cam FORD FIESTA 2007 Owner's Manual

303-00-5 Engine System - General Information 303-00-5
DIAGNOSIS AND TESTING
Symptom
Oil consumption
Possible Sources Action
Use of the wrong type of
engine oil.
Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation or
breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty
and engine oil can enter the
combustion chamber
through the intake manifold.
Turbocharger seals (diesel
engine only).
DETERMINE the last type of
engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
CHECK if the PCV system is
operating correctly and repair
as necessary. REFER to:
Engine Emission Control (303-
08 Engine Emission Control
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 2.OL Duratec-HE (M14),
Diagnosis and Testing),
Engine Emission Control
-
Vehicles With: Vacuum
Exhaust Gas Recirculation
(EGR) Valve (303-08 Engine
Emission Control
- 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 1.6L Duratorq-TDCi (DV)
Diesel, Description and
Operation).
INSTALL a new turbocharger.
REFER to:
Turbocharger (303-04 Fuel
Charging and Controls
-
Turbocharger - I .4L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation),
Turbocharger
- I .6L Duratorq-
TDCi (DV) Diesel (303-04
Fuel Charging and Controls
- Turbocharger - I .6L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation).
2006.0 Fiesta 1212006 GI 52554en
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303-00-6 Engine System - General Information 303-00-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Damaged gaskets or mating
surfaces.
- Cylinder head gasket is
damaged or mating face are
warped.
- Valve stem oil seals are
worn and engine oil can
enter the combustion
chamber between the valve
stem and the valve stem
guide.
Piston ring or cylinder liner
wear.
Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons
- Piston rings (clearance in
groove and end gap)
- Cylinder liners
CHECK the gaskets and
mating surfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine
block mating faces. INSTALL new valve
seals.REFER
to:
Valve Seals (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.3L Duratec-8V (Rocam), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
2.OL Duratec-HE (M14), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
CHECK the running surfaces
and clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
CHECK the pistons.
REFER to: Piston Inspection
(303-00 Engine System
-
General Information, General
Procedures).
CHECK the piston rings.
REFER to: (303-00 Engine
System
- General Information)
Piston Ring-to-Groove Clear- ance (General Procedures),
Piston Ring End Gap (General
Procedures).
2006.0 Fiesta 1212006 GI 52554en
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303-00-7 Engine System - General Information 303-00-7
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Coolant consumption Cooling system components.
Oil cooler.
CHECK the coooling system.
REFER to:
Engine
Cooling (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 2.OL Duratec-HE
(M14), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.4L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.6L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing).
INSTALL a new oil cooler.
Damaged gaskets or warped
mating faces. CHECK the cylinder head
gasket for damage. CHECK the
cylinder head for distortion. - -- - -
Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
- - - - - - - -
DETERMINE the damaged
engine
component(s) and
install new component(s) as
necessary.
Engine will not crank Battery or cables. CHECK the battery, bracket
and
cables.
REFER to: Battery (41 4-01
Battery, Mounting and
Cables, Diagnosis and
Testing).
Starter motor or cables. I CHECK the starting system.
REFER to: Starting System
(303-06 Starting System,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 52554en
I Engine cranks but will not start Fuel tank is empty. CHECK the fuel level.
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303-00-9 Engine System - General Information 303-00-9
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
lgnition system (petrol engines
only).
CHECK the ignition system.
REFER to:
Engine
lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine
lgnition (303-07 Engine
lgnition - 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
Incorrect valve timing. CHECK and adjust the valve
timing. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), I n-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Broken or damaged timing
beltltiming chain or
pulleylsprocket.
CHECK the timing beltltiming
chain and sprocketslpulleys.
INSTALL new components as
necessary. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
2006.0 Fiesta 12,2006 GI 52554en
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303-00-1 0 Engine System - General Information 303-00-1 0
DIAGNOSIS AND TESTING
Symptom
Very poor power output or fuel
consumption too high or engine
running rough
Possible Sources Action
Fuel system. CHECK the fuel system.
REFER to:
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Diagnosis and
I Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.3L Duratec-8V
(Rocam), Diagnosis and
Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- I .4L Duratorq-
TDCi (DV) Diesel, Diagnosis and Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.6L Duratorq-
TDCi (DV) Diesel, Diagnosis
and Testing).
Engine intake air system. CHECK the intake air system.
REFER to: lntake Air Distribu-
tion and Filtering
(303-12
lntake Air Distribution and
Filtering, Diagnosis and
Testing).
Exhaust system blocked. I CHECK the exhaust system.
REFER to: Exhaust System
(309-00 Exhaust System,
Description and Operation).
Engine management system.
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
Fault in ignition system (petrol
engines only). CHECK the ignition system.
REFER to:
Engine lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine lgnition (303-07 Engine
lgnition
- 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 I Engine System - General Information 303-00-1 I
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action --
Turbocharger (diesel engine
only).
CHECK the turbocharger.
REFER to:
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.6L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
Incorrect valve timing. Timing
beltltiming sprocket or
pulleylsprocket damaged. CHECK
and adjust the
valve
timing. REFER to:
Timing
Belt (303101 Engine -
I .25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Ignition timing incorrect (petrol
engines only).
CHECK the electronic engine
controls.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 2 Engine System - General Information 303-00-1 2
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Noisy running Engine auxiliary components
loose or damaged. CHECK
engine auxiliary
components for damage or
looseness. REFER to:
Timing Belt
(303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Timing Chain
(303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain
(303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing Belt
(303-01 Engine -
I .4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Noisy running, misfiring, back-
firing or knocking
Incorrect fuel DETERMINE which type of fuel
was last put in the tank (note
the country specific fuel
specifications).
Valve timing incorrect, timing
beltlchain or pulleylsprocket
damaged.
Water in fuel or fuel contamin-
ated.
CHECK and adjust the valve
timing. REFER to:
CHECK the fuel system for
water or other contamination.
Timing Belt
(303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
I n-vehicle Repair),
Crankshaft Pulley
(303-01
Engine - 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt
(303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
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303-00-1 3 Engine System - General Information 303-00-1 3
DIAGNOSIS AND TESTING
Symptom
Noisy running or valve train
noise
Possible Sources Action
Valve clearance too large due
to
faulty valve tappets or worn
valve train components.
Timing
belt or timing chain
damaged.
INSTALL new hydraulic lash
adjusters or adjust the valve
clearance. REFER to:
Valve Clearance Adjustment
(303-01 Engine
- 1.25L
Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
General Procedures),
Camshaft
Followers (303-01
Engine - 1.3L Duratec-8V
(Rocam), In-vehicle Repair),
Valve Clearance Adjustment
(303-01 Engine
- 2.OL
Duratec-H E (M 14), General
Procedures),
Hydraulic Lash Adjuster (303-
01 Engine
- I .4L Duratorq-
TDCi (DV) Diesel, In-vehicle
Repair),
Camshaft (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
INSTALL a new timing belt or
timing chain. REFER to:
Timing Belt (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel,
In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 4 Engine System - General Information 303-00-1 4
DIAGNOSIS AND TESTING
Symptom
Possible Sources
Action
Timing belt or timing chain
incorrectly tensioned.
CHECK the timing belt or
timing chain tension. INSTALL
a new timing belt or timing
chain as necessary. REFER to:
Timing Belt (303-01 Engine
-
I .25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing Belt
(303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Belt (303-01 Engine
-
I .6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Noisy running or engine noise
Engine components
- Pistons
- Piston rings
- Connecting rod big end,
main bearing or thrust
bearing journals
- Connecting rods bent or
damaged.
CHECK the engine compon-
ents for wear or damage. Make
sure all components are within
specification. INSTALL new
components as necessary.
Engine - Oil Leaks
NOTE: Before installing new gaskets or seals, make
sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet
(UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a
suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
A WARN1NG:Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five
minutes. 4.
Switch off the engine.
N0TE:lf no leak can be found, road test the vehicle
under various loads and check the engine for leaks
again.
5. Check the engine for oil leaks using a suitable
UV lamp.
'
6. Rectify any leaks found and check the engine
for oil leaks.
Measure the compression pressure
N0TE:The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
disconnected. This error message must be deleted
from the fault memory using WDS after completing
the compression test.
(' ,
'I N0TE:Valve clearance must be set correctly before
performing a compression test. Make sure the
engine is at the normal operating temperature.
2006.0 Fiesta 1212006 GI 52554en
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303-00-22 Engine System - General Information 303-00-22
DIAGNOSIS AND TESTING
11. Install the fuel pump relay.
I2 Install the air cleaner.
REFER to: Air Cleaner - 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-16V (Sigma)/l .6L
Duratec-I 6V (Sigma) (303-1 2 Intake Air
Distribution and
Filtering, Removal and
Installation).
13 Using worldwide diagnostic system (WDS), clear
the fault codes from the PCM.
Measure the compression ressure
(Engine
- 1 .3L Duratec-8V P Rocam)) N0TE:Twist the spark plug connectors slightly
1. Open the
central junction box (CJB) and remove
the
fuel pump relay.
before disconnecting them. Pull on the connector
and not on the
cable.
5. Disconnect the spark plug connectors.
N0TE:The engine will start, run for a few seconds
and then stop. 6. Remove the spark plugs.
2. Start the engine.
3. Remove the air
cleaner.
REFER to: Air Cleaner - 1.3L Duratec-8V
(Rocam) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
N0TE:Operate the starter motor with wide open
throttle until the reading on the compression tester
stops rising.
7. Carry out the measurement in accordance with
the instructions
supplied with the measuring
device on every
cylinder using a suitable
4. Disconnect the electronic ignition (El) coil compression pressure recorder
with the suitable (:
electrical connector from the El coil. adapter.
2006.0 Fiesta 1212006 GI 52554en
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