Ford Fiesta and Fusion 2001 - 2002

Problem: Knock from rear suspension on rough road surfaces.

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

Problem: Loss of power and EAC FAIL displayed.

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:

Pedal fault codes

P2120 – Pedal sensor 1 electrical error

P2122 – Pedal sensor 1 electrical error short to ground or open circuit

P2123 – Pedal sensor 1 electrical error short to battery

P2125 – Pedal sensor 2 electrical error

P2127 – Pedal sensor 2 electrical error short to ground or open circuit

P2128 – Pedal sensor 2 electrical error short to battery

P2138 – Pedal sensor 1 & 2 ratio error  

Throtlle body fault codes

P0120 – Throttle position sensor 1 electrical error

P0122 – Throttle position sensor 1 electrical error short to ground

P0123 – Throttle position sensor 1 electrical error short to battery or line break

P0220 – Throttle position sensor 2 electrical error

P0222 – Throttle position sensor 2 electrical error short to ground or open circuit

P0223 – Throttle position sensor 2 electrical error short to battery

P2135 – Throttle position sensor ratio error

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.

PCM fault codes

P2107 - Processor monitoring on the main controller fault

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

P0641 – Sensor voltage supply circuit 1 noisy signal

P0642 – Sensor voltage supply circuit 1 short to ground or open circuit

P0643 – Sensor voltage supply circuit 1 short to battery

P0651 – Sensor voltage supply circuit 2 noisy signal

P0652 – Sensor voltage supply circuit 2 short to ground or open circuit

P0653 – Sensor voltage supply circuit 2 short to battery


Ford Fiesta & Fusion 2002 - 2003

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.


Ford Fiesta & Fusion 2002 - 2003

Problem: Intermittent rough engine idle at high ambient temperatures.

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.


Ford Focus and Fiesta 1.8 Endura diesel engine 2001

Problem: Exhaust gas leak from exhaust manifold.

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

Problem: Excessive noise from the accessory drive belt.

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.


Ford Fiesta 2002

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.


Ford Fiesta, Ka, Puma 2000

Problem: Low brake fluid warning lamp comes on too early.

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.


Ford Fiesta 1.8 Endura left hand drive

Problem: Vibrations from accelerator pedal between 2000-4000 rpm.

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

Problem: Unable to alter the heater temperature.

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.


Ford Fiesta, Ka and Puma upto 1999

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.


Ford Fiesta 1996, Ford Escort 1996

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.


Ford Fiesta 1996

Problem: Excessive engine noise in the passenger compartment.

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

Problem: Water ingress in rear wheel cylinder.

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

Problem: Brake drag or brake pedal slow return.

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.

To rectify these problems:

1. Decipher which brakes are dragging.

- If it is just the rear brakes, re-adjust the parking brake cable.
- if it is the front brakes only, go to step
- If all four brakes are dragging, re-adjust the parking brake cable and then go to step 2.

2. Both front bleed screws need to be loosened.

- 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.

4. Raise the vehicle.

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.

6. Lower the vehicle.

7. Take off the connecting linkage-servo operating/cross-shaft.

- 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.

8. Apply some grease to the inside of the cross-shaft RHS bearing.

9. Apply grease to the inside of cross-shaft LHS bearing, around the shaft.

10. Install all the components in reverse order.

11. Bleed the brake system.

12. Bleed the clutch system.

13. The vehicle needs to be road tested.


Ford Fiesta 1996

Problem: White smke from the exhaust and/or lack of power.

Solution: The powertrain control module (PCM) injector drive circuit may have been damaged by water getting through the bulkhead into the front fender apron joint. To rectify this, apply sealer to the affected body joint, install a new PCM and heated oxygen sensor, and change the engine oil and filter.