lock FORD FIESTA 2007 Workshop Manual

303-00-5 Engine System - General Information 303-00-5
DIAGNOSIS AND TESTING
Symptom
Oil consumption
Possible Sources Action
Use of the wrong type of
engine oil.
Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation or
breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty
and engine oil can enter the
combustion chamber
through the intake manifold.
Turbocharger seals (diesel
engine only).
DETERMINE the last type of
engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
CHECK if the PCV system is
operating correctly and repair
as necessary. REFER to:
Engine Emission Control (303-
08 Engine Emission Control
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 2.OL Duratec-HE (M14),
Diagnosis and Testing),
Engine Emission Control
-
Vehicles With: Vacuum
Exhaust Gas Recirculation
(EGR) Valve (303-08 Engine
Emission Control
- 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 1.6L Duratorq-TDCi (DV)
Diesel, Description and
Operation).
INSTALL a new turbocharger.
REFER to:
Turbocharger (303-04 Fuel
Charging and Controls
-
Turbocharger - I .4L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation),
Turbocharger
- I .6L Duratorq-
TDCi (DV) Diesel (303-04
Fuel Charging and Controls
- Turbocharger - I .6L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation).
2006.0 Fiesta 1212006 GI 52554en
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303-00-6 Engine System - General Information 303-00-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Damaged gaskets or mating
surfaces.
- Cylinder head gasket is
damaged or mating face are
warped.
- Valve stem oil seals are
worn and engine oil can
enter the combustion
chamber between the valve
stem and the valve stem
guide.
Piston ring or cylinder liner
wear.
Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons
- Piston rings (clearance in
groove and end gap)
- Cylinder liners
CHECK the gaskets and
mating surfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine
block mating faces. INSTALL new valve
seals.REFER
to:
Valve Seals (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.3L Duratec-8V (Rocam), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
2.OL Duratec-HE (M14), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
CHECK the running surfaces
and clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
CHECK the pistons.
REFER to: Piston Inspection
(303-00 Engine System
-
General Information, General
Procedures).
CHECK the piston rings.
REFER to: (303-00 Engine
System
- General Information)
Piston Ring-to-Groove Clear- ance (General Procedures),
Piston Ring End Gap (General
Procedures).
2006.0 Fiesta 1212006 GI 52554en
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303-00-8 Engine System - General Information 303-00-8
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 GI 52554en
Water
in fuel (diesel engine
only).
Fuel filter blocked.
Engine intake air system.
Glow plug faulty (diesel engine
only).
Engine management system.
. Drain the water from the fuel
system. Engine
- I .4L
Duratorq-TDCi (DV)
DiesellEngine - 1.6L Duratorq-
TDCi (DV) Diesel.
REFER to: Fuel System
- I .4L
Duratorq-TDCi (DV)
Diesel11 .6L Duratorq-TDCi
(DV) Diesel (31 0-00 Fuel
System
- General Informa-
tion, Diagnosis and Testing).
INSTALL a new fuel filter.
REFER to: (31 0-01 Fuel Tank
and Lines)
Fuel Filter
- 1.4L Duratorq-TDCi
(DV) Diesel (Removal and
Installation),
Fuel Filter
- I .6L Duratorq-TDCi
(DV) Diesel (Removal and Installation).
CHECK the intake air system.
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering, Diagnosis and
Testing).
. CHECK the glow plugs.
INSTALL new glow plugs as
necessary. REFER to:
Glow Plug (303-07 Glow Plug
System - 1.4L Duratorq-TDCi
(DV) Diesel, Removal and
Installation),
Glow Plugs (303-07 Glow Plug
System - 1.6L Duratorq-TDCi
(DV) Diesel, Removal and
Installation).
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic Engine Controls, Diagnosis
and Testing).
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303-00-1 0 Engine System - General Information 303-00-1 0
DIAGNOSIS AND TESTING
Symptom
Very poor power output or fuel
consumption too high or engine
running rough
Possible Sources Action
Fuel system. CHECK the fuel system.
REFER to:
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Diagnosis and
I Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.3L Duratec-8V
(Rocam), Diagnosis and
Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- I .4L Duratorq-
TDCi (DV) Diesel, Diagnosis and Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.6L Duratorq-
TDCi (DV) Diesel, Diagnosis
and Testing).
Engine intake air system. CHECK the intake air system.
REFER to: lntake Air Distribu-
tion and Filtering
(303-12
lntake Air Distribution and
Filtering, Diagnosis and
Testing).
Exhaust system blocked. I CHECK the exhaust system.
REFER to: Exhaust System
(309-00 Exhaust System,
Description and Operation).
Engine management system.
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
Fault in ignition system (petrol
engines only). CHECK the ignition system.
REFER to:
Engine lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine lgnition (303-07 Engine
lgnition
- 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 5 Engine System - General Information 303-00-1 5
DIAGNOSIS AND TESTING
N0TE:The varying design of compression checking
% devices and fluctuating starter motor speeds
normally only allows for a comparison to be made
of the compression pressures in all cylinders.
Measure the compression pressure
Engine
- 1.4L Duratorq-TDCi (DV)
biesel)
1. Remove the air cleaner.
REFER to: Air Cleaner
- 1.4L Duratorq-TDCi
(DV) Diesel (303-12 Intake Air Distribution and
Filtering, Removal and
Installation). 4. Detach the exhaust gas recirculation (EGR) tube
from the cylinder block and from the EGR valve
(if equipped).
I I 2. Disconnect the fuel injector wiring harness main
connector. 5. Detach the EGR tube from the EGR cooler (if
equipped).
3. Disconnect the glow plug relay electrical
connector.
6. Remove the EGR tube from the intake manifold
assembly.
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 7 Engine System - General Information 303-00-1 7
DIAGNOSIS AND TESTING
14. N0TE:Check the EGR tube O-ring seal.
Install a new seal
if necessary. I
, Install the EGR tube to the intake manifold
assembly.
18 Connect the fuel injector wiring harness main
connector.
19 Install the air cleaner.
REFER to: Air Cleaner
- 1.4L Duratorq-TDCi
15 Attach the EGR tube to the cylinder block and (DV) Diesel (303-12 Intake Air Distribution
and
to the EGR valve (if equipped). Filtering, Removal
and Installation).
Using worldwide diagnostic system (WDS), clear
the fault codes from the PCM.
Measure the compression pressure
Engine
- 1.6L Duratorq-TDCi (DV)
biesel)
WARNINGS:
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable mixtures are always
16 Attach the EGR tube to the EGR cooler (if present and can ignite. Failure to follow
equipped). these instructions may result in personal
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below
30' C,
whichever is the greater. Failure to follow
these instructions may result in personal
injury.
I. Using datalogger in world wide diagnostic
system (WDS), check that the fuel pressure has
dropped to zero and that the fuel temperature
17. Connect the glow plug relay electrical connector. has
either reached ambient temperature or is
below 30°C, whichever is the greater.
2. Raise and support the vehicle. REFER to:
(1 00-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
2006.0 Fiesta 1212006 GI 52554en
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303-00-39 Engine System - General Information 303-00-39
GENERAL PROCEDURES
Cylinder Bore Taper
1. N0TE:The main bearing caps or lower
crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness or
tapering.
If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if
aplicable/allowed).
2006.0 Fiesta 1212006 GI 7628en
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303-00-51 Engine System - General Information 303-00151
GENERAL PROCEDURES
Cylinder Block Distortion
1. Using a Straight Edge and a Feeler Gauge,
measure the cylinder
blocWcylinder head
distortion.
Measure the mating face distortion. If the value is not to specification rework the
mating face (if allowed).
2006.0 Fiesta 1212006 GI 7639en
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303-01 A-I Engine
. 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I
6V (Sigma)ll . 6L Duratec-1 6V (Sigma)
303-01 A-I
SECTION 303-01A Engine . 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)/l . 6L Duratec-1 6V
(Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
.............................................. Specifications
Engine Data
. 1.25L ........................................................................\
................................
Engine Data . I . 4L ........................................................................\
..................................
Engine Data . 1.6L ........................................................................\
..................................
Oil pressure ........................................................................\
.............................................
Engine Oil Capacity . - 1.25Ll1.4L ........................................................................\
............
Engine Oil Capacity - 1.6L ........................................................................\
......................
Valve Clearance - 1.25LlI . 4L ........................................................................\
..................
Valve Clearance - 1.6L ........................................................................\
............................
Cylinder block - 1.25L ........................................................................\
.............................
Cylinder block - 1.4L ........................................................................\
...............................
........................................................................\
............................... Cylinder block - 1.6L
........................................................................\
.......................................... Cylinder head
Piston
-1.25L ........................................................................\
...........................................
Piston -1.4L ........................................................................\
.............................................
Piston - l.6L ........................................................................\
............................................
PAGE
DESCRIPTION AND OPERATION
........................................................................\
......................................................... Engine 303-01A-9
........................................................................\
.................... 1.4Ll1.6L Duratec 16V engine 303-01A-9
DIAGNOSIS AND TESTING
........................................................................\
......................................................... Engine 303-01A-12
GENERAL PROCEDURES
........................................................................\
....................... Valve Clearance Adjustment 303-01 A-I 3
IN-VEHICLE REPAIR
Crankshaft Front Seal ........................................................................\
......... (21 467 0)
Valves ........................................................................\
..................................... (21 21 5 4)
Intake Manifold ........................................................................\
....................... (21 183 0)
Valve Cover ........................................................................\
............................ (21 141 0)
Valve Seals ........................................................................\
............................. (21 238 0)
Camshafts ........................................................................\
........................ (21 284 0)
Camshaft Seal ........................................................................\
................... (21 288 0)
Timing Belt ........................................................................\
.......................... (21 304 0)
Exhaust Manifold ........................................................................\
.................... (21 187 0)
Cylinder Head ........................................................................\
...................... (21 163 0)
Oil Pan ........................................................................\
............................. (21 154 0)
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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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