303-14-1 Electronic Engine Controls 303-14-1

SECTION 303-14 Electronic Engine Controls

VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE

SPECIFICATIONS
Specifications...................................................................................................................... 303-14-2

DESCRIPTION AND OPERATION

Electronic Engine Controls . 1.25L Duratec-16V (Sigma)/l.4L Duratec-I 6V (Sigma)/l .6L
Duratec-16V (Sigma)........................................................................................................

cardiagn.com
Overview.............................................................................................................................
Throttle Control Unit (TCU).................................................................................................
CPP switch......................................................................................................................
(Brake Pedal Position) BPP switch.................................................................................
APP sensor .....................................................................................................................
Electronic Engine Controls - 2.OL Duratec-HE (M14).......................................................
System Overview, 2.OL Duratec HE (M14) Engine.............................................................
Components.......................................................................................................................

DIAGNOSIS AND TESTING

Electronic Engine Controls............................................................................................. 303-14-14
Principles of Operation....................................................................................................... 303-14-14
MIL Code List..................................................................................................................... 303-14-17
Inspection and Verification.................................................................................................. 303-14-21

REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) . 1.25L Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l.GL Duratec-16V (Sigma)......................................... (29 200 0) 303-14-22
Powertrain Control Module (PCM) -2.OL Duratec-HE (M14), Vehicles With: PCM Security
Shield ........................................................................................................................... 303-14-24
Powertrain Control Module (PCM) - 2.OL Duratec-HE (M14), Vehicles Without: PCM
Security Shield.................................................................................................................. 303-14-27
Heated Oxygen Sensor (H02S).................................................................. (29 220 0) 303-14-30
Crankshaft Position (CKP) Sensor................................................................................... 303-14-32
Knock Sensor (KS)........................................................................................................ 303-14-35
303-14-2 Electronic Engine Controls 303-14-2
SPECIFICATIONS
-
Torque Specifications vehicles with 1.3L Duratec-8V (Rocam) engine
Description Nm Ib-ft Ib-in I/
I Powertrain control module (PCM) retaining bolts I 3 I - I 27 I\
I Knock sensor (KS) retaining bolt I 20 I 15 I - I
I Crankshaft position (CKP) sensor retaining bolt I 10 I - I 89 I
I Camshaft position (CMP) sensor retaining bolt I
I Throttle position (TP) sensor screws I 5 I - I 44 I
I Idle air control (IAC) valve retaining bolts I 10 I - I 89 I
Ignition coil pack retaining bolts 6 - 53
Exhaust manifold heatshield retaining bolts 10 - 89
Heated oxygen sensor (H02S) 47 35 -

cardiagn.com
Catalyst monitor sensor (CMS) 47 35 -
-
Torque Specifications vehicles with 1.25L Duratec-16V (Sigma)ll.4L Duratec-16V (Sigma)ll .6L
Duratec-I 6V (Sigma) engine

I Powertrain control module (PCM) retaining bolts I 3 I - I 27 I

I Knock sensor (KS) retaining bolt I 20 I 15 I - I
Cylinder head temperature (CHT) sensor 25 18 -
Crankshaft position (CKP) sensor retaining bolt 10 - 89
I Camshaft position (CMP) sensor retaining bolt I 10 I - I 89 I
I Engine coolant temperature (ECT) sensor I 20 I 15 I - I
I Idle air control (IAC) valve I 10 I - I 89 I
I Heated oxygen sensor (H02S) I 47 I 35 I - I
I Catalyst monitor sensor (CMS) I -
- - --

47 35 1 I
-
Torque Specifications vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine
Description Nm Ib-ft lb-in
Powertrain control module (PCM) retaining nuts
and retaining bolts
1 Timing belt upper cover retaining bolts I 4 I - I 35 I
I Timing belt lower cover retaining bolts I 6 I - I 53 I
I Camshaft position (CMP) sensor retaining bolt I 5 I - I 44 I
I Crankshaft position (CKP) sensor retaining bolt I 8 I - I 71 I
I Crankshaft pulley retaining bolt I a I - I - I
I.
-

For additional information, refer to: Crankshaft Position (CKP) Sensor - 1.4L Duratorq-Ci D ) Diesel (303-14 Electronic Engine
''

I Controls, Removal and Installation).

2006.0 Fiesta 1212006 Gl48226en

303-14-3 Electronic Engine Controls 303-14-3
SPECIFICATIONS
-
Torque Specifications vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine
Description Nm Ib-ft lb-in
control module (PCM) retaining nuts
and retaining bolts
Timing belt upper cover retaining bolts 4 - 35
Timing belt lower cover retaining bolts 6 - 53
I Camshaft position (cMP) sensor retaining bolt I 5 I - I 44 I
I Crankshaft position (CKP) sensor retaining bolt I 8 I - I 71 I
I Crankshaft pulley retaining bolt I a I - I - I
I For additional information, refer to: Crankshaft Position(CKP) Sensor - 1.6L Duratorq-TDCi(DV) Diesel (303-14 Electronic Engine I
I Controls, Removal and Installation).
I

cardiagn.com
-
Torque Specifications vehicles with 2.OL Duratec-HE (M14) eng ine
I Description I Nm
I Powertrain control module (PCM) retaining bolts I 10 I - I 89 I
I PCM mounting bracket retaining bolts I 25 I 18 I - I
I Knock sensor (KS) retaining bolt I 20 I 15 I - I
I Crankshaft position (CKP) sensor retaining bolt I 7
' 1 Camshaft position (CMP) sensor retaining bolt I 6
I Ignition coil pack retaining bolts I 6 I - I 53 I
I Exhaust manifold heatshield retaining bolts
-- -
I 10 I - I 89 I
Heated oxygen sensor (H02S) 47 35 -
Catalyst monitor sensor (CMS) 47 35 -

2006.0 Fiesta 1212006 GI 48226en

303-14-4 Electronic Engine Controls 303-14-4
DESCRIPTION AND OPERATION

Electronic Engine Controls - 1.25L Duratec-16V (Sigma)/lAL

Duratec-I 6V (Sigma)/l.GL Duratec-16V (Sigma)
Overview

cardiagn.com

2006.0 Fiesta 1212006 G204204en

303-14-5 Electronic Engine Controls 303-14-5
DESCRIPTION AND OPERATION

cardiagn.com

Item Description Item Description

I I
1 Temperature and Manifold Absolute 3 1
Knock Sensor (KS)
pressure (T-MAP) sensor 4 Sensor - Engine Coolant Temperature
2 Throttle Position (TP) sensor (ECT)

2006.0 Fiesta 1212006 G204204en

303-14-6 Electronic Engine Controls 303-14-6
DESCRIPTION AND OPERATION
Item Descri~tion Throttle Control Unit (TCU)
1 5 1
Crankshaft Position (CKP) sensor 1
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
9 Vehicle Speed Sensor (VSS) (only on
vehicles without Anti-lock Braking System
(ABS))
1 10 1 Brake Pedal Position (BPP) switch I
11 Accelerator Pedal Position (APP) sensor
1 12 1 Clutch Pedal Position (CPP) switch I
1 13 1 Generator I

cardiagn.com
1 14 1 Current supply relay I
1
-
15 1 Ignition key I
16 Battery
17 Powertrain Control Module (PCM)
-

18 Data Link Connector (DLC)

19 Fuel Pump (FP) relay
1 20 1 Inertia fuel shut-off switch I
1 21 1 Fuel Pump Driver Module (FPDM) I
1 22 1 Fuel injectors I
1 23 Evaporative emissions (EVAP) solenoid
lvalve
I
Item
I ITPsensor
Descri~tion
I
1 24 1 Idle Air Control (IAC) valve 1 1 2 1 Electric motor
1 25 1 Throttle Control Unit (TCU) I The electronically controlled throttle control unit I
11 I1
26 Air Conditioning (AIC) compressor clutch
1 blower switch
(TCU) consists of the following components:
Housing
27 Injector Driver Module (IDM) I Throttle flap
1 28 1 Start inhibit relay I Throttle flap spindle
1 29 1 Instrument cluster I Gear set
Electric motor with pinion
TP sensor
Stop screw
Throttle flap return spring

2006.0 Fiesta 1212006 G204204en

 303-14-7 Electronic Engine Controls 303-14-7
DESCRIPTION AND OPERATION
Function The throttle flap position is adjusted and monitored
in a closed control loop. The TP sensor provides
I A CAUTI0N:The throttle control unit (TCU) the PCM with the information on the actual position
must not be dismantled. No adjustments of the throttle flap.
or repairs can be made to the TCU.

Standby function
If a fault develops in the throttle control unit (TCU),
a standby function is carried out. This standby
function allows a slight opening of the throttle flap,
so that enough air passes through to allow limited
engine operation.
For this purpose, there is an throttle flap adjustment
screw on the throttle housing. The return spring
closes the throttle flap until the stop of the toothed
segment touches the stop screw. In this way a

cardiagn.com
defined throttle flap gap is formed for limp home
mode.
The stop screw has a spring loaded pin, which
holds the throttle flap open for limp home mode.
In normal operating mode, this spring loaded pin
is pushed in by the force of the electric motor when
the throttle flap must be closed past the limp home
position (e.g. for idle speed control or overrun
shutoff).

CPP switch

Item Description
I I
I stop screw I
1 2 IToothed segment I
1 3 1 Throttle flap spindle I
1 4 1 Throttle flap return spring I
1 5 1 Intermediate shaft with gear I
1 6 1 Electric motor with pinion I
The APP sensor sends the data containing the
driver's acceleration requirement to the PCM. This The CPP switch is located directly on the pedal
information depends directly on the movement of box.
the accelerator pedal. The engine management recognises gearshifts
The PCM processes this information and converts through the CPP switch and thus improves engine
it into an output signal for the throttle control unit running characteristics.
(TCU). This output signal is the control for the The CPP switch passes a ground signal to the
electric motor. PCM when the clutch pedal is depressed
The electric motor moves the throttle flap spindle (disengaged).
by means of the gear set.

2006.0 Fiesta 1212006 G204204en

 Electronic Engine Controls
DESCRIPTION AND OPERATION
(Brake Pedal Position) BPP switch APP sensor

There are two brake pedal switches at the pedal

box: the brake lamp switch and the BPP switch.

cardiagn.com
The brake lamp switch only serves to switch on
the brake lamps. The BPP switch is used for engine
management purposes.
The BPP switch provides the PCM with the
information that the vehicle will be decelerated.
The BPP switch is closed in the rest state (brake
pedal not depressed) and sends a ground signal
to the PCM.
If when the APP sensor has failed, the BPP is
operated, the engine will be controlled to run at
idle speed by the PCM.
In order that the engine power output can be
matched to that required by the driver, the PCM
needs to know the position of the APP sensor.
The APP sensor is a variable resistor whose
resistance varies with the accelerator position. It
is a sliding contact potentiometer (2 potentiometers
in total).

If a fault occurs in the APP sensor or the throttle

control unit (TCU) during vehicle operation, then
this will be briefly indicated by a digital display in
the instrument cluster after the ignition is switched
on, and a trouble code will be stored in the PCM.

2006.0 Fiesta 1212006 G204204en

303-14-9 Electronic Engine Controls 303-14-9
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.

cardiagn.com

2006.0 Fiesta 1212006 G204204en

303-14-10 Electronic Engine Controls 303-14-10
DESCRIPTION AND OPERATION

Electronic Engine Controls - 2.OL Duratec-HE (M14)

System Overview, 2.OL Duratec HE (M14) Engine

cardiagn.com

--

2006.0 Fiesta 1212006 G422229en

303-14-11 Electronic Engine Controls 303-14-1I
DESCRIPTION AND OPERATION
Item Description Components
Manifold absolute pressure and
temperature (MAPT) sensor
MAPT sensor
1 2 1 Camshaft position (CMP) sensor I
1 3 1 Knock sensor (KS) I
v l ~ A m e % a i temperature
r 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

cardiagn.com
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
1 12 1 Accelerator pedal position (APP) sensor signal from the MAPT sensor is used to modify the
1 13 1 Clutch pedal position (CPP) switch ignition and fuel delivery.
1 1 Brake pedal position (BPP) switch
14
115 1 Stoplamp switch CMP sensor
1 16 1 Power steering pressure (PSP) switch I
117 1 Catalyst monitor sensor I
F I G t e d 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
I1 I122 Throttle position (TP) sensor (part of
throttle body)
23 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

303-14-12 Electronic Engine Controls 303-14-12
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.

Intake manifold tuning valve solenoid

The powertrain control module is located within the

engine compartment below the battery and is

cardiagn.com
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 The solenoid for the intake manifold tuning system
connectors it is necessary to remove the security is located on the transmission side of the cylinder
shield. head.
The PCM monitors and processes the signals from Vacuum is supplied by a central vacuum
the sensors and compares these with stored connection from the intake manifold.
parameters. The PCM uses this information to The solenoid for the intake manifold tuning system
calculate the output signals to the actuators. is supplied with either the maximum voltage or zero
Communications between the PCM and other voltage, i.e. the valves are either fully open or fully
control units (for example, the stability assist and closed.
the instrument cluster) including the DLC for Actuation depends on the engine speed and the
diagnosis of the system, take place on the engine load.
controller area network (CAN).
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

located on the pedal box and provide the PCM with \
tt(r

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

303-14-13 Electronic Engine Controls 303-14-13
DESCRIPTION AND OPERATION
The BPP switch is connected to the instrument When the brake pedal is pressed again the engine
cluster via a CAN bus. In its rest state the switch speed drops to idle speed. When the brake pedal
is closed and sends a ground signal to the PCM. returns to its rest position the engine speed is
The signal from the BPP switch is used in the event increased again.
of failure of the APP sensor for the emergency
operating mode.

Accelerator pedal position (APP) sensor

cardiagn.com
The PCM requires the pedal position from the APP
sensor in order to regulate the power output of the
engine according to the driver request for power.
The APP sensor is a double contact-less inductive
sensor.
If a concern occurs with the APP sensor while
driving, a diagnostic trouble code (DTC) is stored
in the PCM.
If both sensors of the APP sensor fail, the engine
is regulated to a maximum engine speed of up to
4000 revlmin after a single operation of the BPP
switch and the stop lamp switch and a subsequent
comparative plausibility test. The vehicle can only
be accelerated to a maximum speed of 56 kmlh.

2006.0 Fiesta 1212006 G422229en

303-14-14 Electronic Engine Controls 303-14-14
DIAGNOSIS AND TESTING

Electronic Engine Controls

General Equipment
I
Worldwide Diagnostic system (WDS)
Warm-up Cycle C'
The warm-up cycle is an operation that consists of
key on, engine start and a coolant temperature
increase of 22"C, exceeding 71OC on completion.
Principles of Operation
Drive Cycle
For Principles of Operation on the electronic
accelerator control system A drive cycle commences when the engine is
started (cold or warm) and ends when the engine
REFER to: Acceleration Control (310-02A, is switched off.
Diagnosis and Testing).
Trip
European On-Board Diagnostics (EOBD)
A trip begins when the engine is started and is
EOBD is a diagnostic system integrated into the complete when all the EOBD monitors have

cardiagn.com
powertrain control module (PCM). This system completed a self-test. This may take place over a
continuously monitors vehicle emission number of drive cycles. On diesel variants, the
components. The system includes a malfunction information gathered from one drive cycle is not
indicator lamp (MIL) which indicates when there is carried over to a subsequent cycle or cycles.
a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC When a concern has been rectified, particularly
memory can be accessed using a generic scan after electronic engine control components have
tool or WDS. been changed, the DTC memory, which is part of
the EEPROM must be cleared of all trouble codes.
EOBD is mandated within European Union When the DTC memory has been cleared, the code .
regulations from the year 2000 for passenger PI000 (known as the readiness code) is set in the
vehicles with petrol engines and from 2003 PCM memory, which indicates that since the
onwards for passenger vehicles with diesel EEPROM has been cleared, not all of the
engines. monitoring systems have completed their tests.
EOBD Functions: PI000 can only be cleared by carrying out a trip,
Establishes when and how emissions control which includes driving the vehicle under variable
conditions of speed, load and time so that all of the
faults must be indicated.
monitors are completed. As PI000 will not
Actuates emission control malfunction indicator illuminate the MIL it is not necessary to carry out
lamp (MIL) and fault memory. the trip before returning the vehicle to the customer.
Indicates operating conditions in which the
concern occurred (freeze frame data). Freeze Frame Data
Standardized output of operating data such as When a concern is detected, various data is stored
engine speed, engine coolant temperature etc. depending on application including:
Standardized names and abbreviations for Diagnostic trouble code.
components and systems.
Vehicle speed.
Standardized DTCs for all manufacturers.
Engine coolant temperature.
Standardized communicationwith the diagnostic
Engine speed.
equipment.
Engine load.
Standardized 16-pin data link connector (DLC)
in area of the instrument panel. Mixture formation trim value (trim value for
Concern display must be possible using a engine wear) (All except vehicles with diesel
engine).
generic scan tool.
State of oxygen sensor control (open and closed
EOBD consists of the following elements: loop) (All except vehicles with diesel engine).
Distance covered since the concern was first
registered.

2006.0 Fiesta 1212006 G384566en

 303-14-15 Electronic Engine Controls 303-14-15
DIAGNOSIS AND TESTING
Monitors Throttle Position (TP) Sensor.
The purpose of the monitors is to continuously Vehicle Speed Sensor (VSS).
check the operation of the emission related sensors Boost Pressure Sensor.
and actuators. It then establishes if they are Cam-Crank Phasing Sensor.
operating within specified tolerances. All monitors
EEPROM.
carry out their functions in such a way as to be
unnoticeable by the driver of the vehicle. Each one High Pressure Fuel Injection Pump.
is carried out under specific conditions of load, Exhaust Gas Recirculation(EGR) Valve Monitor.
speed and engine temperature. The Fuel Injectors.
Comprehensive Component Monitor, Combustion Turbocharger.
Misfire Monitor and AirIFuel Ratio Monitor operate
continuously. The remaining monitors are only Combustion Noise Monitor.
invoked under certain operating conditions. On Barometric Pressure (BARO) Sensor.
diesel variants, all of the monitors operate under
normal driving conditions: There are no monitors Combustion Misfire Monitor (All except vehicles
which intervene and cause special operating with diesel engine)
modes to enable the monitors to work. Some diesel The combustion misfire monitor operates

cardiagn.com
monitors are non-continuous. This means that in independently of the others, and can detect misfires
a drive cycle, monitoring is done as and when caused by the ignition system, fuel system or
suitable driving conditions exist and potential faults mechanical engine components. As each cylinder
are accumulated and compared with acceptance fires, a characteristic crankshaft acceleration is
criteria. Examples of this type are the turbocharger produced. The monitor detects irregularities in the
boost pressure and exhaust gas recirculation acceleration pattern using the crankshaft position
(EGR) monitors on vehicles with common rail fuel (CKP) sensor, thus detecting the misfire. It can
injection. also detect which cylinder has misfired.
Combustion misfires can be categorized as follows:
( Comprehensive Component Monitor (CCM)
Type A: These can cause catalytic converter
When the CCM detects a component operating out damage due to excessive internal temperatures.
of tolerance, it sets a Diagnostic Trouble Code If a certain number of misfires occur over a
(DTC), which is stored in the EEPROM. If the same pre-determined number of engine revolutions, the
concern is confirmed during the next trip the MIL MIL will be switched on to alert the driver of the
will be switched on. The CCM monitors many concern.
components, sub-systems and signals. The
following is a list of those that can effect emissions Type B: These can lead to an increase in emissions
depending on application: to a point above the EOBD threshold. If the misfire
is detected during a second trip, over a,
Electronic Ignition (El) System. pre-determined number of engine revolutions, the
Crankshaft Position (CKP) Sensor. MIL will be switched on. If the misfire does not
Ignition Coil. occur over the next three trips, the MIL will be
Electronic Throttle Control Unit. extinguished
Camshaft Position (CMP) Sensor. AirIFuel Ratio (AFR) Monitor (All except vehicles
Air Conditioning (AIC) Clutch. with diesel engine)
Idle Air Control (IAC) Valve. The H02S fitted before the catalytic converter
Mass Air Flow (MAF) Sensor. (upstream) measures the oxygen content of the
Manifold Absolute Pressure (MAP) Sensor. exhaust gas and the variations in it. This then
enables the PCM to adjust the opening times of
Intake Air Temperature (IAT) Sensor. the fuel injectors to maintain the correct AFR. This
Engine Coolant Temperature (ECT) Sensor. is known as Short Term Fuel Trim (STFT). If the
Cylinder Head Temperature (CHT) Sensor. same variation is registered a pre-determined
Heated Oxygen Sensor (H02S). number of times, a permanent correction factor is
Catalyst Monitor Sensor. applied. This is known as Long Term Fuel Trim
(LTFT), which is stored in the EEPROM. When the
Charge Air Temperature Sensor. correction factors exceed pre-determined limits a
Knock Sensor (KS). DTC will be set in the EEPROM. If a concern is

2006.0 Fiesta 1212006 G384566en

 Electronic Engine Controls
DIAGNOSIS AND TESTING
detected in either the STFT or LTFT, and it is still switches over or until the end of a delay. If this
present on a second trip, the MIL will be switched delay expires or the sensor does not switch, the
on. sensor is treated as failed.
Heated Oxygen Sensor (H02S) Monitor (All except Combustion Noise Monitor (Vehicles with common
vehicles with diesel engine) rail fuel injection)
This monitors the operation of the pre (upstream) In diesel variants, the Combustion Noise Monitor
and post (downstream) catalytic converter H02S is used to trim the fuel injection pulse lengths. Each
sensors. It will detect deviations in airlfuel ratios fuel injector has an associated set of correction
(AFR) and sensor faults. data that is determined during a production end of
The H02S will cause emission increase when its line test. The Combustion Noise Monitor is used
response time increases too much. To diagnose to determine how the fuel injector characteristic
a sensor a period is measured and the number of changes from this initial calibration over the life of
leanlrich transitions are counted. The sum of valid the fuel injector.
periods is then calculated. To avoid EGR Monitor (Vehicles with diesel engine)
non-representative measurements, the period is

cardiagn.com
valid only if the H02S has been below a low The functionality of the EGR system is checked by
threshold and above a high threshold between 2 comparing either the MAP sensor output or EGR
consecutive leanlrich transitions. A failure is valve lift potentiometer output (depending upon
declared when the sum of the measured periods application) with expected values.
exceeds the sum of the corresponding limit (held
Diagnostic Requirements
within the PCM) and the MIL is illuminated.
Vehicles equipped with EOBD, can be diagnosed
Catalytic Converter Efficiency Monitor (All except using the WDS. In order for the EOBD system to
vehicles with diesel engine) be invoked, a number of criteria must be met. After
The efficiency of a catalytic converter is measured any repair, which could affect emissions, a trip must
by its ability to store and later release oxygen to be carried out on the vehicle, to make sure that
convert harmful gases. The efficiency is reduced engine management system operates correctly.
if the converter becomes contaminated as it ages,
Malfunction Indicator Lamp (MIL)
and at high gas flow rates, because the exhaust
gas does not remain in the converter long enough The MIL is located in the instrument cluster and is
to complete the conversion process. fitted to alert the driver to the fact that an abnormal
This monitor checks for the oxygen storage condition has developed in the engine management
capacity (OSC) of the catalytic converter. During system, that is having an adverse effect on
a controlled period, the catalyst monitor sensor emissions. In cases of misfires which are likely to
signal is analyzed to evaluate the OSC of the cause catalytic converter damage, it is switched
catalyst. It represents the quantity of oxygen that on immediately. With all other faults it will illuminate
is really used for the oxidation-reduction reaction continuously from the second trip after the condition
by the catalytic converter If a fault has occurred occurred. Under normal operation it should
with the catalyst monitor sensor during the catalyst illuminate at key-on and go out almost as soon as
diagnosis, a sensor diagnosis is carried out. During the engine is started.
the controlled diagnosis phase, the catalyst monitor Diagnostic Trouble Codes (DTCs)
sensor activity is measured and is compared to the
OSC of the catalyst. If this activity is high (low The DTCs given by the PCM are standardized,
0SC)theMILwillbeilluminated.Ifthroughoutthe whichmeansthatgenericscantoolscanread
controlled phase, repeated several times, the results from all vehicles.
downstream sensor output has not moved, the
closed loop mode is delayed in order to test the
sensor. If the catalyst monitor sensor is set to rich,
the injection time is forced to lean and conversely
if the downstream sensor is set to lean, the
injection time is forced to rich until the sensor

2006.0 Fiesta 1212006 G384566en

 303-14-17 Electronic Engine Controls 303-14-17
DIAGNOSIS AND TESTING
The DTC is always a 5 digit alphanumerical The third digit of a code (numeric) identifies the
code, for example "POI00". sub-system which has set the code.
The first digit of a code (letter) identifies the - 'Pxlxx' for metering of fuel and air supply
system which has set the code. Provision has - 'Px2xx' for metering of fuel and air supply
been made for a total of four systems to be - 'Px3xx' for ignition system - combustion
identified although only the 'PI code is required misfires
for EOBD.
- 'B' for the body - 'Px4xx' for auxiliary emission control
equipment
- 'C' for the chassis - 'Px5xx' for vehicle speed, idle setting and
- 'P' for the powertrain other related inputs
- 'U' for the network communications systems - 'Px6xx' for trip computer and other related
All of the "xOxxxWcodes are standardized codes. outputs
However, any manufacturer can use additional - 'Px7xx' for transmission.
codes over and above the standardized codes. - 'Px8xx' for transmission.
These will be labelled "xlxxx"
- 'Px9xx' category to be determined

cardiagn.com
- 'PxOxx' category to be determined
When a concern occurs, the actions taken
include storage of the relevant information and
actuation of the MIL occurs in line with the
relevant legislation.

MIL Code List

! ' MILCode Description

I PO030 I Heated oxygen sensor (H02S) heater open circuit I
- 1 H02S heater low voltage I
I PO032 I H02S heater high voltage I
PO036 1 - ' Catalyst monitor sensor heater open circuit I
PO037 Catalyst monitor sensor heater low voltage
-

PO038 Catalyst monitor sensor heater high voltage

PO053 H02S heater resistance out of limits
I PO054 I Catalyst monitor sensor heater resistance out of limits I
I PO106 I Manifold absolute pressure (MAP) sensor plausibility malfunction I
I PO107 I MAP sensor circuit low input I
PO108 MAP sensor circuit high input
PO109 MAP sensor temporary malfunction
PO112 Intake air temperature (IAT) circuit low input
PO113 IAT circuit high input
PO114 IAT intermittent failure
I
PO116 Engine coolant temperature (ECT) signal stuck at low level
I PO117 I ECT circuit low input I
PO118 ECT circuit high input

2006.0 Fiesta 1212006 G384566en

303-14-18 Electronic Engine Controls 303-14-18
DIAGNOSIS AND TESTING
MIL Code Description
PO119 ECT intermittent failure
PO122 Throttle position (TP) sensor circuit 1 low input
I PO123 I TP sensor circuit Ihigh input I
I PO130 I H02S circuit open circuit I
I PO131 I H02S circuit low voltage I
PO132 H02S circuit high voltage
PO133 H02S circuit slow response
pol34 r- HO~S
IOW amplitude I
I PO136 I Catalyst monitor sensor circuit open circuit I
I PO137 I Catalyst monitor sensor circuit low voltage I

cardiagn.com
PO138 Catalyst monitor sensor circuit high voltage
PO139 Catalyst monitor sensor circuit slow response
PO171 Fuel system error, lean limit
PO171 Fuel system error , NOx emissions
I PO172 I Fuel system error, rich limit I
PO172 Fuel system error, HClCO emissions
PO201 Cylinder No. I- injector circuit open circuit
PO202 Cylinder No. 2 - injector circuit open circuit
I PO203 I Cylinder No. 3 - injector circuit open circuit I
I PO204 I Cylinder No. 4 - injector circuit open circuit I
- 1 TP sensor circuit 2 low input I
1 PO223 1 TP sensor circuit 2 high input I
I PO231 I Fuel pump input low voltage I
PO232 Fuel pump input high voltage
PO261 Cylinder No. 1 - injector circuit low voltage
PO262 Cylinder No. 1 - injector circuit high voltage
PO264 Cylinder No. 2 - injector circuit low voltage
-- -

PO265 Cylinder No. 2 - injector circuit high voltage I

1 PO267 1 Cylinder No. 3 - injector circuit low voltage I
1 PO268 1 Cylinder No. 3 - injector circuit high voltage I
I . PO270 I Cylinder No. 4 - injector circuit low voltage I
PO271 Cylinder No. 4 - injector circuit high voltage
PO300 Random misfire detected
PO301 Cylinder No. 1 misfire detected
- - -

PO302 Cylinder No. 2 misfire detected

2006.0 Fiesta 1212006 G384566en

 Electronic Engine Controls
DIAGNOSIS AND TESTING
MIL Code Description
/

I PO303 Cylinder No. 3 misfire detected

I PO304 I Cylinder No. 4 misfire detected I
PO315 Flywheel segment adaptation at the Limit
PO324 Knock sensor (KS) communication error or implausible signal
KS implausible signal I
1 PO335 1 Crankshaft position (CKP) sensor implausible signal I
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

cardiagn.com
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
PO500 Vehicle speed sensor (VSS) signal malfunction
PO500 Vehicle speed via CAN (VS CAN) implausible signal
-3 I VSS signal too high I
PO511 Idle air control (IAC) valve circuit malfunction
PO560 Battery system voltage malfunction high voltage
PO562 Battery system voltage malfunction open circuit
PO571 Brake switch plausibility error
I PO603 I Powertrain control module (PCM) error NVMY or EEPROM error 1
I PO604 I PCM error RAM error I
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
PO625 Generator low voltage
I

PO626 Generator high voltage

11 PO628 Fuel pump primary circuit low voltage I
71 Fuel pump primary circuit high voltage I
2006.0 Fiesta 1212006 G384566en
303-14-20 Electronic Engine Controls 303-14-20
DIAGNOSIS AND TESTING
MIL Code Description
PO641 Transmission sensor power supply 1 noisy signal
i
PO642 Transmission sensor power supply Ilow voltage
1 PO643 1 Transmission sensor power supply 1 high voltage I
1 PO646 1 Air conditioning (NC) clutch relay circuit low voltage I
1 PO647 1 N C clutch relay circuit high voltage I
I PO651 I Transmission sensor power supply 2 noisy signal I
PO652 Transmission sensor power supply 2 low voltage
PO653 Transmission sensor power supply 2 high voltage
PO654 Engine run output circuit malfunction
PO686 Main relay malfunction low voltage

cardiagn.com
PO687 Main relay malfunction high voltage
PO691 Cooling fan 1 control circuit low voltage
1 PO692 1 Cooling fan 1 control circuit high voltage I
1 PO693 1 Cooling fan 2 control circuit low voltage I
1 PO694 1 Cooling fan 2 control circuit high voltage I
PO704 Clutch switch implausible signal
P I000 EOBD system readiness test not complete
I PI500 I Vehicle speed sensor (VSS) output circuit malfunction I
Generator command malfunction I
P I794 Battery voltage malfunction too high or too low
P2100 Engine throttle body H-bridge malfunction
I P2107 I Safety failure level 3 I
I P2108 I Safety failure level 2 error I
P2119 Engine throttle body throttle flap malfunction
P2122 Accelerator pedal position (APP) sensor circuit 1 low input
APP sensor circuit 1 high input I
1 P2127 1 APP sensor circuit 2 low input I
1 P2128 1 APP sensor circuit 2 high input I
P2128 APP sensor circuits Iand 2 plausibility error
P2135 TP sensor circuits 1 and 2 plausibility error
1 P2176 1 Engine throttle body adaptive algorithm failed 1
P2280 Air cleaner obstruction or leakage
P2282 Air leakage between throttle and inlet valves
I UOOOl I Control Area Network (CAN) bus-off or mute I
I UOlOl I CAN missing frame from TCU I
2006.0 Fiesta 1212006 G384566en
 303-14-21 Electronic Engine Controls 303-14-21
DIAGNOSIS AND TESTING
MIL Code Description
U0121 CAN missing frame from ABS
U0122 CAN missing frame from ESP
U0155 CAN missing frame from HEC
B1213 Number of Passive Anti-Theft System (PATS) programmed keys is below minimum
B1600 PATS ignition key transponder signal is not received
B1601 PATS received incorrect key-code from ignition key transponder
B1602 PATS received invalid format of key-code from ignition key transponder
B1681 PATS transceiver module signal is not received
B2103 PATS immobilizer antenna not connected
B2139 PATS immobilizer challenge response doesn't match

cardiagn.com
B2141 PATS immobilizer no PCM-ID transferred
B2431 PATS immobilizer transponder programming failure
U2510 PATS immobilizer problem with messages on data link

lnspection and Verification

1. Verify the customer concern by operating the
( I system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart
Mechanical I Electrical
- Sensors
- Actuators - Wiring harness
- Electrical
connector(s)
- Powertrain control
module (PCM)

3. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom and refer to WDS or equivalent scan
tool for further diagnostics.

- -

2006.0 Fiesta 1212006 G384566en

303-14-22 Electronic Engine Controls
REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) - I.25L Duratec-16V

(Sigma)/l.4L Duratec-16V (Sigma)/l .6L Duratec-16V
(Sigma)(29 200 0)
c
Special Tool(s) 3. Insert the special tool into the PCM electrical
connector.
Drill Bush, Powertrain Control
Module
4 18-537(29-0 16)

cardiagn.com
Removal
N0TE:lf a new PCM is being installed connect
WDS. Upload the PCM configuration information
using the programmable modules installation
routine prior to commencing the removal of the
PCM. 4mACAUTION:M~~~ sure the special tool is
used to guide the drill bit. Failure to follow
1. Remove the battery tray. this instruction may result in damage to the
For additional information, refer to: Battery electrical connector.
Tray (414-01, Removal and Installation). f
Using the special tool as a guide, drill into (
2. Position the PCM on the battery tray support the shear bolt using a 6mm drill bit, until the
panel. head is removed.
5. Remove the special tool from the PCM
electrical connector and clean all foreign
material from the electrical connector.
6. Disconnectthe PCM electrical connector and
remove the PCM.

2006.0 Fiesta 1212006 GI 00753en

 303-14-23 Electronic Engine Controls 303-14-23
REMOVAL AND INSTALLATION
7. Remove the remains of the shear bolt from 4. If a new PCM is being installedconnect WDS.
/ the PCM using grips. Downloadthe PCM configuration information
usingthe programmable modules installation
routine.
5. N0TE:Do not press the accelerator pedal
during the initialization period as this will
prevent the complete initialization of the
throttle body.
Turn the ignition key to position I1and wait
for one minute to initialize the throttle body.
6. Turn the ignition key to the OFF position.

Installation

cardiagn.com
I.
Install a new shear bolt and securing clip,
using the special tool to push the clip onto
the shank of the bolt.

2. Install the PCM electrical connector to the

PCM.
Tighten the bolt until the head shears off.

3. Install the battery tray.

For additional information, refer to: Battery
Tray (414-01, Removal and Installation).
303-14-24 Electronic Engine Controls 303-14-24

Powertrain Control Module (PCM) - 2.OL Duratec-HE (M14),

Vehicles With: PCM Security Shield
N0TE:lf a new PCM is being installed connect the 4. Remove the PCM mounting bracket lower
c
Worldwide Diagnostic System (WDS). Upload the retaining bolt.
PCM configuration information using the
programmable modules installation routine prior to
commencing the removal of the PCM.
1. Remove the battery tray.
For additional information, refer to: Battery
Tray (414-01, Removal and Installation).
2. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description

cardiagn.com
and Operation).
3. Disconnect the ambient air temperature
sensor electrical connector and detach the
wiring harness from the retaining clip. 5. Lower the vehicle.
6. Remove the PCM mounting bracket upper
retaining bolt.

7. Position the PCM, PCM retaining bracket and

PCM mounting bracket on the battery tray
support panel.
8. Remove the components in the order
indicated in the following illustration(s) and
table(s).

2006.0 Fiesta 1212006 G422234en

303-14-25 Electronic Engine Controls 303114-25
REMOVAL AND INSTALLATION

cardiagn.com
Item Description Item Descri~tion
1 PCM security shield shear bolts 1 6 1PCM mounting bracket I
See Removal Detail
See Installation Detail 1 I removal Detail

I I 2 PCM security shield

See Removal Detail
11FEKGPCMitrica1connectors I
9. To install, reverse the removal procedure.
N0TE:lf a new PCM is being installed connect
WDS. Downloadthe PCM configuration information
PCM retaining bolts using the programmable modules installation
See Removal Detail routine after the installation of the PCM.
1 1 PCM retaining bracket I
-- -

2006.0 Fiesta 121~0o6 G422234en

303114-26 Electronic Engine Controls 303-14-26
REMOVAL AND INSTALLATION
Removal Details
Item 1 PCM security shield shear bolts
Item 4 PCM retaining bolts
1. Remove the PCM security shield shear bolts.
1. Support the PCM, PCM retaining bracket and
Drill a 3 mm pilot hole in the center of the PCM mounting bracket while removing the
PCM security shield shear bolts. PCM retaining bolts.
Drill a 8 mm hole in the PCM security shield
shear bolts and remove the PCM security Item 7 PCM
shield.
I.
Remove the PCM from the PCM retaining
bracket.

cardiagn.com
Item 2 PCM security shield
I.
Remove the PCM security shield.
1. Swing the PCM security shied away from the
PCM retaining bracket.
2. Slide the PCM security shield from the PCM
retaining bracket.

Installation Details
Item 1 PCM security shield shear bolts
1. Tighten the PCM security shield shear bolts
until the head of the bolt shears off.

2006.0 Fiesta 1212006 G422234en

303-14-27 Electronic Engine Controls 303-14-27
REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) - 2.OL Duratec-HE (M14),

Vehicles Without: PCM Security Shield
N0TE:lf a new PCM is being installed connect 2. Disconnect the ambient air temperature
WDS. Upload the PCM configuration information sensor electrical connector and detach the
using the programmable modules installation wiring harness from the retaining clip.
routine prior to commencing the removal of the
PCM.
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect (414-01 Battery, Mounting and
Cables, General Procedures).

cardiagn.com
3. Remove the components in the order
indicated in the following illustration(s) and
table(s).

2006.0 Fiesta 1212006 G422233en

303-14-28 Electronic Engine Controls 303-14-28
REMOVAL AND INSTALLATION

cardiagn.com
Item Description Item Description
I I I I
-- -

I I
1 PCM electrical connectors See Removal Detail

11 2 1 1
3
PCM retaining bolts
See Removal Detail
PCM retaining bracket I
4. To install, reverse the removal procedure.
N0TE:lf a new PCM is being installed connect
WDS. Downloadthe PCM configuration information
using the programmable modules installation
1 4 1 PCM mounting bracket I routine after the installation of the PCM.

Removal Details

2006.0 Fiesta 1212006 G422233en

 303-14-29 Electronic Engine Controls 303-14-29
REMOVAL AND INSTALLATION
Item 2 PCM retaining bolts
I.Support the PCM and PCM retaining bracket
, while removing the PCM retaining bolts.

1. Remove the PCM from the PCM retaining

bracket.

cardiagn.com

2006.0 Fiesta 1212006 G422233en

303-14-30 Electronic Engine Controls 303-14-30
REMOVAL AND INSTALLATION

Heated Oxygen Sensor (H02S)(29 220 0) /

Special Tool(s) 4. Disconnect the H02S electrical connector. (. .. >k,

Socket, Fuel Injector (22mm)

310-063 (23-050)

23050

Removal
1. Remove the air cleaner. For additional
information, refer to Section 303-12 [Intake

cardiagn.com
Air Distribution and Filtering]. 5. Remove the exhaust manifold heat shield.
2. Disconnect the ignition coil pack electrical
connector.

6. Using the special tool, remove the H02S.

3. Detach the ignition coil pack and position it

to one side

Installation
A CAUTI0N:When installing a new H02S, it
is possible that the new component will be
supplied with a longer cable than the one
(- ,

removed. It is important that the cable is

routed and secured in such a way that it

2006.0 Fiesta 1212006 G210054en

303-14-31 Electronic Engine Controls 303-14-31
REMOVAL AND INSTALLATION
cannot be damaged by heat or moving
components and will not cause a noise,
vibration or harshness (NVH) issue.
1. To install, reverse the removal procedure.

cardiagn.com

2006.0 Fiesta 1212006 G210054en

303-14-32 Electronic Engine Controls 303-14-32
REMOVAL AND INSTALLATION

Crankshaft Position (CKP) Sensor

General Equipment e nM6 x 18 mm bolt finger-tight
A ~ i ~ h t the L,. '
I , x 18 mm
~ o l t~6 only.
CKP alignment tool Rotate the crankshaft pulley clockwise until
the crankshaft pulley timing bolt, M6 x 18
I.
Raise and support the vehicle. mm can be installed through the crankshaft
For additional information, refer to: Lifting pulley timing hole into the engine front cover.
(100-02, Description and Operation).
2. Remove the splash shield

cardiagn.com
4. Remove the components in the order
indicated in the following illustration(s) and
3. CAUTIONS:
A 0 n l y turn the crankshaft pulley in the
normal direction of rotation.

2006.0 Fiesta 1212006 en

~423211
303-14-33 Electronic Engine Controls 303-14-33
REMOVAL AND INSTALLATION

cardiagn.com
Item Description Item Description
I 1 I CKP sensor electrical connector I
I See Installation Detail
I J

2 CKP sensor retaining bolts 5. To install, reverse the removal procedure.

See Installation Detail
1 3 1 CKP sensor
Installation Details
Item 3 CKP sensor 2. Align the CKP sensor with the crankshaft
pulley sensor ring.
1. Install the CKP sensor alignment tool to the
CKP sensor.

2006.0 Fiesta 1212006 ~ 4 2 3 2 1en

1
303-14-34 Electronic Engine Controls 303-14-34
REMOVAL AND INSTALLATION
Item 2 CKP sensor retaining bolts
I.Install the CKP sensor retaining bolts.
2. Remove the CKP sensor alignment tool.

cardiagn.com

2006.0 Fiesta iz1~006 ~423211

en
303-14-35 Electronic Engine Controls 303-14-35
REMOVAL AND INSTALLATION

Knock Sensor (KS)

1. Detach the KS electrical connector from the 2, Remove the intake manifold.
intake manifold.
For additional information, refer to: Intake
1

-
Manifold (303-01 Engine 2.OL Duratec-HE
(M14), Invehicle Repair).
3. Remove the components in the order
indicated in the following illustration(s) and
table(s).

cardiagn.com
Item Description Item Description

;
1 KS electrical connector
I I See Removal Detail
See Installation Detail
I

I I 2 Coolant hose I

See Removal Detail 4. To install, reverse the removal procedure.

Removal Details

2006.0 Fiesta 1212006 G426587en

303-14-36 Electronic Engine Controls 303-14-36
REMOVAL AND INSTALLATION
Ifem 2 Coolant hose kern 3 KS
I.Detach the coolant hose from the coolant N0TE:Make a note of the position of the KS and
hose retaining clip and position it to one make sure it is positioned in the same position .
side. when installed.

Installation Details
ltem 3 KS
NOTE: Prior to installing the KS, clean the engine
block and KS mating surfaces.
N0TE:Make sure the KS is installed in the same
position as removed.

cardiagn.com
(I.

2006.0 Fiesta 1212006 G426587en