303-01A FORD FIESTA 2007 Workshop Manual

303-01 A-I Engine
. 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I
6V (Sigma)ll . 6L Duratec-1 6V (Sigma)
303-01 A-I
SECTION 303-01A Engine . 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)/l . 6L Duratec-1 6V
(Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
.............................................. Specifications
Engine Data
. 1.25L ........................................................................\
................................
Engine Data . I . 4L ........................................................................\
..................................
Engine Data . 1.6L ........................................................................\
..................................
Oil pressure ........................................................................\
.............................................
Engine Oil Capacity . - 1.25Ll1.4L ........................................................................\
............
Engine Oil Capacity - 1.6L ........................................................................\
......................
Valve Clearance - 1.25LlI . 4L ........................................................................\
..................
Valve Clearance - 1.6L ........................................................................\
............................
Cylinder block - 1.25L ........................................................................\
.............................
Cylinder block - 1.4L ........................................................................\
...............................
........................................................................\
............................... Cylinder block - 1.6L
........................................................................\
.......................................... Cylinder head
Piston
-1.25L ........................................................................\
...........................................
Piston -1.4L ........................................................................\
.............................................
Piston - l.6L ........................................................................\
............................................
PAGE
DESCRIPTION AND OPERATION
........................................................................\
......................................................... Engine 303-01A-9
........................................................................\
.................... 1.4Ll1.6L Duratec 16V engine 303-01A-9
DIAGNOSIS AND TESTING
........................................................................\
......................................................... Engine 303-01A-12
GENERAL PROCEDURES
........................................................................\
....................... Valve Clearance Adjustment 303-01 A-I 3
IN-VEHICLE REPAIR
Crankshaft Front Seal ........................................................................\
......... (21 467 0)
Valves ........................................................................\
..................................... (21 21 5 4)
Intake Manifold ........................................................................\
....................... (21 183 0)
Valve Cover ........................................................................\
............................ (21 141 0)
Valve Seals ........................................................................\
............................. (21 238 0)
Camshafts ........................................................................\
........................ (21 284 0)
Camshaft Seal ........................................................................\
................... (21 288 0)
Timing Belt ........................................................................\
.......................... (21 304 0)
Exhaust Manifold ........................................................................\
.................... (21 187 0)
Cylinder Head ........................................................................\
...................... (21 163 0)
Oil Pan ........................................................................\
............................. (21 154 0)
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
Oil Pump ...
Crankshaft
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 71 4 0) 303-01
A-66
Rear Seal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 468 4)
303-01
Engine ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01 A-70
Engine - Vehicles With: Automatic Transaxle ................................................................... 303-01A-82
DISASSEMBLY
Engine
........................................................................\
............................. (21 134 8) 303-01A-95
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (21 165 6) 303-01A-105
ASSEMBLY
Engine
........................................................................\
.................................... (21 134 8) 303-01A-108
INSTALLATION
Engine..
.... .. .... .................... . . . ............ ...... ....... . ...... . . ...... . . . . . . . . . . ....... . . . . ....... . . 303-01A-122
Engine - Vehicles With: Automatic Transaxle.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01 A-1 34
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 2 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01A-I 2
DIAGNOSIS AND TESTING
Enaine
REFER to Section 303-00 [Engine System -
General Information].
2006.0 Fiesta 1212006 GI 7645en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 5 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-01A-I 5
IN-VEHICLE REPAIR
4. Install the timing belt.
1 For additional information, refer to: Timing I Belt (303-01 Engine - I .25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma), Invehicle Repair).
2006.0 Fiesta 1212006 G21046en
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Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
303-01A-I 9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-OIA-I 9
IN-VEHICLE REPAIR
Intake Manifold(21 183 0)
Removal 6. Remove the intake manifold lower retaining
bolt.
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 mixtures
are always present and may ignite. Failure
to follow these instructions may result in
personal injury.
1. Release the fuel system pressure. For
additional information, refer to
Section
31 0-00 [Fuel System - General
Information].
2. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and 7. Disconnect the engine wiring harness
Cables]. electrical connector.
3. Remove the air cleaner. For additional
information, refer to Section
303-1 2 [Intake
Air Distribution and Filtering].
4. Detach the power steering fluid reservoir
from the bracket and position
it to one side.
5. Remove the accessory drive belt. For
additional information, refer to
Section
303-05 [Accessory Drive].
8. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV.
2006.0 Fiesta 1212006 GI 83728en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-31 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-31
IN-VEHICLE REPAIR
Remove the valve spring retainer and the
valve springs.
7. Using the special tool, remove the valve
seals.
N0TE:lnstall new valve seals.
N0TE:Coat the valve seal lip and the valve stem
with clean engine oil.
Using the special tool, install the valve seal.
Discard the valve seals. 3. Remove the mounting sleeve.
4. Using the special tool, install the valve
springs.
lnstall the valve spring retainer and the valve
springs.
Compress the valve spring.
Install the valve collets.
Installation
1, Install a valve stem mounting sleeve over
the valve
collet groove (valve shown
removed for clarity).
*' ACAUTION:T~~ intake valve seal are
colored green, and the exhaust valve seals
are colored brown.
5. Remove the special tools.
2006.0 Fiesta 1212006 GI 83730en
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Engine - 1.25L Duratec-1 6V (Sigma)lIl4L
303-01 A-37 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-01A-37
IN-VEHICLE REPAIR
Timing Belt(21 304 0)
Gauge, Bolt Angle
303-1 74
' Special Tool(s)
# 15030A
Locking Tool, Timing Belt
I Tensioner
303-1054
Universal Flange Holding
Wrench
205-072
303748
General Equipment
Locking Tool, Crankshaft
303-748
I Trolley jack I
General Eaui~ment
I Wooden block I - --
Materials
Name
S~ecification
High-Temperature
Grease
Removal
All vehicles
1. Remove the valve cover.
For additional information, refer to: Valve
Cover
(303-01A Engine - 1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1
6V (Sigma), In-vehicle Repair).
2. Loosen the coolant pump pulley retaining
bolts.
3. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 1.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V (Sigma), Vehicles
With: Air Conditioning (303-05 Accessory
Drive, Removal and Installation).
2006.0 Fiesta 1212006 GI 83738en
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Engine - I .25L Duratec-1 6V (Sigma)llm4L
303-01A-45 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-45
IN-VEHICLE REPAIR
lnstall the engine front mount.
27. Remove the
trolley jack.
28. Attach the generator.
1. lnstall the stud and nut.
2. lnstall the bolt.
3. Tighten the bolt.
31. lnstall the timing belt upper cover retaining
bolts.
32. N0TE:Do not tighten the coolant pump
pulley retaining bolts at this stage.
lnstall the coolant pump pulley.
I 33. lnstall the accessory drive belt.
29. Connect the generator electrical connector.
For additional information, refer to:
Accessory Drive
Belt - 1.4L Duratec-1 6V
(Sigma)ll.GL Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive,
Removal and
Installation).
30. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
2006.0 Fiesta 1212006 GI 83738en
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Engine - 1.25L Duratec-I 6V (Sigma)llm4L
303-01 A-46
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-46
IN-VEHICLE REPAIR
34. Tighten the coolant pump pulley retaining
bolts.
35. Install the valve cover.
For additional information, refer to: Valve
Cover
(303-01A Engine - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
In-vehicle Repair).
36. Attach the power steering fluid reservoir to
the bracket.
37. Attach the coolant expansion tank to the
bracket.
2006.0 Fiesta 1212006 GI 83738en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-61 Duratec-1 6V (Sigma)/l .6L Duratec-I 6V (Sigma) 303-OIA-61
IN-VEHICLE REPAIR
11. Connect the engine coolant temperature 14.
Using the special tool, connect the coolant
/ (ECT) sensor electrical connector.
hose to the coolant distribution assembly.
12. Using the special tool, connect the degas 15.
Connect the fuel return line quick release
hose to the cylinder head. coupling.
13. Using the special tool, connect the coolant
hose to the coolant distribution assembly. For additional
information, refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
16. Connect the fuel supply line quick release
coupling.
For additional information, refer to: Quick
Release Coupling (310-00 Fuel System
-
General Information, General Procedures).
2006.0 Fiesta 1212006 GI 83740en
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