Fuel System - Rough/Rolling/High Idle/Stalling
Article No.03-4-4
03/03/03
^ DRIVEABILITY - ROUGH, ROLLING, OR HIGH IDLE
OR STALL - MAINLY AFTER COLD START - SVT
MODELS ONLY
^ ENGINE - INTAKE SEPARATION AT RUBBER
BOOTS - SVT MODELS ONLY
FORD:
2002 FOCUS
ISSUE
Some 2002 SVT Focus vehicles may exhibit a rough idle, rolling idle, stall, high idle, or backfire mainly after a cold start. Some vehicles may also exhibit a hesitation or surge at steady cruise, or MIL (Malfunction indicator Lamp) illuminated condition. In some cases the intake manifold may separate at the rubber boots. This may be caused by PCM (Powertrain Control Module) calibration and/or poor intake clamp sealing. A revised PCM calibration and intake boot clamp replacement procedure has been developed for these conditions.
ACTION
If the vehicle exhibits a rough idle, rolling idle, stalls, high idle, backfire, hesitation, surge, or MIL lamp illuminated concern, refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. For all drivability concerns thoroughly inspect the intake manifolds boots and boot clamps. If they are loose, mis-positioned, or separated, perform Step 2, if the intake boot clamps are OK proceed to Step 3. For MIL lamp concerns perform all relevant Workshop Manual and/or PC/ED Manual Diagnosis and repairs. Once these are complete follow Step 3.
2. Replace the boot clamps. Remove the fuel rail as described in Workshop Manual Section 303-04C - Fuel Injection Supply Manifold (remove fuel rail and injectors as one unit, ensuring that no dirt contaminates the sealing surfaces or gets into the intake ports. Replace the injector O-rings.
a. Release the eight (8) hooking clips that are clamping the rubber boots to the manifold. Unhook the clamp to open completely to remove from around the boot.
b. Unscrew the worm drive clamps (W525939-S300) completely and open them up very carefully into a C shape. Place the new clamps around the boots in the same place as the hooking clips (Figure 1).
c. Torque the clamps to 35 +/- 4 Lb-in. (4 +/- 0.5 N.m).
d. Reinstall fuel rail with injectors as described in Workshop Manual Section 303-04C - Fuel Injection Supply Manifold.
e. Visual check that the boots are seated to both sides of the intake manifolds properly, and that the PCV hose and all vacuum hoses are connected.
f. Pressurize fuel rail with key on to ensure there are no fuel leaks. Continue on to Step 3.
3. Using WDS with the latest software version reprogram the PCM. Verify that the PCM Part Number updates to 2S4Z-12A650-AFF after the reprogram is complete.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
030404A Reprogram Powertrain 1.2 Hrs.
Control Module Inspect
And Replace Clamps On
Intake Manifold (Includes
Time To Replace Fuel
Injector To Intake Manifold
0-Rings)
030404B Reprogram Powertrain 0.4 Hr.
Control Module (Includes
Time To Inspect Intake
Manifold Boots And
Clamps)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9424 33
OASIS CODES: 603300, 607000, 608000, 608400, 610000, 610600, 611000, 611500, 612000, 612600, 613000, 613500, 618400, 619400, 698298
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