autoteam

Magazine for the Ford Dealer Service Team Issue 4

Eight steps to success:

Interactive Reception

Diesel engines: The new pump nozzle injection system Marketing: Dealerships designed for customers
Replacement parts: Advantages for the customer and Mondeo: The engine range
y S nd st
fet Mo Fir

the environment
yst e o
Ne fety

em
Sa
Sa w

1
Missed opportunity

A few months ago a new colleague joined us. Meanwhile he has

ordered a new Ford Focus, which will be the first Ford he owns.

Not surprisingly, he was very interested to experience first hand

how Interactive Reception in a Ford dealership works, even
before he took delivery of his new Focus. And he actually found
a good opportunity to gain this experience, when another colleague
needed to bring the first Ford she owned to a Ford dealership for
routine maintenance.

Unfortunately, it turned out to be an experience that disappointed

both our colleagues. Although the Ford dealership they visited
has a dedicated Interactive Reception area, they never got to see
it. The Service Advisor simply filled out the repair order and told
them when they could pick up the Focus. No offer was made to
check the vehicle in their presence.

The comment from our new colleague when he returned to the

office was quite candid: “I was somewhat disappointed. I’ve
become accustomed to an excellent Interactive Reception process
at the non-Ford dealership where I took my previous car. If I
didn’t know that other Ford dealerships consistently carry out
the Interactive Reception process, I might be questioning myself if
my new Focus would actually get the service quality it deserves
and that I've come to expect. So I will make sure of one thing:
I’ll only be taking my new Focus to a dealership with a good
Interactive Reception process.”

This experience is not the reason why this issue of autoteam fea-
tures an article on the Interactive Reception process. But it did
Contents
confirm to us how important the process is, and we urge you to
read the article carefully. High pressure and precise control 4
How to remove and install a unit injector on Galaxy's
The editorial team 1.9 Litre TDI engine. Ford's diesel injection systems:
Distributor Fuel Injection Pump, Unit Injector and
Common Rail.

Eight steps to success 8

The key role of Interactive Reception in customer contact.

New service 11
The Extended Period Maintenance now includes an air
conditioning check. What is to be checked?
No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form, electronic, mechanical, photocopying, recording, trans-
Danger ahead! Be prepared! 12
lating or other means without the prior permission of Ford Motor Company
Limited. Are you aware of the risks when handling hazardous
materials? Observe danger warning symbols and handling
The illustrations, technical information and data contained in this publication were
procedures!
correct at the time of going to print.

The articles in autoteam based around dealer visits, reflect the conditions and Power Sources 14
practices of the country featured. Where the procedures described differ from local
New Mondeo's engine variants range from 1.8 to
practice, the latter should apply. No liability can be accepted for any inaccuracies
or omissions in this publication, although every possible care has been taken to 2.5 litres and from 90 to 170 PS. Let's have a look at
make it as complete and accurate as possible. some interesting new features.

Published by:
Ford of Europe Incorporated
Ford Customer Service Division

Issue 4 (January 2001)

Produced by ilypsys communications (formerly Palmer Hargreaves Team).
 Power
Sources
We introduce you the engines of
the New Mondeo. 14

Filter change 17 Competition 25

A new oil filter, a new tool and a new tightening procedure.
Marketing for everybody 26
Born again 18
How you as a dealer can benefit from the use Manipulation 30
of Ford remanufactured parts, and the things you WDS, issue 7, Datalogger III: How to manipulate
need to be aware of. output signals to test the respective actuators.

Safety First 22 Ford Facts: Corporate Citizenship 32

The New Mondeo has an new Advanced Restraint How Ford puts social involvement into practice.
System (ARS). How does it work and how to handle
it in service.

TSB résumé 25

First impressions count

The third instalment of our “Marketing for everybody” series shows you how dealership
layout and design can increase customer satisfaction. 26

Unit Injector System
High pressure and precise control
Is it really a Diesel? You’ll search
in vain for injection nozzles, high
pressure pipes and fuel injection
pump on the new Ford Galaxy’s
1.9 Litre turbo diesel. The answer
is: Unit injector system. The heart
of the system was revealed to
autoteam.
The special feature of the Ford Galaxy
1.9 L TDI engine is that each cylinder has
its own injection pump. Each of these
pumps is combined with a solenoid valve
control unit and an injector forming one
compact unit. These unit injectors enable
high fuel injection pressure and precise fuel
metering (see panel), and are installed
underneath the cylinder head cover.
4 autoteam
All seals are replaced. During
dismantling take care that no
burrs are formed on the O-ring
seats.
Removal rocker arms. With their piston springs they
“What if one of these units has to be look like a normal valve train.
removed?” “Piece of cake!”, according to
Toni Ernst. “You have to pay careful atten- Toni first disconnected the electrical connec-
tion to certain things, but the unit injector tors from the unit injector’s solenoid valves.
system has neither high pressure pipes nor
fuel leakage pipes to disconnect and renew.”
Toni is an automotive technician foreman in
the Training Department of Ford Europe in
Cologne and demonstrated to us how to
remove and install the unit injector.
The cylinder head cover had to be removed
before we could see the unit injectors. They
are individually actuated by an additional
cam on the camshaft by means of roller
Lever the electrical connectors off. The
unit injectors with their springs and rocker
arms look like a valve train.
Issue 4

➨ Engage the removal
To do this he placed a screwdriver on one
side and held a finger against the other.
“This avoids twisting the connector”
explained Toni.
No tension
Toni began with the two units on the clutch
side. Using a jacked up front wheel he
turned the crankshaft until the two fuel
injection cam lobes were in an evenly
upright position, i.e. until the two roller
rocker arms overlapped. He then loosened
the locking nuts and unscrewed the adjust-
ing screws of the roller rocker arms until
they were no longer under tension. The
spring plates of the units now touched the
roller rocker arms. “This way I make sure
that the re-installation can be done under
absolutely no tension”, explained Toni.
Next he loosened the four screws of the
roller rocker arm shaft from the outside
inwards and removed the shaft together
with the rocker arms. The other two roller
Unit injector complete with seals and O-ring
installer tool.
autoteam Issue 4
The retaining block
fits in the unit
injector groove
and holds the unit
firmly in the
cylinder head.
tool in place of the
retaining block.
rocker arms (timing belt side) were removed
the same way after the crankshaft had been
turned until the respective cams point
upwards.
Hint
Toni then removed the retaining blocks
which held the unit injectors in the cylinder
head. Depending upon the position of the
valve cams, the retaining block cannot be
pushed back out of the groove. But Toni has
a hint: “Hold the solenoid valve and turn
unit injector counter clockwise just a touch
and the retaining block can be pulled out
forwards. And the removal tool can then be
positioned from the front too.” Toni next
inserted the removal tool 310-086 (23-060)
into the lateral groove of the unit injector
where the retaining block was before. Some
light taps with the body of the tool and the
injector unit can be pulled out of the cylin-
der head.
Seal
Toni then showed us the three O-ring seals
on the shaft of the unit injector that seal the
fuel supply and fuel-return channels.
In addition, a heat protection seal is fitted
on the nozzle tip. This brass ring, secured
by a snap ring, seals off the combustion
chamber. “All rings are always renewed.
When removing them you must make sure
that no burrs are formed on the seating for
the O-rings.” Then the unit was thoroughly
cleaned, because cleanliness is of paramount
importance when working on the precision
components of a diesel injection system.
Toni now placed the Seal Installer 310-087
(23-061) for the upper O-ring over the shaft
of the unit injector. Whilst he pushed the
new O-ring over the oiled installer into the
seal groove he warned: “Don’t try this with-
out the special tool as the seal could be
damaged all too easily. Make sure also that
the O-ring sits in the groove untwisted.”
He proceeded to fit the middle and lower
O-rings with the help of the special tools
310-089 (23-063) and 310-088 (23-062)
respectively. Finally he fitted the new heat
protection seal and snap ring.
Dimension X
The O-rings were lubricated with engine oil
and the unit was carefully and fully inserted
into the cylinder head. Toni then refitted the
retaining block with a new bolt. “I don’t
tighten the screw down yet as the unit injec-
tor must be precisely positioned. If it is not
installed at right angles to the cylinder head,
the injector nozzle fuel spray pattern will
not be positioned correctly in the combus-
tion chamber. In addition, the retaining bolt
can work loose. In both cases, damage to
the engine is inevitable,” he cautioned and
5
 Push the new O-
ring over the oiled
installer tool into
the O-ring seat
without twisting it.

Fit the heat

protection seal
and snap ring.

picked up a vernier gauge (measuring range
400 mm).
The right-angled position of the pump
nozzle units is ensured when the dimension
“X” is set. “X” is established in each case
between the solenoid valve body of the unit
and the edge of the cylinder head and
equates to 65 mm, 153 mm, 244 mm and
332 mm for the respective cylinders. Toni
adjusted each injector unit by turning it
until the vernier indicated the appropriate
value. Only then he torqued the retaining
block bolts to 12 Nm + 270°.
Having first re-aligned the cam shaft injec-
tion cam lobes in an evenly upright posi-
tion, Toni could refit the respective roller
rocker arm shaft using new retaining bolts
which he torqued to 20 Nm + 90°.
Stop block and back
“Now the plunger stroke of each injector
unit is adjusted” Toni explained:
■ “Rotate the crankshaft in the direction
of engine rotation until the cam shaft
injection cam lobe is approaching the
highest point and the roller rocker arm
is approaching the maximum stroke.
■ Install a dial indicator gauge to the cylin-
der head and position the tip to the
adjusting screw on the roller rocker arm.
■ Carefully continue to rotate the crank-
shaft and establish the lowest position
of the roller rocker arm.
■ Remove the dial indicator gauge and
carefully rotate the rocker arm adjusting
screw clockwise until the injector plunger
reaches the stop block. This can be iden-
tified by feeling a distinct resistance.
■ Unscrew i.e. rotate anticlockwise the
adjusting screw through 225 degrees =
5/8 of a turn.
■ Tighten the screw locking nut. Make sure
that the adjusting screw does not move.
Note: No further check is possible,
unlike when adjusting valve clearances.
While Toni progressed through each step he
explained how important the correct adjust-
ment of the plunger stroke is. “If the stroke
is too short, the fuel metering will be inac-
curate. If it is too long, the injector plunger
could strike the stop block and cause
mechanical damage to the unit injector.”
Having reconnected the unit injector sole-
noid valve electrical connectors, the unit
injector system is once again operational
and Toni can complete the engine. (more
information see TSB 95/1999)

Align the unit

injector at right
angle, adjust
dimension “X”.

The dial indicator

gauge shows when
the lowest position
of the roller rocker
arm is obtained.

6 autoteam Issue 4
How does the pressure reach the nozzle?
Power output, noise, fuel consumption and
pollutant emissions are largely dependent
upon mixture formation and combustion
process. Apart from the air swirl (turbu-
lence) in the combustion chamber, the fuel
injection – atomization and metering – is
of crucial importance in diesel engines.
Important factors are pressure generation
and pressure distribution. The following
diesel injection systems are used by Ford:
Distributor Fuel Injection Pump
This system uses only one pump element to
create injection pressure for all cylinders.
A rotating distribution piston feeds the
injector nozzles of the individual cylinders.
This system has for decades determined the
development of modern light diesel engines
and thanks to electronically controlled
injection pumps meets all of today’s require-
ments. For example, on the 2 L DuraTorq-
DI of the new Mondeo a pilot injection
(pre-injection) and pump pressure of 1300
bar were achieved. (See article “Power
Sources”.)
But in future the Distributor Fuel Injection
Pump System will reach its design limits. Its
main drawbacks are: The pressure, which
opens the injector nozzle, has to be first
built up in the injection pipes between
pump and injector. This absorbs up to 30%
of the pump’s efficiency and requires time as
the injection pipes inflate and “swallow”
a certain volume. In addition, the fuel
becomes to a degree compressible under
high pressure. The pressure waves created
this way and travelling in the injection pipe
at speeds greater than sound to the injector
nozzle, can be utilised under certain operat-
ing conditions to increase pressure at the
Principle of Distribution Pump
System
1) Distribution injection pump
2) High pressure lines
3) Injectors
4) Engine management
autoteam Issue 4
injector nozzle (up to 1900 bar on the 2 L
DuraTorq-DI). But these pressure waves can
also cause problematic oscillations in the
system. The limitations of the system in
respect of injection pressure and fuel meter-
ing control are obvious.
Unit Injector System
With the Unit Injector System each cylinder
has its own injection pump which forms a
unit with the injection nozzle in the cylinder
head. The injection pressure is thus pro-
duced directly in the injector body itself.
Fuel injection lines with their disadvantages
as described above are not required. The
pumps are operated by the camshaft so
there is no variability in output.
Control is via a solenoid valve which is
actuated by the engine management system
(PCM). The valve is open in the resting
position, i.e. it clears the path from the
high-pressure chamber to the fuel return so
that the downward travelling pump plunger
cannot create any pressure. Only when the
valve is actuated by the PCM and closes,
can pressure be built up, the nozzle needle
opens and injection starts. The injection
process ends when the PCM stops actuating
the solenoid valve and opens the fuel return,
pressure drops and the nozzle needle closes.
The hydraulic compactness of the Unit
Injector System enables the highest injection
pressures with very fine fuel atomisation
(up to 2050 bar in the Galaxy 1.9 L TDI).
All parameters including a pilot injection
(pre-injection) can be controlled very pre-
cisely. The system has an important devel-
opment potential and will also meet future
requirements.
Principle of Unit Injector System
1) Camshaft
2) Pump Injector unit
3) Engine management
4) Solenoid valve
5) Fuel (low pressure)
Common-Rail
Whereas the injection pressure is created
just at the moment of injection in the
Distributor Fuel Injection Pump System and
the Unit Injector System, the Common Rail
System ensures permanent pressure at all
injector nozzles (metering valves). Fuel
injection is triggered by a solenoid valve in
the injector activated by the IDM (Injector
Driver Module). The injection pressure is
provided by a separate high-pressure pump
which feeds into the pressure supply mani-
fold, the so-called Common Rail. The injec-
tion system with common rail (or fuel injec-
tion supply manifold) is, therefore, also
termed Storage Injection System. A pressure
of up to 1600 bar is achieved on the 1.8 L
DuraTorq-TDCi of the Ford Focus 2001.5.
The Common Rail System offers the devel-
opment engineer greatest flexibility as pres-
sure generation and injection is independent
in timing and location: The injection pres-
sure can be controlled independently of
engine speed and injection quantity. Pilot
injection as well as multiple injection can
be freely specified.
Common Rail prevails more and more over
the Distributor Fuel Injection Pump; its
development potential ensures it will meet
future requirements of exhaust emission
standards, economy and smoothness of
operation.
Principle of Common Rail System
1) Fuel from high pressure pump
2) Pressure sensor
3) Fuel supply manifold (Common Rail)
4) Injectors with solenoid valves
5) Engine management
7

Eight steps
to success
Many things play a role in developing and
maintaining a successful Service business,
but one of the most crucial elements is the
way customers are handled when they come
to your dealership.
Excellent customer handling begins with
having the right processes in place. And
one of the most important processes is
Interactive Reception which, in turn, is one
element of the Service Upgrade process.
0 Pro-Active Customer Contact
1 Customer Appointment Scheme
2 Personalized Customer Reception
3 Menu Pricing/Committed Price to Customer
4 Customer Care & Convenience
5 Workshop Scheduling
6 Advanced Info to Parts Department/Parts Pre-Picking
7 Repair Order Processing and Quality of Work
8 Repair Order Completion and Invoicing
9 Customer Information and Car Return
10 Customer After-Service Contact
11 Concern Resolution and Prevention
8 autoteam
The Service Upgrade Process
The Service Upgrade process was developed
to give Ford customers the best possible
service every time they visit a Ford dealer-
ship’s Service department. With the excep-
tion of carrying out the actual servicing or
repair job, the process covers all steps neces-
sary to ensure that customer requirements
are met in an extremely professional way.
The Service Upgrade process has three
major goals:
1. to ensure that the servicing or repair job
with all related tasks, such as workshop
scheduling, parts pre-picking, repair order
completion, and invoicing run smoothly,
efficiently and on time;
2. to provide the customer with the highest
possible levels of convenience – through
an appointment system and customer care
actions – and with the assurance that the
job will be done completely, by the agreed
time and at the agreed price – to the cus-
tomer’s full satisfaction;
3. to make available the time that needs to
be spent with the customer in order to
identify fully his servicing and repair needs.
A key step in the Service Upgrade process,
required to achieve these goals, is Inter-
active Reception, where the vehicle is
checked in the presence of the customer.
It is in this step that the groundwork is laid,
on which the effectiveness of all other
Service Upgrade elements depends.
Because the vehicle check, together with the
customer, is so important, Ford is making
available a special training course for
Service Advisors, which thoroughly covers
this subject. This article cannot replace the
training course, but it does acquaint you
with some of the essential elements of
Interactive Reception and demonstrates
how important it is to participate in the
training.
Other elements of this comprehensive
training package involve the Service
Manager and other members of the Service
department and include topics such as:
customer appointment scheme, workshop
scheduling, pro-active customer contact, etc.
Issue 4
 The eight step vehicle check:
Drive the vehicle to the
Welcome customer at hoist/lift. Check the
reception. controls (lights, clutch,
Accompany customer to vehicle. brakes, etc.)
Apply protective covers.

Examine boot/tail-
lights.

Examine left-
hand side and
roof.
Examine right-
hand side and
roof.

Examine the interior/

controls. Make a note of
the kilometre reading, check
documentation, release
bonnet.

Raise
Examine front/headlights. vehicle.
axles/suspension,
fluids levels undercar area tyres, brake discs
Open bonnet and belts condition
Examine: exhaust system and pads, shock
hoses leaks each wheel absorbers,
check.
battery steering
Use prescribed tools.

The central role of Interactive
Reception
Personal customer contact
Personal contact is one of the most impor-
tant factors in any business relationship –
and a customer visit to your Service depart-
ment is indeed part of a business relation-
ship. It is not just the quality of a product
or a service job that determines customer
satisfaction and motivates the customer to
return for further business. It is also the way
he is handled as a person that can be deci-
sive in winning and keeping his loyalty. And
nowhere is customer contact more intense
than during Interactive Reception.
Determination of repair requirements
A thorough Interactive Reception process
is also the best means of ensuring that the
actual servicing or repair job can be done
completely and to the customer’s require-
ments. Repairs that are overlooked or cus-
tomer requirements that are not identified
during Interactive Reception will lead to an
incomplete repair order and, consequently,
to an inadequate repair. Interactive Recep-
tion is the perfect opportunity to identify all
required work and make sure the customer’s
vehicle is kept in perfect condition and the
customer is kept loyal to the dealership.
The four phases of Interactive
Reception
Phase 1: Customer Welcome
Customer welcome is the first phase in the
Interactive Reception process. Because this
is the first contact you as a Service Advisor
have with the customer during his visit, it’s
important that the welcome itself demon-
strates to the customer that he can have full
trust in your abilities as a Service Advisor.
Greeting the customer by name, showing
that you are aware of the reason for his
visit, making a personal comment, demon-
strating that you are familiar with the vehi-
cle history, all confirm to the customer that
you are prepared for his visit and can be
trusted to continue the process in a profes-
sional manner.
Phase 2: 8-step vehicle check
The focus of Interactive Reception is the
8-step vehicle check. By checking the vehicle
in the presence of the customer, by demon-
strating care in going through all check
items, and by interacting with customer
during the check, you will not only establish
technical competence with the customer.
More importantly, you will show your com-

autoteam Issue 4 9

petence as a true advisor to the customer,
a partner who makes an effort to recognise
the customer’s needs and who gives expert
advice, which will ensure that the cus-
tomer’s vehicle is properly maintained or
repaired.
The trust built during customer welcome
will be cemented if you show professional-
ism and competence during the 8-step
vehicle check. Many customers feel uneasy
about leaving their car for servicing or
repair. The vehicle check is the perfect
opportunity to convince your customers
that when they leave your car with you,
they are leaving it in capable hands.
In addition, the 8-step vehicle check is the
basis for determining the work that needs
to be carried out on the customer’s vehicle.
Although this could be done in the work-
shop without the customer present, the
8-step check allows you to obtain on-the-
spot customer agreement to identified
repair needs. This often avoids having to
contact the customer later to ask permis-
sion to carry out any identified add-on
work.
The check is also the ideal opportunity to
offer your customer services he originally
did not intend to purchase. For example,
he may be pleasantly surprised when you
offer to remove a small dent in the body-
work (using Paintless Dent Removal tech-
niques) at a price much lower than your
customer would have expected.
Of course, you must always take care not
to “oversell” such offers, because your cus-
tomer must see you first and foremost as an
advisor, not a salesman.
10
Check the functioning of the switches
together with the customer.
Step by step
The diagram on the facing page shows the
8 steps required for the vehicle check. It’s
important to take these steps in the
sequence shown. This not only ensures that
nothing is missed, it also saves time.
Also shown is a brief explanation of each
step, including examples of the items that
need to be checked. A complete list of all
check items is included on a new Interactive
Reception checklist, that has been specifi-
cally developed to reflect the
8-step process.
During the entire 8-step check, ensure you
keep the customer involved, by showing
him any defects you discover or, alterna-
tively, telling him that the items are in order.
Where appropriate, you should also compli-
ment him on the excellent condition of his
vehicle.
Phase 3: Agree work, price, and time
The 8-step check enables you agree the
required work with the customer and to
quote an all-inclusive committed price for
the job, which go a long way towards estab-
lishing the competitiveness and trustworthi-
ness of your dealership. And by
agreeing a firm completion time
for the job you will also demon-
strate that your dealership oper-
ates with organised and efficient
processes that the customer can
rely on – yet another indicator
that he is leaving his car in the
hands of true professionals who
he can trust.
Phase 4: Courtesy services
Depending on your customer’s
In the service reception, each
wheel is individually tested.
needs, you can demonstrate that your dealer-
ship not only takes perfect care of his vehicle,
but also of him. Be it a courtesy vehicle,
agreed when the appointment was made or
found to be necessary because unexpected
work was discovered during the 8-step check,
be it some alternative form of transportation,
or a convenient waiting area if the customer
can wait for the work to be carried out. Such
services further enhance the positive impres-
sion you make and show your customer that
you really care.
Complete process – complete
success
Experience in many dealerships has shown
that a perfect Inter-active Reception process
is a prerequisite for ongoing customer satis-
faction and Service business success. But it
only works, if it is done completely. This
applies particularly to the 8-step check.
Make sure you offer it to your customers as
a matter of course, and if they don’t agree
immediately, convince them that it’s worth
their time. And remember: for you and your
dealership’s success, the time you spend
checking the raised vehicle with your cus-
tomer present, is certainly time well spent.
autoteam Issue 4
The temperature check should show a
temperature of between 3 and 8 ° C.
A/C Check
New service
In order to provide an additional
service to our customers, and
also to avoid the risk of expensive
repairs such as compressor
damage, an air conditioning
(A/C) check has been introduced.
The A/C check has been added
to Extended Period Maintenance
and will be carried out every
3 years.
The aim of the check is to determine
whether the level of refrigerant in the
system has fallen to an unacceptable level.
NOTE: A small percentage of refrigerant
will escape from the A/C system each year.
The test is divided into four sections:
✓ Pressure check
✓ Temperature check
✓ Compressor cycletime check
✓ Visual inspection
If the results from any of the first three tests
fall outside the permitted ranges this is a
Type of A/C system
Fixed orifice tube Fiesta ‘96, Focus, Ka, Puma, Mondeo, Probe,
Explorer and Windstar
Expansion valve Escort, Fiesta ‘96 Freshline, Scorpio and Galaxy
autoteam Issue 4
Count how many times the compressor Carry out a visual inspection under the
cycles in one minute. hood.
good indication that the refrigerant level has Vehicle with fixed orifice tube
dropped to a point where the compressor (FS10 compressor)
could be damaged. Number of cycles 1-3
Visual inspection Vehicle with fixed orifice tube
Visually inspect all A/C lines, hoses and (scroll compressor)
connectors for damage or leaks. Although Number of cycles 1-2
the refrigerant evaporates without leaving
a trace there will be a trail of oil (oil is Vehicle with expansion valve
mixed with the refrigerant) from the No check possible
damaged or leaking area.
If any damage or leaks are found or if the
Preparation results of any of the other tests were outside
Connect the Service Station to the A/C their permitted ranges, the customer should
system and start the vehicle’s engine. All be informed and further action discussed.
checks should be run with the engine at idle.
All readings should be taken at normal Pressure check
ambient temperature. Before commencing Close all the doors and windows, set circu-
the checks a thermometer should be placed lation to ON and set the blower to the
in the centre vent. highest speed setting and select the lowest
temperature. Pressure test the A/C system
Compressor cycle time check on both the high and low pressure sides.
Note: This check is not carried out on vehicles
with expansion valves. Keep the doors and Vehicle with fixed orifice tube
windows closed, set the circulation to ON High pressure side 7 - 14 bar
and select the highest speed setting for the Low pressure side 1.6 - 3.1 bar
blower with the lowest temperature. Record
the number of cycles (one cycle is the time Vehicle with expansion valve
taken for the compressor to switch ON and High pressure side 9 - 12 bar
OFF) of the A/C system in one minute. Low pressure side 0.6 - 1.2 bar
Temperature check
With the other conditions remaining the
Vehicle same close all the side vents and after
5 minutes record the temperature of the A/C
system. The temperature should be between
3 ° C and 8 ° C.
11
 1 6 11

1 Power steering fluid, 2 Antifreeze, 7

10
3 Windscreen washer fluid concentrate,
4 Engine oil, 5 Transmission fluids/oils, 2 5
6 Fuel, 7 High tension current, 8 Air
conditioning refrigerant, 9 Battery acid, 9
10 Air filter, 11 Brake fluid
4
3
8

Always be aware of the dangers

you face during your daily work!
The risks of handling fuels, oils,
paints and antifreeze, refrigerants
and cleaners as well as many
other hazardous materials are
frequently underestimated. Many
operations are performed rou-
tinely without anything ever going
wrong. You will become imprudent,
danger warnings will be ignored.
Danger ahead!
Sooner or later an accident will
happen.
Be prepared!
Reason enough to describe and explain in
this third article on “Health and Safety” the Some hints for your health – and that of your colleagues
most important Danger Warning Symbols,
their significance and handling procedures. The following hints only can be of course Exceptionally, only use properly
Their meanings are given together with a choice of all operations and procedures labelled and shatterproof containers if
examples of hazardous materials used in carried out in the workshop. the original containers are no longer
the workshop. Avoidance of accidents is available.
simple providing the correct handling of ■ Work conscientiously and observe the
hazardous materials is learned and the all procedures as well as restricting, ■ Always wear suitable protective goggles
respective Danger Warning Symbols and warning and precaution symbols! and gloves when working with automo-
instructions are consequently followed. Think of personal protective clothing tive batteries. Observe the No Smoking
and equipment. policy and never inhale battery acid
By the way, Health and Safety Precautions vapours.
are detailed on every TIS-CD under ■ The skin fulfils vital functions in the
“General Information”. Please consult human body. Skin protection is, there- ■ Always observe the danger warning
these attentively to deepen your knowledge fore, of paramount importance when symbols – they are there for your own
of this subject. carrying out many operations associ- personal protection and safety of your
ated with vehicle maintenance (e.g. colleagues at work. If anything is
also when changing oils). Follow to the unclear to you, talk to your Safety
letter the rules for prevention of skin Representative or your Workshop
diseases and all useful instructions on Foreman!
how to protect and care for your skin.
■ Before using a new product containing
■ Never store hazardous materials hazardous material the Materials Safety
(oils, acids, antifreeze, adhesives, etc.) Data Sheet must be consulted. It con-
in food or drink containers – they could tains information about the chemical
be mistaken for what is on the label! composition, possible dangers, first aid
procedures, fire extinguishing instruc-
tions, material properties, handling,
Reckless: working on batteries without storage and disposal and of course the
protective gloves, but with a glowing name of the supplier.
cigarette stub instead. Ignoring warnings
puts yourself and others in great danger!
(Note: this scene was enacted by
autoteam).

12 autoteam Issue 4
 The following table itemises important symbols issued by the European Committee
Commission relevant to the automotive repair business. Please note that the symbols as
well as their significance can nevertheless be subject to local national interpretation. The
list is not exhaustive and represents just a selection!

Restriction symbols rbotszeichen

Significance Usage examples in the workshop

Smoking forbidden Applies to the whole working area (except

where explicitally allowed, f.i. rest area)

Fire, naked lights and Boiler rooms, enclosures for gas cylinders,
The three typical hazardous materials smoking forbidden fuels, batteries, cleaners, paints, certain
adhesives, airbags
and their respective warning symbols
found in every workshop are: Brake Use of water to extinguish Fuel overflow containers,
cleaner (flammable), battery acid forbidden fuel collection point
(corrosive) and antifreeze (harmful).
Water not drinkable Re-use of waste water

Keep out of childrens reach Vehicle battery

This is how hazardous
materials should be stored:
Brake cleaner, paint aerosol Warning Symbols*
cans, paint touch-up pencils,
Highly flammable material or Brake cleaner, paint spray, cleaning materials,
antifreeze, engine oil, brake high temperature touch-up pencils, fuels, refrigerants, airbag
fluid, battery acid and inflator propellant
others in lockable fireproof
cabinet with appropriate Hazardous or irritant Antifreeze, refrigerant, windscreen adhesive
material
warning symbols.
Corrosive material Battery acid, cleaning materials

First Aid in Accidents with

Hazardous Materials Explosive material Vehicle batteries (oxyhydrogen), airbag infla-
tor propellant
Run through your mind an emergency Dangerous high voltage Engine high tension ignition system, switch
situation in your workshop: How can I electric current room, various electric tools, washing machine
help the injured? Where is the first aid without a safety fuse
box? Where the fire extinguisher? Which
hazardous material is the cause of acci-
Mandatory symbols
dent? What does the Materials Safety Wear eye protection Changing batteries, use of certain cleaning
Data Sheet say? Where is the nearest tele- materials, grinding, grind-cutting, sawing,
phone and which number must I dial? drilling, renewal of refrigerant fluid, sand-
blasting, working on inflated airbag, some
adhesives
Only if you are prepared for such situa-
tions, can you react in the case of an Wear full facial protection Welding, sandblasting
accident sensibly and quickly. In every
workshop there is someone (e.g. mana-
ger/foreman), who is familiar with the Wear ear protection Grind-cutting, sawing, working with engine
running (e.g. exhaust emission test)
exact safety regulations. Thus always
best address your questions about safety Wear protective gloves Changing batteries, refrigerant, oil, welding,
procedures to this person and make working on inflated airbag, fibre glass ma-
yourselves knowledgeable. terials, some adhesives.

Wear respiratory protection Painting, dry-sanding without adequate venti-

A person’s life (e.g. that of your col-
lation, working on brakes, handling of parts
leagues) can sometimes depend upon the containing asbestos (older vehicles), welding,
following 3 measures being carried out soldering, some adhesives
sensibly and quickly:
1. Apply first aid measures (refer to Wear protective clothing Painting, welding, spilled airbag propellant,
some adhesives
Materials Safety Data Sheet).
2. Call the Emergency Doctor.
3. Have the packaging or container with Consult relevant instructions Unfamiliar materials: Check documentation
the hazardous material available for or ask Safety Representative
the doctor.

*Symbols on containers containing hazardous materials reflect the Warning Symbols,

but are square in shape and the background colour is orange (see picture above left).

autoteam Issue 4 13

New Mondeo
Power Sources
One of them is very well known
to us, we are familiar with close
relations of two of them and three
are brand new family members.
We’re referring to the new
Mondeo’s engines which we
will look at here in more detail.
New Mondeo’s engine range is comprehen-
sive. The variants range from 1.8 to 2.5
litres and from 90 PS to 170 PS. All of them
– petrol and diesel – are 16 valves engines.
Let’s begin with the newest engine design.
Duratec-HE
The all new Duratec-HE petrol engine is
installed in the new Ford Mondeo as a 1.8 L
developing 110 PS or 125 PS as well as a
2.0 L developing 145 PS. autoteam puts
14
some particularly noteworthy features of
this light alloy engine under the magnifying
glass.
Lightweight and Solid basis
The aluminium and silicon alloy cylinder
block with spun cast iron cylinder liners
contribute to the fact that the Duratec-HE
engines are currently the lightest in their
class. The cylinder block has deep-
drawn side walls and the main
bearing caps are combined
into a stiffening ladder.
Solid cast aluminium stiffening
frame incorporating the main bearing
caps (Duratec-HE).
Ford Duratec-HE Petrol Engine, 1.8 L
and 2.0 L.
Together with the structured aluminium
oil pan this results in an extremely solid
unit. Advantage: Low noise emission levels
and a very stiff engine/transmission assem-
bly.
Minute Tolerances
The minute crankshaft assembly bearing
clearances ensure extremely smooth
running. Dependent upon the bearing
journal and bore sizes, the bearing shell
pairs with the minutest tolerances are cho-
sen in production from 7 different bearing
sizes and 13 combinations of upper and
lower bearing shells. Since this exactness
cannot be duplicated in the workshop no
repairs whatsoever are permitted on the
crank assembly. If necessary, the complete
cylinder block and crank must be replaced.
The driving comfort is further improved
through the dual-mass flywheel, which
absorbs any torsional vibrations which
may occur, particularly at low revolutions.
Valve Gear
The two camshafts are made from solid
chilled cast iron, and are driven by a low-
noise, maintenance-free, pinned link chain,
operating the valves directly through bucket
tappets. The correct sizes are selected during
production assembly and they are fitted
without adjusting shims. By optimising the
materials used, the weight of the compo-
nents and the cam profiles, the development
engineers were able to reduce valve gear
wear to such minute levels that checking
and adjustment of the valve clearances is
not necessary.
Air Swirl
The intake manifold made of friction
welded plastic is an elementary part of the
lightweight design concept for the Duratec-
HE. But what makes this part with a high
recyclable content so special, are the swirl
plates in the intake ducts, operated by a
vacuum diaphragm unit. They are closed at
low engine speeds and reduce the intake
cross-section to only 25%. This
produces increased
autoteam Issue 4
 Dual-mass flywheel absorbs torsional
vibrations (Duratec-HE).
intake air swirl at partial engine load for a
better combustion air/fuel mixture.
Simulator
At higher engine temperature the mechani-
cal efficiency of the engine is improved by
the reduction in friction; fuel consumption
falls and the exhaust emission (CO and HC)
is reduced. Therefore the coolant thermostat
with expansion element is set to ensure an
operating temperature of 98° C; the usual
temperature is 80 to 90° C. At full load,
however, when much heat is generated
which must be dissipated, this temperature
would be too high and damage could result.
The engineers delved, therefore, into their
bag of tricks and
attached an elec-
Friction-welded plastic intake
manifold with swirl plates
(Duratec-HE).
autoteam Issue 4
Electrically heated thermostat (Duratec-HE):
1 to radiator
2 to heater
3 electrical connection
4 heated expansion element
5 from water pump
6 bypass
tric heating resistor to the expansion ele-
ment. This way the expansion element is
heated only at full engine load to simulate
a higher temperature level. The thermostat
then opens sooner or wider and the temper-
ature is reduced down to 80° C.
New Management
The engine management system “Black
Oak” is an all new development by Visteon.
With the new 32-bit-Processor from
Motorola and a doubled memory capacity,
this powertrain control module (PCM) can
perform even more functions at even greater
speeds. For instance, in addition to fuel
injection and ignition amongst others, TCS,
ESP, automatic transmission, automatic air
conditioning, PATS, generator charging
control and EOBD.
Duratec-VE V6
The top of the range 170 PS engine is the
Duratec-VE. The smooth as silk V-six cylin-
der with its modern engine concept can also
be specified in the new Mondeo range. The
Duratec-VE V6 is well known from the pre-
vious Mondeo and from the Cougar, and
has already been the subject of several
autoteam articles.
DuraTorq-DI
The design concept of the two diesel engines
of the new Mondeo was, just a few years
ago, reserved for particularly sporty
petrol engined cars: two overhead
camshafts and four valves per
cylinder. The 2.0 L DuraTorq DI
with either 90 PS or 115 PS, based
on the Transit DuraTorq diesels,
has been modified for use in the
Mondeo. Some of the most important
innovations are described below.
Timing chain (pin-linked): Inner toothing for quiet
operation, smooth outer running surface for low
noise and low friction tensioning (Duratec-HE).
Pilot Injection
The pressure for the direct injection is
achieved by a Bosch distributor type fuel
injection pump controlled by means of an
EEC V PCM. The 6-hole fuel injectors with
two different valve needle springs first inject
a tiny quantity of fuel into the cylinder that
initialises combustion. The main injection
follows a few milliseconds later.
The advantage of this so-called pilot injec-
tion: continuous combustion pressure build
up, reduced combustion noise, reduced
nitrogen oxides in the exhaust gas,
minimised black smoke.
Variable Turbocharger
Usually the boost pressure is regulated by a
flap valve. At high engine speeds this valve
directs part of the exhaust gas to a turbine
bypass to avoid excessive boost pressure.
On the 115 PS engine this control function
is done by adjustable vacuum controlled
vanes on the turbine entrance. The vanes
adjust the angle at which the exhaust gas
stream strikes the turbine blades and thus
control the turbine speed and boost pres-
sure. This has achieved an increase in out-
put power and torque of between 10 and
20%.
Overboost Function
The engine management can increase the
turbocharger boost pressure momentarily
by means of the overboost function (over-
charging). The engine’s maximum
torque of 245 Nm is increased to
280 Nm (90PS), or from 280
Nm to 310 Nm (115PS), and
improves the acceleration
performance.
15
 Ford DuraTorq-DI- Immensely strong forged steel
Turbodiesel. crankshaft (DuraTorq-DI).

when the engine is running or when

switched off. It is only closed for a few
seconds by vacuum when the engine is
switched off. This interrupts the air intake
to the cylinders and prevents the unpleasant
habit of diesel engines shaking when
switched off.

Reduced Exhaust Gas Emissions

The DuraTorq DI Diesels in new Mondeo
easily meet the requirements of Euro
Exhaust Emission Standards. A number
of features in addition to the precise fuel
metering system contribute substantially:
The DuraTorq DI represents the latest in
diesel technology and has ample potential
to meet future exhaust emission standards,
fuel economy, comfort and safety require-
ments.

■ Water-cooled exhaust gas recirculation.

Intake Manifold Valve
A valve in the intake manifold of the
DuraTorq DI engine, similar to the throttle
valve of a petrol engine, is fully opened
The cooling by as much as 200 degrees
enables high recirculation rates without
impairing the cylinder filling through
excessive air intake temperatures.
■ Quick “starting” oxidation catalyst
directly on the exhaust manifold.

Adjustable turbocharger vanes (DuraTorq-DI 85 kW (115 PS):

Emission Self-Test
To monitor emission related components
all Mondeo petrol engines are equipped
with EOBD. The European On Board
Diagnostics system warns the driver of
an emission control fault in his vehicle by
illuminating a warning lamp (MIL).

EOBD is integrated in the engine

a) moderate exhaust gas stream strikes
the vanes far out
= high turbine performance.
management system and requires no
additional components, with the excep-
tion of an additional downstream cata-
lyst lambda sensor. (Please refer to
autoteam’s “EOBD” Special Information
Issue.)
b) strong exhaust gas stream guided
towards the centre of the vanes
= reduced turbine performance.

The new Mondeo engines at a glance

Typ Capacity Bore/Stroke Compression Max. power output Max. Torque Engine max. Speed
cm3 mm ratio kW (PS) at 1/min Nm at 1/min Cont./Max.

Petrol
Duratec-HE 1.8 1798 83/83,1 10,8:1 81(110)/5500 165/3950 5950/6175
Duratec-HE 1.8 1798 83/83,1 10,8:1 92(125)/6000 170/4500 6500/6800
Duratec-HE 2.0 1999 87,5/83,1 10,8:1 107(145)/6000 190/4500 6400/6675
Duratec-VE V6 2.5 2499 81,7/79,5 9,7:1 125(170)/6250 220/4250 6500/6700

Turbodiesel
DuraTorq-DI 2.0 1998 86/86 19,1:1 66(90)/4000 245 (280)/1900 4800/4800
DuraTorq-DI 2.0 1998 86/86 19,1:1 85(115)/4000 280 (310)/1900 4800/4800

16 autoteam Issue 4
At the end of last year the oil
filter used on both the 2.5L DI
Diesel Transit engine and the
1.8L Endura DI Diesel Focus
engine has been replaced with
an improved part.
Filter
change
Over the years the operating conditions
for the filter have become more severe with
higher power engine variants, more con-
fined installation spaces and extended
service periods. The improvements to the
filter will compensate for these more ardu-
ous operating conditions and ensure total
sealing over the entire service period.
What’s new?
Visually the old and new designs can be
differentiated by the new filter having a
“fluted” can design. This is similar to the
filter already used on 1.8L Endura DE
Diesel engines. The design allows the use
of a specific tool, available at the same time
as the launch of the new filter, to aid fitting
and removal (Ford Tool No. 303-704
[21-255]). Other changes to the filter
include a new sealing ring material, which
is softer than the current ring and more
resistant to the effects of oil at elevated
temperatures over extended periods, plus
improved graphics to aid the fitting process.
New tightening requirements.
The changes to the filter can and sealing
ring have allowed optimisation of the fitting
procedure. Use of the tightening tool will be
required to achieve the rotation required on
the filter. By following the procedure
autoteam Issue 4
detailed below the filter will stay tight and
leak free between service intervals.
Tightening procedure:
1. Lubricate the entire seal with fresh, clean
oil. This is best achieved by dipping the
seal into the oil. Smearing the seal with
oil will not usually provide enough lubri-
cation of the seal and will prevent the
correct angle of rotation being achieved
during tightening.
2. Fit the filter to the engine and run it
down until the seal touches the sealing
face. Only light hand pressure is required
at this stage.
3. Using the filter tightening tool rotate the
filter by 1 complete revolution. (N.B.
The new canister has 8 symbols around
the top of the can. The amount of rota-
tion achieved can be monitored by lining
one of these up and then rotating the
filter until the symbol is back at its start-
ing position.) It is essential to ensure one
complete revolution is obtained to give
acceptable sealing performance over the
service period.
4. Clean off any excess oil from around the
filter-sealing ring.
Any old filters?
The Part Number for the filter will change
from XS4Q-6714-AA for the old filter to
XS4Q-6714-AB for the new one. Old filters
are still acceptable for use on both engine
applications, and you should keep using
them until all stocks are exhausted, but you
must use the old tightening process when
using the old filter.
Which oil?
For use in the 2.5L DI Diesel engine in the
Transit, Ford recommends the use of Ford
XR+ oil. Alternatively SAE 10W-40 oils
meeting ACEA A3/B3 quality may also be
used in this engine.
We recommend the use of Ford Formula E
oil in the Focus 1.8L Endura DI Diesel
engine. The engine has been designed
around this specification of oil which gives
the user increased long term stability against
oil thickening and an increase in fuel econ-
omy over and above ACEA A1/B1 oils.
Alternatively, other SAE 5W-30 oils meeting
Ford specification WSS-M2C913-A can also
be used in this engine.
17
For more than 50 years, Ford has
been working with remanufac-
tured parts. These parts have
many advantages: the customer
benefits from the lower price of
the parts and the environment
benefits, as the recycling of parts
saves on raw materials and
energy. At the same time, the
quality of remanufactured parts
is identical to that of original
parts. The following article shows
the advantages to your dealership
of using remanufactured parts,
but also the things you should
pay attention to.

Born again
Ford has the largest range of remanufac-
tured parts for Ford vehicles – from the
engine to the brake calliper, from audio
equipment and gearboxes to engine control
units. The scheme brings significant cost
benefits to your dealership’s customers: on
average, remanufactured parts of the same
quality cost a quarter less than new parts.
However, remanufactured parts are far from
a cheap product: there are no corners cut in
terms of quality and all parts are subjected
to strict testing. Furthermore, remanufac-
tured parts are supplied complete with all
components, allowing fast and value for
money fitting. In contrast, if you order parts
from other remanufacturers, some compo-
nents will be missing – this increases the
repair costs.
Environmental protection
in practice
The parts cycle also protects the environ-
ment. Experts have calculated that the
reconditioning of engines at Ford has saved
enough steel in the last five years to rebuild
the Eiffel Tower once or, purely on the basis
of calculation, the Golden Gate Bridge more
than three times. In terms of energy con-
sumption, a newly manufactured engine is
80% more costly than a reconditioned unit.
Cost savings for the customer and environ-
mental protection with consistent quality
of the parts are convincing arguments for
using remanufactured parts in your dealer-
ship. However, the cycle can only function
if meticulous care is taken throughout the
process. Due to the quality achieved, Ford
provides a one-year warranty for remanu-
factured parts throughout Europe, with no
mileage restrictions. Engines are just one
example of the cycle from a used original
part to an as-new reconditioned part.
The foundations for Ford’s remanufactured
parts are laid in product development. In
Ford’s vehicle development centres in
Cologne and Dunton, there are engineers
working exclusively on the reconditioning
of entire units. For example, reconditioned
engines are subjected to an endurance test,
in which they run for 180 hours at maxi-
mum speed.

Reconditioning Ford remanufactured engines:

Used engine as supplied Dismantling the engine Cleaning the parts Second cleaning and
washing cycle

18 autoteam Issue 4

At Schmitz + Krieger, one of four engine and
gearbox reconditioning companies,
autoteam saw for itself how Ford’s high
quality requirements are implemented when
reconditioning engines.
At Schmitz + Krieger in Cologne, Germany,
used engines are completely reconditioned.
The Cologne company specialises in the
reworking of engines and gearboxes. The
staff of around 100 at the three sites in
Cologne, Aachen and Bonn know the most
diverse engines inside out – from vintage
engines, which are sent to be overhauled, to
engines from mass-produced passenger cars
and commercial vehicles through to drive
units for locomotives. Schmitz + Krieger is
currently passing through certification to be
a Ford Q1 supplier, which means that the
products satisfy the highest demands.
To meet these high demands, Schmitz +
Krieger use highly qualified specialists and
high-tech machines to recondition engines.
“The repair process is precisely defined,”
explains Achim Birr, Managing Director of
the Cologne company. “It is based on Ford
specifications and the RAL RG 797 regula-
tions.”
Strict requirements from Ford
If a car engine with a seized piston is to
be turned into a remanufactured engine
according to Ford specifications, and
with an RAL quality mark, quality is the
absolute priority in reconditioning. “For
this reason, Schmitz + Krieger relies on
quality management in accordance with EN
ISO 9002 throughout our operational
Working on the cylinder heads
autoteam Issue 4
Exemplary environmental protection:
Water used in the reconditioning process
is purified and cooled.
processes”, Birr emphasises. Ford then puts ing in the design of the parts”. This makes
the company’s work under the microscope things easier for the 37-year old mechanical
according to its own standards. engineer and his staff. Only parts which
When an engine is delivered, the Cologne have sufficient mass retain the necessary
specialists first of all completely dismantle strength after boring and honing. What is
it and clean all the components. “For more, the manufacturers offer special com-
engine reconditioning, we distinguish ponents for the second life of the engine,
between wear and tear parts and structural for example over-dimensioned pistons.
parts. Wear and tear parts and irreparably To achieve the oil clearances specified by
damaged components are replaced immedi- Ford, at Schmitz + Krieger, all pistons are
ately”, explains Achim Birr from Schmitz + individually pre-measured and the bores are
Krieger. This means that pistons and piston honed to the piston clearance specified by
rings, as well as bearings and seals do not the manufacturer on each cylinder, as
get a second chance – they are immediately described above.
replaced with original components.
The cylinder block, cylinder head, crank-
shaft, camshaft and connecting rods, on the Reconditioned Ford engines waiting
other hand, are valuable structural parts – it to be sent to Cologne-Merkenich.
is therefore worthwhile making them fit for
a second engine life. For this, the cylinder
has to be set to exactly the correct tolerance
and with a faultless surface structure. This
is achieved by pre-boring and honing (cross-
sanding): honing consists of the fine-bored
cylinder bearing surface being ground with
silicon stones. A special oil cools down
the grinding stones and washes away the
ground particles. At the end of this process,
all traces of any piston seizing or jamming
are completely removed from the used
engine. For honing, the tolerance is half a
hundredth of a millimetre – by comparison,
a hair from a Central European person has
a diameter of four to five hundredths of a
millimetre. This precision work allows
an optimum running-in process and high
running performance with minimal oil con-
sumption – the same requirements which
are applied to an original part.
Achim Birr is pleased that “Ford includes
the reconditioning of the engine in its think-
Reconditioning the
crankshaft
19

The strictest quality standards every step
of the way.
The cylinder head is then tested for frac-
tures using special equipment. Once this is
done, the engineers plane the sealing face
for the head gasket, grind the valve seats,
and replace or repair the valves, guides and
seat rings. The rocker and rocker shaft,
bearing bushes, valve springs and tappets
are also repaired and, if necessary, replaced.
The next stage is to check and recondition
the crankshaft. “This requires several
steps”, explains Achim Birr. “Each shaft is
checked for true running and hardness.”
The crankshaft can have been damaged by
a seized piston or bearing damage. Minimal
deviations from the ideal line can be cor-
rected – for this Schmitz + Krieger employ
a special tool, the “Theilack tool”.
Corresponding exactly with Ford
specifications
Heat, caused by bearing damage and con-
stant loads in the engine can lead to frac-
tures in the crankshaft. In Cologne, they
identify this kind of damage by “magnetic
particle testing”.
Reconditioning the crankshaft
20
The crankshaft is magnetised and com-
pletely moistened with an iron oxide solu-
tion. Disturbances in the magnetic field
(fractures) are made visible using an ultravi-
olet light source.
“Up to a certain depth, fractures can be
removed by grinding”, says Achim Birr.
Schmitz + Krieger has a lot of experience in
this area, as the company was established
back in 1911 as a crankshaft grinding shop.
They pay particular attention to the bearing
necks: these are precision-ground and
polished until their radius, tolerance, repair
stages and surface roughness correspond
exactly to Ford’s specifications. If the dia-
meter of the shaft at a particular bearing has
been reduced by grinding, Schmitz + Krieger
use bearing shells with a smaller interior
diameter when replacing the shaft in the
engine, so that the bearing does not have
too much clearance. These so-called under-
dimensioned bearings, which the manufac-
turer always offers in different dimensions,
are subject to the same strict quality
requirements.
The shaft is now tested for imbalance. If
necessary, material is removed from the
shaft faces until the shaft runs in balance
again. A crankshaft must be flexible within
certain limits, but must, at the same time,
have a very hard surface. However, the
surface can soften due to material fatigue.
“For this reason, we test it with the sclero-
meter”, explains Achim Birr. This measur-
ing device works on the principle of a metal
pin falling onto the shaft. The height to
which it rebounds is measured. Birr puts the
test method in simple terms, “The harder
the shaft, the higher the pin is thrown”.
Drilling and grinding the cylinder block
If the material is not sufficiently hard,
Schmitz + Krieger boost it with flame
hardening: with precisely metered heating
followed by shock cooling with water, the
shaft regains its old hardness. Only at the
end of this expensive procedure can a
crankshaft be re-used – it is now assured
that it is just as durable as a part direct from
the factory.
Strict quality regulations apply
right up to final assembly
In the next stage of the overhaul, the con-
necting rods are put on the test stand. The
bearings of the connecting rod bolts are
exchanged. The bottom bore is adjusted to
the required dimension by Scotch-yoking.
If necessary, the connecting rod bushing is
replaced. Testing the weight and squaring
are also on the checklist.
The camshaft and auxiliary shaft are, if
possible, reworked but, if there is any
doubt, they are replaced – after all, quality
is the primary requirement.
“Even the secondary units are painstakingly
tested”, Achim Birr emphasises. Here, the
Schmitz + Krieger experts check injection
pumps, injectors, oil coolers and water
pumps.
At the end of the costly process, recondi-
tioned and brand new parts are re-assem-
bled into a complete engine. Strict quality
regulations also apply to this final assembly.
The completely assembled unit still has to
demonstrate on the performance test stand
that the reconditioning has been successful –
only then is the engine sent to the central
Ford warehouse in Cologne-Merkenich.
autoteam Issue 4
Benefits for the dealership and for
the environment
The collection of parts is done by the
dealership. There, the used parts are
checked for basic damage, securely pack-
aged for transportation and sent to the for-
warding agent P&O in Cologne. There,
another check determines whether the com-
ponents are complete, suitable for recondi-
tioning and properly packaged. From P&O,
the used parts are then distributed to the
specialised overhaul centres.
In this way, your workshop may soon be
able to re-use a used part, which has been
saved from being scrapped by the remanu-
factured parts scheme and the know-how
of an overhaul centre – for the benefit of
your customer, the environment and for
your own benefit. After all, your dealership
will benefit financially from this.
Your dealership plays a crucial role in the
recycling process, as your company is the
collection point for used parts. The work-
shop and parts department must work hand
in hand here. If you submit the used parts
which you collect promptly and regularly,
you help to prevent damage caused by long
storage times and you allow an even work-
load for the companies involved in the recy-
cling scheme. Before your company sends
back a part, a basic check is required. First
of all, it should be established whether or
not that part is actually included in the
remanufactured parts scheme. If your com-
pany sends in parts, which are not included
in the scheme, you will receive a bill for the
disposal costs. The remanufactured parts
scheme covers the following components:
■ Alternators
■ Distributors
■ Anti-lock braking system (ABS)
Assembly of the Final assembly of the
cylinder head engine
autoteam Issue 4
■ Engine control units
■ Audio units
■ Front axle repair kits
■ Axle/drive shafts/drive shaft linkages
■ Petrol engines
■ Brake callipers
■ Catalysts
■ Clutch assemblies
■ Starter motors
■ Cylinder heads
■ Steering gears
■ Diesel engines
■ Gearboxes/overdrives
■ Diesel injection equipment
■ Digital instrument panels
Check first - then despatch
Next, a basic check for visible damage is
required. Parts, which are heavily soiled
or rusted, cannot be included in the reman-
ufactured scheme. Components, which are
incomplete or partially dismantled, are also
excluded. For example, cylinder heads with
an overhead camshaft must be returned
complete with the upper camshaft bearing
shells, and in some cases even with the
camshaft itself. Housings, which have been
broken or torn by external forces, should
be scrapped, not reconditioned. In general,
parts which show signs of damage due to
an accident or external factors should be
removed. Drive shafts are an exception here
– they can be submitted even if they are
warped. The CD-ROM “Ford remanufac-
tured parts scheme – Process and organisa-
tion” contains more detailed information.
After this first check, it must be ensured that
the used part returned exactly matches the
scope of delivery of the remanufactured
part. All add-on parts must be available.
Engine on the test stand
Prior to despatch, all oil, fuel or brake fluid
must be drained from engines, gearboxes,
diesel injection pumps and brake callipers.
If this does not take place, the company
submitting the parts can be invoiced for
the disposal costs.
Correct packaging saves costs
For despatch, the used part should be
cleaned and despatched in the packaging
of the remanufactured part. The inspection
plug and protective caps supplied with the
remanufactured part must be used. Careful
packaging ensures that the used parts arrive
intact at the reconditioning company. This
will benefit your dealership, as any parts
which cannot be used for reconditioning
due to transport damage will be scrapped
and your dealership will be charged for
them, or you will not receive a credit note
which, depending on the part, can amount
to up to £ 650.
Engines and gearboxes should only be
transported in the special remanufactured
parts packaging; that is to say in the steel
frame and wooden crate. Cylinder heads
and short blocks, i.e. cylinder blocks with
driving gear, must be individually packaged
in original boxes, to protect the valve train
and the sealing surfaces.
Diesel injection pumps, carburettors and
brake callipers must be drained of all fuel or
brake fluid and packaged in original boxes.
Steering mechanisms, drive shafts, starter
motors, generators and clutches, on the
other hand, should not be packaged. These
used parts should be despatched in a rolling
container.
Reconditioned engine
21
 yst o
y S de
em
fet o n
Sa w M
Ne
The vehicle’s chassis systems
are the safest we have ever
known. New Mondeo has an
Advanced Restraint System (ARS)
which includes new features
not seen on its predecessor, the
Supplementary Restraint System
(SRS). How do these systems
work and how to handle them in
service.
Clearly visible seam markers
identify the covers used for air
bag equipped seats.
22
Safety
First
Crash test deployment of
a side air curtain.
Staged driver and front passenger airbags
are fitted as standard. This new staged
deployment system means that inflation of
the airbag is now more controlled than pre-
viously seen on Mondeo. Side airbags and,
for the first time, side air curtains are avail-
able as optional or standard equipment.
Through precise evaluation of the crash sit-
uation, the new ARS provides significantly
improved occupant protection in a number
of ways. Various airbags can be deployed on
the basis of the following crash criteria:
■ Severity of impact
■ Position of the driver’s seat
■ Occupation of the passenger front seat
■ Use of the seat belt
To ensure optimum airbag function, the
airbag system has been modified and a
number of extra sensors added:
■ Airbag control module (modified)
■ Front crash sensor (new)
■ Side impact sensor (modified)
■ Driver seat position sensor (new)
■ Seat belt buckle switch (new)
■ Seat occupant sensor (new)
■ Clockspring (modified)
■ Seat belt “not in use” warning indicator
(new)
■ “Airbag deactivated” warning indicator
(new)
The new staged airbags have two electrical
connectors on the airbag module, which
are of different shape and colour (black
and brown) to prevent incorrect connection.
Because there are now two connectors,
the clocksping has been provided with two
further tracks.
The driver’s airbag has two different sizes
of gas generator, which are fired consecu-
tively. The interval between the two firings
determines the rate of inflation and shock
absorbing characteristics of the airbag.
When the driver’s seat is in a forward posi-
tion, only the first stage of the airbag will
be deployed since there is a very high proba-
bility that the driver will be adequately pro-
tected by the first stage.
For safety reasons, both generators always
fire, but the interval between the two firings
determines the speed of filling and thus the
inflation characteristic of the bag. This can
vary between 70 and 100 per cent of the
total volume.
autoteam Issue 4
Front crash sensor located in the engine compartment, behind the
radiator grille.
The staged front passenger airbag is
deployed in the same way as previous
Mondeo, but now with a gas cartridge con-
taining inert gas compressed to approxi-
mately 300 bar instead of a gas generator.
Care should be taken when renewing seat
covers to ensure that the correct replace-
ments are fitted. The new covers must have
clearly visible seam markers close to the air
bag.
Control
The airbag control module is located in the
middle of the vehicle, on the central tunnel,
just in front of the gear lever. After an
airbag has deployed, the control module
must be checked for damage followed by a
diagnostic self-test. The various crash sen-
sors may also be reused provided they suc-
cessfully pass an examination and self-test.
autoteam Issue 4
Side impact sensor located at the bottom of the B-pillar.
In addition to signalling the airbags, the
control module also opens the central lock-
ing, switches off the fuel pump and sends an
SOS signal in the case of vehicles fitted with
the Ford Telematics system.
There is a crash sensor located in the engine
compartment, behind the radiator grille.
Its external shape correctly determines the
installation position of the crash sensor.
The sensor measures the longitudinal decel-
eration of the vehicle according to the sever-
ity of the impact and supplies the correct
signal to the airbag control module. The
sensor receives power via the airbag control
module. Should the sensor develop a fault,
a code will be stored in the control module.
The side impact sensors, which look similar
to the front crash sensor, are located at the
bottom of the B-pillars, behind the trim
panel. Like the front crash sensor, they now
Seat position
sensor.
Pyrotechnic
front seat belt
pretensioners
now have a Hall
sensor located in
the buckle.
only supply a signal (according to transverse
acceleration) to the airbag module for eval-
uation. The airbag module, not the sensor,
now carries out the plausibility check. Only
when the parameters are satisfied will the
respective airbags activate.
Driver seat position is an essential factor in
steering wheel airbag deployment. In order
to determine the driver seat position, a Hall
sensor is mounted on the inside of the inner
seat rail. When the seat is in the forward
position, only the first stage of the airbag is
deployed, as this should provide adequate
protection.
The pyrotechnic front seat belt pretension-
ers now have a Hall sensor, which signals
the airbag module when a front seat belt is
buckled-up. If it is indicated that the driver
or front seat passenger is not wearing a seat
23
Front seat belt pretensioner pyrotechnic cylinder. A 10-pin connector is located under each front seat.

belt, only the first stage of the respective
airbag will be deployed. If a front seatbelt
is not being used, a warning light is illumi-
nated in the instrument cluster.
Another development in ARS is the front
passenger seat occupant sensor. This con-
sists of a sensor pad comprising 110 pres-
sure cells. These cells have their own mod-
ule located under the cover of the front
passenger seat. The module processes infor-
mation from the pad sensors and passes the
relevant signal to the airbag module. When
the front passenger seat is unoccupied, the
airbag is deactivated.
As with the SRS, care should exercised
when working on the Mondeo ARS. After
disconnecting the battery, always wait for
30 seconds to allow system capacitors to
fully discharge. When testing the system
with WDS, always ensure you use the cor-
rect airbag simulators.
And finally, whenever you carry out WDS
tests of any kind, never rest the unit or any
tools in close proximity to an airbag. If the
vehicle should be involved in a traffic acci-
dent during testing, a deployed airbag could
propel an unsecured object at a vehicle
occupant causing severe injury.
A first for Mondeo is the use of active head
restraints on the front seats. This purely
mechanical device is designed to reduce
whiplash injuries in rear-end collisions.
The vertical two head restraint supports
are joined together inside the seat back with
strong fabric strip. In a rear-end collision, the
occupant’s back presses against the strong
fabric strip, causing the top part of the head
restraint to pivot upward and forward.
Looking at the press and publicity photos,
you’ll realise the New Mondeo body style
looks clean and fresh, but delve deeper and
you’ll soon discover it’s also one of the
safest cars in its class.

Stop Press
At the launch of New Mondeo, it was stipulated that
the body front crossmember must be completely
renewed if suffering crash damage. However, this
stipulation has been relaxed and it is now permissi- Body front crossmember.
ble to repair the crossmember.

Sectional replacement is achieved by drilling out the

2x6 press-joined connections. New separate cross-
member components are not serviced through Parts
Operations, so a new crossmember assembly must be
dismantled in the same way prior to welding the new
parts in position.
Crossmember construction:
1 Resistance spot welds
2 Press-joined connections

24 autoteam Issue 4
 TSB résumé
No: 142/2000 No: 145/2000 No: 147/2000

Section: 501-25A (44) Section: 204-04 (11) Section: 412-04 (34)

Model: All vehicles with overbody Modell: Transit 2000.5 and Model: Ka, Fiesta ‘96, Puma, all built
protective film applied Transit 2001 up to 09/99 (build code XJ) inclusive

Subject: Overbody paint protective
film removal
In order to provide enhanced protection
from bird lime and other airborne conta-
minants, a protective, adhesive backed
plastic film may be applied in produc-
tion. This protective film is in white
colour and must be left on the vehicle
until it is prepared for delivery to a
customer, but must be removed after a
maximum storage period of six months.
A date stamping on the protective film
will indicate the required removal date.
This TSB describes the removal proce-
dure.
Betrifft: Wheel nut tightening
torques
The tightening torque for the wheel
nuts on steel and alloy wheels has been
increased from 185 Nm to 200 Nm.
Please amend the torque figure for
Transit 2000.5 and Transit 2001 to
200 Nm in the 8/2000 Technical Data
Booklet.
Subject: Blower motor inoperative in
settings 1, 2 or 3 and/or there is a notice-
able smell of melting plastic and smoke
coming from the lower part of the crash
padding
Should a customer express such a con-
cern, the cause may be a poor electrical
contact at the blower motor resistor
multiplug. The high current passing
through the blower motor resistor may
cause the multiplug to melt. To resolve
the concern, a modified multiplug should
be installed on the wiring harness to the
resistor and a modified blower motor
resistor installed. This TSB describes the
detailed installation.

Competition
All those who return their answer cards after answering the questions set in this issue are eligible to enter this competition.

Mr. Best would like to lay out a circular water lily pond in
front of his Ford dealership to add a visually pleasing
element to the dealership’s surrounding. When he buys the
water lily, it has two leaves. Once in a fortnight the leaf
number doubles. That means the water lily has 4 leaves
after a fortnight, 8 leaves after 28 days ... After 98 days
80 % of the pond surface is covered with water lily leaves.

Assuming, the size of one water lily leaf is 230 cm2, which
diameter (in meters) does Mr. Best’s water lily pond have?
(note: π = 3,14)

Answer to the competition in autoteam 3/2000:

At a speed of 30 km/h Michael needs two minutes for one David two hours or 120 minutes later at a speed of 20 km/h
kilometre and at a speed of 20 km/h three minutes. In other than at a speed of 30 km/h, David lives 120 kilometres away
words: With the slower speed he needs one additional minute from Michael.
for every single kilometre. Because Michael would be with

autoteam Issue 4 25
 Marketing for
everybody,
(Part 3)

• Price •
e

e • Pric

P ri
ce •
P eo pl

ic

P
r ic
e • Pr

e
ple •

• Peo Place •
eo

pl

Place •
e • P

Place •
duct • P
ro Place •
ro
uct • P

duct • Pr

m o t ion
ro
od

o t i o n• P

od r
•
uct • P
p r o mot
m

io
n • P ro

Place – an element of marketing:

First impressions count

It is a normal working day for Mike Wilson,
Service Advisor in a large Ford dealership.
His morning in Service Reception ends with
the visit of John Finch, a long-standing cus-
tomer of the company. John has come to
bring his Mondeo in for its annual service
and to have some slight accident damage
repaired. He has not visited the dealership
for some time and he hardly recognises it –
the building has been altered since his last
visit.

“It’s changed around here”, John marvels,

as he looks around Service Reception. Since
the alterations, Service Reception and the
Vehicle Sales area are only separated by

A friendly design for your reception is

your dealership’s calling card.

26 autoteam Issue 4
 It is never too early for
customer care.
glass panels. A waiting area has also been
installed, with comfortable armchairs, a
coffee machine and corner for children to
play.
“If you have a bit of time, I’d be happy to
show you around afterwards”, Mike offers
his customer. He then agrees the scope of
the service and the repair work with John.
The Mondeo will need to be painted, so
they agree that it will be picked up the fol-
lowing day. Once Mike has completed the
repair order, he shows the customer the
workshop. John notices how orderly and
clean the workshop is, although it is a hive
of activity. After a short look at the parts
depot and the office block, Mike accompa-
nies his customer to Reception, where John
receives the keys and documents for the
courtesy car ordered.
It is only later that it occurs to Mike that
he has spent a long time talking to the cus-
tomer about the dealership’s design and
equipment. At lunch, he speaks to his
Service Manager Tony Moore about this.
Tony has already proved himself to be a
well-versed marketing specialist (autoteam
3/2000), and, on this occasion too, he does
not keep his knowledge to himself.
“Place plays an important role in marke-
ting”, Tony says. “But the issue has many
facets. Of course, accessibility and location
have a role to play. But it is more important
that your workshop does not look like it
autoteam Issue 4
belongs to a backyard mechanic. If it does,
then no-one will believe that you do quality
work.”
Mike now looks at his company through
the eyes of a customer. The dealership is on
the edge of town and can easily be reached
by Motorway or by two main roads.
“Anyway, we could not simply move”, he
points out. “You’re right”, Tony counters,
“but if we did have to look for a new loca-
tion, we would start by carrying out a loca-
tion analysis, with accessibility as one of the
important criteria.”
“After the location comes the design”, Tony
continues. “A good Ford dealership has to
offer something special these days. What
would you look out for if you were visiting
a car dealer?” Mike considers this for a time
and then lists some things. During the con-
versation, the Service Advisor learns from
his boss that a good dealership should have
a strikingly designed entrance from the
road. The customer must be able to park
in front of the entrance. There should not,
therefore, be any vehicles awaiting collec-
tion parked there. The salesroom and the
range of used cars should be immediately
obvious. Trucks delivering parts should, if
at all possible, have their own access, to pre-
vent them blocking the customer car park.
Another feature of a good dealership
is a tidy spare parts warehouse.
When a customer appointment is cancelled
during the afternoon, Mike pops in to
see Tony for a while, to continue their
lunchtime discussion. In the meantime,
Tony has found a manual published by
Ford, containing instructions for the design
of dealerships. With the help of these docu-
ments, he explains to Mike the requirements
which must be met when designing a dealer-
ship: “In short, the entire premises should
be customer-friendly and functional, so
that they create a good impression.”
Tony recommends to Mike that he take
another quick look at the dealership with
these aspects in mind. Mike uses the short
breather provided by the cancellation of
his appointment for a tour of the dealership.
He imagines that he is a customer seeing the
dealership for the first time.
Interactive Reception is marked with a
very visible sign on the outside. The large
sectioned doors with glass panels allow day-
light in, and the door towards the sales area
is also made of glass. There is a PC work-
station between the two hydraulic lifts.
Mike can use this equipment to prepare cost
estimates while the customer is with him.
On the wall, there is a poster advertising
Ford’s Parking Distance Sensor. Mike has
sold this “rear eye” on several occasions in
Interactive Reception. Those who bought
27

A friendly atmosphere for the customer is the sign of a good dealership.
it were customers who came in with a
damaged bumper and wanted to prevent
the same kind of damage in the future. He
notices that the poster showing the effect of
wiper blade wear looks a little messy –
Mike fetches a new one from the office.
His next stop is the workshop. Since the
alterations, it has one entrance and one exit,
The sales room should always be clean and well cared for.
28
to save the mechanics the time-consuming
task of shunting vehicles around. Jim, the
Workshop Manager, sees Mike looking
around and speaks to him.
In the course of their discussion, Jim
explains how much consideration and care
is required to plan a modern workshop.
Like most Ford Dealers, the dealership
where they work achieves a large propor-
tion of its profit from the workshop. As a
result, productivity and efficiency are the
most important issues.
“Previously, every mechanic must have
wasted ten working hours a month because
some diagnoses were not exact enough
or because the diagnosis took too long.
Now, we have modern equipment, which
we can use to identify problems much more
quickly, the WDS for example. This can be
used to measure the ignition voltage even
on a test drive.”
Jim then explains that the workshop and
paint shop must, of course, meet all envi-
ronmental and health and safety conditions.
Above all, however, in the planning of the
workshop, particular attention was paid to
ensuring that further alterations will be
possible at a later date. The Workshop
Manager points out a Service Technician,
who has just completed a job and is now
tidying his working area. “We keep the
workshop meticulously clean and tidy”,
says Jim. “This not only increases produc-
tivity, but also the safety of the technicians.
We also do neat work.”
The workshop exit leads to the rear of the
dealership. Here, cars which have been
repaired are parked in covered spaces, to
protect them from the elements. This also
means that the parking bays in front of the
main entrance are free for customers. The
staff parking spaces are also situated at the
rear of the building.
Next, Mike has a look around the sales
area. The room gives the impression of
being clean and well cared-for.
There are displays for accessories, at the
cash desk there is a range of small items to
encourage spontaneous purchase: car care
products, touch-up paint and first aid kits.
Mike sorts out the newspapers laid out in
the waiting area.
To be on the safe side, he also quickly
inspects the customer toilet. There he
discovers a crack in the washbasin.
autoteam Issue 4
At lunch the next day, Mike tells the Service Tony is particularly interested in the range too late as, in their mind, the customers are
Manager about his tour. Tony is generally of products in the sales area and at the cash already on their way home.” In the after-
satisfied with the results and explains why desk – after all, the customers should not noon, John Finch comes in to collect his
a customer-friendly design is so important only feel well, they should also buy some- Mondeo. Mike offers him a coffee, explains
for a dealership. “We want our customers to thing. After lunch, therefore, he has another the invoice and then returns the vehicle to
feel well here so that they’re happy to come look around the sales area with Mike. him. John is pleased to get his car back on
back.” Tony suggests that, in future, the displays time and announces that he will not wait
with brochures and products should, if so long before his next service. He thanks
Mike and Tony agree to regularly check that possible, be positioned on the right, as Mike again for the tour the previous day
the dealership continues to radiate function- viewed from the entrance: “Market research and leaves with the words: “When I see the
ality and customer-friendliness and create a has shown this to be better as many cus- practical and considered way that every-
well cared for impression. Tony emphasises tomers only notice displays on the left when thing is laid out here, I immediately feel that
the fact that this does not take much time they are on their way out. By then it is often I am in good hands.”
but can have an extremely significant effect.
He notes the damage to the washbasin, so Exemplary design: Customers feel good in this kind of dealership.
that a new one can be fitted as soon as pos-
sible. “You should assume that customers
judge the whole place on the basis of such
small details. I recently read a survey of air-
line passengers. Do you know what makes
people have doubts about the condition of
the plane? The folding table in front of their
seat. If it is dirty, many people think that the
rest of the plane is not kept in a proper con-
dition either.”

Tidiness and cleanliness are the basis of a

good workshop.
Ordnung und Sauberkeit sind die Basis für

autoteam Issue 4 29

WDS, issue 7: Datalogger III
Manipulation
In the previous two autoteam
issues you have already read
what the Datalogger in WDS –
Ford’s Worldwide Diagnostic
System – can do, how it is set
up and how data can be saved.
In this issue, you will learn how
certain output signals can be
“manipulated” in order to test the
reaction of the respective actua-
tors.
Output State Control mode (OSC) is
the Datalogger feature which enables you
to overwrite certain output signals, i.e. you
can manipulate them within “safe limits”
(see panel). This is possible with all output
signals that are marked with a “#” in
the signal selection menu and Datalogger
screens. The signal options differ depending
upon vehicle system and module.
30
180 km/h in the
workshop! The
speedometer is
tested at a standstill
thanks to WDS.
Here are some engine management examples: lar position.” Or: “The idle speed is occa-
sionally too fast”. Of course, you immedi-
■ EGRVR # ately have a suspicion, but are the instru-
EGR Vacuum Regulator ment cluster or the idle air control really at
■ FP # fault? In the OSC mode you can – with the
Fuel Pump vehicle at a standstill – modify the control
■ HFC # signal for the speedometer and watch how
High Fan Cooling the indicator needle reacts. And OSC allows
■ LFC # you to select in exactly the same way the
Low Fan Cooling idle air control valve while you watch
■ IAC # whether and how the engine idle speed
Idle Air Control changes.
But you can also influence other output In the case of the speedometer, you could
signals for testing purposes when in quickly establish that the instrument itself
Datalogger’s OSC mode, e.g. for the is intact and that the fault is possibly within
electronic speed indicator as well as door the vehicle speed sensor (VSS). But once
locks and horn (safety system). again, as for all Datalogger functions, it is
assumed that you are sufficiently trained in
What for? vehicle electronic systems. OSC mode in
The customer complains, for instance: “The WDS is then a further valuable diagnostic
speedometer sometimes sticks in a particu- help in difficult cases.
autoteam Issue 4
 ➊
How to do it
Example: idle air control.

Picture ➊
The Datalogger is activated showing the signals: Engine
Speed (RPM, top), Idle Air Control (IAC, centre) and
Throttle Position (TP, lower). The engine is running at
normal idle speed (RPM = 871; IAC = 443mA).

1. Select IAC # signal (“#” = overwritable signal).

2. Activate the # Icon (OSC mode): Further icons appear

under this icon: “Activate control position”, together
➋
with “Plus” and “Minus” icons.

3. Press the “Activate control position” icon. The IAC can

now be modified using the “Plus” or “Minus” icons.

4. Changes can be deleted with the Clear icon (lower).

Picture ➋ (Recording)
The IAC is gradually opened by repeatedly pressing the
“Plus” icon, the engine speed has increased accordingly
(RPM = 2200; IAC = 1A 3mA).

Picture ➌ (Recording) ➌
The IAC is gradually closed by repeatedly pressing the
“Minus” icon, the engine speed slows accordingly (at RPM
= 258 the engine stopped running; IAC = 0A).

Note that the TP signal (lower) remained unchanged at all

engine speeds shown. This proves that the engine speed
changes were independent of the throttle valve position.

Note: Screen texts are shown here in English; WDS will of

course show these in the selected language.

Within safe limits WDS-news

Don’t be afraid to test in OSC mode! Component protection is
guaranteed by Datalogger, i.e. you cannot change a signal in such
a way that a component could be damaged. Furthermore,
“manipulation” (overwriting) of the signals is only possible
during the test and is not permanent. All parameters are reset
automatically to their normal values when you leave OSC mode.
So an unintentional reprogramming of a control module is not
possible.
A new diagnostic information newsletter is now available. But
unlike its predecessor FDS 2000 News it is not in printed form
but you will find it on WDS-CDs. “WDS news” will be issued
four times per year and gives you information about the all latest
of Ford’s World Wide Diagnostic System. Furthermore, “WDS
news” deals with your questions and suggestions about diagno-
sis. Simply write down your opinion clearly marked “WDS” on
your autoteam answer sheet.

autoteam Issue 4 31
Ford Facts
Ford practices “Corporate
Citizenship”
Ford places great importance on the trust
and esteem of its customers, staff and share-
holders. But not only that, Ford also makes
a great effort to get involved in the commu-
nity, and gives society far more than pro-
ducts and services. Activities, in which the
focus is not on profit, come under the head-
ing of “Corporate Citizenship”. Corporate
Citizenship is part of Ford's company phi-
losophy and, above all, affects our involve-
ment in social affairs, in environmental
issues and our commitment to “diversity”,
that is to say tolerance and equal treatment
for all groups in society. For example, on
two working days each year, Ford gives its
350,000 staff worldwide the opportunity to
take part in events in aid of charity. This is
based on our view that a stable and well
functioning society is the foundation for
commercial success.
A good example of our practical implemen-
tation of Corporate Citizenship is the
“Mondeo sectional model” project. At the
beginning of March 2001, Ford chaired a
European insurance conference, which took
place in the Portuguese capital of Lisbon.
For insurance companies, the safety stan-
dards the Mondeo is setting in its class are
of great interest. Therefore, Ford wanted to
use a sectional model to present the new
model’s technology and to explain its safety
features and the easy-to-repair new body-
work.
The idea of Corporate Citizenship
prompted Ford to give the order for the
construction of the sectional model to the
training workshop at Herford (Germany)
prison. The local dealership, Niebaum and
Hamacher, supported the complex and
interesting project, and assisted in providing
the prisoners with all the details of the state
of the art vehicle technology.
As a result of skilled craftsmanship and
creative solutions for numerous individual
parts of the vehicle, the sectional model was
produced within two weeks – faster than
had been planned. As a spontaneous token
of gratitude, Jochen Coelsch, Business
Development Director of Ford Customer
Service Division – Europe, presented the
offenders support organisation at Herford
prison with a donation of DM 10,000. The
organisation will use this money to promote
training for young offenders and to help
them look for jobs.
IRL