head FORD FIESTA 2007 Owner's Manual

21 1 -02-30 Power Steering 21 1 -02-30
REMOVAL AND INSTALLATION
Steering Gear to Power Steering Fluid Reservoir Return Line -
2.OL Duratec-HE (M14) RHD (' ,
Centralize the steering and lock it in position. table(s).
Special Tool(s)
2006.0 Fiesta 1212006 G458167en
2. Detach the steering column shaft from the
steering gear pinion.
Discard the steering column shaft to steering
gear pinion retaining bolt.
Pp
205524
24003
Alignment Pins, Subframe
205-524
Removerllnstaller, Hose
Clamp
303-397
General Equipment
Transmission jack 3. Remove the front wheels and tires.
Materials For
additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
Name Specification and Installation).
4. Lower the vehicle.
Grease
1. N0TE:Make sure that the road wheels are in 5. Remove the components in the order
the straight ahead position.
indicated in the following illustration(s) and
SA-M 1 C9107-A
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21 1 -02-38 Power Steering 21 1 -02-38
REMOVAL AND INSTALLATION
Steering Gear(l3 11 6 0)
I I Separator, Ball Joint Discard
the retaining bolt.

3. Remove the wheels and tires.
I I I For additional information, refer to: Wheel I I I
General Equipment I I
and Tire (204-04 Wheels and Tires, Removal
and Installation).
Removal
All vehicles
Transmission jack 1 4. Disconnect the power steering fluid reservoir
I. N0TE:Make sure that the road wheels are in
the straight ahead position.
Materials
Centralize the steering and lock
it in position. return
hose quick release coupling.
2. Detach the steering column shaft from the
steering gear pinion.
return hose quick release coupling.
Allow the fluid to drain into a suitable
container.
Name Specification 1. Press the power steering fluid reservoir return
5m &AUTION:O~~~ bending of the exhaust
flexible pipe may cause damage resulting in
failure.
2006.0 Fiesta 1212006 GI 05648en
hose quick release coupling locking tangs.
Grease
2. Disconnect the power steering fluid reservoir ( SA-M 1 C9107-A
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211 -02-41 Power Steering 21 1-02-41
REMOVAL AND INSTALLATION
15. Detach the power steering lines from the 19. Lower the front axle crossmember to gain
steering gear (left-hand drive shown). access
to the steering gear.
i 20. Remove the steering gear.
16. Disconnect the power steering lines from
the steering gear valve body.
1. Remove the retaining bolt.
2. Rotate the clamp plate.
Allow the fluid to drain into a suitable
container.
Discard the O-ring seals.
17.
Using a transmission jack and a wooden
block, support the front axle crossmember.
18. Remove the front axle crossmember
retaining bolts on both sides.
21. Remove and discard the steering gear
bulkhead floor seal.
22. Remove the exhaust heat shield.
2006.0 Fiesta 1212006 GI 05648en
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21 1-02-42 Power Steering 21 1 -02-42
REMOVAL AND INSTALLATION
Installation
All vehicles
1, Install the exhaust heat shield. Using
a transmission jack, wooden block
and the special tools, position and align the
front axle crossmember.
'' &AUTION:W~~I~ tightening the front axle
2. Install a new steering gear bulkhead floor crossmember
retaining bolts, make sure that
seal. the
crossmember does not move.
3. Install the steering gear. Install the
front axle crossmember retaining
bolts on both sides.
6. Remove the special tools.
7. lnstall the front axle crossmember inner
retaining bolts on both sides.
4. N0TE:Use the front axle crossmember inner
retaining bolts to locate the special tools.
a
TI E0030774
2006.0 Fiesta 1~2006 GI 05648en
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2 1 1 -04-4 Steering Column 21 1 -04-4
REMOVAL AND INSTALLATION
Steering Wheel(l3 524 0)
Removal
I. Remove the driver air bag module.
For additional information, refer to: Driver
Air Bag Module
(501-20 Supplemental
Restraint System, Removal and
Installation).
2. N0TE:Make sure that the road wheels are in
the straight ahead position.
Centralize the steering and lock
it in position.
3. Remove the steering wheel.
Installation
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 GI 05653en
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2 1 1 -04-6 Steering Column 21 1 -04-6
REMOVAL AND INSTALLATION
2. Release the steering column locking lever. Depress the locking tangs.
1--
7. N0TE:Make sure that the road wheels are in 10. Disconnect the passive anti-theft system
the straight ahead position.
(PATS) transceiver, windshield
Centralize the steering and lock it in position. wiperlwasher
switch and clockspring
electrical connectors.
Depress the locking tangs.
8. Detach the steering column shaft from the
steering gear pinion.
Discard the retaining bolt. 11. Remove the steering column.
Discard the retaining nuts.
9. Disconnect the ignition switch and turn
signal electrical connectors.
Installation
1. WARNINGS:
2006.0 Fiesta 1212006 GI 05654en
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303-00-1 Engine System = General Information 303-00-1
SECTION 303-00 Engine System . General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
DESCRIPTION AND
OPERATION
Engine
........................................................................\
......................................................... 303-00-3
Engineltransmission combinations ........................................................................\
........ 303-00-3
DIAGNOSIS AND TESTING
........................................................................\
.......................................................... Engine
. Engine Oil Leaks ........................................................................\
........................................
Ultraviolet (UV) Testing ........................................................................\
...............................
Measure the compression pressure ........................................................................\
...........
.............. Measure the compression pressure (Engine . 1.4L Duratorq-TDCi (DV) Diesel)
Measure the compression pressure (Engine
. 1.6L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine . 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V
........................................................................\
......... (Sigma)ll . 6L Duratec-I 6V (Sigma))
Measure the compression pressure (Engine
. 1.3L Duratec-8V (Rocam)) ........................
Measure the compression pressure (Engine . 2.OL Duratec-HE (M14)) .............................
. Measure the oil pressure (Engine 1.4L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.6L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
........................................................................\
......... (Sigma)/l . 6L Duratec-1 6V (Sigma))
. Measure the oil pressure (Engine 1.3L Duratec-8V (Rocam)) .........................................
. Measure the oil pressure (Engine 2.OL Duratec-HE (M14)) ...............................................
Valve train analysis . static (engine off) ........................................................................\
......
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
........................................................................\
..........
Camshaft Bearing Journal Clearance ........................................................................\
.........
Camshaft End Play ........................................................................\
.....................................
Camshaft Surface Inspection ........................................................................\
.....................
........................................................................\
...................................... Camshaft Lobe Lift
Crankshaft Main Bearing Journal Diameter
........................................................................\

Crankshaft End Play ........................................................................\
...................................
Cylinder Bore Taper ........................................................................\
....................................
Piston Inspection ........................................................................\
........................................
Piston Pin to Bore Diameter ........................................................................\
.......................
Piston Diameter ........................................................................\
..........................................
Piston Ring End .Gap ........................................................................\
...................................
............................................ ................................... Piston Ring-to-Groove Clearance ......
Piston Pin Diameter ........................................................................\
.....................................
Connecting Rod Large End Bore ........................................................................\
................
Valve Stem Diameter ........................................................................\
..................................
Flywheel Inspection ........................................................................\
....................................
............................................... Flywheel Inspection - Vehicles With: Dual Mass Flywheel
Cylinder Head Distortion ........................................................................\
.............................
Cylinder Block Distortion ........................................................................\
.............................
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303-00-6 Engine System - General Information 303-00-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Damaged gaskets or mating
surfaces.
- Cylinder head gasket is
damaged or mating face are
warped.
- Valve stem oil seals are
worn and engine oil can
enter the combustion
chamber between the valve
stem and the valve stem
guide.
Piston ring or cylinder liner
wear.
Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons
- Piston rings (clearance in
groove and end gap)
- Cylinder liners
CHECK the gaskets and
mating surfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine
block mating faces. INSTALL new valve
seals.REFER
to:
Valve Seals (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.3L Duratec-8V (Rocam), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
2.OL Duratec-HE (M14), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
CHECK the running surfaces
and clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
CHECK the pistons.
REFER to: Piston Inspection
(303-00 Engine System
-
General Information, General
Procedures).
CHECK the piston rings.
REFER to: (303-00 Engine
System
- General Information)
Piston Ring-to-Groove Clear- ance (General Procedures),
Piston Ring End Gap (General
Procedures).
2006.0 Fiesta 1212006 GI 52554en
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303-00-7 Engine System - General Information 303-00-7
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Coolant consumption Cooling system components.
Oil cooler.
CHECK the coooling system.
REFER to:
Engine
Cooling (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 2.OL Duratec-HE
(M14), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.4L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.6L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing).
INSTALL a new oil cooler.
Damaged gaskets or warped
mating faces. CHECK the cylinder head
gasket for damage. CHECK the
cylinder head for distortion. - -- - -
Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
- - - - - - - -
DETERMINE the damaged
engine
component(s) and
install new component(s) as
necessary.
Engine will not crank Battery or cables. CHECK the battery, bracket
and
cables.
REFER to: Battery (41 4-01
Battery, Mounting and
Cables, Diagnosis and
Testing).
Starter motor or cables. I CHECK the starting system.
REFER to: Starting System
(303-06 Starting System,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 52554en
I Engine cranks but will not start Fuel tank is empty. CHECK the fuel level.
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303-00-33 Engine System - General Information 303-00-33
GENERAL PROCEDURES
Camshaft Bearing Journal Clearance
1. N0TE:Make sure that the following stages The value that is read off is the bearing
are followed exactly. The tappets or followers clearance.
must be removed to carry out this
measurement.
N0TE:Make sure that the camshaft is to
specification.
N0TE:The bearing caps and journals should be
free from engine oil and dirt.
Position on a width of plastigage on the
bearing cap.
Insert the camshaft, without lubrication, into
the cylinder head.
Position
a plastigage strip, which should be
equal to the width of the bearing cap, on the
bearing journal.
2. Following the tightening specification, install
the camshaft bearing caps. Refer to the
corresponding Section 303-01.
3.
N0TE:Do not strike the bearing caps.
Remove the camshaft bearing caps, refer to
the corresponding Section 303-01.
'4. Using the Plastigage, read off the
measurement.
Compare the width of plastigage with the
plastigage scale.
2006.0 Fiesta 1212006
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