303-01 FORD FIESTA 2007 Repair Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-0 I Am82 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 Am82
REMOVAL
Lifting Bracket, Engine
303-1 22 (21 -068A)
Engine - Vehicles With: Automatic Transaxle
Special Tool(s) present and may ignite. Failure to follow (.
2. Remove the air cleaner.
622
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
I I 1 3. Drain the cooling system.
Wrench, Hydraulic Line Union
"-269 (13-027)
I I Remover/lnstaller, Hose I
these instructions may result in personal
injury.
1. Release the fuel system pressure.
For
additional information, refer to: Fuel
System Pressure Release (31 0-00 Fuel
System - General Information, General
Procedures).
General Eaui~ment
I Engine hoist I
I Securing straps I
I Workshop table I
All vehicles
WARNINGS:
A Refer to the Material Safety Data Sheets
for the Automatic Transmission
Fluid
E-AW. Failure to follow this instruction may
result in personal injury. Certain
Transmission and Power Steering fluids
supplied to Ford contain additives which
may cause skin irritation or other skin
reactions after contact.
For
additional information, refer to: Health
and Safety Precautions (1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any
fuel related components.
Highly flammable vapors are always
For additional information, refer to: Cooling
System Draining, Filling and Bleeding -
1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma)llm3L Duratec-8V (Rocam) (303-03A,
General Procedures). ,'
4. Remove the front wheels and tires. C'
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
5. Disconnect the powertrain control module
(PCM) electrical connector.
For
additional information, refer to:
Powertrain
Control Module (PCM) - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-14
Electronic Engine Controls, Removal and
Installation).
6. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
--
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-83 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-83
REMOVAL
7. Disconnect the fuel return line quick release 10. Detach the power steering fluid reservoir
coupling. from the
bracket and position
it to one side.
For additional information, refer to: Quick
Release Coupling
(31 0-00 Fuel System -
General Information, General Procedures).
8. Disconnect the fuel supply line quick release
coupling.
For additional information, refer to: Quick
Release Coupling
(310-00 Fuel System -
General Information, General Procedures).
9. Detach the fuel line and the degas line from
the intake manifold.
Remove the cable tie.
11. Using the special tool, disconnect the
degas hose from the cylinder head.
12. Detach the coolant expansion tank from
the bracket and position
it to one side.
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)lIl4L
303-01 A-86 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-86
REMOVAL
25. Disconnect the generator electrical
connectors. 29. Detach the engine ground cable from the
transaxle.
J
26. Remove the right-hand headlamp assembly.
30. Remove the engine wiring harness support
For additional information, refer to: brackets.
Headlamp Assembly
(41 7-01 Exterior
Lighting, Removal and Installation).
27. Disconnect the engine coolant temperature
(ECT) electrical connector.
28. Disconnect the electronic ignition (El) coil
electrical connector. 31.
Disconnect the turbine shaft speed (TSS)
sensor electrical connector.
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
303-01 Am88 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303101 A-88
REMOVAL
38. Disconnect the vehicle speed (VSS) sensor
40. Disconnect the oil pressure switch
electrical connector. electrical connector.
/
39. N0TE:Mark the position of the transmission
fluid cooler supply line and the
transmission fluid cooler return line.
Disconnect the transmission fluid cooler
lines from the transaxle.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Allow the fluid to drain into a suitable
container.
For additional information, refer to: Health and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
41. Raise and support the vehicle.
For additional information, refer to: Lifting
(1 00-02 Jacking and Lifting, Description
and Operation).
42. Disconnect the crankshaft position (CKP)
sensor electrical connector.
43. Disconnect the ignition switch to starter
motor solenoid and battery to starter motor
solenoid cables.
2006.0 Fiesta la2006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-89 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-01 A-89
REMOVAL
44m ACAUTION:~~~~ bending of the exhaust Vehicles with air conditioning
I flexible pipe may cause damage resulting 47.
Disconnect the air conditioning (NC)
, in failure. low-pressure cutoff switch electrical
Support the exhaust
flexible pipe with a connector.
suitable support
wrap or suitable splint.
48. Disconnect the NC compressor clutch
45. Detach the exhaust flexible pipe from the electrical connector.
catalytic converter.
Discard the nuts and the gasket.
46. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive
Belt - I .4L Duratec-I 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and
Installation)
I Accessory Drive Belt - I .4L Duratec-I 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
49. Disconnect the NC high-pressure cutoff
switch
electrical connector.
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 Am90 Duratec-I 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-01 A-90
REMOVAL
50. Detach the AIC compressor from the See - Transmission Fluids.
cylinder block and position it to one side.
All vehicles
53. Using the special tool, detach the power
steering line from the power steering pump.
51. Detach the power steering line support For
additional information, refer to: Health
bracket from the engine block. and
Safety Precautions (1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Allow the fluid to drain into a suitable
container.
52. Disconnect the power steering line from
the steering pump.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Allow the fluid to drain into a suitable
container.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation). For
additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
2006.0 Fiesta 1212006 G380458en
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Engine - I .25L Duratec-1 6V (Sigma)llI4L
303-01 Am92 Duratec-1 6V (Sigma)lll6L Duratec-1 6V (Sigma) 303-01 Am92
REMOVAL
Allow the fluid to drain into a suitable
container.
For additional information, refer to: Health
and Safety Precautions (1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Discard the snap ring.
60. 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.
See - Transmission Fluids.
1 61. Remove the engine support insulator.
N0TE:Plug the transaxle to prevent fluid loss or
dirt ingress.
62m ACAUTION:D~ not support the engine
For additional information, refer to: Health and directly on the oil pan.
Safety Precautions (1 00-00 General Information, N0TE:Using suitable securing straps, secure the
Description and Operation).
enaine and the transaxle on a workshop table. - See - Transmission Fluids. Using suitable wooden blocks, support the
Detach the right-hand halfshaft and the
engine and transaxle assembly.
intermediate shaft from the transaxle and
secure
it to one side.
Discard the center bearing cap and locknuts.
Allow the fluid to drain into a suitable
container.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
63. Remove the engine rear mount nut. ('- ;!
2006.0 Fiesta 1212006 G380458en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A199 Duratec-1 6V (Sigma)/Il6L Duratec-1 6V (Sigma) 303-01 A199
DISASSEMBLY
19. Using the special tool, remove the spark 23. Remove the timing belt lower cover.
plugs.
I i
Engines with eccentric cam timing belt
20. Set the crankshaft to approximately 20 tensioner
degrees before TDC. 24. Slacken the timing belt tensioner and
21. Using the special tool, lock the crankshaft. remove
the timing belt.
22. Remove the crankshaft pulley.
Discard the bolt.
Discard the timing belt.
25. Remove the timing belt tensioner.
Engines with slotted bracket timing belt
tensioner
26. Remove the timing belt tensioner and the
timing belt.
2006.0 Fiesta 1212006 G 1 54224en
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Engine - I .25L Duratec-1 6V (Sigma)ll.4L
303-01A-100 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-I 00
DISASSEMBLY
Discard the timing belt.
Vehicles built 0912003 onwards
27. Remove the timing belt.
Tension the timing belt tensioner by pulling
the timing belt and lock it with the special
tool.
Discard the timing belt. r-: 'Ii
Tension the timing belt tensioner by pulling 30. Remove the timing belt tensioner. the timing belt and lock it with the special
tool.
Discard the timing belt.
28. Remove the timing belt tensioner.
Vehicles built 0412005 onwards
29. Remove the timing belt.
All vehicles
31m &~~~l~~:lnstall a hose (order no.
E890438S) to the special tool studs, to
prevent damage to the camshaft sprockets.
Remove the camshaft pulleys.
Discard the retaining bolts.
2006.0 Fiesta 1212006 GI 54224en
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Engine - 1.25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)lI.GL Duratec-1 6V (Sigma) 303-01A-101
DISASSEMBLY
32. Remove the crankshaft timing belt pulley. 35. Disconnect the positive crankcase
ventilation (PCV) hose from the PCV cover.
33. Remove the timing belt rear cover.
34m ACAUTION: ~ee~ the camshaft bearing
caps and the camshafts in order for
installation.
36. Detach the oil level indicator and tube from
the intake manifold.
Detach the knock sensor (KS) electrical
connector from the oil level indicator tube.
Remove the camshafts. 37. Remove the intake manifold lower bolt.
Slacken each camshaft bearing cap retaining
bolt in the sequence shown by one turn until
the camshaft is released.
Remove the camshaft bearing caps.
Remove and discard the camshaft seals.
38.
CAUTIONS:
A~~ace the cylinder head on a suitable
soft surface.
A~emove the cylinder head bolts in the
sequence shown.
2006.0 Fiesta 1212006 G 1 54224en
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