gasket FORD FIESTA 2007 Owners Manual

Engine Emission Control - 2.OL Duratec-HE
303-08B-3
(MI41 303-08B-3
DESCRIPTION AND OPERATION
Engine Emission Control
1 2 1 EGRvalve gasket I oxide exhaust emissions.
Item Description introduced to the incoming charge in the intake
1
The exhaust gas recirculation (EGR) system allows
intake manifold by the EGR valve.
Exhaust gas recirculation (EGR) valve
--
3
a measured quantity of exhaust gas to be directed The EGR valve is controlled by an input from the back
to the intake manifold. The exhaust gas is powertrain control module
manifold, where it dilutes the air fuel mixture and
lowers the peak gas temperature, reducing nitrogen
2006.0 Fiesta 1212006 G37563en
the cylinder head from the exhaust manifold to the
-
EGR outlet The exhaust gas
is drawn through a passage within
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Engine Emission Control - 2.OL Duratec-HE
303-08B-6
(MI41 303-08B-6
DIAGNOSIS AND TESTING
Engine Emission Control
lnspection and Verification
General Equipment Visual Inspection Chart L..
I. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Worldwide Diagnostic System
(WDS)
- Hose(s)/hose joints
- Gasket(s)
- Positive crankcase
ventilation (PCV)
valve
- PCV separator
Mechanical
- Exhaust gas recircu-
lation (EGR) valve
Electrical
- Electrical
con
nector(s)
- Wiring harness
- Fuse(s)
- Relay
- EGRvalve
- Powertain control
module (PCM)
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 concern is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Symptom Possible Sources Action
I
Poor engine performance EGR valve.
Using WDS, CHECK the EGR
Valve Duty Cycle input signal
I to the EGR vacuum regulator
valve. If the result is 0%,
REMOVE the EGR valve.
REFER to Exhaust Gas Recir-
culation (EGR) Valve
- in this
section.
INSPECT the EGR valve and
valve seat for damage. Make
sure that the EGR valve is in
the closed position. If the EGR
valve is not closed. INSTALL
a
new EGR valve. TEST the
system for normal operation. If
the result is not 0% continue
the engine diagnostic using
WDS.
2006.0 Fiesta 1212006 G334290en
Excessive crankcase pressure Blocked or damaged PCV
hose(s).
Blocked crankcase vent oil
separator. CHECK
the PCV system
components for blockages, CLEAN or INSTALL new
components as necessary.
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Engine Emission Control - 2.OL Duratec-HE
303-08B-10 (MI41 303-08B-10
REMOVAL AND INSTALLATION
Crankcase Vent Oil Separator
Removal
I. Remove the intake manifold. For additional Discard the gasket.
information, refer to Section 303-OIA
[Engine
-- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I 6V (Sigma)ll .6L Duratec-I 6V
(Sigma)] I 303-01 B [Engine -- 1.4L
Duratorq-TDCi (DV) Diesel] I 303-01 C [Engine
-- 1.3L Duratec-8V (Rocam)] I 303-01 D
[Engine
-- 2.OL Duratec-HE (M14)] 1 303-01 E
[Engine
-- 1.6L Duratorq-TDCi (DV) Diesel].
2. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV valve.
Installation
I. N0TE:lnstall a new crankcase vent oil
separator gasket.
To
install, reverse the removal procedure.
3. Remove the PCV
valve from the crankcase
vent
oil separator.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.
4. Remove the crankcase vent oil separator.
- - --
2006.0 Fiesta la2006 G37566en
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
REMOVAL AND INSTALLATION
17. Disconnect the ignition switch to starter Support
the exhaust flexible pipe with a
motor solenoid and battery to starter motor suitable
support wrap or suitable splint.
solenoid cables.
21. Detach the exhaust flexible pipe from the
18. Remove the accessory drive belt cover. catalytic
converter.
Discard the nuts and the gasket.
19. Remove the engine support insulator.
22m &AUTION:L~~~~ the tie-rod end retaining
nut in place to protect the ball joint stud.
N0TE:Use a 5mm Allen key to prevent the ball
joint stud from rotating.
20m ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
in failure. Loosen
the right-hand tie-rod end retaining
nut.
2006.0 Fiesta 1212006 G371506en
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Automatic Tra
Vehicles Wit
307-01 -72 Transm nsmission/Transaxle -
h: 4-Speed Automatic
ission
(AW81-40) 307-01 -72
REMOVAL AND INSTALLATION
Install the intermediate shaft center bearing
cap. Attach
the lower arm to the wheel knuckle
on both sides.
f
20. CAUTIONS: 22m AwARNING:~~~~~~~ a new tie-rod end
A~he inner joint must not be bent more
retaining nut. Failure to follow this
than
18 degrees. The outer joint must not
instruction may result in personal injury.
be bent more than 45 degrees.
N0TE:Use a 5 mm Allen key to prevent the ball
ADO not damage the halfshaft seal. joint stud from rotating.
A~ake sure the snap ring is correctly Attach the right-hand tie-rod end
to the wheel
seated. knuckle.
N0TE:lnstall a
new snap ring.
Attach the left-hand halfshaft to the
transaxle.
Remove the protective sleeve before fully
installing the halfshaft.
ACAUTION:M~~~ sure that the heat shield
is installed to prevent damage to the ball
joint.
N0TE:The lower arm pinch bolt must be installed
from the rear of the wheel knuckle.
23. N0TE:lnstall new exhaust flange nuts and
a new exhaust flange gasket.
Attach the exhaust flexible pipe to the
catalytic converter.
2006.0 Fiesta 1212006 G371506en
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308-03-27 Manual TransmissionlTransaxle 308-03-27
REMOVAL
23. Detach the coolant expansion tank from Discard the gasket.
, . the bracket and position it to one side.
24m ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
25. Disconnect the vehicle speed sensor (VSS)
electrical connector (if equipped).
26. Detach the exhaust flexible pipe from the
catalytic converter.
27. Remove the battery tray support bracket.
28. Remove the engine and transaxle rear
mount.
Discard the nuts.
2006.0 Fiesta 1212006 GI1 3290en
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308-03-33 Manual Transmission/Transaxle 308-03-33
REMOVAL
Discard the gasket.
,
23. Using the special tools, lower the engine
and transaxle assembly.
21. Remove the battery tray support bracket.
24. Remove the engine and transaxle rear
mount retaining bracket.
22. Remove the engine and transaxle rear
mount.
Discard the nuts. 25. Raise and support the vehicle. For
additional information, refer to:
(1 00-02
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
26. Remove the transaxle lower retaining bolts.
27. N0TE:Secure the transaxle with a retaining
strap on the transmission jack.
2006.0 Fiesta 1212006 G453416en
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308-03-38 Manual Transmission/Transaxle 308-03-38
DISASSEMBLY
Discard the snap ring. 4. Pull out the blanking plug.
15. Using the special tool, remove the fifth
18. Using the special tool, remove both
gear. halfshaft oil seals (left-hand side shown).
16. Remove the fifth gear housing.
Discard the bolts.'
17. Remove the fifth gear housing gasket, the
snap rings and the blanking plug.
1. Remove and discard the gasket.
2. Remove the output shaft snap ring.
3. Remove the input shaft snap ring.
Only remove the reversing lamp switch if
there is evidence of leakage.
19. Separate the two halves of the transaxle
housing (14 bolts).
Carefully separate the transaxle housing.
20. Remove the selector shaft guide sleeve
upper snap ring.
I' j '\.
1. Remove and discard the upper snap ring.
2006.0 Fiesta 1212006 G23118en
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308-03-57 Manual Transmission/Transaxle 308-03-57 I I
ASSEMBLY
21. Apply sealer on the inside edge of the Install
the fifth gear housing gasket.
1. transaxle housing mating face.
22. Assemble the transaxle housing and tighten 26m ACAUTION:M~~~ sure the snap rings are
in the correct position. Failure to follow this
the bolts.
instruction may cause damage to the fifth
23. N0TE:lnstall new input and output shaft
snap rings. gear
housing.
Turn the snap rings to the position shown.
Raise the and shafts 'lightly 27. NOTE:lnstall new fifth gear housing
and install the snap rings.
retaining bolts.
' 24. Using a suitable thread die, clean all the Install
the fifth gear housing.
-I hole threads in the fifth gear housing.
25. N0TE:lnstall a new fifth gear housing 28. Remove the transaxle from the mounting
stand.
gasket.
2006.0 Fiesta 1212006 G23119en
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308-03-63 Manual Transmission/Transaxle 308-03-63
INSTALLATION
4. Install the transaxle left-hand retaining bolt. Install the
engine rear mount.
5. Remove the retaining strap. 11. Remove the special tools.
6. Remove the transmission jack.
7. Install the engine and transaxle rear mount
retaining bracket.
12. N0TE:lnstall new exhaust flange nuts and
a new exhaust flange gasket.
Attach the exhaust flexible pipe to the
8. Lower the vehicle. catalytic
converter.
9. Using the special tools, raise the engine and
transaxle assembly.
10. N0TE:Do not tighten the engine rear mount
retaining nuts at this stage.
NOTE:
Install new engine rear mount retaining nuts.
2006.0 Fiesta 1212006 GI1 3293en
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