engine FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
Oil Pump ...
Crankshaft
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 71 4 0) 303-01
A-66
Rear Seal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 468 4)
303-01
Engine ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01 A-70
Engine - Vehicles With: Automatic Transaxle ................................................................... 303-01A-82
DISASSEMBLY
Engine
........................................................................\
............................. (21 134 8) 303-01A-95
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 165 6) 303-01A-105
ASSEMBLY
Engine
........................................................................\
.................................... (21 134 8) 303-01A-108
INSTALLATION
Engine..
.... .. .... .................... . . . ............ ...... ....... . ...... . . ...... . . . . . . . . . . ....... . . . . ....... . . 303-01A-122
Engine - Vehicles With: Automatic Transaxle.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01 A-1 34
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Engine - 1.25L Duratec-1 6V (Sigma)l184L
Duratec-1 6V (Sigma)/186L Duratec-1 6V (Sigma)
SPECIFICATIONS

I Code - Stage Ill I FUJBlM7JA I
Engine Data - 1.25L
- - I
I Firing order I 1 -3-4-2 I
Description
Code
- Stage IV
1 Bore I 71.9 mm I
FUJAIM7JB
1 Stroke I 76.5 mm I
1 Displacement I 1242 cc I
I Compression ratio I 1O:I I
I Torque at 3500 rpm I 110 Nm I
Power output at 5700 rpm (Engine codes M7JAIM7JB)
Power output at 5700 rpm (Engine codes FUJAIFUJB)
I Maximum permissible engine speed continuous I 5950 rpm I
51 kW (70 PS)
55
kW (75 PS)
meperissible engine speed intermittent I 6175 rpm I
I Idle speed I 750 rprn I
I Maximum oil consumption I 0.5Ll1 OOOkm I
Engine Data - 1.4L
I Description
Code
FXJAIFXJ B
I Firing order I 1-3-4-2 I
Bore
Stroke
I Power output at 5700 rpm I 59 kW (80 PS) I
76.0 mm
76.5 mm
Displacement
Compression ratio
I Torque at 3500 rpm I 124 Nm I
1388 cc
11:l
I Maximum permissible engine speed continuous I 6450 rpm I
I Maximum oil consumption I 0.5Ll1 OOOkm I
Maximum permissible engine speed intermittent
ldle speed
Engine Data
- I .6L Description 6800 rpm
750 rprn
I Engine code I FYJAIFYJB I
I Firing order I 1 -3-4-2. I
1 Bore I 79.0 mm I
1 Stroke I 81.4 mm I
2006.0 Fiesta 1212006 GI 54208en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
SPECIFICATIONS
I Power output at 6000 rpm I 74 kW (1 00 PS) I
Description
Displacement
Compression ratio 1595
cc
11:l
Torque at 4000 rpm
Maximum permissible engine speed continuous
I Idle speed I 750 rpm I
1
146 Nm
6450 rpm
I Maximum permissible engine speed intermittent
I Maximum oil consumption I 0.5U1 OOOkm I
6800 rpm
Oil
Dressure
I Description I bar I
I Oil pressure (minimum, oil temperature 80°C) at 800 rpm I 1 .O I
I Oil pressure (minimum, oil temperature 80°C) at 2000 rpm I 2.5 I
I Pressure relief valve opening pressure I 4 1
Engine Oil Capacity - 1.25U1.4L
I Service fill including oil filter (EFLI 0) I 3.80 I
Description
Initial fill including oil filter
Service fill including oil filter
(EFL500)
I Service fill excluding oil filter I 3.50 I
Liters
4.25
3.75
I Initial fill including oil filter (EFLGOO) I 4.50 I
Engine Oil Capacity - 1.6L
I Initial fill including oil filter (EFLI 0) I 4.30 I
Description
I Service fill including oil filter (EFLGOO) I 4.25 I
Liters
I Service fill including oil filter (EFLI 0) I 4.10 I
I Service fill excluding oil filter I 3.75 I
Valve Clearance - 1.25U1.4L
Valve Clearance - 1.6L
Description
Valve clearance (engine cold), intake
Valve clearance (engine cold), exhaust
Description mm
I!{
mm
0.17 - 0.23
0.27
- 0.33
I Valve clearance (engine cold), intake I 0.17 - 0.23 I
I Valve clearance (engine cold), exhaust I 0.31- 0.37 I
2006.0 Fiesta 1212006 GI 54208en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)llm6L Duratec-1 6V (Sigma)
SPECIFICATIONS
Cylinder block - 1.25L
Description mm
71.900 - 71.910
I Cylinder bore diameter, class 2 I 71.91 0 - 71.920 I
I Cylinder bore diameter, class 3 I 71.920 - 71.930 I
I Crankshaft end float I 0.300 - 0.800 I
Cvlinder block - 1.4L
I Description I mm I
I Cylinder bore diameter, class 1 I 76.000 - 76.010 I
I Cylinder bore diameter, class 2 I 76.01 0 - 76.020 I
I Cylinder bore diameter, class 3 I 76.020 - 76.030 I
I Crankshaft end float I 0.300 - 0.800 I
I Cylinder bore diameter, class 1 I 79.000 - 79.01 0 I
Cylinder block - 1.6L
I Cylinder bore diameter, class 2 I 79.010 - 79.020 I
Description mm
Cvlinder head

I Piston diameter, class 1 (uncoated) I 71.875 - 71.885 I
Cylinder bore diameter, class 3
Crankshaft end float
Piston
-1.25L
I Piston diameter, class 2 (uncoated) I 71.885 - 71.895 I
79.020 - 79.030
0.300
- 0.800
Description
I Piston diameter, class 3 (uncoated) I 71.895 - 71.905 1
mm
Ips, upper I 0.1 70 - 0.270 I
I Piston ring gaps, middle I 0.700 - 0.900 I
I Piston ring gaps, lower I 0.200 - 0.900 I
I Piston ring end float, upper I 0.040 - 0.080 I
I Piston ring end float, middle I 0.025 - 0.070 I
I Piston diameter, class 1 (uncoated) I 75.960 - 75.970 I
Piston -1.4L
I Piston diameter, class 2 (uncoated) I 75.970 - 75.980 I
Description
I Piston diameter, class 3 (uncoated) I 75.980 - 75.990 I
mm
2006.0 Fiesta 1212006 GI 54208en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)Il.GL Duratec-1 6V (Sigma)
SPECIFICATIONS
2006.0 Fiesta 1212006 GI 54208en
Ib-in
-
-
-
-
-
-
-
-
-
80
-
80
-
35
-
80
-
-
-
-
-
-
80
80
-
-
-
53
-
80
80
Ib-ft
41
35
66
35 35 18
30
18
35
-
20
-
15
-
21
-
11
-
-
13
-
35
-
-
11
15
15
-
-
-
-
Description
Engine front mount bracket to cylinder block
retaining bolts
Engine front mount retaining nuts and bolts
Engine rear mount center retaining nut
Engine rear mount outer retaining nuts
Engine support insulator retaining bolts Power steering line support bracket retaining bolts
Power steering line to power steering pump
Air conditioning
(AIC) compressor to cylinder block
retaining bolts
Generator to cylinder block top rear and lower
retaining bolts
Water pump retaining bolts
Water pump pulley retaining bolts
Oil pump to cylinder block retaining bolts
Oil pan to cylinder block retaining bolts
Oil level indicator tube bracket retaining bolt
Engine oil drain plug
Oil pump pickup pipe to cylinder block retaining
bolts
Oil pressure switch
Cylinder head bolts
Valve cover retaining bolts
Intake manifold to cylinder head retaining bolts
Exhaust manifold to cylinder head
Exhaust manifold to cylinder block
Camshaft position (CMP) sensor
Timing belt rear cover retaining bolts
Spark plugs Engine rear lifting eye retaining bolts
Coolant distribution housing retaining bolts
Ignition coil to coolant distribution housing
Camshaft bearing cap retaining bolts
Timing belt upper cover to cylinder block retaining
bolts
Timing belt lower cover to cylinder block retaining
bolts
Nm
55
48 90
48
48 25
40 25
47
9
27 9
20 4
28 9
15
a)
a)
18
a)
47 9
9
15
20
20
6
a)
9
9
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Engine - I .25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)ll .6L Duratec-I 6V (Sigma)
SPECIFICATIONS
1 Description I Nm I Ib-ft I Ib-in I
I Camshaft pulley retaining bolt I 60 I 44 I - I
Timing belt tensioner two bolts fixing
Timing belt tensioner central bolt fixing
Crankshaft position (CKP) sensor bracket to
cylinder block retaining bolts
I Crankshaft rear oil seal carrier retaining bolts I 9 1 - I 80 I
20
25
I Cylinder block blanking plug I 20 I 15 1 - I
I Crankshaft pulley retaining bolt I a) I - I - I
15
18
I Engine coolant temperature (ECT) sensor I 18 I 13 I - I
-
-
I Exhaust manifold studs I 10 I - I 89 I
Positive crankcase ventilation (PCV) cover retaining
1 bolts Fuel
rail to intake manifold
Knock sensor (KS) retaining bolt
I Thermostat housing retaining bolts I 9 I - 1 80 I
I Flywheel to crankshaft retaining bolts I a) I - I - I
15
20
I Selector lever cable bracket to transaxle I 20 I 15 I I
11
15
Transaxle retaining bolts
Torque converter retaining nuts
I Intermediate shaft center bearing cap retaining nuts 1 25 I 18 I - I
-
-
I Ground cable to cylinder head retaining bolt I 18 I 13 I - I
47
27
Suspension strut and spring assembly top mount
retaining nuts
I a) Refer to procedure in this section.
35
20
2006.0 Fiesta 1212006 GI 54208en
-
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Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
303-01 A-9 Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma) 303-01 A-9
DESCRIPTION AND OPERATION
Engine
i
1.4U1.6L Duratec 16V engine
Overview
The 1.4L and 1.6L Duratec 16V inline engines have The intake air routing and the air cleaner housing
already been installed on Focus vehicles under the have
also been changed. The pistons and piston
name of the Zetec-SE engine. rings
have been modified. The cylinder head cover
Details of this engine have been modified. The is
made of plastic.
routing of the pipes in the intake manifold has been
In addition, the auxiliary drive belt is an elastic
revised, and for the first time the throttle valve is multi-groove belt without a separate tensioning
electronically controlled. roller.
2006.0 Fiesta 1212006 GI 7901 7en
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303-01 A-I 0
Engine - I .25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
DESCRIPTION AND OPERATION
Engine Engine emission control
Cross-mounted 16-valve DOHC engines with 59 European emissions level IV
kW (80 PS) and 74 kW (1 00 PS) respectively.
European on-board diagnosis (EOBD) for the
Valve train with mechanical bucket tappets monitoring of emissions-relevant components.
Cylinder block and cylinder head made of an
aluminium alloy
Diagnosis
Auxiliary drive via a self-tensioning belt without a
belt tensioner WDS diagnosis CD
817.
Instrument cluster (engine indicator lamp)
Engine management
Sequential multi-port fuel injection (SFI)
temperature and manifold absolute pressure (T-MAP) sensor in conjunction with a Siemens
powertrain control module (PCM).
Knock control
PCM with 84 pins and integrated passive anti-theft
system (PATS) immobiliser. Torquelpower
The Duratec 16V engines are characterised by
their high level of running refinement, low emission
levels and balanced development of power.
Description Description
Power curve for the 1.6L-Duratec 16V 3 Torque curve for the 1.6L-Duratec 16V ( ',I
Power curve for the 1.4L-Duratec 16V 4
Torque
curve for the 1.4L-Duratec 16V
2006.0 Fiesta 1212006 GI 7901 7en
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Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 1 Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma) 303-01
A-I 1 - -
DESCRIPTION AND OPERATION
Valve train
B Camshaft timing belt pulleys, 1.411.6L
1 I Duratec 1 6V engine
Item Description
As a significant modification of the valve train, the
camshaft timing belt pulleys are now made of
reinforced plastic. The design has also been
changed in the process.
A
The basic procedure for installing the camshaft
timing belt pulleys remains the same.
Camshaft
timing belt pulleys,
1.411.6L
Zetec SE engine
It should however be noted that plastic sleeves are
located above the stud on Special Tool
205-072
(1 5-030 A) in order to protect the camshaft timing
belt pulley against damage.
2006.0 Fiesta 1212006 GI 7901 7en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 2 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01A-I 2
DIAGNOSIS AND TESTING
Enaine
REFER to Section 303-00 [Engine System -
General Information].
2006.0 Fiesta 1212006 GI 7645en
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