volume 3 FORD FIESTA 2007 Workshop Manual

2007 WQ Fiesta
(including XR4)
Repair Manual
Registered at the National Library,
Canberra, ACT Australia
ISBN 1 921 140 151 (Set)
ISBN 1 921 140 16X (Volume 1 )
ISBN 1 921 140 178 (Volume 2)
ISBN 1 921 140 186 (Volume 3)
O 2007 Ford Motor Company of Australia Ltd.
Registered Office: CAMPBELLFIELD, VICTORIA
A.B.N. 30 004 116 223
Reproduction in whole or in part is prohibited without
written approval.
PRINTED IN AUSTRALIA. May
2007
CONTENTS
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204-0214 Rear Suspension 204-02-4
DESCRIPTION AND OPERATION
suspension will not be correct. The installation .
orientation of the support bearing is indicated with
an arrow.
sensor pick-up ring
1 3 1 stub axle I
1 4 1 Brake back plate assembly with brake I
1 5 1 Bracket I
1 6 1 Spring I
1 7 1 Shock absorber I
A significant modification is the replacement of the
previous Mc-Pherson suspension struts with
separate spring and shock absorber elements. This
results in more space in the area of the suspension
strut turrets, thus increasing the volume of the
luggage compartment. In addition, the forces from
the spring and shock absorber elements are now
dissipated separately and have been individually
optimised.
The shock absorbers are single-tube gas shock
absorbers.
It is important that the correct installation orientation
is adhered to when assembling the support
bearings, as otherwise the geometry of the rear
- -
2006.0 Fiesta 1212006 GI 67083en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Description
Specificatio 1 (,
I
Motorcraft Super Plus 2000 antifreeze
Antifreeze -All vehicles used in climates where daytime ambient air temperature does not regularly
exceed
+46OC (+I 1 5°F)
Specific gravity
(providing no other
additive is in the
coolant) Solidifies
at
Approximate
percentage of anti-
freeze (by volume) Remains
fluid to
Antifreeze
- Vehicles with 1.25U1.4U1 .6L engine used in climates where daytime ambient air
temperature regularly exceeds
+46OC (+I 15OF)
Cooling system, including heater system and coolant expansion tank (all except vehicles
with diesel engine)
1
Specific gravity (providing no other additive is
in the coolant)
Cooling System Refill Capacities Approximate percentage
of antifreeze (by
volume)
Description
I Radiator pressure test I 138 (20) I
Liters
Cooling System Pressure Specification
I Coolant expansion tank cap release pressure I 120 to 150 (17-21) I
Description Pressure kpa (psi)
I Radiator retaining
nut I 10 I - I 89 1
Torque Specifications - vehicles with 1.25U1.4U1 .6L engine
wrpump pulley retaining bolts I 24 I 18 I - I
Ib-in
Description
Thermostat housing retaining bolts
Water pump retaining bolts
I Generator retaining bolts I 45 I 33 I - I
I Generator electrical connector retaining nut I 8 I - I 71 I
Nm
10
10
I Timing belt lower cover retaining bolts I 9 I - I 80 I
I b-ft
Torque Specifications
- vehicles with I .3L engine 1
-
-
I Description I Nm I Ib-ft I Ib-in I,,.
89
89
I Radiator retaining nut I 10 I - I 89 1 '\..
I Water pump pulley retaining bolts I 12 I 9 I - I
Water pump retaining bolts
2006.0 Fiesta 1212006 Gl46257en
10 - 89
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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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Fuel Charging and Controls - 2.OL
303-04B-8 Duratec-HE (M14) 303-04B-8
DIAGNOSIS AND TESTING
lntake manifold
item Description
I 1 I Intake manifold tuning (IMT) swirl plates I Inspection and Verification
121
lntake manifold runner control (IMRC)
throttle plates
The intake manifold for both Ethanol
E85 and
standard unleaded fueled vehicles is the same
construction.
Built into the intake manifold, are the
IMRC throttle
plates and IMT swirl plates.
Under low demand throttle conditions, the air
charge is delivered to the cylinder head intake ports
through the primary air intake chambers. The clean
flow of the air charge is disturbed by the IMT swirl
plates to assist in the mixing of the air fuel mixture
at the fuel injectors.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual lnspection Chart
I Mechanical I Electrical I
- Fuel leak(s)
- Vacuum line(s)
- Gasket(s)
- Seal(s)
- Fuel injector(s)
- Throttle body
- Fuel rail
- Powertrain control
module (PCM)
- Wiring harness
- Electrical
connector(s)
- Throttle body
- Fuel injector(s)
2006.0 Fiesta 1212006 GI 65371en
During high demand throttle conditions, the IMRC
throttle plates are opened and the air charge is - Fuel supply line
allowed to use both primary and secondary intake
chambers. This means a higher volume of air 3. If an obvious cause for an observed or reported
charge can be accommodated by the intake concern
is found, correct the cause (if
possible) (
before proceeding to the next step. \. . manifold. During this high demand throttle
condition, the IMT swirl plates are fully open so as
4. If the cause is not visually evident, verify the
not to restrict the air charge flow.
symptom and refer to the Symptom Chart.
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