air condition FORD FIESTA 2007 Manual PDF

303-05-5 Accessory Drive 303-05-5
DIAGNOSIS AND TESTING
Accessory Drive
lnspection and Verification
1. Verify the customer concern.
2.
Visually inspect for obvious signs of mechanical
damage.
Visual lnspection Chart
I Mechanical I
- Damaged or contaminated accessory drive
belt
- Damaged or contaminated pulley(s)
- lncorrect accessory drive belt
- lncorrect fitment of the accessory drive belt
- Accessory drive belt tensioner
- Accessory drive belt idler pulley
- Generator
- Power steering pump
- Power steering pump leakage
- Air conditioning (AIC) compressor
- Pulley(s)
- Loose hardware
3.
If an obvious cause for an observed or reported
concern is found, correct the cause (if
possible)
before proceeding to the next step.
Accessory Drive Belt Concerns
A CAUTI0N:Do not lubricate the accessory
drive belt, accessory drive belt tensioner
or idler
pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism, accessory
drive belt tensioner pulley bearing and idler
pulley(s) bearing may occur.
Cracking
Accessory drive belts are made from rubber which
hardens with time and can
develop cracks. As the
belt runs on the back of some of the pulleys, the
cracks are opened up.
Small cracks are not
considered to be a
failure of the belt. Only if the
,crack is deep enough to reach the bottom of the
grooveto expose the cord or any chunks are found
to be missing from the
belt, is the belt condition
considered to be
unacceptable.
1. Check the accessory drive belt for cracks. If the
damage exceeds the
acceptable limit, install a
new accessory drive
belt.
REFER to: Accessory Drive Belt - 1.3L
Duratec-8V (Rocam) (303-05 Accessory Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 1.4L
Duratec-1 6V (Sigma)/l.GL Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Power Steering Pump Belt - 1.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Accessory Drive Belt - I .4L
Duratec-I 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma),
Vehicles Without: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Accessory Drive Belt - 1.4L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 2.OL
Duratec-HE (M14) (303-05 Accessory Drive,
Removal and Installation).
Chunking
Chunking describes the condition where long
lengths of rubber become detached from the ribs
of the
belt. This is considered to be a failure of the
belt.
2006.0 Fiesta 1212006 G346263en
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303-05-6 Accessory Drive 303-05-6
DIAGNOSIS AND TESTING
2. Check the accessory drive belt for damage. If
any chunks are found to be missing, install a
new accessory drive
belt.
REFER to: Accessory Drive Belt - 1.3L
Duratec-8V (Rocam) (303-05 Accessory Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 1.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Power Steering Pump Belt - 1.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Accessory Drive Belt - 1.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V
(Sigma), Vehicles Without: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
REFER to: Accessory Drive Belt - I .4L
Duratorq-TDCi (DV)
Diesel (303-05 Accessory
Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive,
Removal and Installation).
REFER to: Accessory Drive Belt - 2.OL
Duratec-HE (M14) (303-05 Accessory Drive,
Removal and Installation).
3. Check the accessory drive belt for pilling. The (.
condition of the belt should be compared against
the
illustration.
1. Small scattered pills. Not considered a
concern. No action required.
Pilling 2. Small scattered pills. Not considered a ,
concern. No action required. Pilling is dust that forms in between the ribs of the
belt from rubber that is worn off the belt when it is
new. There may
also be loose particles left on the
belt during the manufacturing process. These are
worn off and form into
small balls of rubber that
then get trapped in the grooves of the
belt. This
condition
will usually clear itself within 4800 km -
8000 km (3000 miles - 5000 miles) of normal
driving.
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303-05-7 Accessory Drive 303-05-7
DIAGNOSIS AND TESTING
3. Longer pills up to 50% of the rib height. 4.
Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new belt Possible noise
concern. INSTALL a new belt
if noise is apparent. if noise is apparent.
REFER to: Accessory Drive Belt
- 1.3L
Duratec-8V (Rocam) (303-05 Accessory
Drive, Removal and Installation)
1 Accessory Drive Belt
- 1.4L Duratec-16V
(Sigma)/l .6L Duratec-I 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
1 Power Steering Pump Belt
- I .4L
Duratec-1
6V (Sigma)ll .6L Duratec-I 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive, Removal and
Installation)
1 Accessory Drive Belt
- 1.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V (Sigma),
Vehicles Without: Air Conditioning (303-05
Accessory Drive, Removal and Installation)
1 Accessory Drive Belt
- 1.4L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 1.6L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation). REFER to:
Accessory Drive Belt
- I .3L
Duratec-8V
(Rocam) (303-05 Accessory
Drive, Removal and Installation)
1 Accessory Drive Belt
- I .4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
I Power Steering Pump Belt - I .4L
Duratec-1
6V (Sigma)ll .6L Duratec-I 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 lnstallation)
1 Accessory Drive Belt
- 1.4L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive, Removal and Installation)
1 Accessory Drive Belt
- 1.6L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
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303-0518 Accessory Drive 303-0518
DIAGNOSIS AND TESTING
5. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
belt.
REFER to: Accessory Drive Belt - 1.3L
Duratec-8V (Rocam) (303-05 Accessory
Drive,
Removal and lnstallation)
1 Accessory Drive Belt - 1.4L Duratec-I 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive,
Removal and lnstallation)
1 Power Steering Pump Belt - 1.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive, Removal and
Installation)
1 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)
1 Accessory Drive Belt - I .4L Duratorq-TDCi
(DV)
Diesel (303-05 Accessory Drive,
Removal and lnstallation)
1 Accessory Drive Belt - I .6L Duratorq-TDCi
(DV)
Diesel (303-05 Accessory Drive,
Removal and lnstallation)
1 Accessory Drive Belt - 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and lnstallation).
6. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
belt.
REFER to: Accessory Drive Belt - I .3L
Duratec-8V
(Rocam) (303-05 Accessory
Drive,
Removal and Installation)
1 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
lnstallation)
1 Power Steering Pump Belt - I .4L
Duratec-1
6V (Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation)
1 Accessory Drive Belt - I .4L Duratec-16V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning (303-05
Accessory Drive,
Removal and lnstallation)
1 Accessory Drive Belt - 1.4L Duratorq-TDCi
(DV)
Diesel (303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 1.6L Duratorq-TDCi
(DV)
Diesel (303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt - 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal (
and lnstallation).
Fraying - Vehicles without accessory drive belt
tensioner built up to
0212003
Due to the manufacturing process, the belt edge
may appear frayed, but this frayed appearance
does not
necessarily affect the durability or
performance of the
belt. If a concern is raised
during a service or repair over the
level of fraying,
the condition of the
belt should be compared
against the
illustrations.
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Accessory Drive
DIAGNOSIS AND TESTING
2. Fraying just starting. Not considered a
concern. No action required.
3. Slight fraying. Not considered a concern. No
action required.
4. High amount of fraying without cord cuts.
INSTALL a new accessory drive belt.
REFER to: Accessory Drive Belt
- 1.3L
Duratec-8V (Rocam) (303-05 Accessory
Drive, Removal and lnstallation)
1 Accessory Drive Belt
- 1.4L Duratec-l6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
1 Power Steering Pump Belt
- 1.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air Conditioning
(303-05 Accessory Drive, Removal and
Installation)
I Accessory Drive Belt - 1.4L Duratec-l6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
I Accessory Drive Belt - 1.4L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and lnstallation)
1 Accessory Drive Belt
- 1.6L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and lnstallation)
I Accessory Drive Belt - 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and lnstallation).
Symptom Chart
Symptom Chart 5.
High amount of fraying with cord cuts.
INSTALL a new accessory drive belt.
f-
REFER to: Accessory Drive Belt - 1.3L (
Duratec-8V (Rocam) (303-05 Accessory
Drive, Removal and lnstallation)
l Accessory Drive Belt - 1.4L Duratec-1 6V
(Sigma)Il.GL Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
I Power Steering Pump Belt - 1.4L
Duratec-1 6V (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-I 6V
(Sigma)ll.GL Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning (303-05
Accessory Drive, Removal and lnstallation)
I Accessory Drive Belt - 1.4L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and lnstallation)
I Accessory Drive Belt - 1.6L Duratorq-TDCi
(DV) Diesel (303-05 Accessory Drive,
Removal and lnstallation)
I Accessory Drive Belt - 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
Incorrect fitment
Belt noise can be generated by the belt being
incorrectly fitted on the pulley as shown in the
following illustration. Make sure that all the V
grooves on the belt contact correctly with the
pulley.
5. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
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303-05-1 2 Accessory Drive 303-05-1 2
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
I. .
2006.0 Fiesta 1212006 G346263en
Accessory drive belt incorrectly
installed.
Pulley(s).
CHECK
the accessory drive
belt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive
belt as neces-
sary.
REFER to: Accessory Drive
Belt - 1.3L Duratec-8V
(Rocam) (303-05 Accessory
Drive,
Removal and Installa-
tion)
1 Accessory Drive
Belt - 1.4L
Duratec-1 6V (Sigma)ll .6L
Duratec-I
6V (Sigma),
Vehicles With: Air Condi-
tioning (303-05 Accessory
Drive,
Removal and Installa-
tion)
1 Power Steering Pump
Belt -
1.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air
Conditioning (303-05
Accessory Drive,
Removal
and Installation)
1 Accessory Drive Belt - I .4L
Duratec-1
6V (Sigma)ll .6L (
Duratec-I 6V (Sigma),
Vehicles Without: Air Condi-
tioning (303-05 Accessory Drive,
Removal and Installa-
tion)
1 Accessory Drive
Belt - I .4L
Duratorq-TDCi (DV)
Diesel
(303-05 Accessory Drive,
Removal and Installation)
1 Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 2.OL
Duratec-HE (M14) (303-05
Accessory Drive,
Removal
and Installation).
TEST the system for normal
operation.
CHECK the pulley(s) for
damage, freedom of rotation,
stone entrapment and
align-
ment. INSTALL new compon-
ents as necessary. TEST the
system for
normal operation.
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303-05-1 3 Accessory Drive 303-05-1 3
DIAGNOSIS AND TESTING
Symptom Possible
Sources
Lubricant or other contamina-
tion.
Action
CHECK the accessory drive
belt for contamination or
damage. RECTIFY the source
of the
leak and INSTALL a new
accessory drive
belt.
REFER to: Accessory Drive
Belt - 1.3L Duratec-8V
(Rocam) (303-05 Accessory
Drive,
Removal and Installa-
tion)
I Accessory Drive Belt - 1.4L
Duratec-1 6V (Sigma)ll .6L
Duratec-1
6V (Sigma),
Vehicles With: Air Condi-
tioning (303-05 Accessory
Drive,
Removal and Installa-
tion)
I Power Steering Pump Belt -
1.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air
Conditioning (303-05
Accessory Drive,
Removal
and Installation)
I Accessory Drive Belt - 1.4L
1 Duratec-I 6V (Sigma)ll .6L
Duratec-I 6V (Sigma),
Vehicles Without: Air Condi-
tioning (303-05 Accessory
Drive,
Removal and Installa-
tion)
1 Accessory Drive
Belt - 1.4L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - 2.OL
Duratec-H E (M 14) (303-05
Accessory Drive,
Removal
and Installation).
TEST the system for normal
operation.
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303-05-1 7 Accessory Drive 303-05-1 7
DIAGNOSIS AND TESTING
REFER to: Accessory Drive Belt Tensioner -
1.6L Duratorq-TDCi (DV) Diesel, Vehicles i With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and lnstallation).
TEST the system for normal operation.
2. Detach the accessory drive belt in the area of
the accessory drive belt tensioner.
3. N0TE:The accessory drive belt tensioner
has a damping feature, which is usually a
friction device, therefore some friction within
the system is normal.
Using the correct tool, move the accessory drive
belt tensioner from its relaxed position through
its full stroke and back to the relaxed position
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley
and check for damage, freedom of rotation and
alignment. INSTALL a new accessory drive belt
tensioner as necessary.
Accessory Drive Belt Tensioner - Dynamic
Check
The accessory drive belt tensioner may be checked
dynamically as follows:
1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the
A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or
A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner -
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and lnstallation).
( :I. REFER to: Accessory Drive Belt Tensioner - TEST the system for normal operation.
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
2. Excessive accessory drive belt rideout (uneven
With: Air Conditioning (303-05, Removal and
depth of grooves in the accessory drive belt)
Installation). may cause excessive accessory drive belt
REFER to: Accessory Drive Belt Tensioner
- tensioner movement. Check the condition by
1.6L Duratorq-TDCi (DV) Diesel (303-05
installing a new accessory drive belt.
Accessory Drive, Removal and
installation). . REFER to: Accessory Drive Belt - 1.3~
TEST the system for normal operation. Duratec-8V (Rocam) (303-05 Accessory
Drive,
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner.
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel, Vehicles
With: Air Conditioning (303-05, Removal and
Installation).
REFER to: Accessory Drive Belt Tensioner
-
1.6L Duratorq-TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal operation. Removal and Installation).
REFER to: Accessory Drive Belt
- 1.4L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive, Removal and Installation).
REFER to: Accessory Drive Belt - 1.6L
Duratorq-TDCi (DV) Diesel (303-05 Accessory
Drive, Removal and Installation).
REFER to: Accessory Drive Belt
- 2.OL
Duratec-H E (M 14) (303-05 Accessory Drive,
Removal and Installation).
TEST the system for normal operation.
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303-05-1 8 Accessory Drive 303-05-1 8
REMOVAL AND INSTALLATION
Accessory Drive Belt - 1.4L Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma), Vehicles With: Air
Conditioning(21 567 0)
General Equipment 2. Using paint or typing correction fluid, mark
Knife the crankshaft pulley at the 6 o'clock
position.
i
Removal
A CAUTI0N:The accessory drive belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
I. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
2. Detach the power steering line and remove
the crankshaft pulley splash shield.
3. lnstall the installation tool (supplied in the
parts kit) to the crankshaft pulley at the
6
o'clock position. /'
3. Using a suitable knife, cut both accessory
drive belts and remove.
Installation 4. lnstall the accessory drive belt.
1. lnstall the belt around the generator pulley. NOTE: Install a new accessory drive belt and power 2. Install the belt around the air conditioning
steering pump belt. compressor pulley.
I. Wipe clean all of the pulleys to make sure 3. Install the belt around the water pump pulley.
that the accessory drive belt does not slip
during installation.
2006.0 Fiesta 1212006 GI 46274en
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303-05-21 Accessory Drive 303-05-21
REMOVAL AND INSTALLATION
Accessory Drive Belt - 1.4L Duratec-I 6V (Sigma)/l .6L
Duratec-1 6V (Sigma), Vehicles Without: Air
Conditioning(21 567 0)
General Equipment 2. Using paint or typing correction fluid, mark
Knife the crankshaft pulley at the 6 o'clock
position.
Removal
A CAUTI0N:The accessory drive belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
1. Raise and support the vehicle. For additional
information, refer to Section
I 00-02 [Jacking
and Lifting].
2. Detach the power steering line and remove
the crankshaft pulley splash shield.
3. lnstall the installation tool (supplied in the
parts kit) to the crankshaft pulley at the
6
o'clock position.
3. Using a suitable knife, cut the accessory
drive belt and remove.
Installation 4. lnstall the accessory drive belt.
NOTE:
lnstall a new accessory drive belt. 1. lnstall the belt around the generator pulley.
2. lnstall the belt around the power steering
1. Wipe clean all of the pulleys to make sure pump pulley.
that the accessory drive belt does not slip 3. Install the belt around the water pump pulley.
during installation.
2006.0 Fiesta 1212006 Gl49874en
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