Yet another Ford bites the dust!

Have a Ford Mondeo 1.6 Zetec (RK)

Year 1994 (P)

Customer says for some time before the main problem surfaced the car would surge when going downhill and would sometimes cut out. Main problem now is that it will not respond to throttle at all. As soon as you push the accelerator the engine dies. When re starting the engine it takes some time before it will start and idle again and the cooling fan would just run for no reason at all.

On inspection found that insulation on harness leading from multiplug to injectors, ISCV, TPS, and Coolant Temp Sensor had disintegrated. Repaired the harness and re-installed it.  On checking for management voltages and earths at sensor and actuators, I found that TPS had no earth, so checked back and found that pin in ECU was broken. I had to solder a wire in direct from board out to main multiplug. This cured the earth problem to the TPS  and stopped cooling fan from running unnecessarily but engine still does not respond to accelerator and as soon as you push it the engine cuts out.

Checked for management voltage to cam position sensor – no management voltage available but I do have a good earth. I believe these engines do rely on the cam sensor for sequential fuel injection timing. Looking at the diagram I am sure I should be seeing 5 volts going to Cam sensor with ignition on.

Sorry for the long post again!! Any help would be appreciated before this Ford  sends me crazy !!!!

Regards,

Diagnut.

From your description, I would check the coil output, as a bad coil will cause poor starting and flat spot, or stalling, on acceleration.

If I understood women as well as I understand cars, I'd be the envy of every man.

OK, Thanks for that. What i really want to know was whether on the multiplug I should see a voltage going into the sensor as well as the earth that is present with the ignition on.

Forgot to mention that I have already changed the coil pack and HT leads and plugs and none of these made any difference.

Thanks,

Diagnut.

If this is a '94, it's still an EEC IV?  The cam sensor should have a common earth on it's brown/white wire and a pulsing signal [as said 2v] on it's white/violet one.  No reference voltage feed.  Sensor resistance is 200-900 ohms.

Surges going downhill...  Fuel pressure OK?  Fuel type/quality OK?  If it's got a cat; is it blocked or has it had a new one lately?  The exhaust gas pressure sensors can melt internally and short if the cat blocks.  Try disconnecting it.  MAF sensor got a battery feed on pin 5?

ECU feeds and earths OK?  With ign on; live on terminal 1,37,45,57: earth on 16,20,40,60.  The fan [and the fuel-pump?] runs when the ECU goes into limp-home.  The ECU signal normally keeps the fan off!

Try some of those and let us know.

.

This is a 94 model and colours match those on wiring in car. Will carry out some more checks based on your info - Thanks.

Regards,

Diagnut.

I spent ages on one of these. Having repeatedly asking the garage to check the cam timing and them saying it was fine (they hadn't bothered!) that was the fault. You may have already checked it, in which case I apologize, but the basics do get overlooked quite often.

Regards, Ian.

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Experience is something you don't get until just after you need it!

Any chance you could give me colours of wire to match the pins that I should find the live and earth feeds. I did try but got a bit confused with it. I am probing from the back of the plug when it is plugged into the ECU. Got the earths on 20 40 & 60 but not sure about the other pin nos. Thanks.

Ian,

Good point, I will check this and see if the timing is correct.

Thanks,

Diagnut

There is a discrepency in the engine detail you have given. A 1.6 engine would be code L1. The RK engine is a 1.8.

If I understood women as well as I understand cars, I'd be the envy of every man.

Sorry about the quality of pic but you can just make out the numbers, this is the configuration as you look at the plug (connected)

Live feeds:

1 - orange/yellow

37 - green/yellow

45 - blue/red

57 - green/yellow

Earths

16 - black/blue

20 - no colour given

40 - black/yellow

60 - black/yellow

DaveH

   

Yep, I agree wrong engine cc was given should have been 1.8 vice 1.6. Good thing engine codes.

Dave,

The quality of picture should just about give me enough details to go on to check those pins.

Thanks,

Diagnut.