gasket FORD FIESTA 2007 Repair Manual

303-01 B-I 05 Engine - 2.OL Duratec-HE (M14) 303-01 B-105 -- -
ASSEMBLY
57. Install the accessory drive belt idler pulley. Tighten the bolts in the sequence shown.
58. 1 nstall the accessory drive belt tensioner. 61 Install the evaporative emission (EVAP)
valve support bracket.
59. Apply a small bead of sealant to the areas
as shown.
62. Using the special tool, install the spark
plugs.
60. N0TE:lnstall a new valve cover gasket if
necessary.
Install the valve cover.
2006.0 Fiesta 1212006 G451310en
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303-01 B-I 06 Engine - 2.OL Duratec-HE (M14) 303-01 B-106
ASSEMBLY
63. Using the special tool, connect the spark 66. Connect the positive crankcase ventilation
plug electrical connectors.
(PCV) hose to the intake manifold.
{-
64. Install the power steering pump. 67. Install the intake manifold.
65. Using the special tool, install the coolant 68. Install the oil level indicator tube and oil
hoses. level indicator.
69. N0TE:lnstall a new exhaust manifold
gasket.
N0TE:Do not tighten the exhaust manifold
retaining nuts at this stage.
2006.0 Fiesta 1212006 G451310en
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Engine Cooling - I .3L DuratecdV
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
DESCRIPTION AND OPERATION
Components
Coolant pump
The coolant pump is secured to the engine block
at the timing gear end.
Item Description It is driven through a pulley b; the accessory drive
2006.0 Fiesta 1212006 GI 79022en
belt.
The gasket for the coolant pump must not be
reused. 1
2
I
Coolant pump
Coolant pump gasket
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Enaine Cooling - 1.3L Duratec-8V
(~ocah)ll.25L ~Cratec-1 6~ (Sigma)ll.4L
303-03A-7 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-03A-7
DESCRIPTION AND OPERATION
Water outlet housing
Coolant Temperature (ECT)
sensor
Item Description
The water outlet housing is located on the cylinder
head nearest the transmission.
1
2
Among other things, it is used to mount the
Electronic Ignition (El) coil.
Gasket
Water outlet housing
In addition, the ECT sensor is located in the
housing.
2006.0 Fiesta 1212006 GI 79022en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-8 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-8
DIAGNOSIS AND TESTING
Engine Cooling
Special Tool(~)
Pressure Tester,
Cooling
System
303-396 (24-001 A)
General
Equipment
I Worldwide Diagnostic System (WDS) I
Visual Inspection Chart i,
I Mechanical I Electrical I
- Coolant leak(s)
- Coolant level
- Air in system
- Gasketslseals
- Hose(s)lhose joints
- Coolant expansion
tank cap and
seal
- Coolant expansion
tank
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt
- Fuse(s)
- Relay(s)
- Wiring harness
- Electrical
connector(s)
- Cooling fan motor
- Engine coolant
temperature (ECT)
sensor
- Cylinder head
temperature (CHT) sensor
- Powertrain control
module (PCM)
3.
If an obvious cause for an observed or reported Inspection and Verification concern is found, correct the cause (if possible)
before proceeding to the next step.
1. Verify the customer concern.
4.
If the cause is not visually evident, verify the ( 2. Visually inspect for obvious signs of mechanical
symptom and refer to the Symptom Chart.
or
electrical damage.
Symptom Chart
Symptom Chart
Svm
ptom Possible Sources Action
Loss of
coolant INSPECT the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
Radiator. INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03 Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)1ln4L
Duratec-1 6V (Sigma)ll .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-9
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 Gl46258en
Water pump.
Thermostat housing. INSPECT
the water pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
water pump or water pump
gasket as necessary.
REFER to: Water Pump
- I .3L
Duratec-8V
(Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma),
Removal and Installation)
I Water Pump - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Removal and
Installation).
INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing or
thermostat housing gasket as
necessary.
REFER to: Thermostat
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- I .3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V (Sigma)ll.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Removal and
Installation).
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
Coolant expansion tank cap or
seal.
Coolant expansion tank.
Heater core.
Engine. CHECK
the
coolant expansion
tank cap for tightness. If OK,
I
CARRY OUT the Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.
CHECK the heater core for
leaks.
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to:
Cylinder Head (303-
01 Engine
- I .25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l .6L Duratec-
16V (Sigma),
In-vehicle
Repair).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
303-03A-I I Duratec-1 6V (Sigma)/lI6L Duratec-I 6V (Sigma) 303-03A-1 I
DIAGNOSIS AND TESTING
Symptom
The engine overheats (signs of
coolant boiling)
Possible Sources Action
Cooling system does not hold
pressure.
Radiator. CARRY
OUT the Coolant
Expansion Tank Cap Test
Component Test in this section.
INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
INSPECT the water pump or
water pump gasket for damage.
INSTALL a new water pump or
water pump gasket as neces-
sary.
REFER to: Water Pump
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V
(Sigma)ll.4L Duratec-
16V
(Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Removal and
Installation).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine
- 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
1 6V
(Sigma)/l .6L Duratec-
16V (Sigma), In-vehicle
Repair).
INSPECT the radiator for
blockage or damage. CARRY
OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llm4L
303-03A-I 4 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-03A-I 4
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
2006.0 Fiesta 1212006 GI 46258en
Water pump.
Thermostat.
Accessory drive belt
CARRY OUT the Pressure Te
Component Test in this section.
INSPECT the water pump for
leaks. INSTALL a new water
pump or water pump gasket as
necessary.
REFER to: Water Pump
- I .3L
Duratec-8V (Rocam) (303-03
Engine
Cooling - I .3L
Duratec-8V
(Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l.GL Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Removal and
Installation).
CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat
- 1.3L
Duratec-8V (Rocam) (303-03
Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l.GL
Duratec-1 6V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
16V
(Sigma)/l.GL Duratec-
16V (Sigma) (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), Removal and
Installation).
CHECK the accessory drive
belt for correct operation.
,'
REFER to: Accessory Drive '
(303-05 Accessory Drive,
Diagnosis and Testing).
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
303-03A-I 5 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-0344-15
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Cooling fan motor. CHECK the operation of the
cooling fan motor. REFER to
WDS.
Engine. INSPECT
the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l.GL Duratec-
16V (Sigma), In-vehicle
Repair).
, The engine does not reach
normal operating temperature. ECT sensor. CHECK the ECT sensor.
I REFER to WDS.
Temperature gauge. CHECK
the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (41 3-01 lnstrument
Cluster, Diagnosis and
Testing)
I lnstrument Cluster - Vehicles
Built From:
1012005 (41 3-01
lnstrument Cluster, Diagnosis
and Testing).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat
- I .3L
Duratec-8V
(Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L
Duratec-16V (Sigma),
Removal and Installation)
I Thermostat - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)ll .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), Removal and
Installation).
2006.0 Fiesta 1212oo6 GI 46258en
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