Electrical FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
DISASSEMBLY
14. Remove the timing belt upper cover.
15. Remove the engine front mount bracket.
16. Remove the fuel supply and return lines.
17. Disconnect the spark plug electrical
connectors and detach the wires from the
valve cover.
18. Remove the valve cover.
2006.0 Fiesta 121~006 GI 54224en
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)lI.GL Duratec-1 6V (Sigma) 303-01A-101
DISASSEMBLY
32. Remove the crankshaft timing belt pulley. 35. Disconnect the positive crankcase
ventilation (PCV) hose from the PCV cover.
33. Remove the timing belt rear cover.
34m ACAUTION: ~ee~ the camshaft bearing
caps and the camshafts in order for
installation.
36. Detach the oil level indicator and tube from
the intake manifold.
Detach the knock sensor (KS) electrical
connector from the oil level indicator tube.
Remove the camshafts. 37. Remove the intake manifold lower bolt.
Slacken each camshaft bearing cap retaining
bolt in the sequence shown by one turn until
the camshaft is released.
Remove the camshaft bearing caps.
Remove and discard the camshaft seals.
38.
CAUTIONS:
A~~ace the cylinder head on a suitable
soft surface.
A~emove the cylinder head bolts in the
sequence shown.
2006.0 Fiesta 1212006 G 1 54224en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 05 Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma) 303-01 A-1 05
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Cylinder Head(21 165 6)
' Disassembly 5. Remove the fuel supply manifold.
I. Disconnect the temperature and manifold Discard the O-ring seals.
absolute pressure (T-MAP) sensor electrical
connector.
2. Disconnect the throttle plate control motor
(DC-ISC) electrical connector.
3. Disconnect the fuel injector electrical
connectors.
6. Remove the intake manifold.
Discard the gaskets.
7. Remove the engine rear lifting eye.
8. Remove the coolant distribution housing and
1 ~~~0001735 the ignition coil (El).
4. Remove the engine wiring harness.
2006.0 Fiesta 1212006 G202085en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 07 Duratec-I 6V (Sigma)/l.GL Duratec-1 6V (Sigma)
303-01 A-I 07
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Install the intake manifold. 9. Connect the throttle plate control motor
(DC-ISC) electrical connector.
6. N0TE:lnstall new fuel supply manifold O-ring
seals.
10. Connect the temperature and manifold
Install the fuel supply manifold. absolute pressure (T-MAP)
sensor electrical
connector.
7. Install the engine wiring harness.
8. Connect the fuel injector electrical
connectors.
2006.0 Fiesta 1212006 G202085en
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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)llm4L
303-OIA-119 Duratec-1 6V (Sigma)llI6L Duratec-1 6V (Sigma) 303-01 A-1 19
ASSEMBLY
Connect the spark plug electrical connectors 63. Install the timing belt upper cover.
and attach the wires to the valve cover.
I
62. Install the engine front mount bracket.
Tighten the bolts in the indicated order in
three stages.
Stage 1 : Hand tighten bolt 1.
Stage 2: Tighten bolts 2 to 55 Nm.
Stage 3: Tighten bolt 3 to 55 Nm.
64. Install the coolant pump pulley.
2006.0 Fiesta 1~1zoo6 GI 54225en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/lI6L Duratec-1 6V (Sigma)
INSTALLATION
17. Connect the AIC high-pressure cut-off
. switch electrical connector.
20. Using the special tool, attach the power
steering line to the power steering pump.
18. Install the cooling fan motor and shroud. 21. Connect the power steering line to the
1. Push the cooling fan motor and shroud steering pump.
upwards and then downwards to install.
2. Install the cooling fan motor and shroud to
the retaining brackets.
19. Connect the cooling fan motor and cooling
fan resistor electrical connectors.
22. Attach the power steering line support
bracket to the engine block.
2006.0 Fiesta 1212006 GII 31 64en
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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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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 27 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-I 27
INSTALLATION
Attach the exhaust flexible pipe to the
33. Attach the gearshift cables to the bracket
catalytic converter.
and turn the abutment sleeves
counterclockwise.
31. Remove the exhaust flexible pipe support.
Vehicles without automated gearshift
32m ACAUTION:H brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
Connect the clutch slave cylinder supply
line.
Install the spring clip.
34. N0TE:Do not install the air cleaner at this
stage.
Adjust the gearshift cable.
For additional information, refer to: Gearshift Cable Adjustment (308-00 Manual
Transmission/Transaxle and Clutch
General Information, General Procedures).
35.
N0TE:Do not install the air cleaner at this
stage.
Bleed the hydraulic clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
Vehicles with automated gearshift
36. Connect the gearshift actuator electrical
connector (colored grey).
2006.0 Fiesta 1212006
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Engine - 1.25L Dura
303-01 A-I 28 Duratec-16V
(Sigma)/l .r
:eel 6V (Sigma)ll.4L
L
Duratec-1 6V (Sigma) 303-01A-128
INSTALLATION
37. Connect the gearshift actuator electrical All vehicles
connector (colored black). 41. Lower the vehicle.
42. Tighten the engine front mount retaining
nuts and bolts.
38. Install the gearshift actuator cover.
39. Connect the clutch slave cylinder supply
line.
Install the spring clip.
40. Bleed the hydraulic clutch system.
For additional information, refer to: Clutch
System Bleeding
- Vehicles With:
Automated Gearshift
(308-00 Manual
~ransmission/Transaxle and Clutch -
General Information, General Procedures).
43. N0TE:lnstall a new engine rear mount
center retaining nut.
Tighten the engine rear mount center
retaining nut.
44. Attach the power steering line support
bracket to the cylinder head.
2006.0 Fiesta 1212006 GII 31 64en
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