check engine FORD FIESTA 2007 Repair Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-011 Am43 Duratec-1 6V (Sigma)lII6L Duratec-I 6V (Sigma) 303-01 A-43
IN-VEHICLE REPAIR
Vehicles built 0412005 onwards 16. Remove special tool.
/ 14' AWARNING:D~ not remove the special
tool, until the timing belt is correctly
positioned. Failure to follow this instruction
may result in personal injury, or may
damage the timing belt tensioner.
Tension the timing belt.
Remove the special tool.
All vehicles
15. CAUTIONS:
( , nlnstall a hose (order no. E890438S) to
the special tool studs, to prevent damage
to the camshaft pulleys. 17.
Remove the special tool.
ADO not tighten the camshaft pulley bolts 18. N0TE:Only turn the engine in its normal
against the timing plate. direction
of rotation.
N0TE:The camshafts must remain at TDC. Turn
the engine two revolutions.
N0TE:lnstall new camshaft pulley retaining bolts. 19. Install the special tool.
Using the special tool, tighten the camshaft Carefully turn the crankshaft against the
pulleys. special tool.
20. Check the valve timing.
If necessary loosen the camshaft pulleys and
correct the camshaft alignment.
2006.0 Fiesta 1212006 GI 83738en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-65 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-65
IN-VEHICLE REPAIR
3. N0TE:lnstall the oil pan within ten minutes 5. N0TE:Check the oil drain plug seal for
of applying sealant and tighten the bolts damage
and install a new drain plug if
( I within a further 5 minutes. necessary.
Apply a 3-4 mm diameter bead of sealant to Install the oil drain plug.
the oil pan flange.
6. Fill the engine with engine oil.
4. N0TE:Align the oil pan flush with the
cylinder block at the transaxle end.
Install the oil pan.
Tighten the oil pan retaining bolts in the
sequence shown in two stages.
Stage
I : 10 Nm.
( I Stage2:20Nm.
Remove the studs and install retaining bolts.
2006.0 Fiesta 1212006 GI 83741 en
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Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
303-01 A-1 18 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I 18
ASSEMBLY
Carefully turn the crankshaft against the
special tool.
55. Check the valve timing.
If necessary loosen the camshaft pulleys and
correct the camshaft alignment.
56. Remove the special tools.
57. Install the blanking plug.
58. Check the valve clearances, adjust if
necessary.
f:
For additional information, refer to: Valve (.
Clearance Adjustment (303-01 Engine -
1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), General Procedures).
59. Using the
special tool, install the spark
plugs.
Apply grease to the spark plug threads.
60. N0TE:lnstall the stud bolts to positions 5
and 6.
Install the valve cover. (
Tighten the bolts in the sequence shown in
three stages.
Stage I : Tighten bolt 1 by 3 to 4 turns.
Stage
2: Tighten bolts I through 13 to 3 Nm.
Stage
3: Tighten bolts 1 through 13 to 9 Nm.
'Irn CAUTION: Use a suitable blunt object
to avoid damage to the spark
plug
connector gasket. Coat the inside of the
spark
plug connector with silicone grease
to a depth of 5-10 mm. C
2006.0 Fiesta 1212006 GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 34 Duratec-1 6V (Sigma)ll .6L Duratec-I 6V (Sigma) 303-01 A-1 34
INSTALLATION
Engine - Vehicles With: Autom
Special Tool(s)
I I Remover/lnstaller, Hose (
General Eaui~ment
1 Straight edge I
I Securing straps I
atic Transaxle
2. Check the installation depth between the
transaxle flange and the torque converter c
centering spigot.
All vehicles N0TE:Make sure the torque converter centering
spigot engages in the flexplate and the transaxle
A WARNING:Do not smoke or carry lighted engages on the engine flange dowels.
tobacco or open flame of any type when
Install the transaxle to the engine.
working on or near any fuel related
components. Highly flammable vapors are 3. Install the transaxle lower retaining bolts.
always present and may ignite. Failure to I I
Workshop table
Engine hoist
follow these instructions may result in
personal injury.
'' &AUTION:T~~ torque converter must
remain at the correct installation depth
throughout the whole installation procedure.
N0TE:The torque converter hub must engage fully
in the oil pump drive gear.
Check the installation depth of the torque
converter.
*' &AUTION:M~~~ sure that the two locating
dowels are installed.
1. Lay a straight edge on the transaxle flange. I
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 45 Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) 303-01 A-1 45
INSTALLATION
67. Connect the fuel supply line quick release
70. Tighten the strut and spring assembly top
coupling. mount nuts on both sides.
(: , For additional information, refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
68. Connect the fuel return line quick release
coupling.
For additional information, refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
69. Attach the fuel line and the degas line to
the intake manifold.
Install the cable tie.
71. Connect the powertrain control module
(PCM) electrical connector.
For additional information, refer to:
Powertrain Control Module (PCM)
- 1.25L
Duratec-1 6V (Sigma)llm4L Duratec-1 6V
(Sigma)ll.GL Duratec-1 6V (Sigma) (303-14
Electronic Engine Controls, Removal and
Installation).
72, Install the air cleaner.
For additional information, refer to: Air
Cleaner
- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll.GL Duratec-1 6V
(Sigma) (303-1 2 Intake Air Distribution
and Filtering, Removal and Installation).
73. Install the front wheels and tires.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires,
Removal and lnstallation).
74. Fill the engine cooling system.
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)ll.3L DuratecdV (Rocam)
(303-03A, General Procedures).
75. Check the transmission fluid level and top
up with clean automatic transmission fluid
if necessary.
For additional information, refer to:
Transmission Fluid Level Check (307-01
Automatic
Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
--
2006.0 Fiesta 1212006 G380459en
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303-01 B-I 0 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 0 - -- --
DESCRIPTION AND OPERATION
Valve tappets Camshaft drive
Item Description
I 1 I Exhaust valve tappet I
1 2 1 Intake valve tappet I
Mechanical tappets are fitted without adjusting
shims.
Due to the special materials and the optimized
camshaft profiles, the wear in the area of the valve
gear is so minute that checking and adjustment of
the valve clearances is only necessary after the
engine has been in extensive service.
Different sizes of replacement valve tappets are
I ELE0023383
available in the event of wear or repairs to the valve ' '2
gear. Item Description
I 1 I Exhaust camshaft sprocket
1 2 I Timing chain I
1 3 1 Intake camshaft sprocket I
1 4 I ~imin~ chain guide I
1 5 1 Crankshaft sprocket I
1 6 1 Hydraulic timing chain tensioner I
1 7 1 ~imin~ chain tensioner arm 1 - -
The camshafts are driven by a low-noise,
maintenance-free pinned link timing chain.
The timing chain is lubricated by the engine oil
circuit.
An elongated timing chain guide and a timing chain
tensioner arm ensure optimum timing chain
guidance and silent running.
The timing chain is tensioned by a hydraulic timing
chain tensioner which is supplied from the engine
,.
oil circuit.
The timing chain tensioner can be used again after
removal.
The camshaft drive requires no maintenance.
2006.0 Fiesta 1212006 G461395en
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303-01 B-31 Engine - 2.OL Duratec-HE (M14) 303-01 B-31
IN-VEHICLE REPAIR
Rotate the crankshaft one and three quarters Check
the position of the crankshaft pulley
of a rotation until piston no.
1 is approx. 45 - using the M6 x 18 mm bolt.
I degrees before TDC.
18. Install the special tool.
19. N0TE:Only rotate the crankshaft in the
normal direction of rotation.
21. Lower the vehicle.
22. N0TE:H the special tool cannot be attached,
correct the valve timing.
Check the position of the camshafts using
the special tool.
Rotate the crankshaft until no.
1 piston is at
TDC.
23. Remove the special tool.
20m ~CAUTION:T~~~~~~ the M6 x 18 mrn bolt
finger-tight only.
N0TE:lf the M6 x 18 mm bolt cannot be installed,
correct the valve timing.
2006.0 Fiesta 1212006 G451288en
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303-01 B-43 Engine - 2.OL Duratec-HE (M14) 303-01 B-43
IN-VEHICLE REPAIR
23m L?~AUTION:K~~~ the camshaft bearing Coat the camshaft bearing caps with oil.
I caps, the camshafts and the camshaft Tighten the bolts in two stages:
- s~rockets in order for installation. Stage I: 7 Nm. 1 Stage 2: 16 Nm. N0TE:Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps in the
sequence shown.
24. N0TE:Using a suitable piece of wire,
prevent the timing chain and the sprocket
from dropping into the timing case.
I Detach the intake camshaft sprocket from
the intake camshaft.
25m ACAUTION:K~~~ the valve tappets in
order for installation.
Remove the valve tappets.
Installation
1. Install the valve tappets.
2.
N0TE:Do not tighten the camshaft sprocket
retaining bolt at this stage.
Attach the intake camshaft sprocket together
with the timing chain to the intake camshaft
and insert the intake camshaft.
3. CAUTIONS:
Anstall the camshafts approximately at
valve overlap position cylinder No.
4.
nlnstall the camshafts and bearing caps
in their original location.
4. N0TE:Only carry out the following step when
a new cylinder head or new valves are
installed.
Check the valve clearance and adjust
if
necessary.
For additional information, refer to: Valve
Clearance Adjustment (303-01 Engine
- 2.OL
Duratec-HE (M14), General Procedures).
5. N0TE:Do not tighten the camshaft sprocket
retaining bolt at this stage.
Attach the exhaust camshaft sprocket
together with the timing chain to the exhaust
camshaft.
Install the camshafts.
Working in several stages, evenly tighten the
camshaft bearing cap bolts in the sequence
shown, one half turn at a time.
2006.0 Fiesta 1212006
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303-01 B-45 Engine - 2.OL Duratec-HE (M14) 303-01 B-45
IN-VEHICLE REPAIR
Rotate the crankshaft approximately one and
Using a M6 x 18 mm bolt, check the position
three quarter revolutions until piston No.
I of the crankshaft pulley. 1 is 45 degrees before TDC.
18. Lower the vehicle.
15. Install the special tool. 19. N0TE:lf it is not possible to install the
special tool, correct the valve timing.
Using the special tool, check the position of
the camshafts.
16. N0TE:Only rotate the crankshaft in the
normal direction of rotation.
Rotate the crankshaft until piston No.
1 is at
TDC.
20. Remove the special tool.
17' ACAUTION:O~I~ tighten the crankshaft
pulley securing bolt finger tight.
N0TE:lf it is not possible to install the crankshaft
pulley securing bolt, correct the valve timing.
2006.0 Fiesta 1212006 G451293en
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303-01 B-71 Engine - 2.OL Duratec-HE (M14) 303-01 B-71
IN-VEHICLE REPAIR
n~emove the camshaft bearing caps in the Install the
cylinder head.
i sequence shown. Tighten the cylinder head bolts in the
' N0TE:Working in several stages, release each sequence
shown in five stages:
camshaft bearing cap retaining bolt two turns at a Stage I : 5 Nm.
time. Stage 2: 15 Nm.
Remove the camshafts.
~CAUTION:K~~~ the valve tappets in
order for installation.
Remove the valve tappets.
( ' 17' &AUTION:R~~~~~ the cylinder head ' bolts in the sequence shown.
Remove the cylinder head.
Discard the gasket.
Discard the bolts.
Installation
Stage3:45Nm.
Stage 4: 90 degrees.
Stage 5: 90 degrees.
3. Install the valve tappets.
4m &AUTION:W~~~~~~ in several stages,
evenly tighten the camshaft bearing cap
bolts in the sequence shown, one half turn
at a time.
Install the camshafts.
Coat the camshaft bearing caps with oil.
Tighten the bolts in the sequence shown in
two stages:
Stage I: 7 Nm.
Stage 2: 16 Nm.
I i
I. Check the cylinder head for distortion. I I
For additional information, refer to: Cylinder 5. N0TE:Only carry out the following step when
Head Distortion
(303-00 Engine System - a new cylinder head or new valves are
General Information, General Procedures). installed.
2. N0TE:lnstall a new cylinder head gasket and
bolts.
2006.0 Fiesta 1212006 G451308en
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