coolant level FORD FIESTA 2007 Workshop Manual

100-00-23 General Information 100-00-23
DESCRIPTION AND OPERATION
RoadIRoller Testing
I Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the
system(s) being checked can be
extracted.
Pre-Test Checks
A WARNING:lf the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
( , brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
- that there is sufficient fuel in the tank to
complete the test.
- all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
N0TE:On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of
25 kmlh
(15 mileslh). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are
illuminated.
- that the engine temperature gauge registers a reading compatible with the engine temperature.
- that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing
A CAUTI0N:lf road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or
heavy.
- that the initial gear engagement is smooth and
there is no evidence of clutch drag.
- that the parking brake control operates smoothly
and releases quickly and completely.
- that the clutch takes up the drive smoothly,
without slip or judder.
- that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
- the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
- there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
- that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
- that the steering does not pull to one side and
self centers smoothly after cornering.
2006.0 Fiesta 1212006 GI 7375en
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303-00-7 Engine System - General Information 303-00-7
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Coolant consumption Cooling system components.
Oil cooler.
CHECK the coooling system.
REFER to:
Engine
Cooling (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 2.OL Duratec-HE
(M14), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.4L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.6L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing).
INSTALL a new oil cooler.
Damaged gaskets or warped
mating faces. CHECK the cylinder head
gasket for damage. CHECK the
cylinder head for distortion. - -- - -
Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
- - - - - - - -
DETERMINE the damaged
engine
component(s) and
install new component(s) as
necessary.
Engine will not crank Battery or cables. CHECK the battery, bracket
and
cables.
REFER to: Battery (41 4-01
Battery, Mounting and
Cables, Diagnosis and
Testing).
Starter motor or cables. I CHECK the starting system.
REFER to: Starting System
(303-06 Starting System,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 52554en
I Engine cranks but will not start Fuel tank is empty. CHECK the fuel level.
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)Il.GL Duratec-1 6V (Sigma)
SPECIFICATIONS
2006.0 Fiesta 1212006 GI 54208en
Ib-in
-
-
-
-
-
-
-
-
-
80
-
80
-
35
-
80
-
-
-
-
-
-
80
80
-
-
-
53
-
80
80
Ib-ft
41
35
66
35 35 18
30
18
35
-
20
-
15
-
21
-
11
-
-
13
-
35
-
-
11
15
15
-
-
-
-
Description
Engine front mount bracket to cylinder block
retaining bolts
Engine front mount retaining nuts and bolts
Engine rear mount center retaining nut
Engine rear mount outer retaining nuts
Engine support insulator retaining bolts Power steering line support bracket retaining bolts
Power steering line to power steering pump
Air conditioning
(AIC) compressor to cylinder block
retaining bolts
Generator to cylinder block top rear and lower
retaining bolts
Water pump retaining bolts
Water pump pulley retaining bolts
Oil pump to cylinder block retaining bolts
Oil pan to cylinder block retaining bolts
Oil level indicator tube bracket retaining bolt
Engine oil drain plug
Oil pump pickup pipe to cylinder block retaining
bolts
Oil pressure switch
Cylinder head bolts
Valve cover retaining bolts
Intake manifold to cylinder head retaining bolts
Exhaust manifold to cylinder head
Exhaust manifold to cylinder block
Camshaft position (CMP) sensor
Timing belt rear cover retaining bolts
Spark plugs Engine rear lifting eye retaining bolts
Coolant distribution housing retaining bolts
Ignition coil to coolant distribution housing
Camshaft bearing cap retaining bolts
Timing belt upper cover to cylinder block retaining
bolts
Timing belt lower cover to cylinder block retaining
bolts
Nm
55
48 90
48
48 25
40 25
47
9
27 9
20 4
28 9
15
a)
a)
18
a)
47 9
9
15
20
20
6
a)
9
9
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,303-01 B-6 Engine - 2.OL Duratec-HE (M14) 303-01 B-6
SPECIFICATIONS
I Description I Nm' I Ib-ft I Ib-in I
Evaporative emission (EVAP) valve retaining
bracket retaining nut and bolt
Valve cover retaining bolts
I 10 I - I 89 I
Cylinder block blanking plug
Coolant pump pulley retaining bolts
Coolant pump retaining bolts
Oil level indicator and oil level indicator tube upper
retaining bolt
Oil level indicator and oil level indicator tube lower
retaining bolt 20
25
10
Oil pressure switch I 15 I 11 I - I
I Oil pan retaining bolts
15
18
-
-
-
89
I Crankshaft rear seal carrier retaining bolts I 10 I - I 89 I
Oil drain plug
Oil cooler to oil filter adaptor retaining bolt
I Flywheel retaining bolts I a) I - I - I
28
34
I Knock sensor retaining bolt I 20 I 15 I - I
Oil filter adaptor retaining bolts
Positive crankcase ventilation housing retaining
bolts
I Thermostat housing retaining bolts I 10 I - I 89 I
21
25
I Oil pump retaining bolts I a) I - I - I
-
-
25
10
I Oil pump sprocket retaining bolt I 25 I 18 I - I
18
-
-
89
Oil pump chain guide retaining bolts
Oil pump chain tensioner retaining bolt
I Crankshaft position sensor retaining bolts I 7 I - I 62 I
Timing chain guide retaining bolts
Timing chain tensioner retaining bolts
I Accessory drive belt idler pulley retaining bolt I 25 I 18 I - I
10
10
I Intake manifold retaining bolts I 18 I 13 I - I
10
10
I Transaxle left-hand retaining bolts I 44 I 32 I - I
-
-
I Transaxle right-hand retaining bolts I 44 I 32 I - I
89
89
-
-
89
89
Transaxle lower retaining bolts
Halfshaft center bearing carrier retaining bolts
I Lower arm ball joint retaining bolt I 48 I 35 I - I
Intermediate shaft bearing cap retaining nuts
2006.0 Fiesta 1212006 G451278en
40
48
25 30
35 -
-
18 -
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303-01 B-I 06 Engine - 2.OL Duratec-HE (M14) 303-01 B-106
ASSEMBLY
63. Using the special tool, connect the spark 66. Connect the positive crankcase ventilation
plug electrical connectors.
(PCV) hose to the intake manifold.
{-
64. Install the power steering pump. 67. Install the intake manifold.
65. Using the special tool, install the coolant 68. Install the oil level indicator tube and oil
hoses. level indicator.
69. N0TE:lnstall a new exhaust manifold
gasket.
N0TE:Do not tighten the exhaust manifold
retaining nuts at this stage.
2006.0 Fiesta 1212006 G451310en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-8 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-8
DIAGNOSIS AND TESTING
Engine Cooling
Special Tool(~)
Pressure Tester,
Cooling
System
303-396 (24-001 A)
General
Equipment
I Worldwide Diagnostic System (WDS) I
Visual Inspection Chart i,
I Mechanical I Electrical I
- Coolant leak(s)
- Coolant level
- Air in system
- Gasketslseals
- Hose(s)lhose joints
- Coolant expansion
tank cap and
seal
- Coolant expansion
tank
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt
- Fuse(s)
- Relay(s)
- Wiring harness
- Electrical
connector(s)
- Cooling fan motor
- Engine coolant
temperature (ECT)
sensor
- Cylinder head
temperature (CHT) sensor
- Powertrain control
module (PCM)
3.
If an obvious cause for an observed or reported Inspection and Verification concern is found, correct the cause (if possible)
before proceeding to the next step.
1. Verify the customer concern.
4.
If the cause is not visually evident, verify the ( 2. Visually inspect for obvious signs of mechanical
symptom and refer to the Symptom Chart.
or
electrical damage.
Symptom Chart
Symptom Chart
Svm
ptom Possible Sources Action
Loss of
coolant INSPECT the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
Radiator. INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03 Engine
Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)1ln4L
Duratec-1 6V (Sigma)ll .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-I 3 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-03A-I 3
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 GI 46258en
Coolant levellcondition.
Coolant concentration.
Radiator grille. CHECK
the coolant level.
REFILL the cooling system as
necessary.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), General Proced-
u res).
CHECK the coolant condition.
If the coolant is in poor condi-
tion drain and refill with new
coolant.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l.6L Duratec-1 6V
(Sigma), General Proced-
u res).
REFER to: Specifications (303-
03 Engine Cooling
- 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-16V (Sigma),
Specifications).
INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
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303-03B-9 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-9
DIAGNOSIS AND TESTING
.Engine Cooling
' . Special Tool(s)
Pressure Tester, Cooling
System
303-396 (24-001 A)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
( I or electrical damage. Visual
lns~ection Chart
I Mechanical I Electrical I
Coolant leak(s)
Coolant
level
Gasket(s) or seal(s)
Core plug(s)
Hose(s) or hose
joints
Coolant expansion
tank cap and seal
Coolant expansion
tank
Radiator
Coolant pump
Thermostat housing
Heater core
Accessory drive belt
Coolant outlet
connector
Fuse(s)
Relay(s)
Wiring harness
Electrical
connector(s)
Engine coolant
temperature (ECT) sensor
Cooling fan motor
Powertrain control
module (PCM)
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Symptom
Loss of coolant Possible Sources
Action
Hose(s) or hose joint(s).
Radiator. INSPECT
the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling
- 2.OL
Duratec-H E (M 14), Removal
and Installation).
2006.0 Fiesta 1212006 G426582en
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303-03B-12 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-I 2
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action
Coolant level or condition.
Radiator grille.
Coolant pump.
Thermostat. CHECK
the coolant level.
REFILL the cooling system as
necessary.
REFER to: Cooling System
Draining, Filling and Bleeding
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
CHECK the coolant condition
and concentration
REFER to: Specifications (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Specifica-
tions).
If the coolant is contaminated
or the concentration is below
specifications, drain and refill
with new coolant.
REFER to: Cooling System
Draining, Filling and Bleeding
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
CARRY OUT the Pressure Test
Component Test in this section.
INSPECT the coolant pump for
leaks. INSTALL a new coolant
pump or coolant pump gasket
as necessary.
REFER to: Coolant Pump (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal
and Installation).
CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
2006.0 Fiesta 1212006 G426582en
REFER to: Thermostat Housing
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation). ,,
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Fuel Charging and Controls - 2.OL
303-04B-6 Duratec-HE (M14) 303-04B-6
DIAGNOSIS AND TESTING
1 6 1 Heated Oxygen sensor (H02s) I
Item Description Fuel supply
1 7 1 Intake manifold I
5
Fuel injectors
Throttle body
The fuel supply for all petrol fueled variants is
equipped with a return-less fuel system. This
means that the fuel delivery pressure at the fuel
injectors, is monitored and controlled by the fuel
tank module. This control is achived by switching
the fuel pump on and off.
The fuel pump module for both the Ethanol E85
TO maintain the same or similar power output to variant vehicle and the unleaded fueled vehicle are
that of the unleaded fuel vehicle, the fuel injectors
very similar, visual^ the only difference is the fuel
have been replaced with high flow fuel injectors. pump electrical connections which on the Ethanol
E85 variant is sealed. This is not the only
differance, both fuel pump modules have different
(
Fuel composition monitoring fuel level sensor resistor card values.
The quantity of Ethanol E85 in relation to the
quantity of unleaded fuel contained in the fuel tank
at any one time is not monitored at the fuel tank.
The Ethanol percentage volume can only decrease
from its maximum 85% (pure Ethanol
E85), to zero
(1 00% unleaded fuel).
The fuel charging system compensates for the
changes in fuel composition using the signal
received by the power train control module (PCM)
from the
H02s. The PCM adapts the fueling and
ignition calibrations to suit the current fuel tank
content composition.
Cold start
To overcome the problems relating to cold start
inherent with Ethanol E85 vehicles (temperatures
down to -29 degrees centigrade), a block heater
has been installed into the engine coolant system.
The block heater is located to the rear of the engine
under the exhaust manifold. The block heater is
fitted with a dedicated harness which terminates at an external plug connector fitted into the radiator
grill.
2006.0 Fiesta 1212006
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