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Solution: The most likely problem is the shock absorber top mounts. Revised and updated new shock
absorber top mounts should be fitted.
Ford Fiesta & Fusion upto 2003 1.25 1.4 1.6 Duratec
Solution: The EAC FAIL relates to the electronic accelerator control. Vehicles that trigger diagnostic
fault codes (DTCs) / fault codes P2138 with P2122, P2123 or P2127 a common problem is the PCM
(powertrain control module = ECM = engine control module) electrical connector. Check the electrical
connector for the PCM for damage to the terminals and pins. Replace or repair as necessary. On
vehicles that trigger P2119, P2135, P2176, P0120, P0122, P0123, P0220, P0222 or P0223 fault
codes can suffer from the same PCM terminal damage but also suffer from throttle body electrical
connector damage. The throttle body will need to be inspected and tested using an scope or scanner
looking at live data. Check the serial number on the throttle body. Replace with a revised throttle body
of the serial number is below 400000. Fault codes definition:
P0123 – Throttle position sensor 1 electrical error short to battery or line break
P2119 – Throttle plate convergence error. The throttle flap has not moved to the required position.
This can be from an obstruction or incorrect signal. Check wiring and connectors.
P2176 - Throttle plate adaption error. After the ignition is switched off, the throttle body will run
through an adaption cycle and spring check. This confirms correct functioning of the throttle body
through the full range. If other fault codes are stored, they should be investigated first before P2176.
P2100 - H bridge error. Fault in circuit between throttle body motor and PCM.
P2108 - Analogue to digital converter. This can be a number of different sensors and will often be
triggered with other fault codes that are more specific. P2108 can relate to mass air flow, engine
speed, pedal ratio, TPS ratio, torque generation, engine speed limitation etc.
If there is inteferance or the voltage is not regulated correctly, the signal for pedals or throttle body will
be out of range
Problem: When the fan direction is set to windscreen, air is still blown into the footwell.
SOlution: A known problem is a faulty air distribtion flap. To rectify the problem, a revised air
distribution flap should be fitted. The revised flap has been fitted since 06/2003.
Solution: At high temperature environments, the engine increases the engine revs by 250 rpm to
increase the air conditioning performance. However, due to PCM (engine control module) software
issues, the increase can happen with the AC switched off or even in cars without AC. The PCM will
need a software update if the part number precedes:
2S6A-12A650-BN
2N1A-12A650-AG
2N1A-12A650-BE
2N1A-12A650-CD
2U71-12A650-KA
Updated and more reliable calibrations will set the engine revs to increase by 100 rpm when the AC is
switched on and an extra 150 rpm when the AC is running in high temperaure environments.
Solution: The most likely cause is the port 4 upper and lower exhaust manifold bolts working loose.
Revised bolts should be fitted and tightened to 24 Nm.
Ford Fiesta and Focus 2001 - 2002 1.8 TDCi and Di engines with A/C
Solution: The A/C (air conditioning) compressor supporting bracket works its way loose. The bracket
will need to be realigned and tighten the four bolts to 23Nm.
Problem: Whistling noises during high speed form upper windscreen area.
Solution: The most likely cause is the upper weatherstrip of the windscreen vibrating against the metal
of the roof panel. The solution is to apply sealear to the gap along the length of the weatherstrip. Take
care not apply to much sealer at the two ends of the weatherstrip and remove any excess. From
07/2002 a hardened weatherstrip has be used in production.
Solution: This may be due to brake fluid leaking at the connection between the rear brake hose and
wheel cyclinder. The solution is to tighten to a revised torque. Check the hoses and cylinders and
replace if necessary. The revised torque is 21.5 Nm for the Fiesta and Puma and 17.5 Nm for the Ka.
Soultion: The problem could be mechanical movement from the diesel injector pump being
transmitted through to the accelerator pedal. The solution is to apply black body sealant to the rear
cavity behind the accelerator pedal and re-route the accelerator cable between the brake line and
brake booster.
Ford 1996 Fiesta, Ka, Puma
Solution: A number of common failures have been identified including a damaged wiring harness,
damaged electrical connectors, broken heater control valve or kinked heater hoses.
Problem: Smell of melted plastic and fan blower motor does not work on settings 1, 2 or 3.
Solution: This problem may be caused by a poor electrical contact of the blower motor resistor
multiplug. The high current passing through the resistor may be the cause of the melting multiplug.
The solution is to fit a new blower motor resistor that has modified connectors that can withstand the
high temperatures along with a new wiring loom to the resistor. A revised blower motor resistor has
been fitted since 10/1999.
Problem: Squeal from the front end accessary drive belt (FEAD).
Solution: The accessary drive belt may be lacking tension and causing the noise. Install a new belt
and increase its tension to rectify the problem.
Solution: The windshield PU sealant may not be sufficient at the spot weld seam to block the noise
out. Add extra sealant to the spot weld seam to rectify the problem.
Ford Fiesta 1995 - 1999, Ford Puma 1997 - 1999, Ford Ka 1996 - 1999
Solution: This can cause sticking brakes and excessive noise from the rear and/or rear wheel block.
Installing a rubber gasket around the wheel cylinder should alleviate the problem.
Ford Fiesta 1996, Ford Puma 1997 - 1999 and Ford Ka 1996 - 1999
Solution: May be caused by a mechanical problem in the front brake cross shaft and spring. It may
lead to other problems such as, brakes operating without braking, front brakes heating up or smelling
after only a short time, lack of acceleration or the need to make hard use of the accelerator.
- A small amount of fluid will come out when the bleed screw is loosened if the brakes are dragging.
- Re-tighten the front bleed screws.
3. Make sure that the stop light switch on the pedal box is in the correct position.
- Set the switch so that a minimum of 1.5mm of the white portion of the switch is visible when the
brake is off.
- Pull up on the brake pedal to check the setting. If set too low, the switch will ratchet up.
5. The cross shaft return spring should be checked, making sure that the return spring end coil is not
jammed between the black bush and the cross shaft lever.
- Do not remove the two connecting linkage mounting bracket retaining nuts until after the spring is
detensioned, just loosen them.
- Do not remove the connecting linkage mounting bracket until after the spring is detensioned.
- To make sure that the push rod fixing is not stiff, before removal of the servo actuator clevis pin and
clip, move the servo forwards and backwards several times.
- Remove the cross-shaft and install a new one if the fixing is stiff. If it is free to move, continue with
the steps.
- Fiesta only: do not remove the emission component mounting bracket.
- Make sure that the end coil of the sprng is not trapped under the edge of the bush after the spring is
detensioned. Release it if it is.
- Do not detach or remove the LHS mounting bracket.
- Do not remove the cross-shaft from the vehicle.
9. Apply grease to the inside of cross-shaft LHS bearing, around the shaft.