2007 FORD FIESTA fuel tank removal

100-00-12 General Information 100-00-12
DESCRIPTION AND OPERATION
Gross or prolonged skin contact with high boiling
point gas oils may also cause serious skin
disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning
agent.
Flammable
- observe No Smoking policy.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause
irritation or dermatitis. Splashes in the eye may be
slightly irritating.
In normal circumstances the low volatility does not
give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there
is adequate ventilation.
Alternative Fuel
Highly flammable. Observe "NO SMOKING" signs.
Make sure there is adequate ventilation when
working on alternative fuelled vehicles. Great care
must be taken to avoid the serious consequences
of inhalation in the event of vapor build up in
confined spaces.
Inhalation in high concentrations may cause
dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result
in loss of consciousness.
Contact with liquefied petroleum gas (LPG) or
compressed natural gas (CNG) to the skin may
cause cold burns and frost bite.
Long sleeved cotton overalls, steel toe capped
safety boots and rubber neoprene gloves should
be worn during removal and installation of
LPGICNG fuel system components.
LPGICNG fuel leaks could cause a fire and be a
hazard to health that can lead to personal injury,
illness or even death.
If a leak is detected, under no circumstances
attempt to seal the leak by tightening the
unionlconnection until the fuel in the system or
component is depressurized. Once tightened the
system should be checked for integrity following
the specified procedures. If
the fuel tank is to be removed for service or repair
the fuel must be evacuated using dedicated
equipment and following the specified
procedures. (
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and
propane are normally stored in cylinders at
pressures of up to
138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the valve
gear attached. The contents of each cylinder
should be clearly identified by appropriate
markings.
Cylinders should be stored in well-ventilated
enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
and propane, should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from
gas cylinders and lines, and to avoid sources of
ignition.
Only trained personnel should undertake work
involving gas cylinders.
Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
See Viton.
General Workshop Tools and
Equipment
It is essential that all tools and equipment are
maintained in good condition and that the correct
safety equipment is used where required.
Never use tools or equipment for any purpose other
than that for which they were designed. Never
overload equipment such as hoists, jacks, axle and
chassis stands or
lifting slings. Damage caused by
overloading is not always immediately apparent
and may result in a fatal failure the next time that
the equipment is used.
2006.0 Fiesta 1212006 GI 7372en
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100-00-1 9 General Information 100-00-1 9
DESCRIPTION AND OPERATION
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
- the parking brake is applied or the wheels are
securely chocked to prevent the vehicle moving
forwards or backwards.
- the key is removed from key operated hood
locks before any work is carried out around the
front of the vehicle.
- if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
- there is adequate room to raise the vehicle and
remove the wheels, if necessary.
- fender covers are always fitted if any work is to
be carried out in the engine compartment.
- the battery is disconnected if working on the
engine, underneath the vehicle, or if the vehicle
is raised.
Alternative Fuel - Dons
- Do work on the vehicle in a designated area,
that is well ventilated and with access restricted
to qualified personnel only.
- Install new warning labels to their original
locations.
- If possible always isolate the alternative fuel
tank, and run the vehicle on the alternative fuel
until it automatically switches to its normal fuel
prior to taking the vehicle into the workshop
service area.
- Only use tested and approved components and
pipes when repairing or servicing
LPG and CNG
systems.
Alternative Fuel - Do Nots
- Do not vent off LPG fuel.
- Do not use shop air pressure to force LPG fuel
from the fuel tank.
( A CAUTION:When electric arc welding on a - Do not use paint drying ovens above 40°C for vehicle, always disconnect the generator any alternative fuel vehicle. LPG and CNG fuel wiring to prevent the possibility of a surge tanks must be removed from the vehicle prior of current causing damage to the internal to being put into paint drying ovens above 40°C. components of the generator. - Do not modify the system or install new - if using welding equipment on the vehicle, a
components that are not designed for gas
suitable fire extinguisher is readily available.
vehicles.
Alternative Fuel
A WARNING:When servicing the fuel system
always follow the recommended
procedures. Failure to follow these
instructions may result in personal injury.
If the odor of liquefied petroleum gas (LPG) or
compressed natural gas
(CNG) is present in the
air in the workshop, warn all persons in the area
to:
- extinguish all flames and lighted tobacco.
- shut off electrical and air powered equipment.
- evacuate the area.
- ventilate the area.
- contact the fire control authorities.
- remove the vehicle to a dedicated, ventilated
area.
- Do not evacuate fuel tanks unless there is repair
that requires the removal of the fuel tank.
- Do not work on the fuel lines or system
components unless the alternative fuel has been
evacuated and the pressure in the system
reduced to atmospheric or less.
- Do not use anything other than the specified
leak detector fluid to trace fuel leaks.
Be aware of situations that may cause the
LPG or I
CNG fuel system to vent off fuel, such as: I
- extremely hot days.
- parking by a space heater.
- hoisting a vehicle up near a ceiling heater.
Only fully trained personnel, who are conversant
with local standards, are to work on alternative fuel
vehicles.
2006.0 Fiesta 1212006 GI 7373en
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303-00-8 Engine System - General Information 303-00-8
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 GI 52554en
Water
in fuel (diesel engine
only).
Fuel filter blocked.
Engine intake air system.
Glow plug faulty (diesel engine
only).
Engine management system.
. Drain the water from the fuel
system. Engine
- I .4L
Duratorq-TDCi (DV)
DiesellEngine - 1.6L Duratorq-
TDCi (DV) Diesel.
REFER to: Fuel System
- I .4L
Duratorq-TDCi (DV)
Diesel11 .6L Duratorq-TDCi
(DV) Diesel (31 0-00 Fuel
System
- General Informa-
tion, Diagnosis and Testing).
INSTALL a new fuel filter.
REFER to: (31 0-01 Fuel Tank
and Lines)
Fuel Filter
- 1.4L Duratorq-TDCi
(DV) Diesel (Removal and
Installation),
Fuel Filter
- I .6L Duratorq-TDCi
(DV) Diesel (Removal and Installation).
CHECK the intake air system.
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering, Diagnosis and
Testing).
. CHECK the glow plugs.
INSTALL new glow plugs as
necessary. REFER to:
Glow Plug (303-07 Glow Plug
System - 1.4L Duratorq-TDCi
(DV) Diesel, Removal and
Installation),
Glow Plugs (303-07 Glow Plug
System - 1.6L Duratorq-TDCi
(DV) Diesel, Removal and
Installation).
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic Engine Controls, Diagnosis
and Testing).
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Engine - I .25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
REMOVAL
7. Disconnect the fuel return line quick release 10. Detach the power steering fluid reservoir
coupling. from
the bracket and position
it to one side.
i For additional information, refer to: Quick
Release Coupling
(310-00 Fuel System -
General Information, General Procedures).
8. Disconnect the fuel supply line quick release
coupling.
For additional information, refer to: Quick
Release Coupling
(310-00 Fuel System -
General Information, General Procedures).
9. Detach the fuel line and the degas line from
the intake manifold.
Remove the cable tie. 11.
Using
the special tool, disconnect the
degas hose from the cylinder head.
12. Detach the coolant expansion tank from
the bracket and position
it to one side.
2006.0 Fiesta 1212006 GI 131 63en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-83 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-83
REMOVAL
7. Disconnect the fuel return line quick release 10. Detach the power steering fluid reservoir
coupling. from the
bracket and position
it to one side.
For additional information, refer to: Quick
Release Coupling
(31 0-00 Fuel System -
General Information, General Procedures).
8. Disconnect the fuel supply line quick release
coupling.
For additional information, refer to: Quick
Release Coupling
(310-00 Fuel System -
General Information, General Procedures).
9. Detach the fuel line and the degas line from
the intake manifold.
Remove the cable tie.
11. Using the special tool, disconnect the
degas hose from the cylinder head.
12. Detach the coolant expansion tank from
the bracket and position
it to one side.
2006.0 Fiesta 1212006 G380458en
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Engine - I .25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 32 Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) 303-01 A-1 32
INSTALLATION
64. Attach the coolant expansion tank to the
67. Attach the power steering fluid reservoir to
bracket. the bracket.
1'
65. Using the special tool, connect the degas
68. Tighten the strut and spring assembly top
hose to the cylinder head.
mount nuts on both sides.
66. Attach the fuel line and the degas line to
69. Connect the powertrain control module
the intake manifold.
(PCM) electrical connector.
Install the cable tie. For additional information, refer to:
Powertrain Control Module (PCM)
- 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-14
Electronic Engine Controls, Removal and
Installation).
70. Install the air cleaner.
For additional information, refer to: Air
Cleaner
- 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (303-12 Intake Air Distribution
and Filtering, Removal and Installation).
71. Install the front wheels and tires.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires,
c,
Removal and Installation). (\,
2006.0 Fiesta 121zo06 GII 31 64en
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Fuel Charging and Controls - 2.OL
303-048-1 2 Duratec-HE (M14) 303-04B-12
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Incorrect or contaminated fuel. CHECK for signs of
tion such as strange odors from
the fuel tank.
If contaminated fuel is found,
DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(31
0-OOA, General Proced-
u res)
.
INSTALL a new fuel filter.
INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
INSTALL a new fuel rail.
REFER to: Fuel Injection
Supply Manifold
(303-04C,
Removal and Installation).
Low fuel system pressure. Check the fuel system pres-
sure.
RE.FER to: Fuel System Pres-
sure Check (31
0-OOA,
General Procedures).
I Fuel filter blocked. I INSTALL a new fuel filter. I
EGR valve sticking open. REFER to: Engine Emission
Control (303-08 Engine
Emission Control
- 2.OL
Duratec-HE (M14), Diagnosis
and Testing).
INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
CKP sensor. Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
Knock sensor (KS). Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
Fuel injection supply manifold
fuel pressure sensor. Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
2006.0 Fiesta 1212006 GI 65371 en
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Fuel Charging and Controls - 2.OL
303-048-1 4 Duratec-HE (M14) 303-04B-14
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
lncorrect or contaminated fuel. CHECK for signs of
tion such as strange
the fuel tank.
If contaminated fuel is found,
DRAIN the complete fuel
system. FLUSH the
through with clean gasoline.
REFER to: Fuel Tank Draining
(31
0-OOA, General Proced-
ures).
INSTALL a new fuel filter.
INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
INSTALL a new rail.
REFER to: Fuel Injection
Supply Manifold
(303-04C,
Removal and Installation).
I Fuel filter blocked. I INSTALL a new fuel filter. I
REFER to: Engine Emission
Control (303-08 Engine
Emission Control
- 2.OL
Duratec-HE (M14), Diagnosis
and Testing).
I
Vehicle speed sensor (VSS). Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
ECT sensor. Carry out a full engine
diagnosis using the guided diagnostic menu in WDS.
Fuel injectors. INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
Fuel rail fuel pressure sensor. Carry out a full engine
diagnosis using the guided
diagnostic menu in WDS.
I Incorrect valve timing. I CHECK the valve timing. I
Low cylinder compression.
--
CHECK the cylinder compres-
sion.
2006.0 Fiesta 1212006 GI 65371 en
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