FORD FIESTA 2007 Workshop Manual

303-01 B-69 Engine - 2.OL Duratec-HE (M14) 303-01 B-69
IN-VEHICLE REPAIR
Cylinder Head(21 163 0)
Special Tool(s) 5. Remove the timing chain.
I Materials I
24003
I I Name Specification
Remover/lnstaller, Hose
Clamp
303-397
Removal
For additional information, refer to: Timing
Chain (303-01 Engine
- 2.OL Duratec-HE
(M14), Invehicle Repair).
6. Disconnect the exhaust gas recirculation
(EGR) valve electrical connector.
Hypoid Gear Oil
A WARNING: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 present and may ignite. Failure to
7. Using the special tool, disconnect the
follow these instructions may result in coolant hose
from the EGR valve.
personal injury.
/
SQM-2C9002-AA
( I. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling
- 2.OL Duratec-HE
(M14), General Procedures).
2. Remove the exhaust manifold support
bracket retaining bolts.
3. Lower the vehicle.
4. Remove the intake manifold.
For additional information, refer to: Intake
Manifold (303-01 Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair).
8. Using the special tool, disconnect the
coolant hoses from the coolant outlet
connector.
2006.0 Fiesta 1212006 G451308en
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303-01 B-70 Engine - 2.OL Duratec-HE (M14) 303-01 B-70
IN-VEHICLE REPAIR
9. Disconnect the engine coolant temperature 12. Remove the exhaust manifold upper heat
(ECT) sensor electrical connector.
shield (engine shown removed for clarity).
('
10. Remove the power steering pump return 13. Remove the exhaust manifold lower heat
line support bracket.
shield (engine shown removed for clarity).
11. Remove the generator upper retaining bolt. 14. Remove the exhaust manifold retaining
nuts (engine shown removed for clarity).
Detach the exhaust manifold from the
cylinder head and position it to one side.
Discard the gasket and nuts.
15. CAUTIONS: c
n~ee~ the camshaft bearing caps and the
camshafts in order for installation.
2006.0 Fiesta 12/2006 G451308en
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303-01 B-71 Engine - 2.OL Duratec-HE (M14) 303-01 B-71
IN-VEHICLE REPAIR
n~emove the camshaft bearing caps in the Install the
cylinder head.
i sequence shown. Tighten the cylinder head bolts in the
' N0TE:Working in several stages, release each sequence
shown in five stages:
camshaft bearing cap retaining bolt two turns at a Stage I : 5 Nm.
time. Stage 2: 15 Nm.
Remove the camshafts.
~CAUTION:K~~~ the valve tappets in
order for installation.
Remove the valve tappets.
( ' 17' &AUTION:R~~~~~ the cylinder head ' bolts in the sequence shown.
Remove the cylinder head.
Discard the gasket.
Discard the bolts.
Installation
Stage3:45Nm.
Stage 4: 90 degrees.
Stage 5: 90 degrees.
3. Install the valve tappets.
4m &AUTION:W~~~~~~ in several stages,
evenly tighten the camshaft bearing cap
bolts in the sequence shown, one half turn
at a time.
Install the camshafts.
Coat the camshaft bearing caps with oil.
Tighten the bolts in the sequence shown in
two stages:
Stage I: 7 Nm.
Stage 2: 16 Nm.
I i
I. Check the cylinder head for distortion. I I
For additional information, refer to: Cylinder 5. N0TE:Only carry out the following step when
Head Distortion
(303-00 Engine System - a new cylinder head or new valves are
General Information, General Procedures). installed.
2. N0TE:lnstall a new cylinder head gasket and
bolts.
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303-01 B-72 Engine - 2.OL Duratec-HE (M14) 303-01 B-72
IN-VEHICLE REPAIR
Check the valve clearance and adjust if 9. Using the special tool, connect the coolant
necessary. hose to the EGR valve.
/
For additional information, refer to: Valve
Clearance Adjustment
(303-01 Engine - 2.OL
Duratec-HE (M14), General Procedures).
6. Connect the engine coolant temperature
(ECT) sensor electrical connector.
7. Using the special tool, connect the coolant
hoses to the coolant outlet connector.
8. Connect the exhaust gas recirculation (EGR)
valve electrical connector. 10.
N0TE:lnstall a
new exhaust manifold gasket
and nuts.
Tighten the exhaust manifold retaining nuts
(engine shown removed for clarity).
11. Install the exhaust manifold lower heat
shield (engine shown removed for clarity).
2006.0 Fiesta 1212006 G451308en
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303-01 B-73 Engine - 2.OL Duratec-HE (M14) 303-01 B-73
IN-VEHICLE REPAIR
12. Install the exhaust manifold upper heat 16.
Install the intake manifold.
shield (engine shown removed for clarity).
For additional information, refer to: Intake
Manifold (303-01 Engine
- 2.OL Duratec-HE
(M14), ln-vehicle Repair).
17. Raise and support the vehicle. For
additional information, refer to: (1 00-02
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
13. lnstall the generator upper retaining bolt.
18, lnstall the exhaust manifold support bracket
retaining bolts.
19. Fill and bleed the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling
- 2.OL Duratec-HE
14. Install the power steering pump return line
(M14), General Procedures).
support bracket.
15. lnstall the timing chain.
For additional information, refer to: Timing
Chain (303-01 Engine
- 2.OL Duratec-HE
(M14), ln-vehicle Repair).
2006.0 Fiesta 12/2006 G451308en
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303-01 B-74 Engine - 2.OL Duratec-HE (M14) 303-01 B-74
REMOVAL
Engine
Special Tool(s)
I I Remover, Power Steering I
I I Removerllnstaller, Hose
General Equipment
I Workshop table I
I Engine hoist I
I Securing straps I
Removal
A WARNING: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 present and may ignite. Failure to
follow these instructions may result in
personal injury.
1. Remove the air cleaner. c.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (30312
Intake Air Distribution and Filtering,
Removal and Installation).
2. Remove the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and Installation).
3. Loosen the strut and spring assembly top
mount nuts by three turns on both sides.
4. Remove the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
5. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
6. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling
- 2.OL Duratec-HE
(M14), General Procedures).
7. Detach the exhaust flexible pipe from the
exhaust manifold.
For additional information, refer to: Exhaust
Flexible Pipe
- 2.OL Duratec-HE (M14)
(309-00 Exhaust System, Removal and
Installation).
2006.0 Fiesta 1212006 G451290en
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303-01 B-75 Engine - 2.OL Duratec-HE (M14) 303-01 B-75
REMOVAL
8. Disconnect the cooling fan motor and 1. Disconnect the EVAP valve electrical
cooling fan resistor electrical connectors. connector. 1 2. Disconnect the low pressure line from the
EVAP valve.
3. Push the EVAP valve from the support
bracket.
9. Remove the cooling fan motor and shroud.
1. Release the cooling fan motor and shroud
from the retaining brackets.
2. Push the cooling fan motor and shroud 13. Disconnect the brake booster vacuum line upwards and then downwards to remove. from the intake manifold.
10. Lower the vehicle. 14. Remove the battery tray support bracket.
11. Using the special tool, disconnect the
coolant hose from the coolant outlet
connector.
12. Detach the evaporative emission (EVAP)
valve from EVAP valve support bracket.
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303-01 B-76 Engine - 2.OL Duratec-HE (M14) 303-01 B-76
REMOVAL
15. Disconnect the power steering pump switch 18. Remove the engine wiring harness bracket.
electrical connector.
I
19. Detach the power steering high-pressure
16. Disconnect the catalyst monitor sensor
line retaining bracket from the transaxle.
electrical connector.
20. Remove the coolant expansion tank.
17. Disconnect the engine wiring harness
electrical connector.
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303-01 B-77 Engine - 2.OL Duratec-HE (M14) 303-01 B-77
REMOVAL
21. Disconnect the reversing lamp switch Detach the steering gear to power steering
electrical connector. fluid
reservoir return line support bracket
from the generator.
22m CAUTION:^^ brake fluid is spilt on the 25s Using the special tool, disconnect the paintwork, the affected area must be
immediately washed down with cold water. steering
gear to power steering fluid
reservoir return line from the power
Disconnect the clutch slave cylinder supply
steering fluid reservoir.
line.
Remove the spring clip. Allow
the power steering fluid to drain into a
suitable container.
23. Disconnect the air conditioning low 26. Remove the power steering fluid reservoir.
pressure switch connector.
24. N0TE:Note the position of the steering gear 27m &AUTION:C~~ the power steering fluid
to power steering fluid reservoir return line reservoir
to prevent power steering fluid
support bracket to aid installation. loss
or dirt ingress.
2006.0 Fiesta 12/2006 G451290en
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303-01 B-78 Engine - 2.OL Duratec-HE (M14) 303-01 B-78
REMOVAL
Remove and discard the power steering fluid
30. Detach the power steering pump to steering
reservoir O-rings.
gear pressure line from the intake manifold.
28. Using the special tool, remove the power
31. Disconnect the fuel supply line.
steering pump pulley.
For additional information, refer to: Quick
Discard the power steering pump pulley. Release Coupling (310-00 Fuel System - - - - -
General information, General procedures).
,'-
', .
29. Detach the power steering pump to steering
gearpressurelinefromthepowersteering 32. Raiseands~pportthevehicle~For
Pumpm additional information, refer to: (I 00-02
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
33. Remove the air cleaner resonator support
bracket.
2006.0 Fiesta 1212006 G451290en
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