FORD FIESTA 2007 Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 Am1 35 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma)
303-01 A-1 35
INSTALLATION
4m AWARNING:S~~~~~~ the engine and 7. Install the starter motor.
transaxle assembly on wooden blocks and
secure
it with suitable securing straps.
Using the special tool and the engine hoist
position the engine and transaxle assembly
on the workshop table.
8. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
9. Position the engine and transaxle assembly
5. Install the transaxle right-hand retaining in
the engine compartment.
bolts.
Carefully lower the vehicle.
6. N0TE:lnstall new torque converter retaining
nuts.
Install the torque converter retaining nuts.
Rotate the torque converter to gain access
to the remaining studs. 10.
N0TE:lnstall new engine
front mount
retaining nuts.
N0TE:Do not tighten the engine front mount
retaining bolts and nuts at this stage.
Install the engine front mount.
11. N0TE:lnstall new engine rear mount center
retaining nut.
N0TE:Do not tighten the engine rear mount center
retaining nut at this stage.
2006.0 Fiesta iz12006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
303-01A-I36 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303=01A=136
INSTALLATION
Install the engine rear mount center retaining
nut. Attach
the right-hand halfshaft and the
intermediate shaft to the transaxle.
f
12. Install the engine support insulator. 14. CAUTIONS:
13. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than
18 degrees.
The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft seal.
N0TE:lnstall a new center bearing cap and
locknuts.
ASupport the halfshaft. The inner joint
must not be bent more than
18 degrees.
The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft seal.
A~ake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring. c
Attach the left-hand halfshaft to the
transaxle.
15. Attach the lower arm to the wheel knuckle
on both sides (right-hand side shown).
2006.0 Fiesta lu2006 G380459en
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Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-1 37
INSTALLATION
Install the heat shield. 2. Install the cooling fan motor and shroud to
the retaining brackets.
16. Using the special tool, connect the coolant
hose to the distribution pipe.
19. Connect the cooling fan motor and cooling
fan resistor electrical connectors.
17. Using the special tool, connect the coolant
hose to the radiator.
20. Using the special tool, attach the power
steering line to the power steering pump.
18. Install the cooling fan motor and shroud.
1. Push the cooling fan motor and shroud
upwards and then downwards to install.
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-1 38
INSTALLATION
21. Connect the power steering line to the 25. Connect the ignition switch to starter motor
steering pump.
solenoid and battery to starter motor
solenoid cables.
22. Attach the power steering line support
bracket to the engine block.
26. Connect the crankshaft position (CKP)
sensor electrical connector.
23. N0TE:lnstall new exhaust flange nuts and
a new exhaust flange gasket.
27. Connect the oil pressure switch electrical
Attach the exhaust flexible pipe to the connector.
catalytic converter.
24. Remove the exhaust flexible pipe support.
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 39 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I 39
INSTALLATION
Vehicles with air conditioning
28. Attach the air conditioning (AIC)
compressor to the cylinder block. 31.
Connect the air conditioning (AIC)
low-pressure cutoff switch electrical
connector.
29. Connect the
AIC high-pressure cutoff All vehicles
switch electrical connector. 32.
Install the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 1.4L Duratec-16V
(Sigma)ll.GL Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning
(303-05
Accessory Drive, Removal and
Installation)
I Accessory Drive Belt - 1.4L Duratec-1 6V
(Sigma)ll.GL Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning
(303-05 Accessory Drive, Removal and
Installation).
33. Lower the vehicle.
34. Tighten the engine front mount retaining
30. Connect the
AIC compressor clutch
nuts and bolts.
electrical connector.
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 40 Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) 303-01 A-1 40
INSTALLATION
35. Tighten the engine rear mount center
retaining nut. 38. Connect the power steering pressure (PSP)
switch electrical connector.
,/'
36. Connect the transmission fluid cooler line 39. Attach the selector lever cable retaining
to the transaxle.
bracket to the transaxle.
37. Connect the vehicle speed (VSS) sensor
40. Attach the selector lever cable to the
electrical connector. transaxle.
41. Adjust the selector lever cable.
For additional information, refer to: Selector
Lever Cable Adjustment (307-05
Automatic
Transmission/Transaxle
External Controls - Vehicles With:
4-Speed Automatic Transmission
(AW81-40), General Procedures).
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-1 41
INSTALLATION
42. Connect the transmission range (TR) 45. Connect the turbine shaft speed (TSS)
I sensor elecrtrical connector. sensor electrical connector.
43. Connect the transaxle wiring harness
46. Attach the ground cable to the transaxle.
electrical connector.
47. Install the engine wiring harness support
44. Connect the transaxle breather hose. brackets.
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-I42 Duratec-1 6V (Sigma)/l .6L Duratec-I 6V (Sigma)
INSTALLATION
48. Attach the engine ground cable to the
transaxle. 52.
Connect the generator electrical
connectors.
49. Connect the electronic ignition (El) coil
53. Connect the knock sensor
(KS) electrical
electrical connector. connector.
50. Connect the engine coolant temperature
54. Connect the EVAP electrical connector.
(ECT) electrical connector.
51. Install the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 43 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-01 A-I
43
INSTALLATION
55. Connect the engine wiring harness 58. Connect the catalyst monitor sensor
electrical connector. electrical connector.
i
56. Attach the power steering line to the power 59. Connect the heated oxygen (H02S) sensor
steering pump mounting bracket. electrical
connector.
57. Attach the power steering line support 60. Using the special tool, connect the coolant
bracket to the cylinder head. hose
to the coolant distribution housing.
2006.0 Fiesta 1212006 G380459en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 44 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-1 44
INSTALLATION
61. Using the special tool, connect the coolant
hose to the coolant distribution housing. 64. Attach the coolant expansion tank to the
bracket.
/
62. Attach the brake booster vacuum line to 65. Using the special tool, connect the degas
the intake manifold.
hose to the cylinder head.
63. Connect the low pressure evaporate 66. Attach the power steering fluid reservoir to
emission (EVAP) hose to the EVAP valve.
the bracket.
2006.0 Fiesta 12/2006 G380459en
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