FORD FIESTA 2007 Workshop Manual

21 1-05-3 Steering Column Switches 21 1 -05-3
REMOVAL AND INSTALLATION
Depress the locking tangs.
Installation
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 GI 05656en
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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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303-00-2 Engine System - General Information 303-00-2
Exhaust Manifold Cleaning and Inspection ........................................................................\
303-00-52
Bearing Inspection
........................................................................\
..................................... 303-00- -2
Valve Seat Inspection ........................................................................\
................................. 303-00-( ;
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303-00-3 Engine System - General Information 303-00-3
DESCRIPTION AND OPERATION
Enaine
Engineltransmission combinations
Item Description
I 1 I 1.3L Duratec 8V engine I
1 2 1 1.411.6L Duratec 16V engine I
' 1 3 1 1.4L Duratorq TDCi turbodiesel engine I
1 4 1 iB5 manual transmission I
2006.0 Fiesta 1212006 GI 86750en
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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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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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303-00-8 Engine System - General Information 303-00-8
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 GI 52554en
Water
in fuel (diesel engine
only).
Fuel filter blocked.
Engine intake air system.
Glow plug faulty (diesel engine
only).
Engine management system.
. Drain the water from the fuel
system. Engine
- I .4L
Duratorq-TDCi (DV)
DiesellEngine - 1.6L Duratorq-
TDCi (DV) Diesel.
REFER to: Fuel System
- I .4L
Duratorq-TDCi (DV)
Diesel11 .6L Duratorq-TDCi
(DV) Diesel (31 0-00 Fuel
System
- General Informa-
tion, Diagnosis and Testing).
INSTALL a new fuel filter.
REFER to: (31 0-01 Fuel Tank
and Lines)
Fuel Filter
- 1.4L Duratorq-TDCi
(DV) Diesel (Removal and
Installation),
Fuel Filter
- I .6L Duratorq-TDCi
(DV) Diesel (Removal and Installation).
CHECK the intake air system.
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering, Diagnosis and
Testing).
. CHECK the glow plugs.
INSTALL new glow plugs as
necessary. REFER to:
Glow Plug (303-07 Glow Plug
System - 1.4L Duratorq-TDCi
(DV) Diesel, Removal and
Installation),
Glow Plugs (303-07 Glow Plug
System - 1.6L Duratorq-TDCi
(DV) Diesel, Removal and
Installation).
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic Engine Controls, Diagnosis
and Testing).
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