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JW1982

Member Since 02 May 2012
Online Last Active Today, 04:15 PM
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In Topic: More Power

14 September 2014 - 08:15 AM

The 1.6 Duratec engine (Sigma engine family) has a lot of potential. The performance of this engine can be improved relatively easy. It is even a better base to start from than the 1.6 TI-VCT (115 HP) engine. The only question is how much money are you willing to spend to improve performance.

Note that depending on the stock firmware version many of the 1.6 Duratec engines already have more than 100 HP. The few I know from were all between 105 and 112 HP.


I have done some modifications myself on my 1.6 Duratec. In my opinion these modifications make a big difference. Before I started I tested my car on a rolling road. My car has a low mileage and always has run on RON98 fuel. Before modifications it already had 110 HP.

On these engines the air intake is the biggest restriction. To allow more air flowing into the engine I started to optimize the air filter housing and resonator. I removed all restrictions and unnecessary material. I replaced the stock airfilter with a K&N panel filter.

After the air filter housing and resonator were optimized the stock 45 mm throttle body was the biggest restriction. Because there are no larger throttle bodies available for this type of engine I decided to modify a stock 45 mm throttle body. I enlarged the stock throttle body to 50 mm and installed a new 50 mm throttle plate from a Weber carburetor. The larger throttle body makes a big difference. This makes the engine feel a lot smoother and more powerful.

After the air intake was completely optimized I installed a Superchips remap which is also a big improvement. At the moment my car has over 120 HP. My next modification will be a custom made stainless steel exhaust. At the moment I still have the original exhaust which is not bad but for more power it needs to be replaced. Because I can do most modifications myself it did not cost me much.


For more power it is required to do some (more expensive) modifications. There are some engine specialist who can get up to 190 HP out of this engine. To do this you must perform (at least) the following modifications:

* Install adjustable camshaft sprockets and custom camshafts
* Install a custom made inlet manifold with motorcycle throttle bodies.
* Install improved connecting rod bolts (necessary for higher RPM).
* Remove the rev. limiter.
* programmable ECU.



As already said technically there are enough possibilities to get more power out of this engine. The biggest restriction will be your wallet.

In Topic: Software Update/ Module Update

11 September 2014 - 06:38 PM

There are other ways to update the PCM firmware but if you do not have any experience the safest option will be the Ford dealer.

Personally I update the PCM firmware myself using a modified ELM327 and the ELMconfig software. To do this you must know exactly what your doing and which firmware file is suitable for which type/year of car/engine. Next to this I have also access to the Ford IDS diagnostic system and I own a spare PCM for my car. In case something goes wrong I am Always able to get the car running again.

In Topic: Software Update/ Module Update

11 September 2014 - 05:17 PM

All newer engine types are controlled by a computer. On Ford vehicles this computer is called the PCM (Powertrain Control Module). Based on all sensor data the computer calculates the needed amount of fuel for optimal engine performance and efficiency.

The PCM software is being developed during the development of a certain model/engine type. During life of the model/engine type the PCM software is constantly being improved by the software engineers to solve some known problems or make the engine more efficient or improve emmisions to meet (new) regulations.

For some engine types there are over 30 different firmware files. Updating the software to the latest available version can make a huge difference. After I bought my car it had the Original PCM software which was released in 2004. After updating to the latest available software (2010) for my engine type the engine runs much smoother (especially when idling).

In Topic: 2008 Focus Tsb

11 September 2014 - 04:51 PM

I collected a lot of TSB files from the internet over the years. I have got the following information about the TSB you requested. Note that I deleted some non relevant information. Also note that this Ford TSB is no (warranty) recall. The TSB's are only a guide for the mechanic containing known problems and solutions. If the car is not under warranty you have to pay yourself for the repair.


TSB 27/2012
5/14/12 Excessive combustion noise and or hesitation during light load acceleration with the engine at high operating temperature


Subject/Concern: Excessive combustion noise and or hesitation during light load acceleration with the engine at high operating temperature

Model:

Focus 2004.75 (07/2004–07/2011) - stage 4 emission level only Build Date: 07/2008-12/2009
Build Code: 8D-9E
Assembly Plant: Saarlouis
Assembly Plant: Valencia
Engine: 1.8L Duratorq-TDCi (Lynx) Diesel

C-MAX 2003.75 (06/2003–07/2010) - stage 4 emission level only Build Date: 07/2008-12/2009
Build Code: 8D-9E
Assembly Plant: Valencia
Engine: 1.8L Duratorq-TDCi (Lynx) Diesel

Mondeo 2007.5 (02/2007–) - stage 4 emission level only Build Date: 07/2008-12/2009
Build Code: 8D-9E
Assembly Plant: Genk
Engine: 1.8L Duratorq-TDCi (Lynx) Diesel

Transit/Tourneo Connect 2002.5 (06/2002–) - stage 4 emission level only Build Date: 05/2008-01/2010
Build Code: 8C-AL
Assembly Plant: Kocaeli
Engine: 1.8L Duratorq-TDCi (Lynx) Diesel

Markets: All
Summary

If a 1.8L Duratorq-TDCi (Lynx) engine vehicle of the stated build periods, is noted for excessive combustion noise and or hesitation during light load acceleration with the engine at high operating temperature, please check the fuel injector nozzle part number. If the fuel injector nozzle part number end in 3, revised calibrations have been released to improve the fuel injector nozzle performance. These calibrations should not be applied if the fuel injector nozzle part number ends in 2.

This bulletin contains a list of the revised PCM calibrations which should be loaded, in order to rectify the concern.

NOTE: Use IDS-78.05 DVD and IDS-79.01 or a later version.

For markets where FordEtis IDS is used, refer to WB 45/2009 for the policy on using FordEtis IDS for warranty repairs. If FordEtis IDS is used to diagnose a customer's concern(s), select the appropriate customer symptom(s), follow any diagnostic, repair and post repair procedures presented, and ensure the completed diagnostic session file is transmitted to Ford. Failure to follow this process may affect any associated warranty claim submission. For markets where FordEtis IDS is not available, rectify this concern by following the attached service information.


Service Information
See Summary.

For markets where FordEtis IDS is used, connect FordEtis IDS and select the appropriate symptoms from the concern descriptions above. Follow the FordEtis IDS instructions to rectify this concern.


Item Description
- Inspect the part number of the fuel injector nozzle. If the part number end in 3, update the PCM calibration. New calibrations have been released via FordEtis IDS to compensate the fuel injector nozzle loss of performance.


NOTE: These calibrations should not be applied if the fuel injector nozzle part number ends in 2.

NOTE: Use IDS-78.05 DVD and IDS-79.01 or a later version.

NOTE: Before commencing module configuration or programming, connect the vehicle battery to a suitable external power supply in order to maintain a constant battery voltage throughout the procedure.

1. Reprogram the PCM using IDS.


C-MAX 2003.75 and Focus 2004.75

Vehicle PCM calibration chain (12A650) - Increased energy PCM calibration
C-MAX 2003.75 7M51-AU* (e.g. 7M51-AUK) update to 7M51-BPA or later
Focus 2004.75 7M51-BC* (e.g. 7M51-BCG) update to 7M51-BNA or later


Mondeo 2007.5

1.8L Duratorq-TDCi (Lynx) Diesel PCM calibration chain (12A650) - Increased energy PCM calibration
92kW/125PS with 5-Speed Manual Transmission 7G91-P* (e.g. 7G91-PJ) update to 7G91-AEA or later
92kW/125PS with 6-Speed Manual Transmission 7G91-Y* (e.g. 7G91-YK) update to 7G91-AGA or later
92kW/125PS with 5-Speed Manual Transmission Econetic 8G91-J* (e.g.8G91-JC) update to 7G91-AFA or later


Transit /Tourneo Connect 2002.5

1.8L Duratorq-TDCi (Lynx) Diesel(*) PCM calibration chain (12A650) - Increased energy PCM calibration
55kW/75PS without Diesel Particulate Filter (DPF) 7T11-H* (e.g. 7T11-HP) update to 7T11-BA or later
66kW/90PS without Diesel Particulate Filter (DPF) 7T11-D* (e.g. 7T11-DP) update to 7T11-EA or later
55kW/75PS without Diesel Particulate Filter (DPF) 9T11-H* (e.g. 9T11-HJ) update to 9T11-JA or later
66kW/90PS without Diesel Particulate Filter (DPF) 9T11-GJ* (e.g. 9T11-GJ) update to 9T11-NA or later

(*) Turbocharger with fixed turbine geometry only.

In Topic: Guide For Focus Mk2/mk2.5 C-Max/kuga ~Elm 327 Cable And Ff2 Program

11 September 2014 - 03:32 PM

The location of the PCM is different on most engine type. On my 1.6 Duratec the PCM is located in the engine bay behind a cover on the side of the battery box.

The PCM is mounted with shear (fracture) bolts. The head of these bolts breaks loose after the correct tightening torque is achieved which makes removal a lot more difficult. The head of these bolts must be drilled off to remove them.