engine FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 03 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 03
DISASSEMBLY
43. Remove the oil pan retaining bolts. 46. Remove the oil pump.
Discard the gasket.
Discard the crankshaft front seal.
44m ACAUTION:~~ order to prevent damage
to the sealing surfaces, only use the
designated special tool to remove the oil
Vehicles with manual transaxle
PanmDonotuseachiselorscrewdriverfor 47. Removetheclutchdiscandpressureplate.
removal. For additional information, refer to: Clutch
N0TE:Tighten the lock nut against the oil pan and Disc and Pressure Plate (308-01 Clutch,
use several taps to release the oil pan from the Removal and Installation).
cylinder block. 48. Using the special tool, remove the flywheel.
Using the special tools, remove the oil pan.
Discard the bolts.
45. Remove the oil pump pickup pipe. Vehicles with automatic transaxle
Discard the gasket. 49. Using the special tool, remove the flexplate.
2006.0 Fiesta 1212006 GI 54224en
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Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 04
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I 04
DISASSEMBLY
All vehicles Remove the special tools.
50. Remove the crankshaft position (CKP)
sensor.
51. Remove the CKP sensor bracket.
52. Remove the crankshaft rear seal carrier.
Discard the crankshaft rear seal carrier.
53. Detach the cylinder block (short block) from
the mounting stand.
2006.0 Fiesta 1212006 GI 54224en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 05 Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma) 303-01 A-1 05
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Cylinder Head(21 165 6)
' Disassembly 5. Remove the fuel supply manifold.
I. Disconnect the temperature and manifold Discard the O-ring seals.
absolute pressure (T-MAP) sensor electrical
connector.
2. Disconnect the throttle plate control motor
(DC-ISC) electrical connector.
3. Disconnect the fuel injector electrical
connectors.
6. Remove the intake manifold.
Discard the gaskets.
7. Remove the engine rear lifting eye.
8. Remove the coolant distribution housing and
1 ~~~0001735 the ignition coil (El).
4. Remove the engine wiring harness.
2006.0 Fiesta 1212006 G202085en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 06 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-I 06
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Discard the gasket. Install the CMP sensor.
91 Remove the camshaft position (CMP) sensor. 3. NOTE: Install a new coolant distribution
Discard the O-ring seal. housing gasket.
Assembly
1. N0TE:A new cylinder head is supplied
without exhaust manifold studs.
Install the exhaust manifold studs if
necessary.
2. N0TE:lnstall a new camshaft position (CMP)
O-ring seal. Install
the coolant distribution housing and
the ignition coil (El).
4. Install the engine rear lifting eye.
5. N0TE:lnstall new intake manifold gaskets.
2006.0 Fiesta 1212006 G202085en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 07 Duratec-I 6V (Sigma)/l.GL Duratec-1 6V (Sigma)
303-01 A-I 07
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Install the intake manifold. 9. Connect the throttle plate control motor
(DC-ISC) electrical connector.
6. N0TE:lnstall new fuel supply manifold O-ring
seals.
10. Connect the temperature and manifold
Install the fuel supply manifold. absolute pressure (T-MAP)
sensor electrical
connector.
7. Install the engine wiring harness.
8. Connect the fuel injector electrical
connectors.
2006.0 Fiesta 1212006 G202085en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-OIA-1 08 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 08 --
ASSEMBLY
Special Tool(s)
I Universal Flange Holding
Wrench
205-072 (1 5-030A)
Lifting Bracket, Engine
303-1 22 (2 1 -068A)
21 068A
I 1 Alignment Plate, Camshaft I
21 540
Socket, Cylinder Head Bolt
Gauge,
Bolt Angle
303- 1 74 (2 1 -540)
I I Locking Tool, Flywheel I
Special Tool(s)
Installer, Crankshaft Seal
303-395 (21 -1 71 )
Mounting Stand
303-435 (2 1 -1 87)
Mounting Bracket for 303-435
303-435-06 (21 -031
B)
c
Mounting Plate for
2006.0 Fiesta 1212006 GI 54225en
..
ES21202
Socket, Spark Plug
303-499 (21 -202)
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
303-OIA-I 09 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01
A-I 09
ASSEMBLY
, , yl~ockin~ Tool, Timing Belt I
General Equipment
1%
I Five M8 x 20 mm studs I
I Engine hoist I
3031054
Install the crankshaft rear seal carrier.
Tensioner
303-1 054
Materials
Name Specification
3. Install the crankshaft position (CKP) sensor
I Engine Oil - 5W-30 I WSS-~2~91 3-8 bracket.
I Silicone Sealant I WSE-M4G323-A4 I
I Adhesive - Loctite 243 I WSK-M2G349-A7 I
Gasket Eliminator
Sealant
i All vehicles
High-Temperature
Grease
1. Attach the cylinder block (short block) to the
mounting stand.
ESD-M 1 C220-A
Install the special tools. 4. Install the CKP sensor.
2. N0TE:lnstall a new crankshaft rear seal Vehicles with manual transaxle carrier. 5. N0TE:lnstall new flywheel retaining bolts. N0TE:A new crankshaft rear seal carrier is
supplied with an alignment sleeve which must be Using the special tool, install the flywheel.
,removed following installation. I
'NOTE:DO not lubricate the seal lip.
Tighten the bolts in the sequence shown in
two stages.
Stage I: 30 Nm.
- --
2006.0 Fiesta 1212006 GI 54225en
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Engine - 1.25L Dura
303-01A-11 0 Duratec-16V (Sigma)ll.(
:ec-16V (Sigma)llm4L
L Duratec-16V (Sigma)
303-01 A-I 10
ASSEMBLY
Stage 2: 80 degrees. Stage 2: 80 degrees.
6. Install the clutch disc and pressure plate. 9. Remove the special tool from the flexplate.
For additional information, refer to: Clutch
Disc and Pressure Plate
(308-01 Clutch, All vehicles
Removal and Installation). 10. N0TE:lnstall a new oil pump gasket.
7. Remove the special tool from the flywheel.
Install the oil pump.
Vehicles with automatic transaxle
8. N0TE:lnstall new flexplate retaining bolts.
Using the special tool, install the flexplate.
Tighten the bolts in the sequence shown in
two stages.
Stage1:30Nm.
11. N0TE:lnstall a new pickup pipe gasket.
2006.0 Fiesta 1212006 GI 54225en
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303-01 A-I I1
Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I I1
ASSEMBLY
Install the oil pump pickup pipe.
12. Coat the crankshaft front seal lip with clean
engine oil.
13. N0TE:lnstall a new crankshaft front seal.
15. N0TE:Attach the oil pan within ten minutes
of applying sealant and tighten the bolts
within a further five minutes.
Apply a
3 to 4 mm diameter thick bead of
sealant to the oil pan flange.
rnrn ---34
1 + 1 !fl
f
ELE0013938 -
Using the special tool, install the crankshaft
front seal. 16. N0TE:Align the oil pan so that the cylinder
block is flush with the oil pan on the
14' ~CAUTION:T~~ crankcase may be
damaged
if sealant enters the blind holes.
Install five
M8 x 20 mm studs into the blind
holes as shown. flywheel
side.
Install the oil pan, loosely install the retaining
bolts.
Remove the studs and install retaining bolts.
Tighten the oil pan retaining bolts in the
sequence shown in two stages.
Stage I : 10 Nm.
Stage
2: 20 Nm.
17. N0TE:lnspect the oil pan drain plug seal
for damage. Install a new drain plug and
seal
if required.
2006.0 Fiesta i~12006 GI 54225en
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303-01 A-I 12
Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/lm6L Duratec-1 6V (Sigma)
ASSEMBLY
lnstall the drain plug.
lnstall the thermostat housing.
18. Install the positive crankcase ventilation 21. Install the oil pressure switch.
(PCV) cover.
Apply adhesive to the oil pressure switch
threads.
19' ~CAUTION:T~~ knock sensor (KS) cable
must not touch the cylinder head or the
PCV cover. Position the KS cable at
approximately the
10 o'clock position.
lnstall the KS.
20. N0TE:lnstall a new thermostat housing
gasket.
22' ACAUTION:D~ not damage the coolant
pump impeller.
N0TE:lnstall a new coolant pump gasket.
lnstall the coolant pump.
23, Turn the crankshaft to approximately 25
mm before top dead center (BTDC) on
cylinder number
I.
2006.0 Fiesta 1212006 GI 54225en
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