[Printable HTML page]
Circulate to: Service Manager Body Shop Manager Parts Manager Foremen Receptionists Technicians
(c)2002 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: Engine idle hang up during gear changes, engine running rough/hesitant, or engine speed undershoots during deceleration to a stop
Model: Puma Racing
Markets: Britain
Section: 303-14A
Summary
Should a customer express concern of engine idle flare/hang up during gear changes or when coming to a halt, or that the engine is running rough/hesitant and the engine speed undershoots during deceleration to a stop, the probable cause is a corrupt throttle position sensor (TPS) signal due to poor electrical contact at the TPS electrical connector and engine wiring harness electrical connector. This concern should be rectified by installing a new TPS wiring loom and connector and reworking the engine wiring harness electrical connector.
Parts Required
Description Finis Code Quantity
TPS electrical connector and wire assembly 1 150 138 1
Heat shrink sleeving (as required) Locally Procured 1
Insulation tape (as required) Locally Procured 1
Electrical wire - 250 mm in length, approx 1 mm² (3 off) Locally Procured 1
Labor Time
Operation Description Operation No. Time
Install TPS connector and wiring loom assembly and rework engine wiring loom electrical connector - 1.1 hours
Repair/Claim Coding
Causal Part:
ACES Condition Code:
Defect Code: 44
OASIS 607000, 607700, 608000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 611000, 611500, 617400, 619400
Service Instruction
See Summary
TPS connector and wiring harness rework
• NOTE:Prior to commencing this procedure, the following checks should be carried out:
• NOTE:Obtain the correct TPS wiring diagram from the TIS-CD.
• NOTE:Make sure the throttle cable routing is correct. The throttle pedal should not be stiff and the throttle plate should return to the closed idle position.
• NOTE:Confirm that the throttle shaft assembly has not been drilled and that the throttle stop is not bent.
• NOTE:Check the two manifold to engine block stay retaining bolts are correctly torqued.
• NOTE:Check that the TPS electrical connector loom is not taught, kinked or stiff and that no water is present.
• NOTE:Checked that the injector connections are correctly secured and that no water is present. Make sure that the NVH foam block is installed.
• NOTE:Check the ABV is seated correctly and that the gasket is correctly located. Check the torque of the retaining bolts.
• NOTE:Check the Hego sensor for correct function and switching.
1. NOTE:Obtain and record the audio unit keycode and preset radio frequencies.
Disconnect the battery ground cable.
2. Disconnect the TPS electrical connector.
3. Detach the brake servo vacuum hose from the throttle body.
4. Detach the brake vacuum servo hose from the engine.
Detach the retaining clips.
5. Remove the TPS wires from wiring protection.
6. Remove and discard the old TPS connector.
Using suitable tape and pen, mark the wires on the engine loom side prior to cutting.
Using a suitable tool, cut the three wires.
7. Install a new TPS electrical connector and wire assembly (see Parts Required).
Trim 6 mm of insulation from each wire.
Install heat shrink sleeve (see Parts Required) to each wire.
Solder each joint (3 off).
Position heat shrink sleeve over each joint and apply heat using a hot air gun with suitable nozzle/adaptor.
Bind the joints together with insulating tape (see Parts Required).
8. Install wires into wiring protection.
1. Using insulation tape, make sure that no wires are exposed.
1. Install into wiring protection.
Engine wiring harness electrical connector rework
1. Remove the right-hand headlamp assembly. For additional information, refer to Puma Racing Workshop Manual section 417 ‐ 01.
2. Detach the power steering fluid reservoir from the bracket and secure to one side.
3. Detach the engine wiring harness electrical connector from the inner fender.
4. Disconnect the engine wiring harness electrical connector.
5. NOTE:Using suitable tape and pen, mark the wires on the engine loom side prior to cutting.
Using a multi-meter, carry out a continuity check, to locate the correct wires, between the TPS connector pins and the engine wiring loom connector pins.
6. NOTE:Carry out rework on the male (lower) electrical connector first.
Remove the engine wiring harness electrical connector wires from the wiring protection.
7. NOTE:Insulate the loose ends with suitable tape.
Using a suitable tool, cut the three correctly identified wires 50 mm from the electrical connector and install the 3 new wires (see Parts Required).
Trim 6 mm of insulation from each wire.
Install heat shrink sleeve (see Parts Required) to each wire.
Solder each joint.
Position heat shrink sleeve over each joint and apply heat using a hot air gun with suitable nozzle adaptor.
Bind the joints togetherwith insulation tape (see Parts Required).
8. Install wires into wiring protection.
1. Using insulation tape, make sure that no wires are exposed.
1. Install into wiring protection.
9. Connect the engine wiring harness electrical connector.
10. Using steps 14 to 16, carry out the same rework on the female (upper) electrical connector, installing the 3 wires to the wiring harness.
11. Install the components in reverse order.
©Copyright, Ford Motor Company 1994 - 2009 | Privacy Policy