accessory FORD FIESTA 2007 Owner's Guide

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-8 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-8
DIAGNOSIS AND TESTING
Engine Cooling
Special Tool(~)
Pressure Tester,
Cooling
System
303-396 (24-001 A)
General
Equipment
I Worldwide Diagnostic System (WDS) I
Visual Inspection Chart i,
I Mechanical I Electrical I
- Coolant leak(s)
- Coolant level
- Air in system
- Gasketslseals
- Hose(s)lhose joints
- Coolant expansion
tank cap and
seal
- Coolant expansion
tank
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt
- Fuse(s)
- Relay(s)
- Wiring harness
- Electrical
connector(s)
- Cooling fan motor
- Engine coolant
temperature (ECT)
sensor
- Cylinder head
temperature (CHT) sensor
- Powertrain control
module (PCM)
3.
If an obvious cause for an observed or reported Inspection and Verification concern is found, correct the cause (if possible)
before proceeding to the next step.
1. Verify the customer concern.
4.
If the cause is not visually evident, verify the ( 2. Visually inspect for obvious signs of mechanical
symptom and refer to the Symptom Chart.
or
electrical damage.
Symptom Chart
Symptom Chart
Svm
ptom Possible Sources Action
Loss of
coolant INSPECT the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
Radiator. INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03 Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)1ln4L
Duratec-1 6V (Sigma)ll .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llm4L
303-03A-I 4 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-03A-I 4
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
2006.0 Fiesta 1212006 GI 46258en
Water pump.
Thermostat.
Accessory drive belt
CARRY OUT the Pressure Te
Component Test in this section.
INSPECT the water pump for
leaks. INSTALL a new water
pump or water pump gasket as
necessary.
REFER to: Water Pump
- I .3L
Duratec-8V (Rocam) (303-03
Engine
Cooling - I .3L
Duratec-8V
(Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l.GL Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Removal and
Installation).
CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat
- 1.3L
Duratec-8V (Rocam) (303-03
Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l.GL
Duratec-1 6V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l.GL Duratec-
16V (Sigma) (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), Removal and
Installation).
CHECK the accessory drive
belt for correct operation.
,'
REFER to: Accessory Drive '
(303-05 Accessory Drive,
Diagnosis and Testing).
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-21 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-21
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 404 0)
Removal
Vehicles built up to 0412005
Loosen the water pump pulley retaining
bolts.
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove the air
cleaner.
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
3. Drain the cooling system.
6. Lower the vehicle. For additional information, refer to: Cooling
System Draining, Filling and Bleeding - 1.3~ 7. Disconnect the degas hose from the coolant
Duratec-8V (Rocam)ll.25L Duratec-1 6V expansion tank.
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) (303-03 Engine
Cooling - 1.3L DuratecdV (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma), General
Procedures).
4. Remove the crankshaft
pulley splash shield.
5m AWARNING:D~ not remove the water pump
pulley retaining bolts at this stage as the
pulley is under tension from the accessory
drive
belt. Failure to follow this instruction
may
result in personal injury. 8.
Detach the
coolant expansion tank and
secure
it to one side.
2006.0 Fiesta 1212006 GI 89080en
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303-03B-4 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-4
DESCRIPTION AND OPERATION
Components
Coolant Pump (.
Description The coolant pump is of a conventional design and
is driven by the water pump pulley and accessory
drive belt.
It is driven through a pulley by the accessory drive
belt.
The coolant pump gasket must not be reused.
2006.0 Fiesta 1212006 G421219en
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303-03B-7 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-7
DESCRIPTION AND OPERATION
Oil Cooler
Item Description
I I I Oil cooler I
1 2 1 Oil filter adaptor I
1 3 1 Oil filter I
The oil cooler is an oil to water type and is a full
flow system.
The oil cooler and oil filter are fitted to an adaptor
which is mounted on the cylinder block.
The coolant supply for the oil cooler is through the
thermostat by-pass hose.
Coolant Recovery System
A pressurized coolant expansion tank system is
used which continuously separates the air from the
cooling system and replenishes the system through
the coolant expansion tank outlet hose.
A continuous vent from the engine and radiator to
I the coolant expansion tank prevents air locks from
forming in the cooling system.
No manual bleed points are provided on the
system. The coolant expansion tank serves
as the location
for:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the coolant pressure
cap.
Coolant
A WARN1NG:Coolant contains monoethylene
glycol and other constituents which are
toxic if taken internally and can be
absorbed into the skin after prolonged
contact. Failure to follow this instruction
may result in personal injury.
Coolant concentration should be checked through
the neck of the expansion tank with a hydrometer.
The acceptable range of specific gravity (sg) of
correctly balanced fluids is between
1.06 and
1.07kg/l, which represents a coolant concentration
between 40% and 55%. If the concentration falls
below 40% there is insufficient low temperature
protection and the corrosion resistance will be
inadequate. In such cases the concentration must
be brought back to specification.
The coolant used is the orange-colored Motorcraft
Super Plus 2000. Motorcraft Super Plus 2000 is a
non silicated organic acid technology (OAT)
coolant, and must not be mixed with other coolant
types. For cooling system top up, only use coolant
which meets the correct specification and is
compatible with the existing coolant.
Changing Coolant
A WARN1NG:When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to
prevent the possibility of coolant scalding.
Failure to follow this instruction may result
in personal injury.
A CAUTI0N:When draining the coolant or
changing any cooling system components,
it is imperative that no coolant comes into
contact with the camshaft drive belt or
accessory drive belt. If necessary the belt
should be removed. Contamination of the
belt may result in premature belt failure.
N0TE:Providing the coolant has not been
contaminated with other fluids or foreign matter,
the robust corrosion resistance properties of this
2006.0 Fiesta 1212006 G421219en
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303-03B-9 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-9
DIAGNOSIS AND TESTING
.Engine Cooling
' . Special Tool(s)
Pressure Tester, Cooling
System
303-396 (24-001 A)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
( I or electrical damage. Visual
lns~ection Chart
I Mechanical I Electrical I
Coolant leak(s)
Coolant
level
Gasket(s) or seal(s)
Core plug(s)
Hose(s) or hose
joints
Coolant expansion
tank cap and seal
Coolant expansion
tank
Radiator
Coolant pump
Thermostat housing
Heater core
Accessory drive belt
Coolant outlet
connector
Fuse(s)
Relay(s)
Wiring harness
Electrical
connector(s)
Engine coolant
temperature (ECT) sensor
Cooling fan motor
Powertrain control
module (PCM)
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 Chart
Symptom
Loss of coolant Possible Sources
Action
Hose(s) or hose joint(s).
Radiator. INSPECT
the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling
- 2.OL
Duratec-H E (M 14), Removal
and Installation).
2006.0 Fiesta 1212006 G426582en
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Engine Cooling - 2.OL Duratec-HE (M14)
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
I Accessory drive belt. CHECK the condition of the
accessory drive belt.
REFER to: Accessory Drive
(303-05 Accessory Drive,
Diagnosis and Testing).
Cooling fan.
CHECK the operation of the
I cooling fan. REFER to WDS.
Engine. INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head
(303-
01 Engine - I .3L Duratec-8V
(Rocam), I n-vehicle Repair).
The engine does not reach
normal operating temperature. CHECK the ECT sensor.
I REFER to WDS.
Temperature gauge. CHECK the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (41 3-01 lnstrument
Cluster, Diagnosis and
Testing)
I lnstrument Cluster - Vehicles
Built From:
1012005 (41 3-01
lnstrument Cluster, Removal
and Installation).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
REFER to: Thermostat Housing (303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation).
Component Tests
Pressure Test
A WARNING:When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to
- prevent the possibility of coolant scalding.
Failure to follow this instruction may result
in personal injury.
N0TE:lf the coolant expansion tank cap is rotated
counterclockwise by 1 12 a full turn, the pressurized
coolant will be vented to the underside of the
coolant expansion tank cap.
1. Remove the coolant expansion tank cap.
2. Install the special tools 303-396 and 303-396-01
to the coolant expansion tank.
3. Pressurize the system to the coolant expansion
tank cap release pressure.
REFER to: Specifications (303-03 Engine
Cooling
- 2.OL Duratec-HE (M14),
Specifications).
2006.0 Fiesta 1212006 G426582en
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303-03B-19 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-19
REMOVAL AND INSTALLATION
Coolant Pump(24 404 0)
1. Drain the cooling system. 3.
Loosen the coolant pump pulley retaining bolts. - - - - - - -
For additional information, refer to: Cooling -
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 2.OL Duratec-HE
(M14), General Procedures).
2. Remove the crankshaft pulley splash shield.
4. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M 14) (303-05 Accessory Drive, Removal
and Installation).
5. Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G421227en
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303-05-1 Accessory Drive 303-05-1
SECTION 303-05 Accessory Drive
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
PAGE
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-2
DESCRIPTION AND OPERATION
Accessory Drive - 1.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) ....................... 303-05-3
Accessory Drive
- 2.OL Duratec-HE (M14) ........................................................................\
303-05-4
2.OL Duratec HE (M14) engine ........................................................................\
................... 303-05-4
DIAGNOSIS AND TESTING
Accessory Drive.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-5
Inspection and Verification
........................................................................\
.......................... 303-05-5
Accessory Drive Belt Concerns
........................................................................\
............ 303-05-5
Symptom Chart
.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-1 0
Component Tests..
.. .. .. .. .... .. ....... . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-1 6
REMOVAL AND INSTALLATION
Accessory Drive Belt - 1.4L Duratec-16V (Sigma)/l.GL Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning
..... . .. . . . . .. . . .. ........ .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 567 0) 303-05-1 8
Accessory Drive Belt - 1.4L Duratec-16V (Sigma)/l .6L Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 567 0) 303-05-2
1
Power Steering Pump Belt
- 1.4L Duratec-1 6V (Sigma)/l .6L Duratec-16V
(Sigma), Vehicles With: Air Conditioning
...... .. .. . . . . . . .. .. .. ...... . . . . . . . . . . . . . . . . . . . (21 567 0) 303-05-24
Accessory Drive Belt
- 2.OL Duratec-HE (M14) ...... . . . . . . . . . . . . .. .... .. ...... . .. . . . . . . (21 567 0) 303-05-26
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303-05-2 Accessory Drive 303-0512
SPECIFICATIONS
Torque Specifications - vehicles with 1.3L Duratec-8V (Rocam) engine
I retaining bolt I I I I
Description
Accessory drive belt tensioner
I Description I Nm I I b-ft I Ib-in I
Nm
25
Accessory drive belt idler pulley retaining bolt
Accessory drive bracket assembly
retaining bolts
Accessory drive belt tensioner retaining bolts l b-ft
18
Torque Specifications - vehicles with I .4L Duratorq-TDCi (DV)/I .6L Duratorq-TDCi (DV) Diesel
engine 25
30
Accessory drive belt tensioner
retaining bolts
Torque
Specifications
- vehicles with 2.OL Duratec-HE (M14) engine
2006.0 Fiesta 1212006 GI 46273en
I b-in
-
18
22
Description
-
-
Nm I b-ft Ib-in
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