303-01 FORD FIESTA 2007 Workshop Manual

303-01 B-112 Engine - 2.OL Duratec-HE (M14) 303-01 B-112
INSTALLATION
6. Install the transaxle lower retaining bolts. 9. Position the workshop table under the
vehicle and carefully lower the vehicle until
,
the engine and transaxle assembly is in the(
correct position to install the engine mounts.
'.
7. lnstall the starter motor.
8. lnstall the wiring harness retaining bracket.
Attach the wiring harness to the retaining
bracket.
10. N0TE:Do not tighten the engine rear mount
retaining nuts at this stage.
lnstall the engine rear mount retaining nuts.
11. N0TE:lnstall new engine front mount
retaining nuts.
N0TE:Do not tighten the engine front mount
retaining nuts and bolts at this stage.
lnstall the engine front mount retaining nuts
and bolts.
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303-01 B-I 13 Engine - 2.OL Duratec-HE (M14) 303-01 B-113
INSTALLATION
12. Remove the securing straps. 17.
Attach the gearshift cables to the bracket
13. Raise and support the vehicle. For and
turn the abutment sleeves
( additional information, refer to: (I 00-02 counterclockwise.
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
14. Install the engine support insulator.
15. Attach the air conditioning (NC)
compressor to the cylinder block. 18.
Attach the gearshift cables to the selector
levers.
19. CAUTIONS:
A~he inner CV joint must not be bent
more than 23 degrees. The outer CV joint
must not be bent more than 45 degrees.
16. Connect the
NC high pressure switch n~ake sure that the halfshaft seal is not
electrical connector. damaged.
n~ake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring.
Using the special tool, attach the left-hand
halfshaft to the transaxle.
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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
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303-01 B-I 15 Engine - 2.OL Duratec-HE (M14) 303-01 B-115
INSTALLATION
24. Attach the powertrain control module (PCM)
28. Tighten the engine rear mount center
, support bracket to the side member. retaining nut.
25, Install the air cleaner resonator support 29. Tighten the engine front mount retaining
bracket. nuts and retaining bolts.
26. Lower the vehicle.
30. Connect the fuel supply line.
27. Tighten the engine rear mount outer
retaining nuts. For additional information,
refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
2006.0 Fiesta 1212006 ~451291 en
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303-01 B-I 16 Engine - 2.OL Duratec-HE (M14) 303-01 B-I
16
INSTALLATION
31. Attach the power steering pump to steering 34. N0TE:lnstall a new power steering pump
gear pressure line to the intake manifold. pulley.
f
32m &AUTION:C~~~ must be taken to prevent
dirt ingress. Using
the special tool, install the power

steering pump pulley.
-
Using the special tool, install a new O-ring 35. Install new power steering fluid reservoir
seal onto the power steering pump to O-ring
seals.
steering gear pressure line union.
1. Push the O-ring seal onto the special tool.
2. Locate the special tool onto the power
steering pump to steering gear pressure line
union and install the O-ring seal.
33. Attach the power steering pump to steering
gear pressure line from the power steering
Pump.
36. Install the power steering fluid reservoir.
2006.0 Fiesta 12/2006 G451291 en
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303-01 B-I17 Engine - 2.OL Duratec-HE (M14) 303-01 B-117
INSTALLATION
37. Using the special tool, connect the steering
Connect the clutch slave cylinder supply
gear to power steering fluid reservoir return
line.
I I line to the power steering fluid reservoir. Install the spring clip.
38.
Attach the steering gear to power steering 41. Connect the reversing lamp switch
fluid reservoir return line support bracket
electrical connector.
to the generator.
42. Lower the vehicle.
39. Connect the A/C low pressure switch
connector. 43. Install the coolant expansion tank.
40a &AUTION:I~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
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303-01 B-I 18 Engine - 2.OL Duratec-HE (M14) 303-01 B-118
INSTALLATION
44. Attach the power steering high-pressure 47.
Connect the catalyst monitor sensor
line retaining bracket to the transaxle. electrical
connector.
//
45. Install the engine wiring harness bracket. 48.
Connect the power steering pump switch
electrical connector.
46. Connect the engine wiring harness
electrical connector.
49. Install the battery tray support bracket.
2006.0 Fiesta 1212006 G451291 en
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303-01 B-1/19 Engine - 2.OL Duratec-HE (M14) 303-01 B-119
INSTALLATION
50. Connect the brake booster vacuum line to
53. Tighten the strut and spring assembly top
the intake manifold. mount nuts.
/
51. Attach the evaporative emission (EVAP)
valve from EVAP valve support bracket.
I. Connect the EVAP valve electrical connector.
2. Connect the low pressure line to the EVAP
valve.
3. Push the EVAP valve onto the support
bracket.
52. Using the special tool, connect the coolant
hose to the coolant outlet connector. 54.
Install the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
55. Attach the exhaust flexible pipe to the
exhaust manifold.
For additional information, refer to: Exhaust
Flexible Pipe
- 2.OL Duratec-HE (M14)
(309-00 Exhaust System, Removal and
Installation).
56. Install the cooling fan motor and shroud.
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303-01 8-1 20 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 20
INSTALLATION
57. Connect the cooling fan motor and cooling
fan resistor electrical connectors.
58. Install the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
59. Adjust the gearshift cables.
For additional information, refer to:
Gearshift Cable Adjustment (308-00
Manual
Transmission/Transaxle and
Clutch
- General Information, General
Procedures).
60. Bleed the hydraulic clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
61. Install the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and Installation).
62. Install the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (3031 2
Intake Air Distribution and Filtering,
Removal and Installation).
63. Fill and bleed 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).
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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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