section 4 FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-66 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-01 A-66
IN-VEHICLE REPAIR
Oil Pump(21 714 0)
Special Tool(s)
Removal
1. Remove the timing belt.
For additional information, refer to Timing
Belt in this section.
2. Remove the crankshaft timing belt pulley.
3. Detach the air conditioning (AIC) compressor
from the cylinder block and position
it to one
side.
4. Remove the oil pan.
For additional information, refer to Oil Pan
in this section.
5. Detach the oil pick-up tube from the oil pump
and remove the oil pump (engine shown
removed for clarity).
Discard the gaskets.
Remove and discard the crankshaft front oil
seal.
Installation
1. N0TE:lnstall a new oil pump gasket.
Install the oil pump (engine shown removed
for clarity).
2. N0TE:lnstall a new oil pump intake pipe
gasket.
2006.0 Fiesta 1212006 GI 83742en
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
303-01 A-67 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-67
IN-VEHICLE REPAIR
Attach the oil pick-up tube to the oil pump 6. Install the crankshaft timing belt pulley.
(engine shown removed for clarity).
7. Install the timing belt.
3. N0TE:lnstall a new crankshaft front oil seal.
For additional information, refer to Timing
Using the special tool, install the crankshaft Belt
in this section.
front oil seal.
4. Install the oil pan.
For additional information, refer to Oil Pan
in this section.
5. Attach the air conditioning (AIC) compressor
to the cylinder block.
2006.0 Fiesta 1212006 GI 83742en
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303-01 B-I Engine -- 2.OL Duratec-HE (M14) 303-01 B-1
SECTION 303-01 B Engine . 2.OL Duratec-HE (M14)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
.............................................. Specifications
Engine Data
........................................................................\
............................................
Engine Oil ........................................................................\
...............................................
........................................................................\
............................................... Oil system
Engine Oil Capacity
........................................................................\
................................
Valve Dimensions ........................................................................\
...................................
Camshaft Dimensions ........................................................................\
.............................
Crankshaft Dimensions ........................................................................\
...........................
Piston Dimensions ........................................................................\
..................................
Cylinder Head ........................................................................\
.........................................
Cylinder Block ........................................................................\
.........................................
PAGE
DESCRIPTION AND OPERATION
Engine ........................................................................\
......................................................... 303-01 8-8
DIAGNOSIS AND TESTING
Engine ........................................................................\
.........................................................
GENERAL PROCEDURES
........................................................................\
....................... Valve Clearance Adjustment
IN-VEHICLE REPAIR
Intake Manifold ........................................................................\
................. (21 183 0)
Crankshaft Front Seal ........................................................................\
............. (21 467 0)
Crankshaft Pulley ........................................................................\
................... (21 5720)
Valve Seals ........................................................................\
....................... (21 238 0)
Valves ........................................................................\
................................. (21 2154)
Camshafts ........................................................................\
.......................... (21 284 0)
Oil Pan ........................................................................\
................................. (21 154 0)
Oil Pump ........................................................................\
.............................. (21 714 0)
Crankshaft Rear Seal ........................................................................\
.......... (21 468 4)
Engine Front Cover ........................................................................\
............. (21 148 0)
Exhaust Manifold ........................................................................\
........................................
Timing Chain ........................................................................\
........................ (21 314 0)
Cylinder Head ........................................................................\
....................... (21 163 0)
REMOVAL
Engine ........................................................................\
.........................................................
DISASSEMBLY
Engine ........................................................................\
................................ (21 134 8)
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303-01 B-7 Engine - 2.OL Duratec-HE (M14) 303-01 B-7,
SPECIFICATIONS
2006.0 Fiesta 1212006 G451278en
Description
Wiring harness retaining bracket nuts
Starter motor retaining bolts
Air conditioning
(AIC) compressor retaining bolts
Engine rear mount retaining nut
Engine front mount studs to front cover
Engine front mount retaining bolts
Engine front mount retaining nuts
Strut and spring assembly top mount retaining nuts
Spark plugs
a) Refer to the procedure in this section.
Nm
20
35
20 90 12
48
11 5
25 12
I b-fi
15
26 15
66 9
35
85 18 9
Ib-in
-
-
-
-
-
-
-
-
-
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303-01 B-15 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 5
DIAGNOSIS AND TESTING
I : ,. REFER to Section 303-00 [Engine System -
General Information].
2006.0 Fiesta 1212006 G37449en
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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.
--
2006.0 Fiesta 1212006 G323910en
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303-01 B-68 Engine - 2.OL Duratec-HE (M14) 303-01 B-68
IN-VEHICLE REPAIR
2. Install the timing chain guides.
3m ACAUTION:D~ not tighten the camshaft
sprocket retaining bolts at this stage. Make
sure the camshaft sprockets rotate on the
camshafts.
Install the camshaft sprockets.
Install the timing chain.
4. Tension the timing chain.
Apply pressure to the timing chain and
remove the securing pin.
5. N0TE:Hold the camshafts by the hexagon
with an open ended wrench to stop them
from rotating.
Tighten the camshaft sprocket retaining
bolts.
6. Install the engine front cover.
For additional information, refer to Engine
Front Cover
- in this section.
2006.0 Fiesta 1212006 G323910en
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Engine Cooling - I .3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llm4L
303-03A-1 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-I
i
SECTION 303-03A Engine Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................\
....................................... 303-03A-2
DESCRIPTION AND OPERATION
Engine Cooling - 1.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) ......................... 303-03A-4
Overview..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-4
Components..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-5
DIAGNOSIS AND TESTING
Engine Cooling ........................................................................\
........................................... 303-03A-8
Inspection and Verification
........................................................................\
...................... 303-03A-8
j Symptom Chart ........................................................................\
........................................... 303-03A-8
Component Tests..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-4 6
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding - I .3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V (Sigma)/l.GL
Duratec-1 6V (Sigma). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 122 0) 303-03A-19
Draining
........................................................................\
...................................................... 303-03A-19
Filling and Bleeding
........................................................................\
.............................. 303-03A-19
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-1 6V (Sigma). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 404 0) 303-03A-21
Thermostat
- 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma) ........................................................................\
........... . (24 454 0) 303-03A-24
Radiator
........................................................................\
.................................. (24 254 0) 303-03A-26
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-8 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-8
DIAGNOSIS AND TESTING
Engine Cooling
Special Tool(~)
Pressure Tester,
Cooling
System
303-396 (24-001 A)
General
Equipment
I Worldwide Diagnostic System (WDS) I
Visual Inspection Chart i,
I Mechanical I Electrical I
- Coolant leak(s)
- Coolant level
- Air in system
- Gasketslseals
- Hose(s)lhose joints
- Coolant expansion
tank cap and
seal
- Coolant expansion
tank
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt
- Fuse(s)
- Relay(s)
- Wiring harness
- Electrical
connector(s)
- Cooling fan motor
- Engine coolant
temperature (ECT)
sensor
- Cylinder head
temperature (CHT) sensor
- Powertrain control
module (PCM)
3.
If an obvious cause for an observed or reported Inspection and Verification concern is found, correct the cause (if possible)
before proceeding to the next step.
1. Verify the customer concern.
4.
If the cause is not visually evident, verify the ( 2. Visually inspect for obvious signs of mechanical
symptom and refer to the Symptom Chart.
or
electrical damage.
Symptom Chart
Symptom Chart
Svm
ptom Possible Sources Action
Loss of
coolant INSPECT the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
Radiator. INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03 Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)1ln4L
Duratec-1 6V (Sigma)ll .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-9
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 Gl46258en
Water pump.
Thermostat housing. INSPECT
the water pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
water pump or water pump
gasket as necessary.
REFER to: Water Pump
- I .3L
Duratec-8V
(Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma),
Removal and Installation)
I Water Pump - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Removal and
Installation).
INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing or
thermostat housing gasket as
necessary.
REFER to: Thermostat
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- I .3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V (Sigma)ll.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Removal and
Installation).
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