of the throttle control motor.

-- Switch the engine off and the ignition on.

-- Measure the voltage (DC) between EEC IV pins 47 (TPS (+)) und 46 (sensor earth (-)).

-- At idle, the voltage should read 0,6V to 0,8V, and at fully depressed throttle pedal at least 4,0V. Adjustments may be made by bending the potentiometer drive lever.In order to do so, remove the throttle position sensor (TPS).

NOTE:
The engine speed drop may be affected by a change in TPS voltage. A high voltage (0,8 Volt) causes the control motor to return quickly to its original position giving rise to a rapid drop in speed. A low voltage (0,6 Volt) causes a slow drop in engine speed (coasting).



19. Carry out an engine-running test

-- Carry out an engine-running test using the FDS 2000 or the STAR tester, and make a note of any fault codes. Locate these faults using FDS 2000 and rectify them.

-- In service code 60:Check the engine speed (1200 ± 50 rev/min). If the engine speed is within the tolerance range, this means that the control motor is functioning correctly.This engine speed can not and must not be adjusted!Check the ignition timing (10º before TDC) and, if necessary, rectify on vehicles with distributor. On vehicles with the EDIS ignition system, fit a new flywheel if the ignition timing is significantly in advance of 20º before TDC.


20. Check that the HEGO sensor is functioning properly

-- Start the engine and let it run for at least 3 minutes at approx. 3000 rev/min.

-- Set the analog voltmeter (multimeter with a dial hand) to 1 - 2V DC. Measure the voltage between EEC IV pins 29 (HEGO sensor (+)) und 49 (sensor earth (-)). The dial hand of the analog voltmeter should now read between 0,0V and 0,85V at least once a second (or vice versa) and the second afterwards return almost to the initial value. This process should repeat itself constantly without interruption.


Turn the engine off, Remove the Breakout Box, Connect the EEC IV module


21. Concern: Occasional high idle speed

-- In the event of such a concern in vehicles manufactured prior to 12/92, the throttle position sensor (TPS) wiring should be connected by means of a solder shrink connector (see Parts Required) as described in «TSB 63/1994.»

NOTE:
Vehicles built after 12/92 have gold-plated terminals (visual inspection). Gold-plated terminals have no contact resistance, so do not cut the TPS connector in these vehicles.



Let the engine cool down for at least 8 hours


22. Check the fuel pressure

-- Switch the ignition on and measure the fuel pressure straight away: it should read at least 0,6 bar.

-- If the pressure is below this value, check the fuel pump, the injection valve and the pressure regulator.Replace faulty components as necessary.

-- Remove the fuel pressure gauge.


Disconnect the engine analyser


23. Carry out a test drive

-- Start the engine and let it idle.

-- Turn the FDS 2000 or the STAR tester on (continuous test) and pull away. If there are any faults, these will be indicated directly by the fault codes.

NOTE:
Fault codes are for general information only and do not always pinpoint faulty components, but generally identify the system circuit in which the fault has been found.


-- If fault codes are indicated, ask the passenger to measure the input signals by means of the FDS 2000 in monitor mode or the breakout box (see the Vehicle System Test Manual - Engine Management).

Однако какой разброс компрессии по цилиндрам они допускают - 3 бара. Обычно как-то считается что не больше 1 атм.
Понравилось "ради эксперимента поменяйте стартер"

Ежели рекомендуют такой разброс как допустимый, то значит в гарантийный период не хотят ремонтировать при небольших перепадах.

Я думаю, здесь подразумевается и послегарантийный платный ремонт, так что подозревать тис, что он рекомендует нечто нездоровое не стоит.

К тому же статья 15.03.95. К этому времени на всех машинах 91-92 года гарантия уж точно кончилась.

Можно машину и за гарантийный период ухайдакать так, что производитель не узнает.

Кто бы спорил?

Но речь не об этом.

Наши все машины уже давно все ухайдаканные. Данная инструкция позволит их починить.

Будем чинить, а х. делать?