303-01 FORD FIESTA 2007 Workshop Manual

303-01 B-62 Engine - 2.OL Duratec-HE (M14) 303-01 B-62
IN-VEHICLE REPAIR
Tighten bolts 20 to 22 to a torque of 48 Nm. 5. Install the coolant pump pulley.
4. Install the multi-groove belt idler pulley.
6. N0TE:lnstall new front engine mount nuts.
Install the front engine mount.
7, Install the coolant expansion tank.
8. Raise the vehicle.
2006.0 Fiesta 1212006 G451289en
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303-01 B-63 Engine - 2.OL Duratec-HE (M14) 303-01 B-63
IN-VEHICLE REPAIR
9. Connect the CKP sensor electrical
. connector.
10. Install the crankshaft belt pulley.
For additional information, refer to: Crankshaft Pulley (303-01 Engine
- 2.OL
Duratec-HE (M14), In-vehicle Repair).
2006.0 Fiesta 1212006 G451289en
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303-01 B-64 Engine - 2.OL Duratec-HE (M14) 303-01 B-64
IN-VEHICLE REPAIR
Exhaust Manifold
1. Remove the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (303-12
Intake Air Distribution and Filtering,
Removal and Installation). 2.
Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G451285en
Item Description Description
bolts 1
2
See Removal Detail
Exhaust manifold upper heat shield
Exhaust manifold lower heat shield
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303-01 B-65 Engine - 2.OL Duratec-HE (M14) 303-01 B-65
IN-VEHICLE REPAIR
151
Exhaust manifold
See Removal Detail
Item Description Item Description
Removal Details
See Installation Detail
1 6 ~xhaust manifold gasket
I See Installation Detail
1 3. To install, reverse the removal procedure.
Item 4 Exhaust manifold retaining nuts 4.
Remove the engine support insulator center
1. N0TE:Do not remove the exhaust manifold retaining
bolt.
outer retaining nuts at this stage.
Loosen the exhaust manifold outer retaining
nuts by two turns (engine shown removed
for clarity).
i 5. Remove the exhaust flexible pipe.
For additional information, refer to: Exhaust
Flexible Pipe
- 2.OL Duratec-HE (M14)
(309-00 Exhaust System, Removal and
2. Remove the exhaust manifold inner retaining Installation).
nuts (engine shown removed for clarity).
kern 5 Exhaust manifold
Discard the nuts. I. Remove the exhaust manifold outer retaining
nuts.
Discard the nuts.
3. Raise and support the vehicle. For additional
information, refer to: (1 00-02 Jacking and
Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
2006.0 Fiesta 1212006 G451285en
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303-01 B-66 Engine - 2.OL Duratec-HE (M14) 303-01 B-66
IN-VEHICLE REPAIR
l nstallation Details
Ifem 5 Exhaust manifold
Im ACAUTION:N~~~~ use jointing compound
forward of the exhaust manifold.
N0TE:Coat the exhaust manifold studs with
anti-seize grease.
N0TE:lnstall a new gasket and new nuts.
N0TE:Do not fully tighten the exhaust manifold
outer retaining nuts at this stage.
Loosely install the exhaust manifold outer
retaining nuts.
Item 4 Exhaust manifold retaining nuts
I. Install the exhaust flexible pipe.
For additional information, refer to: Exhaust
Flexible
Pipe - 2.OL Duratec-HE (M14)
(309-00 Exhaust System, Removal and
Installation).
2. Install the engine support insulator center
retaining bolt.
3. Lower the vehicle and fully tighten the
exhaust manifold retaining nuts.
2006.0 Fiesta 1212006 G451285en
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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.
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303-01 B-69 Engine - 2.OL Duratec-HE (M14) 303-01 B-69
IN-VEHICLE REPAIR
Cylinder Head(21 163 0)
Special Tool(s) 5. Remove the timing chain.
I Materials I
24003
I I Name Specification
Remover/lnstaller, Hose
Clamp
303-397
Removal
For additional information, refer to: Timing
Chain (303-01 Engine
- 2.OL Duratec-HE
(M14), Invehicle Repair).
6. Disconnect the exhaust gas recirculation
(EGR) valve electrical connector.
Hypoid Gear Oil
A WARNING:Do not smoke or carry lighted
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable vapors are
always present and may ignite. Failure to
7. Using the special tool, disconnect the
follow these instructions may result in coolant hose
from the EGR valve.
personal injury.
/
SQM-2C9002-AA
( I. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling
- 2.OL Duratec-HE
(M14), General Procedures).
2. Remove the exhaust manifold support
bracket retaining bolts.
3. Lower the vehicle.
4. Remove the intake manifold.
For additional information, refer to: Intake
Manifold (303-01 Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair).
8. Using the special tool, disconnect the
coolant hoses from the coolant outlet
connector.
2006.0 Fiesta 1212006 G451308en
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303-01 B-70 Engine - 2.OL Duratec-HE (M14) 303-01 B-70
IN-VEHICLE REPAIR
9. Disconnect the engine coolant temperature 12. Remove the exhaust manifold upper heat
(ECT) sensor electrical connector.
shield (engine shown removed for clarity).
('
10. Remove the power steering pump return 13. Remove the exhaust manifold lower heat
line support bracket.
shield (engine shown removed for clarity).
11. Remove the generator upper retaining bolt. 14. Remove the exhaust manifold retaining
nuts (engine shown removed for clarity).
Detach the exhaust manifold from the
cylinder head and position it to one side.
Discard the gasket and nuts.
15. CAUTIONS: c
n~ee~ the camshaft bearing caps and the
camshafts in order for installation.
2006.0 Fiesta 12/2006 G451308en
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303-01 B-71 Engine - 2.OL Duratec-HE (M14) 303-01 B-71
IN-VEHICLE REPAIR
n~emove the camshaft bearing caps in the Install the
cylinder head.
i sequence shown. Tighten the cylinder head bolts in the
' N0TE:Working in several stages, release each sequence
shown in five stages:
camshaft bearing cap retaining bolt two turns at a Stage I : 5 Nm.
time. Stage 2: 15 Nm.
Remove the camshafts.
~CAUTION:K~~~ the valve tappets in
order for installation.
Remove the valve tappets.
( ' 17' &AUTION:R~~~~~ the cylinder head ' bolts in the sequence shown.
Remove the cylinder head.
Discard the gasket.
Discard the bolts.
Installation
Stage3:45Nm.
Stage 4: 90 degrees.
Stage 5: 90 degrees.
3. Install the valve tappets.
4m &AUTION:W~~~~~~ in several stages,
evenly tighten the camshaft bearing cap
bolts in the sequence shown, one half turn
at a time.
Install the camshafts.
Coat the camshaft bearing caps with oil.
Tighten the bolts in the sequence shown in
two stages:
Stage I: 7 Nm.
Stage 2: 16 Nm.
I i
I. Check the cylinder head for distortion. I I
For additional information, refer to: Cylinder 5. N0TE:Only carry out the following step when
Head Distortion
(303-00 Engine System - a new cylinder head or new valves are
General Information, General Procedures). installed.
2. N0TE:lnstall a new cylinder head gasket and
bolts.
2006.0 Fiesta 1212006 G451308en
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