engine FORD FIESTA 2007 Workshop Manual

Engine Emission Control - 2.OL Duratec-HE
303-08B-10 (MI41 303-08B-10
REMOVAL AND INSTALLATION
Crankcase Vent Oil Separator
Removal
I. Remove the intake manifold. For additional Discard the gasket.
information, refer to Section 303-OIA
[Engine
-- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I 6V (Sigma)ll .6L Duratec-I 6V
(Sigma)] I 303-01 B [Engine -- 1.4L
Duratorq-TDCi (DV) Diesel] I 303-01 C [Engine
-- 1.3L Duratec-8V (Rocam)] I 303-01 D
[Engine
-- 2.OL Duratec-HE (M14)] 1 303-01 E
[Engine
-- 1.6L Duratorq-TDCi (DV) Diesel].
2. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV valve.
Installation
I. N0TE:lnstall a new crankcase vent oil
separator gasket.
To
install, reverse the removal procedure.
3. Remove the PCV
valve from the crankcase
vent
oil separator.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.
4. Remove the crankcase vent oil separator.
- - --
2006.0 Fiesta la2006 G37566en
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303-1 2-1 Intake Air Distribution and Filtering 303-1 2-1
SECTION 303-12 lntake Air Distribution and Filtering
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
Specifications..
. . . . . .. . .. . .. .. . . .. . . . . ....... . . . .. . . . . .. .. . . . . .. . . . . . . .. .. . . . . .. .. . . .. .... ...... .. .. .. . . . . .. . . ........ .. .. .. .. . . . . .
DESCRIPTION AND OPERATION
lntake Air Distribution and Filtering - 1.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma) ........................................................................\
.....................................................
lntake manifold ........................................................................\
...........................................
lntake Air Distribution and Filtering - 2.OL Duratec-HE (M14) ...........................................
2.OL Duratec HE (M14) engine ........................................................................\
....................
DIAGNOSIS AND TESTING
lntake Air Distribution and Filtering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Verification ........................................................................\
..........................
Symptom Chart.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
!. ' REMOVAL AND INSTALLATION
Air
Cleaner - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-I 6V (Sigma)/l .6L
Duratec-1
6V (Sigma) ........................................................................\
............ (23 174 0)
Air
Cleaner - 2.OL Duratec-HE (M14) ..................... .......................... .......... .................... ...
PAGE
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303-1 2-2 Intake Air Distribution and Filtering 303-1 2-2
SPECIFICATIONS
Toraue S~ecifications
1 1.4L Duratorq-TDCi (DV) diesel engine I I I I
Description
Air cleaner intake pipe retaining bolt
- vehicles with
Air cleaner retaining screws
- vehicles with 1.4L
Duratorq-TDCi (DV) diesel engine
Air cleaner outlet hose retaining clip
- vehicles with
1.6L Duratorq-TDCi (DV) diesel engine
Nm
4
Air cleaner intake pipe duct retaining bolts - vehicles
with
I .6L Duratorq-TDCi (DV) diesel engine
Charge air cooler hose retaining clamps
- 1.6L
Duratorq-TDCi (DV) diesel engine
I b-ft
-
Charge air cooler retaining bolts - 1.6L Duratorq-
TDCi (DV) diesel engine
I b-in
35
Radiator support bracket retaining bolts - 1.6L
Duratorq-TDCi (DV) diesel engine
2006.0 Fiesta 1212006 G148224en
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303-1 2-3 Intake Air Distribution and Filtering 303-1 2-3
DESCRIPTION AND OPERATION
lntake Air Distribution and Filtering - 1.4L Duratec-I 6V
I (Sigma)/l .6L Duratec-1 6V (Sigma)
lntake manifold
The 1.41 and 1.61 versions feature a revised intake
manifold. The overall length of the intake pipes has
been increased, but the pipes are of equal length
on all cylinders. This has resulted in increased
torque in the lower engine speed range and a
reduction in noise levels.
I 1 I Mounting for the throttle valve unit I
FIT-MAP sensor I
The mounting for the electronic throttle valve is
located inside the intake manifold between the
intake pipes of cylinders 1 and 2. The T-MAP
sensor, which is used on both the 1.41 and 1.61
versions, is situated next to the throttle valve unit.
2006.0 Fiesta 1212006 GI 79057en
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303-1 2-4 Intake Air Distribution and Filtering 303-1 2-4
DESCRIPTION AND OPERATION
lntake Air Distribution and Filtering - 2.OL Duratec-HE (M14)
(
2.OL Duratec HE (M14) engine
lntake manifold and ancillary components
Item Descri~tion
I 1 I Intake manifold I
1 2 1 lntake manifold tuning valve solenoid I
1 3 ( lntake manifold tuning valve I
141
lntake manifold tuning valve solenoid to
intake manifold vacuum pipe
Item Description
151
lntake manifold tuning valve solenoid to
intake manifold tuning valve vacuum pipe
1 6 1 lntake manifold tuning valve actuator I
1 7 1 Intake manifold tuning valve flaps I
2006.0 Fiesta 1212006 G421936en
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303-1 2-7 Intake Air Distribution and Filtering 303-1 2-7
DIAGNOSIS AND TESTING
Intake Air Distribution and Filtering
Inspection and Verification 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
1. Verify the customer concern. before proceeding
to the next step.
2. Visually inspect for obvious signs of mechanical 4. If the cause is not visually evident, verify the
or electrical damage. symptom and
refer to the Symptom Chart.
Visual
Ins~ection Chart
I Mechanical I Electrical I
- Air cleaner element
- Air cleaner intake
pipe
- Air cleaner outlet
pipe
- Charge air cooler
(Vehicles with
1.6L
Duratorq-TDCi (DV)
Diesel engine)
- Charge air cooler
intake hose
(Vehicles with
1.6L
Duratorq-TDCi (DV)
Diesel engine)
- Charge air cooler
outlet hose (Vehicles
with
I .6L Duratorq-
TDCi (DV) Diesel
engine)
- Mass air flow (MAF)
sensor
- Manifold absolute
pressure (MAP)
sensor (Vehicles with
1.6L Duratorq-TDCi
(DV) Diesel engine)
- Electrical
connector(s)
Symptom Chart
Symptom
Excessive intake air noise Possible Sources
Detached air cleaner
pipe(s).
Detached turbocharger pipe(s)
(Vehicles with Duratorq-TDCi
(DV) Diesel engine or
1.6L
Duratorq-TDCi (DV) Diesel
engine). Detached charge air cooler
hose(s) (Vehicles with 1.6L
Duratorq-TDCi (DV) Diesel
engine). Action
CHECK the
pipe(s) for security
and leaks to atmosphere.
INSTALL new intake air
components as necessary.
TEST the system for normal
operation.
2006.0 Fiesta 1212006 G421937en
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303-1 2-8 Intake Air Distribution and Filtering 303-1 2-8
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Oil in the air intake system Blocked or damaged positive
crankcase
ventilation (PCV)
valve.
Blocked or damaged PCV
pipe(s)/hose(s).
Blocked or damaged crankcase
vent
oil separator.
Vehicles with 1.25L Duratec-
16V
(Sigma)/l.3L Duratec-8V (
(Rocam)/l.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) engine.
REFER to: Crankcase Vent
Oil
Separator (303-08 Engine
Emission
Control - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L
Duratec-1
6V (Sigma),
Removal and Installation).
Vehicles with 2.0L Duratec-HE
(M14) engine.
REFER to: Crankcase Vent
Oil
Separator (303-08C Engine
Emission
Control - 2.OL
Duratec-HE (M14), Removal
and Installation).
Turbocharger (Vehicles with
Duratorq-TDCi (DV)
Diesel
engine or 1.6L Duratorq-TDCi
(DV)
Diesel engine).
Vehicles with 1.4L Duratorq-
TDCi (DV)
Diesel engine.
REFER to: Turbocharger (303- 04
Fuel Charging and
Controls - Turbocharger -
1.4L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
Vehicles with I .6L Duratorq-
TDCi (DV)
Diesel engine.
REFER to: Turbocharger
- I .6L
Duratorq-TDCi (DV)
Diesel
(303-04 Fuel Charging and
Controls - Turbocharger -
1.6L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
Water in the air cleaner Detached air cleaner intake
pipe. CHECK
the air cleaner intake
pipe for security. INSTALL new
intake air system components
as necessary. TEST the
system for
normal operation.
Blocked air cleaner drain. CLEAN
the air cleaner drain.
TEST the system for
normal
operation.
Engine lacks power
Air cleaner element blocked. INSPECT the air cleaner for ,.
new air cleaner element as
i signs of blockage. INSTALL a .
necessary. I_
2006.0 Fiesta 1212006 G421937en
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303-1 2-9 Intake Air Distribution and Filtering 303-1 2-9
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 G421937en
Charge air cooler pipe(s)
(Vehicles with 1.6L Duratorq-
TDCi (DV) Diesel engine).
Charge air cooler blocked
(Vehicles with
1.6L Duratorq-
TDCi (DV) Diesel engine).
INSPECT the charge air cooler
pipes for damage. INSTALL a
new charge air cooler
pipe(s)
as necessary.
INSPECT the charge air cooler
for blockage. INSTALL a new
charge air cooler as necessary.
REFER to: Charge Air Cooler
- 1.6L Duratorq-TDCi (DV)
Diesel (303-12 Intake Air
Distribution and Filtering,
Removal and Installation).
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303-1 2-1 0 Intake Air Distribution and Filtering 303-1 2-1 0
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
2006.0 Fiesta 1212006 G421937en
Fuel charging and controls Vehicles with 1.3L Duratec-8
(Rocam) engine.
REFER to:
Fuel Charging and
Controls (303-04 Fuel Char-
ging and
Controls - 1.3L
Duratec-8V (Rocam),
Diagnosis and Testing).
Vehicles with 1.25L Duratec-
16V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma) engine.
REFER to:
Fuel Charging and
Controls (303-04 Fuel Char-
ging and
Controls - 1.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I
6V (Sigma),
Diagnosis and Testing).
Vehicles with I .4L Duratorq-
TDCi (DV)
Diesel engine.
REFER to:
Fuel Charging and
Controls (303-04 Fuel Char-
ging and
Controls - 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
Vehicles with 2.OL Duratec-HE
(M14) engine.
REFER to:
Fuel Charging and
Controls (303-04 Fuel Char-
ging and
Controls - 2.OL
Duratec-H E (M14), Diagnosis
and Testing).
Vehicles with I .6L Duratorq-
TDCi (DV)
Diesel engine.
REFER to:
Fuel Charging and
Controls (303-04 Fuel Char-
ging and
Controls - 1.6L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
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303-1 2-1 1 Intake Air Distribution and Filtering 303-1 2-1 I
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Turbocharger (Vehicles
with
Duratorq-TDCi (DV) Diesel
engine or
1.6L Duratorq-TDCi
(DV) Diesel engine). Vehicles
with
1.4L Duratorq-
TDCi (DV) Diesel engine.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls
- Turbocharger -
1.4L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
Vehicles with
1.6L Duratorq-
TDCi (DV) Diesel engine.
REFER to: Turbocharger
- 1.6L
Duratorq-TDCi (DV) Diesel
(303-04 Fuel Charging and
Controls
- Turbocharger -
1.6L Duratorq-TDCi (DV)
Diesel, Removal and Installa-
tion).
2006.0 Fiesta 1212006 G421937en
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