wheel FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-70 Duratec-I 6V (Sigma)lll6L Duratec-1 6V (Sigma) 303-01 A-70
REMOVAL
Engine
Special Tool(s)
I I Removerllnstaller, Hose
622
General Eaui~ment
Wrench, Hydraulic Line Union
!:!-269 ( 1 3-027)
I Engine hoist I
I Securing straps I
I Workshop table I
Removal
All vehicles
A WARNING:Do not smoke or carry lighted
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable mixtures
are always present and may ignite. Failure
to follow these instructions may result in
personal injury.
1. Release the fuel system pressure.
For additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System
- General Information, General
Procedures).
2. Remove the air cleaner.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 1.4L
Duratorq-TDCi (DV) Diesel, General
Procedures).
3. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 1.4L
Duratorq-TDCi (DV) Diesel, General
Procedures).
4. Remove the front wheels and tires.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
5. Disconnect the powertrain control module

(PCM) electrical connector.
For additional information, refer to:
Powertrain Control Module (PCM)
- 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-1 4
Electronic Engine Controls, Removal and
Installation).
6. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
2006.0 Fiesta 1212006 GII 31 63en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-77 Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) 303-01 A-77
REMOVAL
46. Disconnect the cooling fan motor and 49. Using the special tool, disconnect the
cooling fan resistor electrical connectors. coolant
hose from the distribution pipe
47. Remove the cooling fan motor and shroud. 50. Detach the lower arm from the wheel -
1. Release the cooling fan motor and shroud knuckle on both sides (right-hand side
from the retaining brackets. shown).
2. Push the coolingfan motor and shroud Remove the heat shield.
upwards and then downwards to remove.
I I 51. CAUTIONS:
48. Using the special tool, disconnect the Asupport the halfshaft. The inner joint
coolant hose from the radiator.
must not be bent more than
18 degrees.
The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft oil seal.
N0TE:PIug the transaxle to prevent oil loss or dirt
ingress.
Using the special tool, detach the left-hand
halfshaft from the transaxle and secure it
to
one side.
Allow the oil to drain into a suitable container.
2006.0 Fiesta 1212006 GI 131 63en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-0 I Am82 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 Am82
REMOVAL
Lifting Bracket, Engine
303-1 22 (21 -068A)
Engine - Vehicles With: Automatic Transaxle
Special Tool(s) present and may ignite. Failure to follow (.
2. Remove the air cleaner.
622
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
I I 1 3. Drain the cooling system.
Wrench, Hydraulic Line Union
"-269 (13-027)
I I Remover/lnstaller, Hose I
these instructions may result in personal
injury.
1. Release the fuel system pressure.
For
additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System - General Information, General
Procedures).
General Eaui~ment
I Engine hoist I
I Securing straps I
I Workshop table I
All vehicles
WARNINGS:
A Refer to the Material Safety Data Sheets
for the Automatic Transmission
Fluid
E-AW. Failure to follow this instruction may
result in personal injury. Certain
Transmission and Power Steering fluids
supplied to Ford contain additives which
may cause skin irritation or other skin
reactions after contact.
For
additional information, refer to: Health
and Safety Precautions (1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any
fuel related components.
Highly flammable vapors are always
For additional information, refer to: Cooling
System Draining, Filling and Bleeding -
1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma)llm3L Duratec-8V (Rocam) (303-03A,
General Procedures). ,'
4. Remove the front wheels and tires. C'
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
5. Disconnect the powertrain control module
(PCM) electrical connector.
For
additional information, refer to:
Powertrain
Control Module (PCM) - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-14
Electronic Engine Controls, Removal and
Installation).
6. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
--
2006.0 Fiesta 1212006 G380458en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
REMOVAL
54. Disconnect the cooling fan motor and 57. Using the special tool, disconnect the
. cooling fan resistor electrical connectors. coolant
hose from the distribution pipe.
55. Remove the cooling fan motor and shroud. 58. Detach the lower arm from the wheel
1. Release the cooling fan motor and shroud knuckle on both sides.
from the retaining brackets. Remove
the heat shield.
2. Push the cooling fan motor and shroud
upwards and then downwards to remove.
Asupport the halfshaft. The inner joint 56. Using the special tool, disconnect the
must not be bent more than 18 degrees.
coolant hose from the radiator.
The outer joint must not be bent more than
'i
45 degrees.
59. CAUTIONS:
ADO not damage the halfshaft seal.
N0TE:Plug the transaxle to prevent fluid loss or
dirt ingress.
For additional information, refer to: Health and
Safety Precautions
(1 00-00 General Information,
Description and Operation).
See
- Transmission Fluids.
Using a suitable tire lever, detach the
left-hand halfshaft from the transaxle and
secure
it to one side.
2006.0 Fiesta 1212006 G380458en
procarmanuals.com

Engine - I .25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
DISASSEMBLY
Engine(21 134 8)
Special Tool(s)
I I Slide Hammer I
I I Universal Flange Holding I
I I Locking Tool, Flywheel
21167
Mounting Stand
303-435 (2 1 -1 87)
Socket, Cylinder Head Bolt
303-392 (21 -1 67)
Mounting Bracket for 303-435
303-435-06 (21 -031
B)
I I Socket, Spark Plug
Special
Tool(s)
Adapter
for 205-047
303-633 (2 1 -227)
0 0
0 ES21212
Locking Tool, Timing Belt
Tensioner
303-1 054
Mounting Plate for
303-435-06
303-435-1 4A (21 -2 12A)
General Equipment
I Securing straps I
I Engine hoist I
I Oil filter strap wrench I
All vehicles
1. Remove the engine wiring harness.
2006.0 Fiesta 1212006 GI 54224en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 03 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 03
DISASSEMBLY
43. Remove the oil pan retaining bolts. 46. Remove the oil pump.
Discard the gasket.
Discard the crankshaft front seal.
44m ACAUTION:~~ order to prevent damage
to the sealing surfaces, only use the
designated special tool to remove the oil
Vehicles with manual transaxle
PanmDonotuseachiselorscrewdriverfor 47. Removetheclutchdiscandpressureplate.
removal. For additional information, refer to: Clutch
N0TE:Tighten the lock nut against the oil pan and Disc and Pressure Plate (308-01 Clutch,
use several taps to release the oil pan from the Removal and Installation).
cylinder block. 48. Using the special tool, remove the flywheel.
Using the special tools, remove the oil pan.
Discard the bolts.
45. Remove the oil pump pickup pipe. Vehicles with automatic transaxle
Discard the gasket. 49. Using the special tool, remove the flexplate.
2006.0 Fiesta 1212006 GI 54224en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-OIA-1 08 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 08 --
ASSEMBLY
Special Tool(s)
I Universal Flange Holding
Wrench
205-072 (1 5-030A)
Lifting Bracket, Engine
303-1 22 (2 1 -068A)
21 068A
I 1 Alignment Plate, Camshaft I
21 540
Socket, Cylinder Head Bolt
Gauge,
Bolt Angle
303- 1 74 (2 1 -540)
I I Locking Tool, Flywheel I
Special Tool(s)
Installer, Crankshaft Seal
303-395 (21 -1 71 )
Mounting Stand
303-435 (2 1 -1 87)
Mounting Bracket for 303-435
303-435-06 (21 -031
B)
c
Mounting Plate for
2006.0 Fiesta 1212006 GI 54225en
..
ES21202
Socket, Spark Plug
303-499 (21 -202)
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)llI4L
303-OIA-I 09 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01
A-I 09
ASSEMBLY
, , yl~ockin~ Tool, Timing Belt I
General Equipment
1%
I Five M8 x 20 mm studs I
I Engine hoist I
3031054
Install the crankshaft rear seal carrier.
Tensioner
303-1 054
Materials
Name Specification
3. Install the crankshaft position (CKP) sensor
I Engine Oil - 5W-30 I WSS-~2~91 3-8 bracket.
I Silicone Sealant I WSE-M4G323-A4 I
I Adhesive - Loctite 243 I WSK-M2G349-A7 I
Gasket Eliminator
Sealant
i All vehicles
High-Temperature
Grease
1. Attach the cylinder block (short block) to the
mounting stand.
ESD-M 1 C220-A
Install the special tools. 4. Install the CKP sensor.
2. N0TE:lnstall a new crankshaft rear seal Vehicles with manual transaxle carrier. 5. N0TE:lnstall new flywheel retaining bolts. N0TE:A new crankshaft rear seal carrier is
supplied with an alignment sleeve which must be Using the special tool, install the flywheel.
,removed following installation. I
'NOTE:DO not lubricate the seal lip.
Tighten the bolts in the sequence shown in
two stages.
Stage I: 30 Nm.
- --
2006.0 Fiesta 1212006 GI 54225en
procarmanuals.com

Engine - 1.25L Dura
303-01A-11 0 Duratec-16V (Sigma)ll.(
:ec-16V (Sigma)llm4L
L Duratec-16V (Sigma)
303-01 A-I 10
ASSEMBLY
Stage 2: 80 degrees. Stage 2: 80 degrees.
6. Install the clutch disc and pressure plate. 9. Remove the special tool from the flexplate.
For additional information, refer to: Clutch
Disc and Pressure Plate
(308-01 Clutch, All vehicles
Removal and Installation). 10. N0TE:lnstall a new oil pump gasket.
7. Remove the special tool from the flywheel.
Install the oil pump.
Vehicles with automatic transaxle
8. N0TE:lnstall new flexplate retaining bolts.
Using the special tool, install the flexplate.
Tighten the bolts in the sequence shown in
two stages.
Stage1:30Nm.
11. N0TE:lnstall a new pickup pipe gasket.
2006.0 Fiesta 1212006 GI 54225en
procarmanuals.com

303-01 A-I I1
Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I I1
ASSEMBLY
Install the oil pump pickup pipe.
12. Coat the crankshaft front seal lip with clean
engine oil.
13. N0TE:lnstall a new crankshaft front seal.
15. N0TE:Attach the oil pan within ten minutes
of applying sealant and tighten the bolts
within a further five minutes.
Apply a
3 to 4 mm diameter thick bead of
sealant to the oil pan flange.
rnrn ---34
1 + 1 !fl
f
ELE0013938 -
Using the special tool, install the crankshaft
front seal. 16. N0TE:Align the oil pan so that the cylinder
block is flush with the oil pan on the
14' ~CAUTION:T~~ crankcase may be
damaged
if sealant enters the blind holes.
Install five
M8 x 20 mm studs into the blind
holes as shown. flywheel
side.
Install the oil pan, loosely install the retaining
bolts.
Remove the studs and install retaining bolts.
Tighten the oil pan retaining bolts in the
sequence shown in two stages.
Stage I : 10 Nm.
Stage
2: 20 Nm.
17. N0TE:lnspect the oil pan drain plug seal
for damage. Install a new drain plug and
seal
if required.
2006.0 Fiesta i~12006 GI 54225en
procarmanuals.com