distribution FORD FIESTA 2007 Repair Manual

303-1 2-5 Intake Air Distribution and Filtering 303-1 2-5
DESCRIPTION AND OPERATION
Air intake system
2006.0 Fiesta 12/2006 G421936en
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303-1 2-6 Intake Air Distribution and Filtering 303-1 2-6
DESCRIPTION AND OPERATION
I 1 I Air cleaner housing cover retaining bolts I
1 2 I Air cleaner housing outlet pipe resonator I
3 Air cleaner housing outlet pipe resonator
I I grommet -
4
5
intake pipe resonator retaining
bracket
Air
cleaner housing
Air cleaner pipe retaining clamps -
6
7
1 9 1 Air cleaner intake pipe resonator I
Air cleaner intake pipe
Air cleaner intake pipe resonator isolators
1 10 1 Air cleaner intake pipe duct I
I 11 1 Air cleaner intake pipe duct retaining bolts I
1 12 1 Air cleaner outlet pipe I
1 13 1 Air cleaner housing resonator I -
14
15
-- -
2006.0 Fiesta 1212006 G421936en
Positive crankcase ventilation (PCV) hose
PCV hose foam filter
16
17
--
Air cleaner element
Air cleaner housing cover
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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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303-1 2-1 2 Intake Air
Distribution and Filtering 303-1 2-1 2
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)
Removal Installation
I. Disconnect the air cleaner outlet pipe and 1. N0TE:Locate the rear isolators onto the rear
the positive crankcase ventilation (PCV) hose
mounting pegs and push down.
from the air cleaner.
To install, reverse the removal procedure.
2. Disconnect the air intake hose from the air
cleaner.
3. Remove the air cleaner.
Remove the retaining bolts and lift the air
cleaner
up at the rear to remove.
2006.0 Fiesta 1212006 G210049en
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303-1 2-1 3 Intake Air Distribution and Filtering 303-1 2-1 3
REMOVAL AND INSTALLATION
Air Cleaner - 2.OL Duratec-HE (M14)
I. Remove the components in the order
indicated in the following
illustration(s) and
ta
ble(s).
Removal Details
Item Description Item Description
Item 2 Air cleaner outlet pipe Ifem 5 Positive crankcase ventilation (PCV) hose
I
2
3
I. Detach the air cleaner outlet pipe from the
throttle body. 1. Detach the PCV hose from the air cleaner.
5
6
7
Air cleaner outlet pipe retaining clip
Air cleaner outlet pipe See Removal Detail
Air cleaner intake pipe retaining clip
' Item 4 Air cleaner intake pipe
Positive crankcase ventilation (PCV) hose
See Removal Detail
PCV hose connector
Air cleaner See Removal Detail
1. Detach the air cleaner intake pipe from the
air cleaner.
2. To install, reverse the removal procedure.
4
2006.0 Fiesta 1212006 G421938en
Air cleaner intake pipe
See Removal Detail
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303-1 2-1 4 Intake Air Distribution and Filtering 303-1 2-1.4
REMOVAL AND INSTALLATION
Ifem 7 Air cleaner
~CAUTION:M~~~ sure the air cleaner is
removed from the air cleaner mountings in
a vertical direction. Failure to follow this
instruction may cause damage to the air
cleaner and air cleaner mountings.
Detach the air cleaner from the air cleaner
mountings and
remov,e the air cleaner.
2006.0 Fiesta 12/2006 G421938en
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