engine FORD FIESTA 2007 Manual PDF

21 1 -02-36 Power Steering 21 1 -02-36
REMOVAL AND INSTALLATION
4. Remove the front axle crossmember rear Attach the stabilizer bar link to the stabilizer
inner retaining bolt and the special tool on
bar on both sides.
both sides.
9m &~uTl~~:Twistin~ the exhaust flexible 5. Install the front axle crossmember rear inner pipe more than two degrees may cause retaining bolts on both sides.
damage resulting in failure.
N0TE:Use a pry-bar to prevent the exhaust flexible
pipe from twisting when installing the exhaust
flexible pipe to catalytic converter retaining nuts.
N0TE:lnstall a new exhaust flexible pipe to
catalytic converter gasket and retaining nuts.
Install the exhaust flexible pipe to catalytic
converter retaining nuts.
6. Lower and remove the transmission jack and
wooden block.
7. Install the engine support insulator.
8. N0TE:Use a 5 mm Allen key to prevent the
stabilizer bar link ball joint from rotating.
lo' ~CAUTION:T~~~ care when installing the
exhaust hanger insulator to prevent
damage.
N0TE:Check the exhaust hanger insulator for
damage. lnstall a new exhaust hanger insulator if
required.
2006.0 Fiesta 12/2006 G458167en
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2 1 1 -02-39 Power Steering 21 1-02-39
REMOVAL AND INSTALLATION
Support the exhaust flexible pipe with a Vehicles with diesel engine
support wrap or splint.
i 8. Detach the exhaust flexible pipe from the
muffler and tailpipe assembly.
&AUTION:T~~~ care when removing the
exhaust hanger insulator to prevent damage.
Discard the exhaust flexible pipe to muffler
and tail pipe assembly retaining nuts.
Remove the exhaust hanger insulator. Vehicles with 2.OL engine
9. Detach the exhaust flexible pipe from the
catalytic converter.
Discard the exhaust flexible pipe to catalytic
converter gasket and retaining nuts.
Vehicles with 1.25L, 1.4L or 1.6L engine
7. Detach the exhaust flexible pipe from the
catalytic converter.
Discard the exhaust flexible pipe to catalytic
converter gasket and retaining nuts.
All vehicles
On &AUTION:L~~~~ the tie-rod end retaining
nuts in place to protect the ball joint studs.
N0TE:Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
2006.0 Fiesta 1212006 GI 05648en
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21 1 -02-40 Power Steering 211=02-40
REMOVAL AND INSTALLATION
Loosen the tie-rod end retaining nut on both Detach the stabilizer bar connecting link from
sides. the stabilizer bar on both sides.
//
'Irn &AUTION:P~~~~~~ the ball joint seal 13.
Remove the engine support insulator.
using a soft cloth to prevent damage.
Using the special tool, detach the tie-rod end
from the wheel knuckle on both sides.
1 . Release the tie-rod end.
2. Remove and discard the tie-rod end retaining
nut.
12. N0TE:Use a 5 mm Allen key to prevent the
stabilizer bar connecting link ball joint stud
from rotating.
14. Detach the power steering line from the
steering gear (left-hand drive shown).
2006.0 Fiesta 1212006 GI 05648en
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21 1 -02-43 Power Steering 21 1-02-43
REMOVAL AND INSTALLATION
8. Remove the transmission jack and wooden 12. Install the engine support insulator.
block.
I 9. N0TE:lnstall new O-ring seals.
Connect the power steering lines to the
steering gear valve body.
1. Rotate the clamp plate.
2. Install the retaining bolt.
Vehicles with 2.OL engine
13. N0TE:Coat the exhaust flexible pipe studs
with grease.
N0TE:lnstall a new exhaust flexible pipe to
catalytic converter gasket and retaining nuts.
Attach the exhaust flexible pipe to the 10. Attach the power steering lines to the
catalytic converter.
steering gear (left-hand drive shown).
Vehicles with diesel engine 11. Attach the power steering line to the
steering gear (left-hand drive shown). 14. N0TE:Coat the exhaust flexible pipe studs
with grease.
N0TE:lnstall new exhaust flexible pipe to muffler
and tailpipe assembly retaining nuts.
2006.0 Fiesta 1212006 GI 05648en
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211 -02-44 Power Steering 211 -02-44
REMOVAL AND INSTALLATION
Attach the exhaust flexible pipe to the muffler Check the exhaust hanger insulator for
and tailpipe assembly. damage. Install a new exhaust hanger
insulator
if required..
Vehicles with 1.25L, 1.4L or 1.6L engine
15. N0TE:Coat the exhaust flexible pipe studs 17' &AUTION:O~~~ bending of the exhaust
with grease.
flexible pipe may cause damage resulting
N0TE:lnstall a new exhaust flexible pipe to in failure.
catalytic converter gasket and retaining nuts. Remove the exhaust flexible pipe support
Attach the exhaust flexible pipe to the wrap
or splint.
catalytic converter.
*- AwARNING:~~~~~~~ new tie-rod end
All vehicles retaining nuts. Failure to follow this
instruction may result in personal injury.
16' AcAu~~oN:Take care when installing the NOTE:"se a 5 mm Allen key to prevent the tie-rod exhaust hanger insulator to prevent
damage. end ball joint stud from rotating.
2006.0 Fiesta iu2006 GI 05648en
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303-00-1 Engine System = General Information 303-00-1
SECTION 303-00 Engine System . General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
DESCRIPTION AND
OPERATION
Engine
........................................................................\
......................................................... 303-00-3
Engineltransmission combinations ........................................................................\
........ 303-00-3
DIAGNOSIS AND TESTING
........................................................................\
.......................................................... Engine
. Engine Oil Leaks ........................................................................\
........................................
Ultraviolet (UV) Testing ........................................................................\
...............................
Measure the compression pressure ........................................................................\
...........
.............. Measure the compression pressure (Engine . 1.4L Duratorq-TDCi (DV) Diesel)
Measure the compression pressure (Engine
. 1.6L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine . 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V
........................................................................\
......... (Sigma)ll . 6L Duratec-I 6V (Sigma))
Measure the compression pressure (Engine
. 1.3L Duratec-8V (Rocam)) ........................
Measure the compression pressure (Engine . 2.OL Duratec-HE (M14)) .............................
. Measure the oil pressure (Engine 1.4L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.6L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
........................................................................\
......... (Sigma)/l . 6L Duratec-1 6V (Sigma))
. Measure the oil pressure (Engine 1.3L Duratec-8V (Rocam)) .........................................
. Measure the oil pressure (Engine 2.OL Duratec-HE (M14)) ...............................................
Valve train analysis . static (engine off) ........................................................................\
......
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
........................................................................\
..........
Camshaft Bearing Journal Clearance ........................................................................\
.........
Camshaft End Play ........................................................................\
.....................................
Camshaft Surface Inspection ........................................................................\
.....................
........................................................................\
...................................... Camshaft Lobe Lift
Crankshaft Main Bearing Journal Diameter
........................................................................\

Crankshaft End Play ........................................................................\
...................................
Cylinder Bore Taper ........................................................................\
....................................
Piston Inspection ........................................................................\
........................................
Piston Pin to Bore Diameter ........................................................................\
.......................
Piston Diameter ........................................................................\
..........................................
Piston Ring End .Gap ........................................................................\
...................................
............................................ ................................... Piston Ring-to-Groove Clearance ......
Piston Pin Diameter ........................................................................\
.....................................
Connecting Rod Large End Bore ........................................................................\
................
Valve Stem Diameter ........................................................................\
..................................
Flywheel Inspection ........................................................................\
....................................
............................................... Flywheel Inspection - Vehicles With: Dual Mass Flywheel
Cylinder Head Distortion ........................................................................\
.............................
Cylinder Block Distortion ........................................................................\
.............................
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303-00-2 Engine System - General Information 303-00-2
Exhaust Manifold Cleaning and Inspection ........................................................................\
303-00-52
Bearing Inspection
........................................................................\
..................................... 303-00- -2
Valve Seat Inspection ........................................................................\
................................. 303-00-( ;
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303-00-3 Engine System - General Information 303-00-3
DESCRIPTION AND OPERATION
Enaine
Engineltransmission combinations
Item Description
I 1 I 1.3L Duratec 8V engine I
1 2 1 1.411.6L Duratec 16V engine I
' 1 3 1 1.4L Duratorq TDCi turbodiesel engine I
1 4 1 iB5 manual transmission I
2006.0 Fiesta 1212006 GI 86750en
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303-004 Engine System - General Information 303-00-4
DIAGNOSIS AND TESTING
Engine
Special Tool(s)
Socket, Spark Plug
303-499
I Adhesive - Loctite 243 I WSK-M2G349A7 I
Materials
1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
k.
Name S~ecification
Leaks from oil carrying
components or basic engine.
E47332
&
21211
CHECK for cracks in oil
carrying components of the
basic engine by means of a
leak test. INSTALL new
components or seals as
necessary.
2006.0 Fiesta 1212006 GI 52554en
Compression Test Adapter
303-1 052
Pliers, Valve Stem Seal
303-508
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart Symptom Possible Sources Action
Visual
Inspection Chart
Loss of oil Mechanical
- Coolant
leaks
- Oil leaks
- Fuel system leaks
- Visibly damaged or
worn parts
- Loose or missing
nuts or bolts Electrical
- Fuse(s)
- Loose
or corroded
connector(s)
- Powertrain control
module
- Damaged or worn
switch(es)
Oil leaks on components that
are
eithei coated in oil them-
selves or on components local
to them.
Internal or external leak at the
oil cooler.
Leak at the crankshaft seal.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
CHECK for evidence of oil
leaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident, INSTALL
new gaskets or components as
required.
CHECK the coolant expansion
tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
INSTALL a new crankshaft
seal.
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303-00-5 Engine System - General Information 303-00-5
DIAGNOSIS AND TESTING
Symptom
Oil consumption
Possible Sources Action
Use of the wrong type of
engine oil.
Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation or
breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty
and engine oil can enter the
combustion chamber
through the intake manifold.
Turbocharger seals (diesel
engine only).
DETERMINE the last type of
engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
CHECK if the PCV system is
operating correctly and repair
as necessary. REFER to:
Engine Emission Control (303-
08 Engine Emission Control
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 2.OL Duratec-HE (M14),
Diagnosis and Testing),
Engine Emission Control
-
Vehicles With: Vacuum
Exhaust Gas Recirculation
(EGR) Valve (303-08 Engine
Emission Control
- 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 1.6L Duratorq-TDCi (DV)
Diesel, Description and
Operation).
INSTALL a new turbocharger.
REFER to:
Turbocharger (303-04 Fuel
Charging and Controls
-
Turbocharger - I .4L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation),
Turbocharger
- I .6L Duratorq-
TDCi (DV) Diesel (303-04
Fuel Charging and Controls
- Turbocharger - I .6L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation).
2006.0 Fiesta 1212006 GI 52554en
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