oil FORD FIESTA 2007 Owners Manual

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
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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
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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
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303-01 A-I 12
Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/lm6L Duratec-1 6V (Sigma)
ASSEMBLY
lnstall the drain plug.
lnstall the thermostat housing.
18. Install the positive crankcase ventilation 21. Install the oil pressure switch.
(PCV) cover.
Apply adhesive to the oil pressure switch
threads.
19' ~CAUTION:T~~ knock sensor (KS) cable
must not touch the cylinder head or the
PCV cover. Position the KS cable at
approximately the
10 o'clock position.
lnstall the KS.
20. N0TE:lnstall a new thermostat housing
gasket.
22' ACAUTION:D~ not damage the coolant
pump impeller.
N0TE:lnstall a new coolant pump gasket.
lnstall the coolant pump.
23, Turn the crankshaft to approximately 25
mm before top dead center (BTDC) on
cylinder number
I.
2006.0 Fiesta 1212006 GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-I13 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-I 13
ASSEMBLY
24n ACAUTION:T~~ thickness of the new 25.
Install the intake manifold lower retaining
, cylinder head gasket must be the same as bolt.
I , that
of the old one (hole marked).
N0TE:lnstall a new cylinder head gasket.
N0TE:Position the cylinder head onto the two
guide sleeves.
Using the special tool, install the cylinder
head.
Tighten the cylinder head bolts in the
sequence shown in three stages.
Stage 1: 15 Nm.
Stage2: 30 Nm.
Stage 3: 90 degrees.
26. Attach the oil level indicator tube to the
intake manifold.
Attach the KS electrical connector to the oil
level indicator tube.
27. Connect the PCV hose to the PCV cover.
28. N0TE:ldentification numbers are provided
on the outer face of the camshaft bearing
caps.
2006.0 Fiesta 1212006 GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)lIl4L
303-01 A-I 14 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-1 14
ASSEMBLY
Apply sealant to the points indicated on the
camshaft bearing cap no.
1 and to the mating
surface of the cylinder head.
29. Coat the camshafts and the camshaft
bearing caps with clean engine oil.
30m A~~~~10~:~osition the camshafts in
place so that none of the cams are at full
lift.
N0TE:The camshaft bearing cap numbering starts
at the timing
belt end with El on the exhaust side
and with
I1 on the intake side.
N0TE:The exhaust camshaft has an additional
cam for the camshaft position (CMP) sensor.
Install the camshafts and camshaft bearing
caps.
Tighten the camshaft bearing cap retaining
bolts in the sequence shown in three stages.
Stage 1: One half turn on each bolt until all
of the camshaft bearing caps are in contact
with the
cylinder head.
Stage
2: 7 Nm.
Stage
3: 45 degrees.
31. Coat the camshaft journals and seal lips
with clean engine oil.
32. N0TE:lnstall new camshaft seals. Using the
special tool, install the camshaft
seals.
f:
33. Install the timing belt rear cover.
34. Set the crankshaft to approximately 20
degrees before TDC.
35. Turn the camshafts to top dead center
(TDC) on cylinder number
I and install the
special tool.
36. N0TE:Do not fully tighten the camshaft
timing pulley retaining bolts at this stage.
Make sure the camshaft pulleys turn on the
camshafts.
N0TE:lnstall new camshaft pulley retaining bolts.
2006.0 Fiesta 1u2oos GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 20 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-I 20
ASSEMBLY
65. Install the generator.
66. N0TE:lnstall a new oil filter.
Install the oil filter.
67. Install the engine wiring harness.
69. Remove the special tools.
70. N0TE:lnstall a new exhaust manifold gasket
and new exhaust manifold retaining nuts.
N0TE:Do not fully tighten the nuts and bolt at this
stage.
Install the exhaust manifold.
68. Using the special tool attach the engine to
an engine hoist.
71. Tighten the exhaust manifold upper
retaining nuts and bolt in the sequence
shown in two stages.
Stage
I: 20 Nm.
Stage 2: 55 Nm.
2006.0 Fiesta 1212006 GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-123 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-I 23
INSTALLATION
5. Install the starter motor and the transaxle Install the engine rear mount.
left-hand retaining bolt.
/'
10. lnstall the battery tray support bracket.
6. Raise and support the vehicle.
For additional information, refer to: Lifting
(1 00-02 Jacking and Lifting, Description
and Operation).
7. Position the engine and transaxle assembly
in the engine compartment.
Carefully lower the vehicle.
8.
N0TE:lnstall new engine front mount
, retaining nuts. ' I ' N0TE:Do not tighten the engine front mount
retaining bolts and nuts at this stage.
Install the engine front mount. 11. Install the engine rear support insulator.
9.
N0TE:lnstall new engine rear mount 12. CAUTIONS:
retaining nuts.
Asupport the halfshaft. The inner joint N0TE:Do not tighten the engine rear mount center must not be bent more than 18 degrees. retaining nut at this stage. The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft oil seal.
N0TE:lnstall a new center bearing cap and
locknuts.
2006.0 Fiesta 1212006 GII 31 64en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 24 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-1 24
INSTALLATION
Attach the right-hand halfshaft and the Install the heat shield.
intermediate shaft to the transaxle.
13. 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.
A~ake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring.
Attach the left-hand halfshaft to the
transaxle.
14. Attach the lower arm to the wheel knuckle
on both sides (right-hand side shown).
15. Using the special tool, connect the coolant
hose to the distribution pipe
16. Using the special tool, connect the coolant
hose to the radiator.
2006.0 Fiesta 1212006 Gll3164en
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303-01 A-I 26 Engine
- 1.25L Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) 303-01A-I26
INSTALLATION
23. Attach the air conditioning (NC)
compressor to the
cylinder block.
27. Connect the reversing lamp switch
electrical connector.
I
24. Connect the NC compressor clutch
28. Connect the crankshaft position (CKP)
electrical connector. sensor electrical connector.
25. Install the accessory drive belt. 29. Connect the oil pressure switch electrical
For
additional information, refer to: connector.
Accessory Drive
Belt - I .4L Duratec-16V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive,
Removal and
Installation).
26. Connect the starter motor electrical
connectors.
30.
N0TE:lnstall new exhaust flange nuts and
a new exhaust
flange gasket.
2006.0 Fiesta 1212006 Gll3164en
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