engine FORD FIESTA 2007 Workshop Manual

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-9
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 Gl46258en
Water pump.
Thermostat housing. INSPECT
the water pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
water pump or water pump
gasket as necessary.
REFER to: Water Pump
- I .3L
Duratec-8V
(Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma),
Removal and Installation)
I Water Pump - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Removal and
Installation).
INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing or
thermostat housing gasket as
necessary.
REFER to: Thermostat
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- I .3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V (Sigma)ll.4L Duratec-
16V (Sigma)/l .6L 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 .6L Duratec-1 6V
(Sigma), Removal and
Installation).
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
Coolant expansion tank cap or
seal.
Coolant expansion tank.
Heater core.
Engine. CHECK
the
coolant expansion
tank cap for tightness. If OK,
I
CARRY OUT the Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.
CHECK the heater core for
leaks.
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to:
Cylinder Head (303-
01 Engine
- I .25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l .6L Duratec-
16V (Sigma),
In-vehicle
Repair).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
303-03A-I I Duratec-1 6V (Sigma)/lI6L Duratec-I 6V (Sigma) 303-03A-1 I
DIAGNOSIS AND TESTING
Symptom
The engine overheats (signs of
coolant boiling)
Possible Sources Action
Cooling system does not hold
pressure.
Radiator. CARRY
OUT the Coolant
Expansion Tank Cap Test
Component Test in this section.
INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
INSPECT the water pump or
water pump gasket for damage.
INSTALL a new water pump or
water pump gasket as neces-
sary.
REFER to: Water Pump
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V
(Sigma)ll.4L Duratec-
16V
(Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Removal and
Installation).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine
- 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
1 6V
(Sigma)/l .6L Duratec-
16V (Sigma), In-vehicle
Repair).
INSPECT the radiator for
blockage or damage. 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)ll.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .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)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-I 2 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-12
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 Gl46258en
Air in system.
Coolant expansion tank cap or
seal.
Coolant expansion tank.
BLEED the cooling system.
REFER to:
Cooling System
Draining,
Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), General Proced-
u res)
.
CHECK the coolant expansion
tank cap for tightness. If OK,
CARRY OUT the
Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-I 3 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-03A-I 3
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 GI 46258en
Coolant levellcondition.
Coolant concentration.
Radiator grille. CHECK
the coolant level.
REFILL the cooling system as
necessary.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), General Proced-
u res).
CHECK the coolant condition.
If the coolant is in poor condi-
tion drain and refill with new
coolant.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l.6L Duratec-1 6V
(Sigma), General Proced-
u res).
REFER to: Specifications (303-
03 Engine Cooling
- 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-16V (Sigma),
Specifications).
INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
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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)llI25L Duratec-1 6V (Sigma)llI4L
303-03A-I 5 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-0344-15
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Cooling fan motor. CHECK the operation of the
cooling fan motor. REFER to
WDS.
Engine. INSPECT
the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l.GL Duratec-
16V (Sigma), In-vehicle
Repair).
, The engine does not reach
normal operating temperature. ECT sensor. 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, Diagnosis
and Testing).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat
- I .3L
Duratec-8V
(Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L
Duratec-16V (Sigma),
Removal and Installation)
I Thermostat - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)ll .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), Removal and
Installation).
2006.0 Fiesta 1212oo6 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-16 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-16
DIAGNOSIS AND TESTING
Component Tests
Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2.
Install the special tools to the coolant expansion
tank.
3. Pressurize the system to the
coolant expansion
tank cap
release pressure.
REFER to: Specifications (303-03 Engine
Cooling - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma),
Specifications).
4. Observe the
cooling system pressure tester
gauge reading for
approximately two minutes.
The pressure
should not drop during this time.
If the system holds pressure, proceed to step
6.
If the system does not hold pressure, check
it
thoroughly for coolant leaks.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and
fill and bleed the cooling system as
necessary.
REFER to:
Cooling System Draining, Filling and
Bleeding - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma) (303-03
Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma), General Procedures).
Clean the radiator thoroughly before leak testing
it, to prevent contamination of the water in the test
tank. Leak test the radiator in
clean water with 138(
kpa (20 psi) air pressure. Check it thoroughly for
air
leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03 Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L Duratec-I 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-I 6V (Sigma), Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the
coolant
expansion tank cap in water .
N0TE:lf the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result. l-
3. Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing, and note the highest pressure
reading obtained.
4.
Release pressure by turning the pressure relief
screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to
make sure the pressure test reading is
repeatable and within acceptable gauge reading
limits of the coolant expansion tank cap.
5.
If the pressure test gauge readings are not
within the
acceptable gauge reading limits,
INSTALL a new coolant expansion tank cap.
6. Recheck the system by repeating steps 3 and
4 at least twice.
Thermostat Test
Radiator Leak Test, Removed From Vehicle
A CAUTI0N:Radiator internal pressure must
not exceed
130 kpa (20 psi) or damage may
result.
1. Connect the WDS to the data link connector
(DLC).
2. Using the WDS
datalogger function, SELECT
the
following sensors (as applicable to the
application):
IAT - intake air temperature (IAT) sensor
ECT
- engine coolant temperature (ECT) sensort
CHT - cylinder head temperature (CHT) sensori
LOAD - engine load
VSS - vehicle speed sensor (VSS)
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - I .3L Duratec-8V
(Rocam)llm25L Duratec-1 6V (Sigma)ll.4L
303-03A-17 Duratec-1 6V (Sigma)/lm6L Duratec-1 6V (Sigma) 303-03A-17
DIAGNOSIS AND TESTING
RPM - engine speed
i DSRPM - desired engine speed
The IAT sensor output is useful if the engine being
tested is cold or after an over-night cold soak. The
ECT sensor or CHT sensor and the IAT sensor
should either indicate the same value or be within
1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as
it indicates the engine warm-up and opening
temperature for the thermostat. It will initially
indicate a slightly higher reading just before the
thermostat opens and then drops back before
settling to a near flat line output (see graphic
below).
Item Description
I A I Thermostat opens I
B Thermostat settles into a cyclic open and
I I closure pattern
A CAUTI0N:lf the ECT sensor output reaches
the
120°C default line under normal cooling
system pressure, internal damage may be
caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM.
The test should be stopped and the cause
located and corrected. If the cooling
system does not pressurize, the coolant
will boil at
100°C which may also damage
the engine. CARRY OUT the Coolant
Expansion Tank Cap Pressure Test
Component Test in this section.
If the WDS only allows the ECT sensor to be
displayed in volts, refer to the following table for
corresponding Celsius values:
Volts
OCelsius
The CHT sensor output is useful to examine the
cylinder head temperature rise during the warm-up
cycle and later during the normal light throttle cruise
test. This sensor output may vary between vehicles
with manual transmission and vehicles with
automatic transmission and should be used for
reference only.
Volts
0.78
0.60
0.46
0.35
0.27
The
LOAD display is used for reference as it is
necessary to maintain a stable load line during the
test. It is necessary to carry out the test under
normal light throttle cruise driving conditions and
average loads, typically
40% to 70% of the load
value.
OCelsius
80
90
100
11 0
120
The VSS output is used for reference but can help
to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed
which the PCM commands the engine to reach. If
the thermostat opens too early (before the correct
opening temperature has been reached), the
engine will not reach this value.
When using the WDS in data logger mode, the
signals recorded should remain within the
DEFAULT values set by the WDS.
3m AWARNING:M~~~ sure that the WDS is
placed in the vehicle so that it does not
interfere with the safe operation of the
vehicle. Do not place the WDS in the
deployment path of any air bag. Failure to
follow these instructions may result in personal injury.
N0TE:The road test is best carried out with the
aid of another technician in the vehicle to enable
the vehicle to be driven safely while the sensor
outputs are monitored within datalogger. If there
is only one technician available, the WDS can be
set up (using the
recordlcapture mode camera
icon) before leaving the workshop to record a
16
km (1 0 mile) test.
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll125L Duratec-1 6V (Sigma)ll14L
3-03A-18 Duratec-I 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-03A-18
DIAGNOSIS AND TESTING
N0TE:The results from the test are more thermostats may increase the coolant temperature
conclusive if the engine is cold when the test is up to 1
OO°C (212OF) under light engine load
started. conditions.
Carry out a road test. The
engine should start cleanly and the ECT value
REFER to:
RoadlRoller Testing (1 00-00 General
Information, Description and Operation).
4. Drive the vehicle at a constant throttle opening
and set speed until the ECT value settles into
a shallow rise and fall signal, close to a straight
line. This indicates that the thermostat is
functioning correctly.
N0TE:Some thermostats indicate the
temperature(s) in Celsius and Fahrenheit.
The graphic below shows the location and an
example of the opening temperature
(88OC) and
fully open temperature (1
02OC) of a thermostat. will
risequite quickly with smooth progression.
If
the ECT signal appears unstable or erratic, the
ECT sensor, electrical connector and wiring
harness to the PCM need to be visually inspected
for damage, chafing or water ingress.
The temperature should rise to approximately
90°C
for a thermostat that has an 88OC value. The signal
value will then fall as cooler coolant enters the
engine.
If the ECT value fails to maintain a constant value
and falls back to lower figures, typically between
60°C (140°F) and 70°C (1 50°F), the thermostat
and its sealing function within the thermostat
housing must be checked.
5. INSTALL a new thermostat.
REFER to: Thermostat
- 1.3L Duratec-8V
(Rocam) (303-03 Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L Duratec-I 6V
(Sigma)ll.4L Duratec-I 6V (Sigma)ll .6L
Duratec-1
6V (Sigma), Removal and
Installation)
I Thermostat - 1.25L Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-03 Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L Duratec-I 6V
The graphic below shows an alternative method (Sigma)/l.4L Duratec-1 6V (Sigma)ll .6L
used to show the opening temperature
(88OC) and Duratec-1 6V (Sigma), Removal
and
fully open temperature (1
12OC) of a thermostat. Installation).
6. Carry out another road test from step 1 using
the same criteria to confirm that the concern
has been rectified.
7. Using the WDS, clear the PCM keep alive
memory (KAM) or electrically erasable
programmable read only memory (EEPROM)
so that new drive values can be learnt.
Item Description
I A 1 Opening temperature I
I B I Fully open temperature I
NOTE:Generally, most thermostats maintain a
coolant temperature between
88OC (1 90°F) and
92OC (1 98OF) although dual stage electric
2006.0 Fiesta 1212006 GI 46258en
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