FORD FIESTA 2007 Workshop Manual

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.
2006.0 Fiesta 1212006 G346263en
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303-05-1 4 Accessory Drive 303-05-1 4
DIAGNOSIS AND TESTING
Symptom
N0TE:Squeal is defined as a
continuous shriek, most noticeable
when the engine is being acceler-
ated or with electrical load.
Accessory drive belt squeal
N0TE:Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt whine
Possible Sources Action
Accessory drive belt tensioner
worn, damaged or contamin-
ated with oil.
Poor surface finish on
accessory drive belt idler pulley
flat
surface(s).
CHECK the accessory drive
belt tensioner for correct opera
tion, damage or contamination.
REFER to the Accessory Drive
Belt Tensioner Component
Test in this procedure.
INSTALL a new accessory
drive belt tensioner as neces-
sary.
REFER to: Accessory Drive
Belt Tensioner
- 1.6L
Duratorq-TDCi (DV) Diesel,
Vehicles With: Air Condi-
tioning (303-05, Removal and
Installation)
1 Accessory Drive Belt
Tensioner
- I .6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal
operation.
REMOVE the accessory drive
belt.
REFER to: Accessory Drive
Belt
- 1.3L Duratec-8V
(Rocam) (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)
1 Accessory Drive Belt Tensioner
- 1.6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal
and Installation)
I Accessory Drive Belt - 2.OL
Duratec-H E (M14) (303-05
Accessory Drive, Removal
and Installation).
INSPECT the idler
pulley(s) for
surface finish. INSTALL a new
idler
pulley(s) as necessary.
TEST the system for normal
operation.
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303-05-1 5 Accessory Drive 303-05-1 5
DIAGNOSIS AND TESTING
Symptom
N0TE:Chirp is defined as a twit-
tering noise, often intermittent
Accessory drive belt chirp Possible
Sources Action
Accessory drive belt idler pulley
bearing failure.
Pulley misalignment (usually
evident at idle). REMOVE
the 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
Duratorq-TDCi (DV) Diesel
(303-05 Accessory Drive,
Removal and Installation)
I Accessory Drive Belt - I .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).
INSPECT the idler
pulley(s) for
smooth rotation. INSTALL a
new idler
pulley(s) as neces-
sary. TEST the system for
normal operation.
CHECK that the accessory
drive belt is running centrally
on the flat pulleys. TEST the
system for normal operation.
CHECK the pulleys for
excessive end float and bent
flanges.
With the engine running at idle,
use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
2006.0 Fiesta 121~oo6 G346263en
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303-05-1 6 Accessory Drive 303-05-1 6
DIAGNOSIS AND TESTING
Symptom
N0TE:Rattle is defined as a
metallic knocking noise
Accessory drive belt rattle
Accessory drive belt fraying
Possible Sources Action
Accessory drive belt tensioner
hitting the end stops.
Loose components or hard-
ware.
Accessory drive belt.
CHECK the accessory drive
belt tensioner for correct
operaJ
tion or damage. REFER to the
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a new
accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive
Belt Tensioner
- 1.6L
Duratorq-TDCi (DV) Diesel,
Vehicles With: Air Condi-
tioning (303-05, Removal and
Installation)
1 Accessory Drive Belt
Tensioner
- I .6L Duratorq-
TDCi (DV) Diesel (303-05
Accessory Drive, Removal and Installation).
TEST the system for normal
operation.
CHECK the components or
hardware for correct installation
and tighten as necessary.
TEST the system for normal
operation.
CHECK the extent of the
fraying by referring to the illus-
trations shown in the Visual
lnspection section. Only
INSTALL a new accessory
drive belt if the fraying is within
the criteria quoted in the Visual
lnspection section. TEST the
system for normal operation.
CHECK the pulley(s) for
damage, freedom of rotation
and alignment. INSTALL new
components as necessary.
TEST the system for normal
operation.
Component Tests 1. Inspect the area surrounding the accessory
drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
Accessory Drive Belt Tensioner - Static installing a new accessory drive belt tensioner.
Check If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as
the(
The accessory drive belt tensioner may be checked
damping mechanism inside may be damaged.
statically as follows:
INSTALL a new accessory drive belt tensioner
as necessary.
2006.0 Fiesta 1212006 G346263en
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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.
2006.0 Fiesta 12/2006 G346263en
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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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303-05-1 9 Accessory Drive 303-05-1 9
REMOVAL AND INSTALLATION
4. Install the belt around the installation tool.
Install the belt guide tool (supplied in the
parts kit) to the accessory drive belt (shown
I from above for clarity).
5. Make sure that the accessory drive belt is
correctly positioned in the grooves of the
pulleys.
8. Install the belt guide tool to the generator
6. N0TE:Only turn the engine in the normal mounting
bracket.
direction of rotation.
N0TE:Guide the accessory drive belt onto the
pulleys as the engine is rotated.
Turn the engine until the paint mark is at the
8 o'clock position.
9.
N0TE:Only turn the engine in the normal
direction of rotation.
N0TE:Guide the accessory drive belt onto the
pulleys as the engine is rotated.
Turn the engine until the paint mark is at the
7. N0TE:The curved end of the tool fits around 3 o'clock position
the belt and the cranked end of the tool fits
around the generator mounting bracket.
10. Remove the installation tool from the
crankshaft pulley.
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303-05-20 Accessory Drive 303-05-20
REMOVAL AND INSTALLATION
11. N0TE:Only turn the engine in the normal N0TE:Guide the power steering pump belt onto
direction of rotation. the pulleys as the engine is rotated. (.
Turn the engine through 360 degrees. Turn
the engine until the tool is at the 9
12.
Check that the accessory drive belt is o'clock
position.
correctly positioned in the grooves of the
pulleys.
Repeat the installation procedure if the
accessory drive belt is misaligned.
13. Remove the belt guide tool from the
accessory drive belt.
Discard the belt guide tool.
14. lnstall the installation tool to the crankshaft
pulley at the
12 o'clock position.
18. Remove the installation tool from the
crankshaft pulley.
19. N0TE:Only turn the engine in the normal
direction of rotation.
Turn the engine through
360 degrees.
20. Check that the power steering pump belt
is correctly positioned in the grooves of
the pulleys.
I I Repeat the installation procedure if the power
15. lnstall the power steering pump belt. steering pump belt is misaligned.
Discard the installation tool.
1. lnstall the power steering pump belt around
the power steering pump pulley.
21. Install the crankshaft pulley splash shield.
2. lnstall the power steering pump belt around
the installation tool.
16. Make sure that the power steering pump
belt is correctly positioned in the grooves
of the pulleys.
17. N0TE:Only turn the engine in the normal
direction of rotation.
22. Lower the vehicle.
- --
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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303-05-22 Accessory Drive 303-05-22
REMOVAL AND INSTALLATION
4. Install the belt around the installation tool. Install the belt guide tool (supplied in the
parts kit) to the accessory drive belt (shown
from above for clarity).
5. Make sure that the accessory drive belt is
correctly positioned in the grooves of the
pulleys.
8. Install the belt guide tool to the generator
6. N0TE:Only turn the engine in the normal mounting
bracket.
direction of rotation.
N0TE:Guide the accessory drive belt onto the
pulleys as the
e'ngine is rotated.
Turn the engine until the paint mark is at the
8 o'clock position.
9. N0TE:Only turn the engine in the normal
direction of rotation.
N0TE:Guide the accessory drive belt onto the
pulleys as the engine is rotated.
Turn the engine until the paint mark is at the
7. N0TE:The curved end of the tool fits around 3 o'clock position
the belt and the cranked end of the tool fits
around the generator mounting bracket.
10. Remove the installation tool from the
crankshaft pulley.
2006.0 Fiesta 1212006 Gl49874en
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