Electrical FORD FIESTA 2007 Workshop Manual

308-03-31 Manual TransmissionlTransaxle 308-03-31
REMOVAL
5. Remove the transaxle upper retaining bolts. Detach the wiring harness from the retaining
bracket.
6. Detach the power steering high-pressure line
retaining bracket from the transaxle. 10.
Disconnect the reversing lamp switch
electrical connector.
7. Remove the front wheels and tires.
11. Remove the gearshift cables cover.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
I
and Installation).
8. Remove the wiring harness retaining bracket.
9. Remove the starter motor. 12.
Detach the gearshift cables from the
transaxle.
1. Detach the gearshift cables and the selector
cable from the selector levers.
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2006.0 Fiesta 1212006 G453416en
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308-03-64 Manual Transmission/Transaxle 308-03-64
INSTALLATION
13. Connect the vehicle speed sensor (VSS) 16. Raise and support the vehicle. For
electrical connector (if equipped). additional information, refer to
Section 100-02 [Jacking and Lifting].
17. CAUTIONS:
Asupport the halfshaft. The inner joint
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.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
14' ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
Connect the clutch slave cylinder supply
line.
Install the spring clip.
15. Attach the coolant expansion tank to the
bracket. 18.
N0TE:lnstall a
new center bearing cap and
locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heat shield.
3. Install the locknuts.
19. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
2006.0 Fiesta 1212006 GI I 3293en
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308-03-66 Manual Transmission/'rransaxle 308-03-66
INSTALLATION
24. Attach the gearshift cables to the selector 27. Install the gearshift actuator cover.
levers.
Vehicles with automated gearshift
25. Connect the gearshift actuator electrical
connector (colored grey).
26. Connect the gearshift actuator electrical
connector (colored black).
28. Connect the clutch slave cylinder supply
line.
Install the clip.
All vehicles
29. Connect the reversing lamp switch
electrical connector.
30. Install the starter motor.
2006.0 Fiesta 1212006 GII 3293en
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308-03-67 Manual Transmission/Transaxle 308-03-67
INSTALLATION
Attach the starter motor electrical connector 34. Tighten the engine rear mount outer
/- . to the starter motor. retaining nuts. /'
31. Lower the vehicle. 35. Tighten the engine rear mount center
32. Tighten the strut spring assembly top retaining nut.
mount nuts on both sides.
36. Install the battery tray support bracket.
33. Install the transaxle upper retaining bolts.
Attach the engine wiring harness bracket to
the transaxle.
2006.0 Fiesta 1212006 GI1 3293en
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308103168 Manual Transmission/Transaxle 308103168
INSTALLATION
37. Connect the powertrain control module
(PCM) electrical connector to the PCM.
38. Install the front wheels and tires. For
additional information, refer to
Section
204-04 wheels and Tires].
Vehicles without automated gearshift
39. Adjust the gearshift cables. For additional
information, refer to Section
308-00
[Manual Transmission/Transaxle and Clutch
- General Information].
40. Bleed the clutch system. For additional
information, refer to Section
308m00
[Manual Transmission/Transaxle and Clutch
- General Information].
All vehicles
41. Install the battery tray. For additional
information, refer to Section
41 4-01
[Battery, Mounting and Cables].
42. With the vehicle on a level surface, fill the
transaxle until the oil level is just below the
bottom of the filler hole.
Vehicles with automated gearshift
43m ACAUTION:T~~ worldwide diagnostic
system (WDS) gearshift actuator bleed
option must be carried out
if any part of the
clutch hydraulic system is opened or any
new components are installed.
N0TE:When the WDS gearshift actuator bleed
option is selected, the learn transmission and learn
clutch parameter options will automatically be
completed.
Bleed the clutch system. For additional
information, refer to Section
308-00 [Manual
Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GII 3293en
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308-03-72 Manual Transmission/Transaxle 308-03-72
INSTALLATION
20. Attach the gearshift cables to the bracket 23. Connect the reversing lamp switch
and turn the abutment sleeves electrical connector.
counterclockwise.
I I
24. Install the starter motor.
21. Attach the gearshift cables to the selector
levers.
22. Install the gearshift cables cover. 25.
Install the wiring harness retaining bracket. Attach the wiring harness to the retaining
bracket.
26. Lower the vehicle.
2006.0 Fiesta 1212006 G453417en
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Manual Transmission/Transaxle External
Controls
REMOVAL AND INSTALLATION
Gearshift Lever(l6 524 0)
Removal
I. Remove the gearshift lever trim panel.
Disconnect the cigar lighter electrical
connector.
2. Detach the gearshift cables from the
gearshift lever.
4. Remove the gearshift lever front retaining
bolts.
5. Remove the gearshift lever.
Remove the bolts.
Installation
1. To install, reverse the removal procedure. 3. Detach the gearshift cables from the
retaining bracket. 2. Adjust the gearshift cables. For additional
information, refer to Section
308-00 [Manual Turn the abutment sleeves clockwise. Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GI 86744en
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309-00-6 Exhaust System 309-00-6
REMOVAL AND INSTALLATION
Catalytic Converter - 2.OL Duratec-HE (M14)
/'
Materials Support
the exhaust flexible pipe with a (,
support wrap or splint.
Name Specification
1 Grease I SA-M 1 C9107-A I --
N0TE:lf installing a new catalytic converter to the
original exhaust system, a new muffler and tailpipe
assembly must also be installed.
1. Raise and support the vehicle. For additional
information, refer to:
(1 00-02 Jacking and
Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
*' CAUTION:^^^^ bending of the exhaust
flexible pipe may cause damage resulting in 3. Remove the components in the order failure.
indicated in the following illustration(s) and
table(s).
Item Description Item Description
2006.0 Fiesta 1212006 G453448en
2
3
See Removal Detail
See Installation Detail
1
Catalytic converter monitor sensor
electrical connector
Catalytic converter monitor sensor
Exhaust hanger insulator
4 Catalytic converter to exhaust flexible pipe
retaining nuts
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309-00-9 Exhaust System 309-00-9
REMOVAL AND INSTALLATION
Itern Description Item Descri~tion
Heated oxygen sensor (H02S) electrical
connector See
Removal Detail
See lnstallation Detail
3. To install, reverse the removal procedure.
3
A CAUTI0N:Never use jointing compound
Exhaust flexible pipe to muffler and tailpipe forward of the catalytic converter.
assembly retaining nuts Exhaust
flexible pipe to exhaust manifold
retaining nuts
See Removal Detail
Removal Details
Item 3 Exhaust flexible pipe to exhaust manifold Ifem 4 Exhaust flexible pipe to muffler and
retaining nuts tailpipe assembly retaining nuts
Im &AUTION:O~~~ bending of the exhaust Im &Au~l~N:Twistin~ the exhaust flexible
flexible pipe may cause damage resulting in pipe more than
2 degrees may cause damage
failure. resulting in failure.
Support the exhaust flexible pipe with a
N0TE:Use a pry-bar to prevent the exhaust flexible
support wrap or splint. pipe from twisting when removing the exhaust
flexible pipe to catalytic converter retaining nuts.
Remove the exhaust flexible pipe to catalytic
converter retaining nuts.
Installation Details
Item 4 Exhaust flexible pipe to muffler and
tailpipe assembly retaining nuts
A~AuT10~:Twistin~ the exhaust flexible
pipe more than
2 degrees may cause damage
' resulting in failure.
N0TE:Use a pry-bar to prevent the exhaust flexible
pipe from twisting when installing the exhaust
flexible pipe to catalytic converter retaining nuts.
2006.0 Fiesta 1212006 G458157en
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31 0-00-2 Fuel System - General Information 31 0-00-2
DIAGNOSIS AND TESTING
Fuel System - 1.3L Duratec-8V (Rocam)/l.25L Duratec-1 6V
(Sigma)/2.0L Duratec-HE (M14)/1.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V (Sigma)
lnspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
- Fuel level
- Fuel leak(s)
- Fuel line(s)
- Fuel filter (if
equipped)
- Fuel tank
- Fuel tank filler pipe
- Fuel filler cap
Visual lnspection Chart
- Electrical
connector(s)
- Wiring harness
- Inertia fuel shutoff
(IFS) switch
- Fuel pump module
I Mechanical
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step
4. If the cause is not visually evident, verify the
symptom and refer to WDS.
Electrical
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