wheel FORD FIESTA 2007 Workshop Manual

303-01 B-83 Engine - 2.OL Duratec-HE (M14) 303-01 B-83
DISASSEMBLY
Engine(21 134 8)
/ 1
Special Tool(s)
Universal Flange Holding
Wrench
205-072 (1 5-030A)
Adapter for 205-072
205-072-02 (1 5-03OA-02)
Locking Tool, Flywheel
303-254 (2 1 -1 35)
Mounting Plate for
303-435-06
303-435-1
1A (21 -146D)
Socket, Spark Plug
303-499 (2 1 -202)
Pliers, Valve Stem Seal
303-508 (2 1-2 1 1 )
I I Removerllnstaller, Hose I Disassembly
1. Disconnect the generator electrical
connector.
Mounting Stand
303-435 (21 -1 87)
2006.0 Fiesta 1212006 G451309en
procarmanuals.com

303-01 B-93 Engine - 2.OL Duratec-HE (M14) 303-01 B-93
DISASSEMBLY
Discard the gasket. 59. Using
the special tool, lock the flywheel in
position.
56. Remove the crankcase vent oil separator.
60. Remove the flywheel.
Discard the bolts.
57.
Remove the oil filter adapter.
Discard the gasket.
61.
Remove the special tool.
62. Remove the oil pan.
58. Remove the clutch disc and pressure plate.
For additional information, refer to: Clutch
Disc and Pressure 'late (308-01 Clutch, 63. Remove the crankshaft rear seal carrier.
Removal and Installation).
2006.0 Fiesta 1212006 G451309en
procarmanuals.com

303-01 B-96 Engine - 2.OL Duratec-HE (M14) 303-01 B-96
ASSEMBLY
Tighten the bolts in the sequence shown. 7. N0TE:lnstall new flywheel bolts.
Install the flywheel.
Clean the mating faces of the cylinder block
I
and the oil pan with a suitable metal surface
cleaner.
8. Using the special tool, lock the flywheel in
position.
N0TE:lnstall the oil pan within 10 minutes
of applying the sealant and tighten the
retaining bolts within a further
5 minutes.
Apply a
3 mm bead of sealant to the oil pan.
9. Tighten the flywheel bolts.
Tighten the bolts in the sequence shown in
three stages.
5. Using a suitable straight edge, align the oil Stage 1: 50 Nm.
pan to the cylinder block mating face on the Stage 2: 80 Nm.
timing chain side. Stage 3: 11 2 Nm. I I
6. Tighten the oil pan retaining bolts.
Tighten the bolts in the sequence shown.
l I. -.
10. Remove the special tool.
2006.0 Fiesta 1212006 G451310en
procarmanuals.com

303-01 B-I 14 Engine - 2.OL Duratec-HE (M14) 303-01 B-114
INSTALLATION
20. CAUTIONS: 22m ACAUTION:M~~~ sure that the lower arm
ball joint heat shield is installed to prevent
A~he inner CV joint must not be bent damage
to the ball joint.
Remove the special tool before fully installing Tighten the center bearing cap retaining nuts.
more than 23 degrees. The outer CV joint
Install the lower arm ball joint heat shield.
must not be bent more than
45 degrees. I
the halfshaft.
A~ake sure the halfshaft seal is not
damaged.
I -
Using the special tool, attach the right-hand
halfshaft and intermediate shaft assembly
to the transaxle.
Remove the special tool before fully installing
the halfshaft.
21.
N0TE:lnstall a new intermediate shaft
center bearing cap and retaining nuts.
N0TE:Make sure that the intermediate shaft center
bearing is correctly positioned in the intermediate
shaft center bearing retaining bracket.
Install the intermediate shaft center bearing
cap.
Position the center bearing cap.
Position the intermediate shaft center bearing
heat shield (if equipped).
23m ACAUTION:T~~ lower arm pinch bolt must
be installed from the rear of the wheel
knuckle.
Attach the lower arm ball joint to the wheel
knuckle.
-- -
2006.0 Fiesta 1212006 ~451291 en
procarmanuals.com

303-06-3 Starting System 303-06-3
DESCRIPTION AND OPERATION
Starting System
Starting system
1 tern Description
I 1 I lgnitionlstarter switch I
1 2 1 Starter relay I
1 3 1 Electric starter motor I
1 4 1 Powertrain control module (PCM) I
1 5 1 Sensor,- crankshaft position ( CKP) I
The purpose of the starting system is to turn the
engine crankshaft at a speed which enables the
engine to start.
The engine is started as follows:
Ignitionlstarter switch in position
Ill.
The starter relay is activated by the PCM .
The solenoid is supplied with voltage.
The solenoid engages the starter motor pinion
with the flywheel ring gear.
The solenoid applies battery current to the
starter.
The starter turns the crankshaft until the engine
starts. The key can then be released and it
automatically returns to position
I I.
The system incorporates the "Smart
StartingWstrategy. This makes starting faster and
protects the starter.
If the driver fails to release the key immediately
after the engine starts, the PCM interrupts
activation of the starter relay and thus switches off
the electric starter motor.
The speed signal provided by the CKP sensor is
used for monitoring the starting procedure.
2006.0 Fiesta 1212006 GI 63308en
procarmanuals.com

303-06-5 Starting System 303-06-5
DIAGNOSIS AND TESTING
Symptom
The engine cranks slowly
Unusual starter noise
The starter spins but the engine
does not crank
Possible Sources Action
Relay.
Battery.
Starter motor.
Starter motor.
Flywheel ring gear.
Starter motor.
Flywheel ring gear.
CARRY OUT the relay
Component Test. REFER to
the wiring diagrams.
GO to Pinpoint Test B.
REFER to: Charging System
(414-00 Charging System
-
General Information,
Diagnosis and Testing).
CARRY OUT the starter motor
Component Test using WDS.
GO to Pinpoint Test C.
REMOVE the starter motor.
REFER to: (303-06 Starting
System)
Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-I 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) (Removal and
Installation),
Starter Motor - 1.4L Duratorq-
TDCi (DV)
Diesel (Removal
and Installation).
INSPECT the starter motor
gear for damage. INSTALL a
new starter motor as neces-
sary.
INSPECT the flywheel for
damage.
REMOVE the starter
motor.REFER to: (303-06
Starting System)
Starter Motor
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma) (Removal and
Installation),
Starter Motor - 1.4L Duratorq-
TDCi (DV)
Diesel (Removal
and Installation).
INSPECT the starter motor
gear for damage. INSTALL a
new starter motor as neces-
sary.
INSPECT the flywheel for
damage.
2006.0 Fiesta 1212006 Gl51301en
procarmanuals.com

Electronic Engine Controls
DIAGNOSIS AND TESTING
I PO304 I Cylinder No. 4 misfire detected I
/ I
KS implausible signal I
MIL Code
PO303
PO31 5
PO324
1 PO335 1 Crankshaft position (CKP) sensor implausible signal I
Description
Cylinder No. 3 misfire detected
Flywheel segment adaptation at the Limit
Knock sensor (KS) communication error or implausible signal
1 PO336 1 CKP sensor missing teeth I
1 PO336 1 CKP sensor loss of synchronization I
1 PO336 1 CKP sensor no signal I
I PO340 I Camshaft position (CMP) sensor no signal I
I PO341 I CMP sensor implausible signal I
I PO351 I Ignition coil A primary malfunction I
1 PO352 1 Ignition coil B primary malfunction I
I PO420 I Catalyst system efficiency below threshold I
1 PO444 1 Evaporative mission canister purge valve open circuit I
1 PO458 1 Evaporative mission canister purge valve low voltage I
I '1 PO459 1 Evaporative mission canister purge valve high voltage I
I PO460 I Fuel tank level malfunction from instrument cluster I
-3 I VSS signal too high I
PO500
PO500
Vehicle speed sensor (VSS) signal malfunction
Vehicle speed via CAN (VS CAN) implausible signal
PO51 1
PO560
I PO603 I Powertrain control module (PCM) error NVMY or EEPROM error 1
Idle air control (IAC) valve circuit malfunction
Battery system voltage malfunction high voltage
PO562
PO571
I PO604 I PCM error RAM error I
Battery system voltage malfunction open circuit
Brake switch plausibility error
PO605 I PCM error checksum error I
I PO610 I VID block checksum not correct or not programmed I
I PO617 I Starter relay malfunction I
I PO620 I Generator circuit malfunction I
1 PO628 1 Fuel pump primary circuit low voltage I
I
7 1 Fuel pump primary circuit high voltage I
2006.0 Fiesta 1212006 G384566en
PO625
PO626
Generator low voltage
Generator high voltage
procarmanuals.com

Automatic TransmissionlTransaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
A WARN1NG:Refer to the Material Safety
Data Sheets for the Automatic Transmis-
sion 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.
Automatic transmission fluid
Grease
Capacities
Specif icat
ions
WSS-M2C 924-A
WSD-MI C
230-A
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids. Automatic transmission fluid
(including cooler and tubes)
I Transaxle to engine flange retaining bolts I 47 I 35 I - I
Litres
5.75
Torque Specifications
I Engine ground cable to transaxle retaining nut I 25 I 18 I - I
I Torque converter retaining nuts I 27 I 20 I - I
lb-in Item
I Starter motor retaining bolts I 47 I 35 I - I
,I Engine and transaxle rear mount retaining bolt I 80 I 59 I - I
Nm
I Lower arm to the wheel knuckle I 48 I 35 I - I
I b-ft
I tie-rod end to the wheel knuckle I 48 I 35 I - I
I Exhaust flexible pipe to catalytic converter I 44 I 32 I - I
I Engine support insulator bolts I 48 I 35 I - I
IGnition switch to starter motor solenoid cable I 7 I - I 62 I
I Battery to starter motor solenoid cable I 12 I 9 I - I
-I indicator tube to transaxle retaining bolt I 25 I 18 I - I
I Selector lever cable bracket retaining bolts I 20 I 15 I - I - -
I Ground cable to transaxle retaining bolt
I Engine rear mount outer retaining nuts
I Engine rear mount center retaining nut I 90 I 66 I - I
I Battery tray retaining bolts I 25 I 18 I - I
I Strut and spring assembly top mount nuts I 25 I 18 I - I - -
Transaxle drain plug
Vehicle speed sensor (VSS) heat shield retaining
1 nut
Turbine
shaft speed (TSS) sensor retaining bolt
Vehicle speed sensor (VSS) retaining stud bolt
2006.0 Fiesta 1212006 G371496en
17
5
13 13 -
-
10
44
-
procarmanuals.com

Automatic Tr;
Vehicles Wil
307-01 -6 Transn
~nsmission/Transaxle -
:h: 4-Speed Automatic
~ission (AW81-40) --
DESCRIPTION AND OPERATION
Item Description
I 1 I I st - 3rd gear clutch 1
1 2 14th gear brake I
1 3 1 Reverse gear clutch I
1 4 )2nd - 4th gear brake I
1 5 1 Reverse gear brake I
1 6 1 3rdl4th gear clutch I
1 7 ITorque converter 1
1 8 1 Transmission input shaft I
1 9 I Fluid pump I - --
[ 10 1 Differential assembly I
~l~put wheel, planetary gearset I
11
1 13 1 Planetary gearset I
Intermediate gear stage
vlIlstgear one-way clutch I
1 15 1 2nd gear one-way clutch I
Torque converter with Torque
Converter Clutch (TCC)
Item Description
I 1 I Torque converter housing and impeller I
1 2 1 Turbine wheel 1
1 4 1 Transmission input shaft I
FlGwith roller-type one-way clutch (
The torque converter hydraulically transmits the
output torque from the engine to the input shaft of
the transmission.
The stator increases the torque up to the clutch
point (approx. 90
% speed difference between the
impeller and the turbine wheel).
In order to increase the efficiency of the automatic
transmission, the torque converter is also equipped
with a hydraulically activated TCC
The TCC is applied with slip to ensure soft
engagement.
i
When the TCC is engaged, the torque is '..
transmitted directly from the crankshaft via the
torque converter housing to the transmission input
shaft.
2006.0 Fiesta 1212006 ~380521 en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: $-Speed Automatic
Transmission
(AW81-40)
DESCRIPTION AND OPERATION
Overview of operation
Item Descri~tion
I 1 I I st - 3rd gear clutch I
1 2 12nd gear one-way clutch I
1 3 12nd - 4th gear brake I
1 4 1 1st gear one-way clutch
1 5 1 Reverse gear brake I
1 6 13rd14th gear clutch
Item Description
1 8 1 Output wheel, planetary gearset
I
1 7 1 From the torque converter
1 9 ( Intermediate gear stage I
I
1 10 1 Differential assembly I
I A I Planetary gearset, rear I
11
12
I B I Planetary gearset, front I
4th gear brake
Reverse gear clutch
2006.0 Fiesta 1212006 ~380521 en
procarmanuals.com