oil FORD FIESTA 2007 Owner's Manual

205-04-9 Front Drive Halfshafts 205-04-9
REMOVAL AND INSTALLATION
6. Install the wheel and tire.
' For additional information, refer to: Wheel - and Tire (204-04 Wheels and Tires, Removal
and Installation).
7m CAUTION:^^^ a socket to tighten the
wheel hub retaining nut to prevent damage.
Tighten the wheel hub retaining nut.
8. Tighten the strut and spring assembly top
mount retaining nuts.
Vehicles with manual transaxle
9. With the vehicle on a level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
10. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill I (307-01 Automatic
Transmission/Transaxle - Vehicles With:
4-Speed Automatic Transmission
(AW81-40), General Procedures).
- - -- -
2006.0 Fiesta 1212006 GII 31 04en
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205-04-1 3 Front Drive Halfshafts 205-04-1 3
REMOVAL AND INSTALLATION
Intermediate Shaft
I
Materials
Name Specification
Removal
Manual transmission
1 fluid
A WARN1NG:Refer to the Material Safety Data
Sheets for the Automatic Transmission
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.
WSD-M2C200-C
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
I. Remove the right-hand halfshaft.
, For additional information, refer to: Front
i, Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
2. Remove the intermediate shaft center
bearing cap.
1. Remove and discard the locknuts.
2. Detach the heatshield from the bearing cap.
3. Remove and discard the center bearing cap.
3m ACAUTION:D~ not damage the halfshaft
oil seal.
N0TE:Plug the transaxle to prevent oil loss or dirt
ingress.
For additional information, refer to: Health and
Safety Precautions
(1 00-00 General Information,
Description and Operation).
See
- Transmission Fluids.
Remove the intermediate shaft.
Allow the oil to drain into a suitable container.
For additional information, refer to: Health
and Safety Precautions
(I 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Slide the heatshield off the intermediate
shaft.
Installation
All vehicles
I' ACAUTION:D~ not damage the halfshaft
oil seal.
Install the intermediate shaft.
Slide the heatshield onto the intermediate
shaft.
2006.0 Fiesta 1212006 GI 52541 en
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205-04-1 4 Front Drive Halfshafts 205-04-1 4
REMOVAL AND INSTALLATION
2. N0TE:lnstall a new intermediate shaft center
bearing cap and locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heatshield to the bearing cap.
3. Install the locknuts.
3. Install the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
Vehicles with manual transaxle
4. With the vehicle on the level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
5. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill
(307-01
Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
2006.0 Fiesta 1212006 GI 52541 en
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205-04-1 5 Front Drive Halfshafts 205-04-1 5
REMOVAL AND INSTALLATION
Inner Constant Velocity (CV) Joint Boot(l4 336 0)
Special Tool(s)
I I Clamping Tool, Boot I
Remover, BearingIGear
205-3 1 0 (1 5-09 1
A~se vise jaw protectors for all operations
in a vise.
N0TE:Secure the halfshaft in a vise.
Detach the inner CV joint housing from the
halfshaft.
1. Remove and discard the CV joint boot
retaining clamps.
2. Remove the CV joint housing and discard
the grease.
I I Installer, Extension Housing I
BushingIOil Seal
308-046 (1 6-0 1 6)
Materials
Name Specification
1 Grease I WSS-M 1 C259A1 I
4. Remove and discard the spider circlip.
Removal 5. Using the special tool, remove the spider.
I. Remove the right-hand halfshaft.
For additional information, refer to Halfshaft
RH in this section.
2. Remove the left-hand halfshaft.
For additional information, refer to Halfshaft
LH in this section.
3. CAUTIONS:
ADO not bent the inner constant velocity
(CV) joint more than
18 degrees and the outer
CV joint more than
45 degrees.
2006.0 Fiesta 1212006 GI 52548en
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211 -00-5 Steering System - General Information 211 -00-5
DIAGNOSIS AND TESTING
Steering System
/ Special Tool(s)
Alignment Pins, Subframe
205-524
Simulator, Driver and
passenger ~ir Bags and Side
Air Curtains 50
1 -073A
General Eaui~ment
I Worldwide Diagnostic System (WDS) I
Principles of Operation
The steering wheel rotational movement is
transferred to the steering gear through the steering
column shaft. The steering gear converts this
rotational movement, through the action of the rack
and pinion gear into lateral movement. This
movement in turn is transferred to the wheel
knuckles through the tie-rods and tie-rod ends.
Hydraulic fluid under pressure is supplied to the
steering gear by the power steering pump. As the
steering wheel is rotated, the hydraulic fluid is
allowed to pass through the steering gear valve to
one side of a double acting piston, dependent on
which direction the steering wheel is rotated. The
fluid moves the piston, which forms part of the
steering gear, giving power assistance to the effort
required to rotate the steering wheel.
Vehicles with petrol engines, due to the extra load
on the engine imposed by the power steering
pump, have a power steering pressure (PSP)
switch. The switch, which is normally closed, sends a signal
to the powertrain control module (PCM)
during low speed parking manoeuvres. The PCM
responds by maintaining the engine idle speed.
lnspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual lnspection Chart
I Mechanical I Electrical I
Tire pressure(s)
Accessory drive belt
Tie-rod ends
Tie-rod (s)
Steering gear housing
Front strut and
spring assemblies
Front suspension
lower arm ball joints
Front suspension
lower arm bushings
Pinch bolt on
steering column
shaft flexible coup-
ling Power
steering pres-
sure (PSP) switch
Wheels and tires
Power steering line
fluid leaks
Steering gear
bellows
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Possible Sources Action
Drift left or right
2006.0 Fiesta 1212006 Gl49906en
Vehicle attitude incorrect (front
or rear is high or low). CHECK for abnormal loading,
coil spring sag or non-standard
springs.
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211 -00-6 Steering System = General Information 21 1 =OO-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
lncorrect wheel alignment. CHECK the wheel alignment
and adjust if necessary.
REFER to: (204-00 Suspension
System
- General Information) r
Specifications (Specifications), Front Toe Adjustment (General
Procedures).
lncorrect front axle cross-
member alignment.
Using the special tool, CHECK
the front axle crossmember
alignment.
Damaged or worn front wheel
bearings. CHECK and INSTALL new
front wheel bearings as neces-
sary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
I CHECK the brake system. I
REFER to: Brake System (206-
00 Brake System
- General
Information, Diagnosis and
Testing).
CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
Wheels and tires. I CHECK the wheels and tires. I
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
Steering wheel 'off center Vehicle attitude incorrect (front
or rear is high or low). CHECK
for abnormal loading,
coil spring sag or non-standard
springs.
lncorrect wheel alignment. CHECK
the wheel alignment
and adjust if necessary.
REFER to: (204-00 Suspension
System
- General Information)
Specifications (Specifications),
Front Toe Adjustment (General
Procedures).
2006.0 Fiesta 1212006 GI 49906en
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303-00-1 Engine System = General Information 303-00-1
SECTION 303-00 Engine System . General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
DESCRIPTION AND
OPERATION
Engine
........................................................................\
......................................................... 303-00-3
Engineltransmission combinations ........................................................................\
........ 303-00-3
DIAGNOSIS AND TESTING
........................................................................\
.......................................................... Engine
. Engine Oil Leaks ........................................................................\
........................................
Ultraviolet (UV) Testing ........................................................................\
...............................
Measure the compression pressure ........................................................................\
...........
.............. Measure the compression pressure (Engine . 1.4L Duratorq-TDCi (DV) Diesel)
Measure the compression pressure (Engine
. 1.6L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine . 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V
........................................................................\
......... (Sigma)ll . 6L Duratec-I 6V (Sigma))
Measure the compression pressure (Engine
. 1.3L Duratec-8V (Rocam)) ........................
Measure the compression pressure (Engine . 2.OL Duratec-HE (M14)) .............................
. Measure the oil pressure (Engine 1.4L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.6L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
........................................................................\
......... (Sigma)/l . 6L Duratec-1 6V (Sigma))
. Measure the oil pressure (Engine 1.3L Duratec-8V (Rocam)) .........................................
. Measure the oil pressure (Engine 2.OL Duratec-HE (M14)) ...............................................
Valve train analysis . static (engine off) ........................................................................\
......
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
........................................................................\
..........
Camshaft Bearing Journal Clearance ........................................................................\
.........
Camshaft End Play ........................................................................\
.....................................
Camshaft Surface Inspection ........................................................................\
.....................
........................................................................\
...................................... Camshaft Lobe Lift
Crankshaft Main Bearing Journal Diameter
........................................................................\

Crankshaft End Play ........................................................................\
...................................
Cylinder Bore Taper ........................................................................\
....................................
Piston Inspection ........................................................................\
........................................
Piston Pin to Bore Diameter ........................................................................\
.......................
Piston Diameter ........................................................................\
..........................................
Piston Ring End .Gap ........................................................................\
...................................
............................................ ................................... Piston Ring-to-Groove Clearance ......
Piston Pin Diameter ........................................................................\
.....................................
Connecting Rod Large End Bore ........................................................................\
................
Valve Stem Diameter ........................................................................\
..................................
Flywheel Inspection ........................................................................\
....................................
............................................... Flywheel Inspection - Vehicles With: Dual Mass Flywheel
Cylinder Head Distortion ........................................................................\
.............................
Cylinder Block Distortion ........................................................................\
.............................
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303-004 Engine System - General Information 303-00-4
DIAGNOSIS AND TESTING
Engine
Special Tool(s)
Socket, Spark Plug
303-499
I Adhesive - Loctite 243 I WSK-M2G349A7 I
Materials
1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
k.
Name S~ecification
Leaks from oil carrying
components or basic engine.
E47332
&
21211
CHECK for cracks in oil
carrying components of the
basic engine by means of a
leak test. INSTALL new
components or seals as
necessary.
2006.0 Fiesta 1212006 GI 52554en
Compression Test Adapter
303-1 052
Pliers, Valve Stem Seal
303-508
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart Symptom Possible Sources Action
Visual
Inspection Chart
Loss of oil Mechanical
- Coolant
leaks
- Oil leaks
- Fuel system leaks
- Visibly damaged or
worn parts
- Loose or missing
nuts or bolts Electrical
- Fuse(s)
- Loose
or corroded
connector(s)
- Powertrain control
module
- Damaged or worn
switch(es)
Oil leaks on components that
are
eithei coated in oil them-
selves or on components local
to them.
Internal or external leak at the
oil cooler.
Leak at the crankshaft seal.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
CHECK for evidence of oil
leaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident, INSTALL
new gaskets or components as
required.
CHECK the coolant expansion
tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
INSTALL a new crankshaft
seal.
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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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