Engine Controls - System/component Tests - 1.8l Ford Escort V

INTRODUCTION

Before testing separate components or systems, perform all procedures listed in the BASIC TESTING article. Since many computer-controlled and monitored components will set a trouble code if they malfunction, also perform procedures listed in the TESTS W/CODES article.

Note. Testing of individual components does not isolate short or open circuits. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless specifically stated otherwise in test procedures. Use ohmmeter to isolate shorts or opens in harness.

System Integrity Check

1. Visually inspect electrical components for damaged connections or insulation. Check vane airflow meter for damage. Check air duct damage for looseness. (Scheme 100)
2. Check vacuum hoses for damage, kinks or poor connections. Check wastegate, actuator and linkage for damage or binding. Ensure turbocharger does not leak oil or make unusual noise when engine is running.

Wastegate Functional Check

1. Remove heat shields from turbocharger area. Disconnect linkage from wastegate. Manually operate lever to verify free movement and full travel. If restriction is felt, replace turbocharger.
2. If no resistance is felt, connect wastegate linkage. Remove actuator hose from solenoid. Apply 8.5 psi (.59 kg/cm 2 ) to actuator hose and check wastegate operation. If wastegate does not open, replace actuator, linkage and mounting plate.

Boost Control Solenoid Valve Check

1. Remove solenoid power connector. Remove solenoid valve bleed hose at engine. Apply low air pressure to hose to ensure valve is closed.
2. Using jumper wire, apply battery voltage to solenoid connector Red/Black wire and attach Brown/Yellow wire to ground. Apply low air pressure to hose to ensure valve is open. If valve does not operate as described, replace boost control solenoid valve.

Intercooler Leakage Check

Check intercooler for damage or restriction. Remove and plug inlet hose. Remove outlet hose. Attach Hose Adaptor (021-00053) with radiator pressure tester. (Scheme 98) Pressurize system. If system does not hold pressure, repair leak or replace intercooler. If system holds pressure, system is okay.

Scheme 98

Overboost Warning Chime Check

Start engine and warm to normal operating temperature. Remove air cleaner upper case. Push vane airflow meter completely open. If overboost chime does not come on, see CIRCUIT TEST SCG in the appropriate TESTS W/CODES article. If overboost chime comes on, the system is okay.

Pressure Switch Check

1. Start engine. Disconnect pressure switch hose and apply 10.5-11.5 psi (.72-.80 kg/cm 2 ) compressed air to switch. Engine should stall or run poorly with air pressure applied. If engine does not function as described, turn ignition off.
2. Disconnect pressure switch connector. Turn ignition on. Using a voltmeter, apply positive lead to Light Green/Black wire and negative lead to ground. Voltage should be 10 volts with 10.5-11.5 psi (.72-.80 kg/cm 2 ) applied, and zero volt with no air pressure applied.
3. If pressure is not as specified, turn ignition off. With 10.5-11.5 psi (.72-.80 kg/cm 2 ) applied, check continuity between switch terminals. Continuity should be present with 10.5-11.5 psi (.72-.80 kg/cm 2 ) applied. Continuity should not be present when no air pressure is applied.

Compressor By-Pass Valve Check

Remove compressor by-pass hose from engine. Using vacuum pump, apply 10-15 in. Hg to port "A". (Scheme 99) Air should flow through port "B". If air does not flow through port "B", replace compressor by-pass valve.

Scheme 99

Lubrication System Check

1. Remove oil return line from turbocharger center housing. Ensure turbocharger and oil return line are not blocked by carbonized oil. If necessary, clean or replace components.
2. Remove air inlet line and exhaust outlet pipe from turbocharger. Check inside pipes and turbo housing for signs of coolant or oil. If any signs of oil or coolant are present, replace turbocharger assembly.

Shaft Defection Check

Remove air inlet line and exhaust outlet pipe from turbocharger. Check turbine wheel and impeller wheel blades for damage or wear. Check rotor axial and radial play to ensure blades do not contact housing. Spin rotor to ensure smooth, quiet rotation. Replace turbocharger if noise or roughness are present.

Scheme 100

CONTROL UNIT GROUND CIRCUITS

1. On Probe 2.2L turbo and 2.2L non-turbo (ATX), use an ohmmeter to check for continuity to ground on ECA terminals 3A, 3B and 3C. On all other models, check for continuity to ground on ECA terminals 2A, 2B and 2C. (Scheme 101) Resistance should be zero ohms. If resistance is not zero ohms, repair open to ground.
2. Using a DVOM, touch negative lead of voltmeter to a good ground. Touch positive lead of voltmeter to each ground terminal. With vehicle running, voltmeter should indicate less than 1 volt. If voltage is greater than 1 volt, check for open, corrosion or loose connection on ground lead.

CONTROL UNIT POWER CIRCUITS

Using a voltmeter, check for battery voltage at ECA terminal 1B. (Scheme 101) If battery voltage is not present, check for open circuit and repair as necessary.

Scheme 101

BAROMETRIC PRESSURE SENSOR

The barometric pressure switch is located inside the ECA and cannot be serviced separately. Faults in barometric pressure sensor should set a fault code in ECA memory. See CIRCUIT TEST BP in the appropriate TESTS W/CODES article in this section.

CLUTCH ENGAGE SWITCH/NEUTRAL GEAR SWITCH (CEC/NES)

See CIRCUIT TEST STG in the appropriate TESTS W/CODES article in this section.

CRANKSHAFT POSITION SENSOR (1.8L & 2.2L TURBO)

The crankshaft position sensor is located inside the distributor. Faults in crankshaft position sensor should set fault code in ECA memory. See CIRCUIT TEST CPS in the appropriate TESTS W/CODES article in this section.

CYLINDER IDENTIFICATION NO. 1 (CID1)

The CID1 (2.2L Turbo) sensor or CID Sensor (1.8L) is located inside the distributor. Faults in CID1 sensor should set fault code in ECA memory. See CIRCUIT TEST CID1 in the appropriate TESTS W/CODES article in this section.

CYLINDER IDENTIFICATION NO. 2 (CID2)

The CID2 sensor (2.2L Turbo) is located inside the distributor. Remove distributor wiring harness connector. Measure resistance between terminals CID2 and CIDREF. (Scheme 102) Resistance should be 210-260 ohms. If resistance is not as specified, replace sensor. For circuit testing, see CIRCUIT TEST CID2 in the appropriate TESTS W/CODES article in this section.

Scheme 102

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Disconnect ECT sensor wiring harness connector. Using DVOM, measure resistance between sensor terminals. See ECT SENSOR RESISTANCE . Replace sensor if resistance is not as specified.

ECT SENSOR RESISTANCE

EXHAUST GAS OXYGEN (EGO) SENSOR

Disconnect EGO sensor connector. Measure voltage between EGO sensor wire and ground. At idle, voltage reading should be 0.2-0.8 volt. Increasing engine speed should increase sensor voltage. Decreasing engine speed should decrease sensor voltage. If voltage is not as specified, replace EGO sensor as necessary. For circuit testing, see CIRCUIT TEST EGO in TESTS W/CODES - EEC article.

Note. Continuously rich or lean operation may be caused by malfunction other than EGO sensor.

EGR Valve Position (EVP) Sensor (2.2L Turbo & Calif.)

1. Disconnect EVP sensor connector. Using a jumper wire, attach VREF and SIGRTN to mating terminals at EVP sensor. (Scheme 103) Leave EVP terminal disconnected.
2. Attach vacuum pump to vacuum port. Turn ignition on. Apply vacuum to port and compare readings with specifications in «EVP SENSOR VOLTAGE»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l). Replace sensor if voltage is not as specified. For circuit testing, see CIRCUIT TEST EVP in the appropriate TESTS W/CODES article in this section.

EVP SENSOR VOLTAGE

Scheme 103

INERTIA SWITCH

1. Turn ignition off. Remove inertia switch. On 1.8L engines, switch is located on right rear strut tower. On 2.2L engines, switch is located on left rear wheel well.
2. Shake inertia switch to force switch into tripped position (switch open). Measure resistance of switch at designated wiring harness terminal (color). See «INERTIA SWITCH RESISTANCE»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l) . Replace switch if resistance is incorrect, or if switch cannot be tripped.

INERTIA SWITCH RESISTANCE

KNOCK SENSOR (2.2L TURBO)

Disconnect knock control sensor connector. Knock sensor is located on right side of engine, next to oil filter. Using DVOM with scale set on AC voltage, measure AC voltage between knock sensor KS terminal (Yellow/Black wire) and GND terminal (Black/Green wire). Observe voltmeter while tapping lightly on engine lifting eye with a 4-oz. hammer. Voltage reading should be greater than .03 volt. Replace sensor if voltage is not as specified.

POWER STEERING PRESSURE SWITCH (PSPS)

For diagnostic procedure, see CIRCUIT TEST SCG in the appropriate TESTS W/CODES article in this section.

THROTTLE POSITION SENSOR

For throttle position switch specifications and adjustment procedures, see ON-VEHICLE ADJUSTMENTS article. For circuit testing, see CIRCUIT TEST TPS in the appropriate TESTS W/CODES article in this section.

VANE AIRFLOW (VAF)

Faults in VAF should set fault code in ECA memory. For diagnostic procedure, see CIRCUIT TEST VAF in the appropriate TESTS W/CODES article in this section.

VANE AIR TEMPERATURE (VAT

Faults in VAT should set fault code in ECA memory. For diagnostic procedure, see CIRCUIT TEST VAT in the appropriate TESTS W/CODES article in this section.

VEHICLE SPEED SENSOR (VSS)

For diagnostic procedure, see CIRCUIT TEST VSS in the appropriate TESTS W/CODES article in this section.

IGNITION DIAGNOSTIC MONITOR (IDM) MODULE

Faults in IDM should set fault code in ECA memory. For diagnostic procedure, see CIRCUIT TEST IDM in the appropriate TESTS W/CODES article in this section.

Note. For ignition module test procedure, see CIRCUIT TEST IDM in the appropriate TESTS W/CODES article in this section.

IGNITION MODULE LOCATION

All 1.8L engines use 3-pin transistorized ignition module to relay spark control signals from ECA to ignition coil. The coil is mounted on coil bracket.

All 2.2L non-turbo engines use a distributor-mounted ignition module with vacuum advance which operates independent of ECA. The coil is mounted inside the distributor.

All 2.2L turbo engines use a 5-pin transistorized ignition module which controls spark by grounding negative side of coil, and returns a feedback signal to ECA. The coil is mounted on coil bracket.

IDLE SPEED CONTROL (ISC) MOTOR

Faults in ISC solenoid should set fault code in ECA memory. For diagnostic procedure, see CIRCUIT TEST SCG in the appropriate TESTS W/CODES article in this section.

CONDENSER FAN RELAY (2.2L)

Install Breakout Box (T83L-50-EEC-IV) to wiring harness connector, leaving ECA disconnected. Turn ignition on. Connect test pin No. 54 to ground while listening to relay. Replace relay if click does not occur when test pin No. 54 is grounded.

COOLING FAN RELAY

For diagnostic procedure, see CIRCUIT TEST STP in the appropriate TESTS W/CODES article in this section.

DAYTIME RUNNING LIGHTS (DRL) RELAY

1. Install Breakout Box (T83L-50-EEC-IV) to wiring harness connector, leaving ECA disconnected. Measure voltage between breakout box test pin DRL and VPWR. With engine at idle speed and parking brake on, voltage should be 10 volts.
2. With engine at idle speed and parking brake off, voltage should be zero volt. If voltage is not as specified, repair circuit between DRL relay and ECA. If voltage is as specified and lights are inoperative, replace DRL relay.

DRL CIRCUIT PIN IDENTIFICATION

WIDE OPEN THROTTLE A/C CUT-OFF RELAY (1.8L)

Install Breakout Box (T83L-50-EEC-IV) to wiring harness connector, leaving ECA disconnected. Turn ignition on. Connect test pin No. 54 to ground while listening to relay. Replace relay if click does not occur when test pin No. 54 is grounded.

EGR VACUUM REGULATOR SOLENOID (2.2L NON-TURBO)

Disconnect vacuum and electrical connections from solenoid. Apply low air pressure to port "A", and ensure air pressure is released at port "B". (Scheme 104) Using jumper wire, connect negative terminal to ground and apply 12 volts to positive terminal. Apply low air pressure to port "A", and ensure air pressure is released at air filter. Replace solenoid if it does not function as specified.

Scheme 104

EGR CONTROL SOLENOID (2.2L TURBO)

Disconnect vacuum and electrical connections from solenoid. Apply low air pressure to control solenoid vacuum hose, and ensure air pressure does not flow through solenoid. (Scheme 105) Using jumper wire, connect terminal "C" to ground and apply 12 volts to terminal "A". Apply low air pressure to control solenoid vacuum hose, and ensure air pressure flows through solenoid. Replace solenoid if it does not operate as specified.

EGR VENT SOLENOID (2.2L TURBO)

Disconnect vacuum and electrical connections from sensor. Apply low air pressure to vent solenoid vacuum hose, and ensure air pressure flows through solenoid. (Scheme 105) Using jumper wire, connect terminal "B" to ground and apply 12 volts to terminal "D". Apply low air pressure to vent solenoid vacuum hose, and ensure air pressure does not flow through solenoid. Replace solenoid if it does not operate as specified.

Scheme 105

FUEL PRESSURE RELEASE

On non-turbo engines, start engine. Disconnect vane airflow meter connector. On turbo engines, remove fuel pump relay. Fuel pump relay is located behind left side of instrument panel, near steering column. Start engine and operate until it stalls. Turn ignition off. Reconnect vane airflow meter connector or fuel pump relay.

FUEL SYSTEM TESTING

Note. For fuel system pressure testing, see the BASIC TESTING article in this section.

FUEL PRESSURE CHECK

Note. For fuel pressure specifications, see FUEL PRESSURE SPECIFICATIONS article.

Release fuel pressure. Install fuel pressure gauge between fuel filter and fuel rail. Using jumper wire, connect fuel system test terminals. (Scheme 106)and (Scheme 107). Turn ignition on but do not start engine. Observe gauge reading and proceed as follows

If fuel pressure is zero , go to FUEL SYSTEM CIRCUITRY CHECK. If fuel pressure is low , go to FUEL SYSTEM PRESSURE TEST. If fuel pressure is normal , go to FUEL INJECTOR TEST.

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. With ignition on and fuel system test terminals connected, measure voltage at fuel pump (Black/Pink wire on 1.8L, or White/Yellow wire on 2.2L). If voltage is 10-14 volts, go step 9). If voltage is NOT 10-14 volts, measure voltage, as described in «FUEL PUMP RELAY SPECIFICATIONS»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l), at fuel pump relay connector. (Scheme 112)for terminal identification. Repair circuit if voltage is not as specified. FUEL PUMP RELAY SPECIFICATIONS Terminal Ignition Position Voltage 1.8L W/R ON 10-14 P START 10-14 2.2L (M/T) BK/W ON 10-14 BK/R START 10-14 2.2L (A/T) BK/W ON 10-14 BK/PK START 10-14
2. If voltage is as specified, turn ignition off and remove fuel pump relay. Connect terminal "B" to battery voltage and terminal "A" to ground. (Scheme 108) Check voltage at terminal "C" as follows. With terminals "D" and "E" open, voltage at terminal "C" should be less than one volt. With Terminal "D" grounded and terminal "E" open, voltage at terminal "C" should be less than 10 volts. With terminal "D" open and "E" grounded, voltage at terminal "C" should be greater than 10 volts. With terminals "D" and "E" grounded, voltage at terminal "C" should be greater than 10 volts.
3. If voltage is not as specified, replace fuel pump relay. If voltage is as specified, measure resistance between relay box BK terminal and ground (Probe), or between fuel pump relay connector Black wire and ground (all others). (Scheme 111)to locate BK terminal of fuel pump relay box on Probe. NOTE: On 2.2L turbo models, ECA wiring harness connector must be disconnected for step 4).
4. If resistance is greater than 5 ohms, repair circuit. If resistance is less than 5 ohms, access VAF meter door. On Probe, measure resistance between LG terminal of relay box and ground. On all others, measure resistance between Light Green wire of fuel pump relay connector and ground.
5. With VAF door closed, resistance should be greater than 10,000 ohms. With VAF door open, resistance should be less than 4 ohms. If resistance is not as specified, go to step 6). If resistance is as specified, go to step 7) (turbo), or go to step 8) (non-turbo).
6. Turn ignition off and disconnect VAF meter wiring harness connector. Measure resistance between designated terminals. See «VAF FUEL PUMP SWITCH SPECIFICATIONS»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l). If resistance is not as specified, replace Black wire (1.8L), or Black/Light Green wire (2.2L). VAF FUEL PUMP SWITCH SPECIFICATIONS Door Position VAF Terminals Resistance (Ohms) 1.8L Closed Light Green & Black Over 10,000 Open Light Green & Black 0-5 2.2L Closed Light Green & Black/Light Green Over 10,000 Open Light Green & Black/Light Green 0-5
7. On 2.2L turbo, install Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. With ignition off, measure resistance between test pins No. 53 and No. 60 of breakout box. Resistance should be greater than 10,000 ohms. Measure resistance between test pin No. 53 of breakout box and LG circuit (Light Green wire) of fuel pump relay. (Scheme 111)for location of LG circuit. Resistance should be less than 5 ohms. If resistance is not as specified, repair LG circuit (Light Green wire). If resistance is as specified, go to next step. NOTE: On 2.2L turbo, ECA must be disconnected for step 8).
8. On all models, disconnect fuel pump relay connector. Turn ignition on. Measure voltage at connector terminal LG (Light Green wire on the 1.8L), or BK (Black wire on the 2.2L). (Scheme 112)On non-turbo engines, if voltage is less than one volt, repair circuit between fuel pump and fuel pump relay. On turbo engines, if voltage is less than one volt, replace ECA. On all models, if voltage is more than one volt, repair circuit short to power.
9. Turn ignition off. Remove fuel pump wiring harness connector. Measure resistance between Black wire (1.8L) or White/Red wire (2.2L) and ground. If resistance is less than 5 ohms, release fuel pressure and attach fuel pressure gauge to fuel pump outlet hose. Disconnect fuel pump wiring harness connector. (Scheme 113)
10. On 1.8L engines, connect jumper wire between fuel pump connector Black wire and Black/White wire terminals. On 2.2L engines, connect jumper wire between fuel pump connector White/Red and White/Yellow wire terminals. Fuel pump should activate. Replace fuel pump if pressure is not 64-85 psi.
11. If pressure is 64-85 psi, turn ignition off. Measure resistance between fuel pump connector Blue wire (1.8L) or White/Red wire (2.2L) and ground. If resistance is less than 5 ohms, repair Blue wire (1.8L) or White/Red wire (2.2L) between fuel pump and inertia switch. Repeat step 1). If resistance is greater than 5 ohms, repair or replace inertia switch. See INERTIA SWITCH under ENGINE SENSORS & SWITCHES.

Scheme 113

FUEL SYSTEM PRESSURE TEST

1. Using jumper wire, connect fuel system test connector. (Scheme 106)and (Scheme 107). Turn ignition on (engine off) to activate fuel pump. Remove fuel pump wiring harness connector. Measure voltage between connector Black/Pink wire (1.8L) or White/Yellow wire (2.2L) and ground.
2. Voltage should be greater than 10.5 volts. If voltage is less than 10.5 volts, turn ignition off and release fuel system pressure. Remove fuel filter and inspect for restriction or contamination. Replace fuel filter if necessary. If fuel filter is okay, go to step 3).
3. With fuel pressure released, install fuel pressure gauge between fuel filter and fuel rail with main valve open and drain valve closed. Start engine and run for 10 seconds. Stop engine and wait for 10 seconds. Start engine and run for 10 seconds.
4. Stop engine and remove vacuum hose from pressure regulator. Check pressure regulator for fuel leakage through diaphragm. If fuel is present, replace pressure regulator. If fuel is not present, start engine and run for 30 seconds. Stop engine and wait 5 MINUTES. If fuel pressure is less than 21 psi, start engine and run for 30 seconds.
5. Stop engine and wait 5 MINUTES. If fuel pressure is still less than 21 psi, replace pressure regulator. If fuel pressure is greater than 21 psi, remove fuel pressure regulator. Check "O" ring, gasket and mounting surface for excessive wear or damage. (Scheme 114) Repair or replace as necessary. Attach vacuum pump to fuel return line.
6. Apply 20 in. Hg for 10 seconds. If vacuum drops below 10 in. Hg, replace pressure regulator. If vacuum does not drop below 10 in. Hg, put fuel pressure gauge drain hose into an empty metal container. Using jumper wire, connect fuel system test connector to activate fuel pump. Turn ignition on (engine off) for 10 seconds. Measure fuel volume and compare to specification. See «FUEL VOLUME SPECIFICATION»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l).
7. If fuel volume is less than specification, service fuel pump inlet screen and repeat fuel volume test. If fuel volume is still less than specification, replace fuel pump. If fuel volume is as specified, jumper test connector test lead and turn ignition on to activate fuel pump. Operate fuel pump for 30 seconds. Observe fuel pressure gauge for 3 MINUTES. If fuel pressure decreases more than 2 psi, replace fuel pump.

FUEL VOLUME SPECIFICATION

Scheme 114

FUEL INJECTOR TEST

1. With engine idling or cranking (no start), use stethoscope to listen for consistent, operational sounds (clicking) coming from each injector. If operational sounds are present go to «FUEL INJECTOR LEAKAGE TEST.»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l__fuel-injector-leakage-test) If operational sounds are not present, remove fuel injector wiring harness connector(s). Using DVOM, check injector resistance. Replace injector if resistance is not within specification. See «FUEL INJECTOR RESISTANCE»(/ford/escort/v-1990-1992/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-18l) .
2. If injector resistance is within specification, connect Fuel Injector Tester/Cleaner (113-00001) to fuel injector wiring harness connector. Start engine. The continuity light should blink, indicating circuit is complete. If light does not blink, check for 12 volts at injector lead. If 12 volts is not present, repair circuit as necessary.

FUEL INJECTOR RESISTANCE

FUEL INJECTOR LEAKAGE TEST

Install Fuel Injector Tester/Cleaner (113-00001). Clean injectors according to tester/cleaner manufacturer's instructions. After injectors are cleaned, check for fuel system pressure loss. If pressure loss is observed, remove injectors and individually check injector's leakage rate. Maximum injector leakage rate is one drop per minute. Replace injector if maximum leakage rate is exceeded.

See also:
• FUEL PRESSURE SPECIFICATIONS
• ECT SENSOR RESISTANCE
• FUEL INJECTOR LEAKAGE TEST.