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#1 mickmezza

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Posted 08 July 2008 - 03:07 PM

hi peeps have a small problem with my engine, its 1.8 16v zetec engine from a r reg escort.
the problem is wen i start it the revs bounce up and down from 300 rpm to 2000 rpm. and will settle after a short while. give it some revs like 3000 then it does it again. any ideas will be appriciated.
thanks mick

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#2 vinnyvangough

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Posted 08 July 2008 - 03:21 PM

Hi and welcome,

Not sure about that one mate?

#3 hotashel

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Posted 09 July 2008 - 07:38 PM

Hi,

Could be idle control valve

#4 mike alexandre

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Posted 11 July 2008 - 12:41 PM

hi peeps have a small problem with my engine, its 1.8 16v zetec engine from a r reg escort.
the problem is wen i start it the revs bounce up and down from 300 rpm to 2000 rpm. and will settle after a short while. give it some revs like 3000 then it does it again. any ideas will be appriciated.
thanks mick

Have you checked the vacumn pipes around the maniflod and fuel system for leaks.

#5 the controller

the controller

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Posted 11 July 2008 - 01:59 PM

Checkk this TSB out mate


TECHNICAL SERVICE BULLETIN No.74/2000
08 June 2000
[Printable HTML page]
Circulate to: Service Manager Body Shop Manager Parts Manager Foremen Receptionists Technicians

©2000 Ford Motor Company Limited. Eagle Way, Brentwood, Essex CM13 3BW, United Kingdom.

This bulletin represents technical service information only. Without exception all gratis repairs and replacements are subject to the individual warranty and policy procedures of the supervisory Ford Company. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of publication.

Subject/Concern: Poor drivability/Poor idle
Model: Escort
Markets: All
Engine: 1.6L Zetec
1.8L Zetec
1.6L Zetec-E
1.8L Zetec-E

Transmission/Transaxle: (ManualTransmission)

Section: 303-14A (29)
Summary

This bulletin details the diagnosis of poor drivability and poor idle concerns for Escort 1.6L/1.8L Zetec or Zetec‐E engines with manual transmission. The concerns in this bulletin can have various causes and symptoms, so it is vital that the procedure is followed carefully and the vehicle is checked and tested exactly as directed.

This bulletin only covers those high idle speeds which are defined as follows: The vehicle is moving and the clutch pedal is depressed, resulting in a high idle speed of over 2000 rev/min which returns to normal when the vehicle is brought to a stop. Any other high idle speeds are caused by other concerns (e.g. faulty alternator, Vehicle Speed Sensor (VSS), air conditioning, etc) and should be investigated accordingly.


Parts Required
Description Finis Code Quantity
Grease (WSB M1C239 A) 5 030 186 1
Electrical Insulating tape (Black) Locally procured 1
Contact spray lubricant Locally procured 1
Wiring loom See Parts Microfiche 1
Heated Oxygen Sensor (HO2S) 1.6L/1.8L (as required) 6 847 908 1
PCV see Parts Microfiche 1
PCV hose see Parts Microfiche 1
Idle air control (IAC) valve 1 063 996 1
Clutch switch see Parts Microfiche 1
PCM: Vehicles in Germany/Austria with D3 Territories 1
1.6 PCM EEC IV with PATS 1 094 167 1
1.8 PCM EEC IV with PATS (vehicles built up to 25.08.97) 1 094 058 1
1.8 PCM EEC IV with PATS (vehicles built 25.08.97 onwards) 1 094 057 1
PCM: All Vehicles except those in Germany/Austria with D3 Territories 1
1.6 PCM EEC IV without PATS 1 042 519 1
1.6 PCM EEC IV with PATS 1 054 503 1
1.8 PCM EEC IV without PATS 1 078 665 1
1.8 PCM EEC IV with PATS (vehicles built up to 25.08.97) 1 078 667 1
1.8 PCM EEC IV with PATS (vehicles built 25.08.97 onwards) 1 078 666 1
Rivet Locally procured 1
Labor Time
Operation Description Operation No. Time
Module - Powertrain control (PCM) - Remove and Install - 29 200 0
WDS/FDS 2000 ‐ Main check - 29 200 0
WDS/FDS 2000 ‐ Idle speed control ‐ Interactive check - 29 200 0
Strip down, inspect HO2S multiplug and replace insulation, inspect DLC and PCM multiplugs, seal wiring loom and road test vehicle - 29 200 0
Clean, dry and grease the HO2S, DLC and PCM multiplugs - 29 200 0
Carry out FDS 2000/WDS check and install new HO2S sensor - 29 200 0
Check PCV, IAC valve - 29 200 0
Check PCM connector and clutch switch circuit - 29 200 0
Repair/Claim Coding
Causal Part:
ACES Condition Code:
Defect Code: 09
OASIS 608400

Production Action
A revised wiring loom has been installed in production since 07.98 (build code WM).

A revised IAC valve has been installed in production since 10.98 (build code WR).

For 1.6 Zetec‐E: A revised D3 PCM has been installed in production since 02.99 (build code XK) and a revised non‐D3 PCM has been installed since 09.98 (build code WB).

For 1.8 Zetec‐E: A revised D3 PCM has been installed in production since 02.99 (build code XK) and a revised non‐D3 PCM has been installed since 10.98 (build code WR).

Service Instruction
See Summary

1. Check whether vehicle is equipped with an EEC IV or EEC V Powertrain control module (PCM).

EEC IV - underfloor catalyst.
EEC V - Close coupled catalyst.

2. Carry out a full diagnosic check using FDS 2000/WDS.

1. Record any codes shown, then exit FDS 2000/ WDS.

3. Road test the vehicle, with customer if possible, to confirm concern.

4. Test the vehicle emissions with a 4 gas analyser.

1. Record all readings.

1. If the oxygen content is too high, go to step 28.

1. If the oxygen content is OK, go to next step.

5. Carry out a full diagnosic check using FDS 2000/WDS.

Identify and record all codes, rectify concerns and clear codes as necessary.
For EEC V PCM: confirm calibration level and follow FDS 2000/WDS instructions to bring PCM to latest level as necessary.


EEC V Vehicles only

1. Check modification state of PCM wiring.

1. Disconnect PCM multiplug.

1. If bridging wire is present between pin 64 and pin 91, remove it and reconnect multiplug.

1. If no bridging wire is present, reconnect multiplug.

2. NOTE:Clutch switch check MUST be carried out with transmission in neutral.

Check clutch switch operation.

1. Using a multimeter, check clutch switch operation.

1. When the clutch pedal is at rest position, the reading should be ”open" circuit.

1. When the clutch pedal is depressed, the reading should be ”closed" circuit.

1. If these readings are not correct, check clutch switch for presence of bridging wire.

1. If bridging wire is present, remove it and re‐check clutch switch operation.

1. If bridging wire is not present, install a new clutch switch (see Parts Required).


All Vehicles

1. Carry out a road test to verify concern.

If concern has been rectified, no further action is required.
If concern is still present, go to next step.

2. Remove the PCM according to Operation Number 29 200 0 (Workshop Manual/ TIS‐CD).




3. Disconnect and detach the heated oxygen sensor (HO2S) multiplug.




4. Strip down the loomside insulation of the HO2S multiplug.

If water or heavy contamination is found, replace wiring loom (see Parts Required). Go to next step.
If no evidence of moisture is present, replace insulation and go to next step.




5. Seal, if required, the wiring loom branch (where the loom branches into the engine compartment, adjacent to the battery) using electrical insulating tape (see Parts Required).

6. Disconnect and inspect the following multiplugs:

PCM
Diagnostic link connector
HO2S (sensor side)
If moisture is present, then clean and dry the terminals and multiplugs and apply grease (see Parts Required) to the terminals.

7. Reconnect the HO2S sensor.

8. Install the PCM according to Operation Number 29 200 0 (Workshop Manual/ TIS‐CD).

9. Road test the vehicle.

If the concern is no longer present, no further action is required.
If the concern is still present, go to next step.

10. Load the vehicle data into FDS 2000/WDS.

11. Connect the portable diagnostic unit (PDU) into the diagnostic link connector.

12. Select ”Datalogger" from the Diagnostic Menu.

13. Select ”Workshop Test".

14. Select ”HO2S".

15. Select the ”Play" icon to obtain a reading.

If the HO2S sensor is not operating correctly, install a new HO2S sensor (see Parts Required).
If the HO2S sensor is operating correctly, go to next step.


Vehicles with EEC IV PCM only

1. For Escorts with 1.8l Zetec‐E engines, a number of concerns resulting from PCM calibration issues have been identified and can be detected by any of the following symptoms:

Engine hesitation/stumbles during deceleration (2000 rev/min).
Occasional single misfire whilst accelerating (2000‐2400 rev/min).
Tip in/tip out.
Engine surging on light throttle application (2000‐3000 rev/min).

2. Once all other possible causes have been eliminated, a revised PCM (see Parts Required) should be installed according to Operation Number 29 200 0 (Workshop Manual/TIS‐CD).

3. For Escorts with 1.6l Zetec‐E and 1.8l Zetec‐E engines that have a PCM for use in D3 Territories (Germany/Austria) only installed, concerns such as a high idle speed after a cold start and/or idle speed hang up at a stop may be caused by the legal requirement to initially heat the catalyst very rapidly. At these speeds it is possible to drive off without touching the accelerator.

4. Install a new PCM (see Parts Required) according to Operation Number 29 200 0 (Workshop Manual/TIS‐CD).

5. For customers in D3 Territories, whose vehicles have the D3 PCM installed, it should be explained that the high idle speed when the engine is cold can be alleviated as follows:

1. After start and before driving away, open the throttle slightly and then close it. This allows the system to dump some of the extra air that was originally required.


All Vehicles

1. Check for air leaks.

Any air leaks found should be rectified, before going to next step.
If no air leaks are found, go to next step.




2. Visually inspect PCV hose.

If any damage is found, replace PCV hose (See Parts Microfiche), then go to next step.
If no damage is found, go to next step.




3. Detach the PCV hose at the PCV and block the end of the hose.

If the concern is rectified, install a new PCV (see Parts Required), unblock and re‐attach hose.
If the concern is still present, go to next step.

4. Remove the idle air control (IAC) valve.




5. Check the IAC valve part number.

1. IAC valve should have part number suffix ”-AC".

1. If suffix is not ”-AC", install a new IAC valve (see Parts Required).

1. If suffix is ”-AC", go to next step.

6. Reinstall IAC valve.

7. Re‐road test the vehicle.

If the concern has been rectified, no further action is required.
If the concern is still present, the cause must be further investigated.



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Action took ms. on wasv243

#6 mike alexandre

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Posted 12 July 2008 - 08:29 AM

Checkk this TSB out mate



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Action took ms. on wasv243

Thanks Controller - you may just have given me a lead on my problem on another thread listed here.

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