clock FORD FIESTA 2007 Owner's Guide

303-1 4-32 Electronic Engine Controls 303-1 4-32
REMOVAL AND INSTALLATION
Crankshaft Position (CKP) Sensor
General Equipment A~i~hten the M6 x 18 mm bolt finger-tight L,. '
2. Remove the splash shield
I ~olt, ~6 x 18 mm
CKP alignment tool
3. CAUTIONS: only.
Rotate the crankshaft pulley clockwise until
A0nly turn the crankshaft pulley in the
normal direction of rotation. the
crankshaft pulley timing bolt,
M6 x 18
I. Raise and support the vehicle.
mm can be installed through the crankshaft
For additional information, refer to: Lifting pulley
timing hole into the engine front cover.
(1 00-02, Description and Operation).
4. Remove the components in the order
indicated in the following
illustration(s) and
2006.0 Fiesta 1212006 ~423211 en
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308-02-8 Clutch Controls 308-02-8
REMOVAL AND INSTALLATION
Disconnect the clutch slave cylinder supply Rotate the clutch master cylinder and clutch
line from the clutch master cylinder and pedal assembly counterclockwise.
position it to one side.
Release the clutch slave cylinder supply line
retaining clip.
8. Remove the clutch master cylinder retaining
bolts.
10. Remove the clutch master cylinder.
1. Remove the clutch pedal return spring.
2. Detach the clutch master cylinder actuating
rod from the clutch pedal.
Installation
9. N0TE:Remove the clutch master cylinder
and the clutch pedal as an assembly.
All vehicles
Remove the clutch master cylinder and the 1. N0TE:Using suitable tape, secure the clutch
clutch pedal assembly.
pedal return spring in position.
Remove the pedal pivot shaft retaining nut Install the clutch master cylinder.
and remove the pivot shaft. I. Attach the clutch master cylinder actuating
rod to the clutch pedal.
2006.0 Fiesta 1212006 GI 52706en
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308-02-9 Clutch Controls 308-02-9
REMOVAL AND INSTALLATION
2. N0TE:lnstall the clutch master cylinder and
2. Install the clutch pedal return spring. Install the clutch slave cylinder supply line
the clutch pedal as an assembly: 5. Connect the clutch master cylinder supply
lnstall the clutch master cylinder and the hose
to the clutch master cylinder.
clutch pedal assembly.
Install the clutch master cylinder supply hose
I
Rotate the clutch master cylinder and the retaining
clip. I I
retaining clip. I I
clutch pedal assembly clockwise.
lnstall the pedal pivot shaft.
3. lnstall the clutch master cylinder retaining
bolts.
4. Connect the clutch slave cylinder supply line
to the clutch master cylinder.
6. Connect the clutch master cylinder supply
hose to the brake fluid reservoir.
2006.0 Fiesta 1212006 GI 52706en
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308-03125 Manual Transmission/Transaxle 308-03-25
REMOVAL
12. Disconnect the gearshift actuator electrical 1. Detach the gearshift cables and the selector
connector (colored grey). cable from the selector levers.
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket.
13. ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
All vehicles immediately washed down with cold water. 16. Remove the accessory drive belt cover.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
Vehicles without automated gearshift
14. Remove the gearshift cables cover.
I*' A~AuT10N:~rotect the ball joint seal
using a soft cloth to prevent damage.
Detach the lower arm from the wheel knuckle
15. Detach the gearshift cables from the on both
sides.
transaxle.
2006.0 Fiesta 1212006 GI 13290en
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308-03-32 Manual Transmission/'rransaxle 308-03-32
REMOVAL
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket. 17' ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
/
in failure. \.
Support the exhaust flexible pipe with a
suitable support wrap or suitable splint.
13. Remove the accessory drive belt cover.
14. Remove the engine support insulator.
15. Remove the left-hand halfshaft.
For additional information, refer to: Front
Halfshaft LH
(205-04 Front Drive
Halfshafts, Removal and Installation).
16. Remove the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH
(205-04 Front Drive
Halfshafts, Removal and Installation).
18. Lower the vehicle.
Igm ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
20.
Detach the exhaust flexible pipe from the
catalytic converter.
2006.0 Fiesta 1212006 G453416en
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308-03-54 Manual Transmission/Transaxle 308-0344
ASSEMBLY
3. Move the third and fourth gear shift forks to
the installation position.
8. N0TE:lnstall a rubber band to the second
selector shaft to aid assembly.
2. lnstall the snap ring.
10. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve upper
snap ring.
- lnstall the input shaft, the output shaft and
the selector forks. 1. Lift the guide sleeve.
2. lnstall the snap rina.
Insert the input shaft to a depth of I
approximately 50 mm and move it slightly to
one side.
Insert the output shaft to the level of the input
shaft and engage the gear wheels.
lnstall the input shaft and the output shaft.
9. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve lower
snap ring.
1. lnstall the guide sleeve.
11. Move the inner gearshift linkage to the fifth
gear.
Before pressing it downwards, turn the
selector shaft clockwise until it reaches the
reverse and fifth gear passage.
12. lnstall the 3.8 mm thick measuring shim
and secure
it with a punch mark.
2006.0 Fiesta 1212006 G23119en
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308-03-59 Manual Transmission/Transaxle 308-03-59
ASSEMBLY
35. N0TE:lnstall a new fifth gear synchronizer
assembly snap ring.
1 , N0TE:Use a new selector fork retaining pin.
lnstall the fifth gear synchronizer assembly
and the selector fork.
lnstall the retaining pin.
lnstall the snap ring.
36. Apply sealer evenly to the inside edge of
the fifth gear housing mating face.
37. lnstall the fifth gear housing cover.
38. lnstall the selector lever.
lnstall the bellows.
39. Engage the fifth gear.
Turn the selector shaft clockwise as far as
possible and push the shaft in.
40. N0TE:lnstall new halfshaft oil seals.
Using the special tools, install both halfshaft
oil seals (left-hand side shown).
2006.0 Fiesta 1212006 G23119en
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308-03-65 Manual Transmission/Transaxle 308-03-65
INSTALLATION
ADO not damage the halfshaft oil seal. 21. Install the engine support insulator.
/ / AMake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring.
Attach the left-hand halfshaft to the
transaxle.
20m ACAUTION:M~~~ sure that the heat shield
is installed to prevent damage to the ball
joint.
N0TE:The lower arm pinch bolt must be installed ' ' from the rear of the wheel knuckle.
22. Install the accessory drive belt cover.
Attach the lower arm to the wheel knuckle
on both sides.
Vehicles without automated gearshift
23. Attach the gearshift cables to the bracket
and turn the abutment sleeves
counterclockwise.
2006.0 Fiesta 1212006 GI 13293en
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308-03-72 Manual Transmission/Transaxle 308-03-72
INSTALLATION
20. Attach the gearshift cables to the bracket 23. Connect the reversing lamp switch
and turn the abutment sleeves electrical connector.
counterclockwise.
I I
24. Install the starter motor.
21. Attach the gearshift cables to the selector
levers.
22. Install the gearshift cables cover. 25.
Install the wiring harness retaining bracket. Attach the wiring harness to the retaining
bracket.
26. Lower the vehicle.
2006.0 Fiesta 1212006 G453417en
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Manual Transmission/Transaxle External
Controls
REMOVAL AND INSTALLATION
Gearshift Lever(l6 524 0)
Removal
I. Remove the gearshift lever trim panel.
Disconnect the cigar lighter electrical
connector.
2. Detach the gearshift cables from the
gearshift lever.
4. Remove the gearshift lever front retaining
bolts.
5. Remove the gearshift lever.
Remove the bolts.
Installation
1. To install, reverse the removal procedure. 3. Detach the gearshift cables from the
retaining bracket. 2. Adjust the gearshift cables. For additional
information, refer to Section
308-00 [Manual Turn the abutment sleeves clockwise. Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GI 86744en
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