cam FORD FIESTA 2007 Workshop Manual

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll125L Duratec-I 6V (Sigma)ll14L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
GENERAL PROCEDURES
9. Switch the engine off.
2006.0 Fiesta iz1~006 GI 46259en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-21 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-21
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 404 0)
Removal
Vehicles built up to 0412005
Loosen the water pump pulley retaining
bolts.
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove the air
cleaner.
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
3. Drain the cooling system.
6. Lower the vehicle. For additional information, refer to: Cooling
System Draining, Filling and Bleeding - 1.3~ 7. Disconnect the degas hose from the coolant
Duratec-8V (Rocam)ll.25L Duratec-1 6V expansion tank.
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) (303-03 Engine
Cooling - 1.3L DuratecdV (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma), General
Procedures).
4. Remove the crankshaft
pulley splash shield.
5m AWARNING:D~ not remove the water pump
pulley retaining bolts at this stage as the
pulley is under tension from the accessory
drive
belt. Failure to follow this instruction
may
result in personal injury. 8.
Detach the
coolant expansion tank and
secure
it to one side.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-22 Duratec-1 6V (Sigma)lIl6L Duratec-1 6V (Sigma) 303-03A-22
REMOVAL AND INSTALLATION
9. Remove the generator.
For
additional information, refer to:
Generator
- 1.25L Duratec-1 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V
(Sigma)
(414-02 Generator and Regulator,
Removal and Installation).
10. Remove the water pump pulley.
Discard the gasket.
Vehicles built 0412005 onwards
13. Remove the timing belt.
For additional information, refer to: Timing
Belt (303-01 Engine - 1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma), ln-vehicle Repair).
11. Remove the timing belt cover (cover shown 14. Drain the cooling system,
removed for clarity). For additional information, refer to: Cooling
12' &AUTION:P~~~~~~ the timing belt and
lower cover from contamination by the
coolant.
Remove the water pump. System
Draining,
Filling and Bleeding -
1.3L Duratec-8V (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V (,
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-03
Engine
Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), General Procedures).
15. Remove the water pump and the timing
belt
tensioner.
Discard the gasket.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-23 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-0349-23
REMOVAL AND INSTALLATION
16. Remove the timing belt tensioner from the
water pump.
Installation
1. N0TE:lnstall a new water pump gasket.
To install, reverse the removal procedure.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-24 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-O3A-24
REMOVAL AND INSTALLATION
Thermostat - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 454 0)
Special Tool(s) 4. Disconnect the heater hose from the
I Removerllnstaller, Cooling I thermostat housing.
Hose Clamp
303-397 (24-003)
Removal
1. Drain the cooling system.
For additional information, refer to Cooling
System Draining, Filling and Bleeding in
this section.
5. Remove the thermostat housing.
2. Remove the generator. For additional
information, refer to Section
414-02
[Generator and Regulator].
3. Using the special tool, disconnect the
radiator lower hose from the thermostat
housing.
6. N0TE:The thermostat is installed with the
jiggle pin at the top.
Remove the thermostat.
I I, '
Installation
I. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G210040en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)Il.GL Duratec-1 6V (Sigma) -- --
REMOVAL AND INSTALLATION
Make sure the rubber seal is located
correctly.
I I
2006.0 Fiesta 1212006 G210040en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
3-03A-26 Duratec-I 6V (Sigma)llm6L Duratec-1 6V (Sigma) 303-03A-26
REMOVAL AND INSTALLATION
Radiator(24 254 0) /'
Special Tool@)
I I Remover/lnstaller, Cooling I
2. Push the cooling fan motor and shroud (.
upwards and then downwards to remove.
24003
Removal
Hose Clamp
303-397 (24-003)
1. Disconnect the battery ground cable. For
additional information, refer to
Section 414-01 [Battery, Mounting and
Cables].
5. Using the special tool, disconnect the
2. Drain the cooling system. radiator
upper hose.
For additional information, refer to Cooling
System Draining, Filling and Bleeding in
this section.
3. Disconnect the cooling fan motor and
cooling fan resistor electrical connectors.
4. Remove the cooling fan motor and shroud.
I. Release the cooling fan motor and shroud
from the retaining brackets.
6. Using the special tool, disconnect the
radiator lower hose.
7. Remove the radiator retainers.
1. Remove the radiator retainer locking screws.
2006.0 Fiesta 1212006 ~210041 en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
REMOVAL AND INSTALLATION
2. Remove the radiator retainers and grommets.
8. Detach the radiator and the air conditioning
(NC) condenser from the support panel.
9m &AUTION:SU~~O~~ the condenser by
positioning it on the support panel.
Slide the
NC condenser to detach it from the
radiator
130. Remove the radiator.
Installation
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 ~210041 en
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303-03B-7 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-7
DESCRIPTION AND OPERATION
Oil Cooler
Item Description
I I I Oil cooler I
1 2 1 Oil filter adaptor I
1 3 1 Oil filter I
The oil cooler is an oil to water type and is a full
flow system.
The oil cooler and oil filter are fitted to an adaptor
which is mounted on the cylinder block.
The coolant supply for the oil cooler is through the
thermostat by-pass hose.
Coolant Recovery System
A pressurized coolant expansion tank system is
used which continuously separates the air from the
cooling system and replenishes the system through
the coolant expansion tank outlet hose.
A continuous vent from the engine and radiator to
I the coolant expansion tank prevents air locks from
forming in the cooling system.
No manual bleed points are provided on the
system. The coolant expansion tank serves
as the location
for:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the coolant pressure
cap.
Coolant
A WARN1NG:Coolant contains monoethylene
glycol and other constituents which are
toxic if taken internally and can be
absorbed into the skin after prolonged
contact. Failure to follow this instruction
may result in personal injury.
Coolant concentration should be checked through
the neck of the expansion tank with a hydrometer.
The acceptable range of specific gravity (sg) of
correctly balanced fluids is between
1.06 and
1.07kg/l, which represents a coolant concentration
between 40% and 55%. If the concentration falls
below 40% there is insufficient low temperature
protection and the corrosion resistance will be
inadequate. In such cases the concentration must
be brought back to specification.
The coolant used is the orange-colored Motorcraft
Super Plus 2000. Motorcraft Super Plus 2000 is a
non silicated organic acid technology (OAT)
coolant, and must not be mixed with other coolant
types. For cooling system top up, only use coolant
which meets the correct specification and is
compatible with the existing coolant.
Changing Coolant
A WARN1NG:When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to
prevent the possibility of coolant scalding.
Failure to follow this instruction may result
in personal injury.
A CAUTI0N:When draining the coolant or
changing any cooling system components,
it is imperative that no coolant comes into
contact with the camshaft drive belt or
accessory drive belt. If necessary the belt
should be removed. Contamination of the
belt may result in premature belt failure.
N0TE:Providing the coolant has not been
contaminated with other fluids or foreign matter,
the robust corrosion resistance properties of this
2006.0 Fiesta 1212006 G421219en
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Engine Cooling - 2.OL Duratec-HE (M14)
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Coolant
pump.
Thermostat housing.
Coolant expansion tank cap or
seal(s).
- -
Coolant expansion tank.
Heater core.
Engine. INSPECT the
coolant pump
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
gasket as necessary.
REFER to: Coolant Pump (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal
and Installation).
INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing and
thermostat housing gasket as
necessary.
REFER to: Thermostat Housing
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation).
CHECK the coolant expansion
tank cap for tightness and
damage. INSTALL a new
coolant expansion cap as
necessary.
INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
CHECK the heater core for
leaks.
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine
- 1.3L Duratec-8V
(Rocam), In-vehicle Repair).
2006.0 Fiesta lu2006 G426582en
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