warning light FORD FIESTA 2007 User Guide

Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
303-01A-I 9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-OIA-I 9
IN-VEHICLE REPAIR
Intake Manifold(21 183 0)
Removal 6. Remove the intake manifold lower retaining
bolt.
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 mixtures
are always present and may ignite. Failure
to follow these instructions may result in
personal injury.
1. Release the fuel system pressure. For
additional information, refer to
Section
31 0-00 [Fuel System - General
Information].
2. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and 7. Disconnect the engine wiring harness
Cables]. electrical connector.
3. Remove the air cleaner. For additional
information, refer to Section
303-1 2 [Intake
Air Distribution and Filtering].
4. Detach the power steering fluid reservoir
from the bracket and position
it to one side.
5. Remove the accessory drive belt. For
additional information, refer to
Section
303-05 [Accessory Drive].
8. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV.
2006.0 Fiesta 1212006 GI 83728en
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Engine - I .25L Duratec-1 6V (Sigma)llm4L
303-01 A-28 Duratec-1 6V (Sigma)llm6L Duratec-1 6V (Sigma) 303-01 A-28
IN-VEHICLE REPAIR
Valve Cover(21 141 0)
Materials 4. Remove the valve cover. (. ,
Name Specification
I Silicone grease IESE-MlC171-AA I
Removal
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 mixtures
are always present and may ignite. Failure
to follow these instructions may result
in
personal injury.
1. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and
Cables].
2. Remove the air cleaner. For additional
information, refer to Section
303-12 [Intake
Air Distribution and Filtering].
3. Disconnect the spark plug electrical
connectors and detach the wires from the
valve cover.
Installation
1. N0TE:Check the valve cover gasket for
damage and install a new valve cover gasket
if necessary.
N0TE:lnstall the stud bolts to positions 5 and 6.
Install the valve cover.
Tighten the bolts in the sequence shown in
three stages.
Stage 1: Tighten bolt 1 by 3 to 4 turns.
Stage 2: Tigthen bolts 1 through 13 to 3 Nm.
Stage 3: Tigthen bolts 1 through 13 to 9 Nm.
2m ACAUTION:~~~ a suitable blunt object to
avoid damage to the spark plug connector
gasket. Coat the inside of the spark plug
connector with silicone grease to depth of
5-10 mm.
- - --
2006.0 Fiesta 1212006 GI 83729en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-70 Duratec-I 6V (Sigma)lll6L Duratec-1 6V (Sigma) 303-01 A-70
REMOVAL
Engine
Special Tool(s)
I I Removerllnstaller, Hose
622
General Eaui~ment
Wrench, Hydraulic Line Union
!:!-269 ( 1 3-027)
I Engine hoist I
I Securing straps I
I Workshop table I
Removal
All vehicles
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 mixtures
are always present and may ignite. Failure
to follow these instructions may result in
personal injury.
1. Release the fuel system pressure.
For additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System
- General Information, General
Procedures).
2. Remove the air cleaner.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 1.4L
Duratorq-TDCi (DV) Diesel, General
Procedures).
3. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 1.4L
Duratorq-TDCi (DV) Diesel, General
Procedures).
4. Remove the front wheels and tires.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
5. Disconnect the powertrain control module

(PCM) electrical connector.
For additional information, refer to:
Powertrain Control Module (PCM)
- 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-1 4
Electronic Engine Controls, Removal and
Installation).
6. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
2006.0 Fiesta 1212006 GII 31 63en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-0 I Am82 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 Am82
REMOVAL
Lifting Bracket, Engine
303-1 22 (21 -068A)
Engine - Vehicles With: Automatic Transaxle
Special Tool(s) present and may ignite. Failure to follow (.
2. Remove the air cleaner.
622
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
I I 1 3. Drain the cooling system.
Wrench, Hydraulic Line Union
"-269 (13-027)
I I Remover/lnstaller, Hose I
these instructions may result in personal
injury.
1. Release the fuel system pressure.
For
additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System - General Information, General
Procedures).
General Eaui~ment
I Engine hoist I
I Securing straps I
I Workshop table I
All vehicles
WARNINGS:
A Refer to the Material Safety Data Sheets
for the Automatic Transmission
Fluid
E-AW. Failure to follow this instruction may
result in personal injury. Certain
Transmission and Power Steering fluids
supplied to Ford contain additives which
may cause skin irritation or other skin
reactions after contact.
For
additional information, refer to: Health
and Safety Precautions (1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
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 vapors are always
For additional information, refer to: Cooling
System Draining, Filling and Bleeding -
1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma)llm3L Duratec-8V (Rocam) (303-03A,
General Procedures). ,'
4. Remove the front wheels and tires. C'
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
5. Disconnect the powertrain control module
(PCM) electrical connector.
For
additional information, refer to:
Powertrain
Control Module (PCM) - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-14
Electronic Engine Controls, Removal and
Installation).
6. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
--
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 22 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-1 22
INSTALLATION
Engine
Special Tool(s) 2. Install the transaxle lower retaining bolts. \.,
622
I I Remover/lnstaller, Hose
Wrench,
Hydraulic Line Union
"-269 (I 3-027)
- --
21 068A
Clamp
303-397 (24-003)
ift tins racket, Engine
303-1 22 (2 1 -068A)
General Equipment
I Securing straps I
I Workshop table I
I Engine hoist I
Installation
All vehicles
A WARN1NG: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 present and may ignite. Failure
to follow these instructions may result in
personal injury.
I' ACAUTION:M~~~ sure that the two locating
dowels are installed.
Install the transaxle to the engine.
3m AWARNING:S~~~~~~ the engine and
transaxle assembly on wooden blocks and
secure
it with suitable securing straps.
Using the special tool and the engine hoist
position the engine and transaxle assembly
on the workshop table.
4. lnstall the transaxle right-hand retaining bolt.
2006.0 Fiesta 1212006 GII 3164en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 34 Duratec-1 6V (Sigma)ll .6L Duratec-I 6V (Sigma) 303-01 A-1 34
INSTALLATION
Engine - Vehicles With: Autom
Special Tool(s)
I I Remover/lnstaller, Hose (
General Eaui~ment
1 Straight edge I
I Securing straps I
atic Transaxle
2. Check the installation depth between the
transaxle flange and the torque converter c
centering spigot.
All vehicles N0TE:Make sure the torque converter centering
spigot engages in the flexplate and the transaxle
A WARNING:Do not smoke or carry lighted engages on the engine flange dowels.
tobacco or open flame of any type when
Install the transaxle to the engine.
working on or near any fuel related
components. Highly flammable vapors are 3. Install the transaxle lower retaining bolts.
always present and may ignite. Failure to I I
Workshop table
Engine hoist
follow these instructions may result in
personal injury.
'' &AUTION:T~~ torque converter must
remain at the correct installation depth
throughout the whole installation procedure.
N0TE:The torque converter hub must engage fully
in the oil pump drive gear.
Check the installation depth of the torque
converter.
*' &AUTION:M~~~ sure that the two locating
dowels are installed.
1. Lay a straight edge on the transaxle flange. I
2006.0 Fiesta 1212006 G380459en
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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-74 Engine - 2.OL Duratec-HE (M14) 303-01 B-74
REMOVAL
Engine
Special Tool(s)
I I Remover, Power Steering I
I I Removerllnstaller, Hose
General Equipment
I Workshop table I
I Engine hoist I
I Securing straps I
Removal
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
follow these instructions may result in
personal injury.
1. Remove the air cleaner. c.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (30312
Intake Air Distribution and Filtering,
Removal and Installation).
2. Remove the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and Installation).
3. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
4. Remove the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
5. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
6. 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).
7. Detach the exhaust flexible pipe from the
exhaust manifold.
For additional information, refer to: Exhaust
Flexible Pipe
- 2.OL Duratec-HE (M14)
(309-00 Exhaust System, Removal and
Installation).
2006.0 Fiesta 1212006 G451290en
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303-01 B-I11 Engine - 2.OL Duratec-HE (M14) 303-01 B-111
INSTALLATION
Engine
i Special Tool(s)
I
I Remover/lnstaller, Hose
General Equipment
I Workshop table 1
I Securing straps I
I Engine hoist I --
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
follow these instructions may result in
personal injury.
1. N0TE:Using suitable retaining straps, secure
the engine on the workshop table.
Support the engine with wooden blocks.
2. Install the transaxle.
3. Install the transaxle upper retaining bolts.
4. Install the transaxle left-hand retaining bolts.
5. Install the transaxle right-hand retaining
bolts.
2006.0 Fiesta 1212006 ~451291 en
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Engine Cooling - I .3L Duratec-8V
(Rocam)llm25L Duratec-1 6V (Sigma)ll.4L
303-03A-17 Duratec-1 6V (Sigma)/lm6L Duratec-1 6V (Sigma) 303-03A-17
DIAGNOSIS AND TESTING
RPM - engine speed
i DSRPM - desired engine speed
The IAT sensor output is useful if the engine being
tested is cold or after an over-night cold soak. The
ECT sensor or CHT sensor and the IAT sensor
should either indicate the same value or be within
1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as
it indicates the engine warm-up and opening
temperature for the thermostat. It will initially
indicate a slightly higher reading just before the
thermostat opens and then drops back before
settling to a near flat line output (see graphic
below).
Item Description
I A I Thermostat opens I
B Thermostat settles into a cyclic open and
I I closure pattern
A CAUTI0N:lf the ECT sensor output reaches
the
120°C default line under normal cooling
system pressure, internal damage may be
caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM.
The test should be stopped and the cause
located and corrected. If the cooling
system does not pressurize, the coolant
will boil at
100°C which may also damage
the engine. CARRY OUT the Coolant
Expansion Tank Cap Pressure Test
Component Test in this section.
If the WDS only allows the ECT sensor to be
displayed in volts, refer to the following table for
corresponding Celsius values:
Volts
OCelsius
The CHT sensor output is useful to examine the
cylinder head temperature rise during the warm-up
cycle and later during the normal light throttle cruise
test. This sensor output may vary between vehicles
with manual transmission and vehicles with
automatic transmission and should be used for
reference only.
Volts
0.78
0.60
0.46
0.35
0.27
The
LOAD display is used for reference as it is
necessary to maintain a stable load line during the
test. It is necessary to carry out the test under
normal light throttle cruise driving conditions and
average loads, typically
40% to 70% of the load
value.
OCelsius
80
90
100
11 0
120
The VSS output is used for reference but can help
to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed
which the PCM commands the engine to reach. If
the thermostat opens too early (before the correct
opening temperature has been reached), the
engine will not reach this value.
When using the WDS in data logger mode, the
signals recorded should remain within the
DEFAULT values set by the WDS.
3m AWARNING:M~~~ sure that the WDS is
placed in the vehicle so that it does not
interfere with the safe operation of the
vehicle. Do not place the WDS in the
deployment path of any air bag. Failure to
follow these instructions may result in personal injury.
N0TE:The road test is best carried out with the
aid of another technician in the vehicle to enable
the vehicle to be driven safely while the sensor
outputs are monitored within datalogger. If there
is only one technician available, the WDS can be
set up (using the
recordlcapture mode camera
icon) before leaving the workshop to record a
16
km (1 0 mile) test.
2006.0 Fiesta 1212006 GI 46258en
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