water pump FORD FIESTA 2007 User Guide

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-21 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-21
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 404 0)
Removal
Vehicles built up to 0412005
Loosen the water pump pulley retaining
bolts.
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove the air
cleaner.
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
3. Drain the cooling system.
6. Lower the vehicle. For additional information, refer to: Cooling
System Draining, Filling and Bleeding - 1.3~ 7. Disconnect the degas hose from the coolant
Duratec-8V (Rocam)ll.25L Duratec-1 6V expansion tank.
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) (303-03 Engine
Cooling - 1.3L DuratecdV (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma), General
Procedures).
4. Remove the crankshaft
pulley splash shield.
5m AWARNING:D~ not remove the water pump
pulley retaining bolts at this stage as the
pulley is under tension from the accessory
drive
belt. Failure to follow this instruction
may
result in personal injury. 8.
Detach the
coolant expansion tank and
secure
it to one side.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-22 Duratec-1 6V (Sigma)lIl6L Duratec-1 6V (Sigma) 303-03A-22
REMOVAL AND INSTALLATION
9. Remove the generator.
For
additional information, refer to:
Generator
- 1.25L Duratec-1 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V
(Sigma)
(414-02 Generator and Regulator,
Removal and Installation).
10. Remove the water pump pulley.
Discard the gasket.
Vehicles built 0412005 onwards
13. Remove the timing belt.
For additional information, refer to: Timing
Belt (303-01 Engine - 1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma), ln-vehicle Repair).
11. Remove the timing belt cover (cover shown 14. Drain the cooling system,
removed for clarity). For additional information, refer to: Cooling
12' &AUTION:P~~~~~~ the timing belt and
lower cover from contamination by the
coolant.
Remove the water pump. System
Draining,
Filling and Bleeding -
1.3L Duratec-8V (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V (,
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-03
Engine
Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), General Procedures).
15. Remove the water pump and the timing
belt
tensioner.
Discard the gasket.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-23 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-0349-23
REMOVAL AND INSTALLATION
16. Remove the timing belt tensioner from the
water pump.
Installation
1. N0TE:lnstall a new water pump gasket.
To install, reverse the removal procedure.
2006.0 Fiesta 1212006 GI 89080en
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303-03B-4 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-4
DESCRIPTION AND OPERATION
Components
Coolant Pump (.
Description The coolant pump is of a conventional design and
is driven by the water pump pulley and accessory
drive belt.
It is driven through a pulley by the accessory drive
belt.
The coolant pump gasket must not be reused.
2006.0 Fiesta 1212006 G421219en
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303-03B-14 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-14
DIAGNOSIS AND TESTING
4. Observe the cooling system pressure tester make sure the pressure test reading
is
gauge reading for approximately two minutes. repeatable
and within acceptable gauge reading
The pressure should not drop during this time. limits of
the coolant expansion tank cap.
( If the system holds Pressure, proceed to Step 5. If the pressure test gauge readings are not 7. If the system does not hold pressure, check
within the acceptable gauge reading limits,
it thoroughly for coolant leaks.
INSTALL a new coolant expansion tank cap.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
Thermostat Test
necessaw.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), General Procedures).
.Recheck the system by repeating Steps 3 and
4 at least twice.
Radiator Leak Test, Removed From Vehicle
CAUTI0N:Radiator internal pressure must
not exceed
130 kpa (20 psi) or damage may
result.
Clean the radiator thoroughly before leak testing
it, to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 138
kpa (20 psi) air pressure. Check it thoroughly for
air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant
-
expansion tank cap in water.
N0TE:lf the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
3. Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing, and note the highest pressure
reading obtained.
4. Release pressure by turning the pressure relief
screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to
I. Connect the WDS to the data link connector
(DLC).
2. Using the WDS datalogger function, SELECT
the following sensors (as applicable to the
application):
IAT
- intake air temperature (IAT) sensor
ECT
- engine coolant temperature (ECT) sensor
CHT
- cylinder head temperature (CHT) sensor
LOAD
- engine load
VSS
- vehicle speed sensor (VSS)
RPM
- engine speed
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 1'. .
) A 1 Thermostat opens I\
B Thermostat settles into a cyclic open and
I I closure pattern
2006.0 Fiesta 1212006 G426582en
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Fuel Charging and Controls - 2.OL
303-04B-5 Duratec-HE (M14) 303-04B-5
DIAGNOSIS AND TESTING
Fuel Charging and Controls
General Equipment
Wgnostic System (WDS) I
Principles of Operation
Ethanol equipped vehicles
Ethanol, is derived from cellulose waste. A large
proportion of Ethanol is distilled from corn, wheat
and sugar cane crops. The product that is to be
used in this vehicle is called Ethanol E85. E85 is
a mixture of 15% gasoline and 85% Ethanol.
Ethanol is a clear liquid and when fully burnt the
combustion gasses remaining are Carbon Dioxide
and water. This makes the use of Ethanol a good
environmental proposition. One drawback with pure
Ethanol is that it is corrosive to certain rubber and
plastic materials. The
introduction of Ethanol E85 has required some
major internal changes to the fuel supply and
delivery system. Some earlier vehicles used an
Ethanol mixture called Ethanol
El 5. This fuel was
made up of 15% Ethanol and 85% gasoline. At this
mixture ratio, no changes to the fuel charging or
delivery system where required, as no degradation
would occur with the cylinder head valves or
material content of the components, although some
performance loss would be noticeable.
The components used by vehicles running Ethanol
appear to be the same in construction as those
that use unleaded fuel only. The changes are
mainly to do with the materials used and increases
in fuel flow rates.
Ethanol has a much higher octane rating than
standard fuel which means that the ignition and
fuel injection calibrations for a vehicle that is
capable of using Ethanol E85 must be adapted
suitably.
I Item Description
I 1 I Fuel injectors
1ue1 rail I
2006.0 Fiesta 1212006 GI 65371 en
Item Description
3
4
Block heater
Fuel pump module
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303-05-1 8 Accessory Drive 303-05-1 8
REMOVAL AND INSTALLATION
Accessory Drive Belt - 1.4L Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma), Vehicles With: Air
Conditioning(21 567 0)
General Equipment 2. Using paint or typing correction fluid, mark
Knife the crankshaft pulley at the 6 o'clock
position.
i
Removal
A CAUTI0N:The accessory drive belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
I. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
2. Detach the power steering line and remove
the crankshaft pulley splash shield.
3. lnstall the installation tool (supplied in the
parts kit) to the crankshaft pulley at the
6
o'clock position. /'
3. Using a suitable knife, cut both accessory
drive belts and remove.
Installation 4. lnstall the accessory drive belt.
1. lnstall the belt around the generator pulley. NOTE: Install a new accessory drive belt and power 2. Install the belt around the air conditioning
steering pump belt. compressor pulley.
I. Wipe clean all of the pulleys to make sure 3. Install the belt around the water pump pulley.
that the accessory drive belt does not slip
during installation.
2006.0 Fiesta 1212006 GI 46274en
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303-05-21 Accessory Drive 303-05-21
REMOVAL AND INSTALLATION
Accessory Drive Belt - 1.4L Duratec-I 6V (Sigma)/l .6L
Duratec-1 6V (Sigma), Vehicles Without: Air
Conditioning(21 567 0)
General Equipment 2. Using paint or typing correction fluid, mark
Knife the crankshaft pulley at the 6 o'clock
position.
Removal
A CAUTI0N:The accessory drive belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
1. Raise and support the vehicle. For additional
information, refer to Section
I 00-02 [Jacking
and Lifting].
2. Detach the power steering line and remove
the crankshaft pulley splash shield.
3. lnstall the installation tool (supplied in the
parts kit) to the crankshaft pulley at the
6
o'clock position.
3. Using a suitable knife, cut the accessory
drive belt and remove.
Installation 4. lnstall the accessory drive belt.
NOTE:
lnstall a new accessory drive belt. 1. lnstall the belt around the generator pulley.
2. lnstall the belt around the power steering
1. Wipe clean all of the pulleys to make sure pump pulley.
that the accessory drive belt does not slip 3. Install the belt around the water pump pulley.
during installation.
2006.0 Fiesta 1212006 Gl49874en
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Manual Transmission/Transaxle and Clutch -
308-00-1 2 General Information 308-00-1 2
GENERAL PROCEDURES
Clutch System Bleeding(l6 843 0)
Special Tool(s) 6. Fill the reservoir of the special tool with (,, .
I Hand Vacuum approximately 100 ml of new brake fluid.
7. N0TE:Make sure that the special tool
reservoir is positioned lower than the bleed
nipple.
Install the special tool.
Super DOT 4 Brake
1 Fluid
I
Materials
Name Specification
ESD-M6C57-A
A WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid contacts the eyes,
flush the eyes for 15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
8. Using the special tool, bleed the clutch
water and induce vomiting. Get medical system.
attention immediately. Failure to follow
Pump approximately 80 ml of brake fluid into
these instructions may result in personal the clutch svstem. (
injury. w
9. Close the bleed nipple. A CAUTI0N:Y brake fluid is spilt on the
paintwork, the affected area must be 10.
Remove the special tool.
immediately washed down with cold water.
11. Lower the vehicle, if necessary.
N0TE:lf proprietary brake bleeding equipment is
available, this can be used to bleed the clutch
system, following the method below. The maximum
pressure must not exceed
1.5 bar.
N0TE:The clutch control system is self-venting.
The components are arranged in such a way that
small amounts of air trapped in the system are
removed automatically during clutch operation.
12. In order to remove any small amounts of
trapped air remaining in the system,
operate the clutch pedal several times
(maximum five times), using the full clutch
pedal travel.
13. Check the fluid level in the brake fluid
reservoir and top up to the MAX mark with
brake fluid if necessary.
1. Remove the air cleaner, if necessaryfor 14. Install the battery tray, if necessary.
additional information, refer to
Section
303-12 [Intake Air Distribution and 15.
Install the battery, if necessary. For
Filtering]. additional
information, refer to
Section 414-01 [Battery, Mounting and
2. Remove the battery, if necessary. For
Cablesl.
additional information, refer to
Section
414-01 [Battery, Mounting and . 16. Install the air cleaner, if necessary. For
Cables]. additional
information, refer to
Section 303-1
2 [Intake Air Distribution and - 3. Remove the battery tray, if necessary.
Filtering]. (' L 4. Drain the brake fluid reservoir.
17. Test the clutch control system for normal "I-
5. Raise and support the vehicle, if necessary. operation.
For additional information, refer to
Section 100-02 [Jacking and Lifting].
2006.0 Fiesta 1212006 GI 83752en
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