table FORD FIESTA 2007 Owners Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 Am1 35 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma)
303-01 A-1 35
INSTALLATION
4m AWARNING:S~~~~~~ the engine and 7. Install the starter motor.
transaxle assembly on wooden blocks and
secure
it with suitable securing straps.
Using the special tool and the engine hoist
position the engine and transaxle assembly
on the workshop table.
8. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
9. Position the engine and transaxle assembly
5. Install the transaxle right-hand retaining in
the engine compartment.
bolts.
Carefully lower the vehicle.
6. N0TE:lnstall new torque converter retaining
nuts.
Install the torque converter retaining nuts.
Rotate the torque converter to gain access
to the remaining studs. 10.
N0TE:lnstall new engine
front mount
retaining nuts.
N0TE:Do not tighten the engine front mount
retaining bolts and nuts at this stage.
Install the engine front mount.
11. N0TE:lnstall new engine rear mount center
retaining nut.
N0TE:Do not tighten the engine rear mount center
retaining nut at this stage.
2006.0 Fiesta iz12006 G380459en
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303-01 B-17 Engine - 2.OL Duratec-HE (M14) 303-01 B-17
GENERAL PROCEDURES
6. Remove the air cleaner retaining bracket. 9. Using the special tool, remove the spark
plugs.
i
7. Remove the evaporative emission (EVAP)
valve support bracket.
10. Remove the valve cover.
8. Using the special tool, disconnect the spark 11. ~CAUTION:Only rotate the crankshaff in plug electrical connectors.
the normal direction of rotation.
Rotate the crankshaft until piston No.
1 is at
top dead center (TDC).
12. N0TE:Make a note of each cylinder number
and the valve clearances measured.
Using a suitable set of feeler gauges,
measure the valve clearances.
2006.0 Fiesta 1212006 G451279en
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303-01 B-32 Engine - 2.OL Duratec-HE (M14) 303-01 B-32
IN-VEHICLE REPAIR
24. Raise the vehicle. For additional N0TE:Make sure that the contact surface for the
information, refer to: (100-02 Jacking and CV joint boot on the intermediate shaft is clean. ,
Lifting)
Slide the inner CV joint boot onto the
Jacking (Description and Operation),
intermediate shaft. (..
Lifting (Description and Operation). Use a suitable screwdriver under the boot to
25. Remove the M6 x 18 mm bolt. allow air to escape.
26. Remove the special tool. 29. N0TE:lnstall a
new boot clamp.
Using a suitable grip wrench, install the inner
CV joint boot clamp.
27. Install the cylinder block lower blanking
plug.
30. N0TE:When installing a new engine front
cover, the crankshaft position sensor
(CKP
sensor) must be aligned using the tool
supplied.
28.
N0TE:Do not damage the boot of the inner
CV joint. Align
the
CKP sensor (engine shown
removed for clarity).
1. Loosen the CKP sensor bolts.
2006.0 Fiesta 1212006 G451288en
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303-01 B-42 Engine - 2.OL Duratec-HE (M14) 303-01 B-42 -
IN-VEHICLE REPAIR
18. Remove the cylinder block lower blanking
plug and install the special tool.
19. Lower the vehicle.
20. Remove the engine front cover upper
blanking plug.
3. Install a suitable M6 x 18 mm bolt through
the blanking plug to secure the timing chain
guide in the detensioned position.
22m ACAUTION:H~I~ the camshaft by the
hexagon with an open-ended wrench to
stop it from turning.
21 ACAUTION:T~ detension the timing chain,
make sure the timing chain tensioner N0TE:Using a suitable piece of wire, prevent the
ratchet is in the released position. timing chain and the sprocket from dropping into
the timing case.
Detension the timing chain. -
Loosen the camshaft sprockets retaining
1. Using a suitable screwdriver, unlock the bolts.
timing chain tensioner ratchet.
2. Carefully turn the exhaust camshaft by the Detach the exhaust camshaft sprocket
hexagon in the normal direction of rotation, together
with the timing chain from the
exhaust camshaft.
to detension the timing chain tensioner.
2006.0 Fiesta 1212006 G451293en
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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.
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303-01 B-46 Engine - 2.OL Duratec-HE (M14) 303-01 B-46
IN-VEHICLE REPAIR
23. Remove the special tool.
21. Raise and support the vehicle. For 26. Install the engine front cover lower blanking
additional information, refer to:
(I 00-02 plug.
27. N0TE:Do not damage the inner constant
velocity (CV) joint boot.
Jacking
and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
22. Remove the crankshaft pulley securing bolt.
N0TE:Make sure that the intermediate shaft mating
surface for the
CV joint boot is clean.
ELE0021907
Attach the inner CV joint boot to the
intermediate shaft.
24. Install the cylinder block lower blanking
plugB 28. N0TE:lnstall a new CV joint boot clamp.
25. Coat the engine front cover lower blanking
plug with sealant. Using
a suitable grip wrench, install the inner
CV joint boot clamp.
2006.0 Fiesta 1212006 G451293en
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303-01 B-50 Engine - 2.OL Duratec-HE (M14) 303-01 B-50 -
IN-VEHICLE REPAIR
8. Drain the engine. 12. Remove the engine front cover lower
Allow the oil to drain into a suitable container. retaining bolts. //
9. N0TE:lnspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required.
lnstall the drain plug.
10. Loosen the transaxle right-hand retaining
bolts approximately
10 mm.
11. Loosen the transaxle left-hand retaining
bolts approximately 10 mm. 13.
Remove the transaxle lower retaining bolts.
14. Slide back the transaxle approximately
8
mm.
15. Remove the oil pan retaining bolts.
2006.0 Fiesta 1212006 G451306en
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303-01 B-56 Engine - 2.OL Duratec-HE (M14) 303-01 B-56
IN-VEHICLE
REPAIR
Crankshaft Rear Seal(21 468 4)
Special Tool(s) Install the drain plug.
Materials Name
S~ecification
1 Cleaner I WSK-M2G342-A I
5. Remove the oil level indicator tube lower
retaining bolt.
- -
d 21 135
4 21 179
I Silicone Sealant I WSE-M4G323-A4 I
Locking Tool, Flywheel
303-254 (2 1 -1 35)
Separator, Oil Pan
303-428 (21 -1
79)
Removal
1. Remove the oil level indicator and oil level
indicator tube upper retaining bolt.
2. Remove the clutch disc and pressure plate.
For additional information, refer to: Clutch
Disc and Pressure Plate
(308-01 Clutch,
Removal and Installation).
3. Drain the engine.
Allow the oil to drain into a suitable container.
4. N0TE:lnspect the oil pan drain plug seal for
damage. Install a new drain plug and seal
if
required.
6. Using the special tool, lock the flywheel in
position.
7. Remove the flywheel.
2006.0 Fiesta 1212006 G451307en
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303-01 B-64 Engine - 2.OL Duratec-HE (M14) 303-01 B-64
IN-VEHICLE REPAIR
Exhaust Manifold
1. Remove the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (303-12
Intake Air Distribution and Filtering,
Removal and Installation). 2.
Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G451285en
Item Description Description
bolts 1
2
See Removal Detail
Exhaust manifold upper heat shield
Exhaust manifold lower heat shield
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303-01 B-67 Engine - 2.OL Duratec-HE (M14) 303-01 B-67
IN-VEHICLE REPAIR
Timing Chain(21 314 0) ,
Removal 4. Remove the timing chain guides.
1. Remove the engine front cover.
For additional information, refer to Engine
Front Cover
- in this section.
2. Detension the timing chain.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suitable
pin punch.
3. N0TE:Hold the camshafts by the hexagon
with an open-ended wrench to stop them
from rotating.
Loosen the camshaft sprocket retaining
5. Remove the timing chain tensioner.
bolts.
Installation
1. Install the timing chain tensioner.
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2006.0 Fiesta 1212006 G323910en
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