2007 FORD FIESTA Air con

Engine Cooling - 2.OL Duratec-HE (M14)
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
I Accessory drive belt. CHECK the condition of the
accessory drive belt.
REFER to: Accessory Drive
(303-05 Accessory Drive,
Diagnosis and Testing).
Cooling fan.
CHECK the operation of the
I cooling fan. REFER to WDS.
Engine. INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head
(303-
01 Engine - I .3L Duratec-8V
(Rocam), I n-vehicle Repair).
The engine does not reach
normal operating temperature. CHECK the ECT sensor.
I REFER to WDS.
Temperature gauge. CHECK the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (41 3-01 lnstrument
Cluster, Diagnosis and
Testing)
I lnstrument Cluster - Vehicles
Built From:
1012005 (41 3-01
lnstrument Cluster, Removal
and Installation).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
REFER to: Thermostat Housing (303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation).
Component Tests
Pressure Test
A WARNING:When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to
- prevent the possibility of coolant scalding.
Failure to follow this instruction may result
in personal injury.
N0TE:lf the coolant expansion tank cap is rotated
counterclockwise by 1 12 a full turn, the pressurized
coolant will be vented to the underside of the
coolant expansion tank cap.
1. Remove the coolant expansion tank cap.
2. Install the special tools 303-396 and 303-396-01
to the coolant expansion tank.
3. Pressurize the system to the coolant expansion
tank cap release pressure.
REFER to: Specifications (303-03 Engine
Cooling
- 2.OL Duratec-HE (M14),
Specifications).
2006.0 Fiesta 1212006 G426582en
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303-03B-14 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-14
DIAGNOSIS AND TESTING
4. Observe the cooling system pressure tester make sure the pressure test reading
is
gauge reading for approximately two minutes. repeatable
and within acceptable gauge reading
The pressure should not drop during this time. limits of
the coolant expansion tank cap.
( If the system holds Pressure, proceed to Step 5. If the pressure test gauge readings are not 7. If the system does not hold pressure, check
within the acceptable gauge reading limits,
it thoroughly for coolant leaks.
INSTALL a new coolant expansion tank cap.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
Thermostat Test
necessaw.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), General Procedures).
.Recheck the system by repeating Steps 3 and
4 at least twice.
Radiator Leak Test, Removed From Vehicle
CAUTI0N:Radiator internal pressure must
not exceed
130 kpa (20 psi) or damage may
result.
Clean the radiator thoroughly before leak testing
it, to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 138
kpa (20 psi) air pressure. Check it thoroughly for
air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant
-
expansion tank cap in water.
N0TE:lf the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
3. Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing, and note the highest pressure
reading obtained.
4. Release pressure by turning the pressure relief
screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to
I. Connect the WDS to the data link connector
(DLC).
2. Using the WDS datalogger function, SELECT
the following sensors (as applicable to the
application):
IAT
- intake air temperature (IAT) sensor
ECT
- engine coolant temperature (ECT) sensor
CHT
- cylinder head temperature (CHT) sensor
LOAD
- engine load
VSS
- vehicle speed sensor (VSS)
RPM
- engine speed
DSRPM
- desired engine speed
The IAT sensor output is useful if the engine being
tested is cold or after an over-night cold soak. The
ECT sensor or CHT sensor and the IAT sensor
(
should either indicate the same value or be within
1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as
it indicates the engine warm-up and opening
temperature for the thermostat. It will initially
indicate a slightly higher reading just before the
thermostat opens and then drops back before
settling to a near flat line output (see graphic
below).
Item Description 1'. .
) A 1 Thermostat opens I\
B Thermostat settles into a cyclic open and
I I closure pattern
2006.0 Fiesta 1212006 G426582en
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303-03B-15 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-15
DIAGNOSIS AND TESTING
A CAUTI0N:lf the ECT sensor output reaches
the
120°C default line under normal cooling
system pressure, internal damage may be
caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM.
The test should be stopped and the cause
located and corrected. If the cooling
system does not pressurize, the coolant
will boil at
1 OO°C which may also damage
the engine. CARRY
OUT the Coolant
Expansion Tank Cap Pressure Test
Component Test in this section.
If the WDS only allows the ECT sensor to be
displayed in volts, refer to the following table for
corresponding Celsius values:
The CHT sensor output is useful to examine the
cylinder head temperature rise during the warm-up
cycle and later during the normal light throttle cruise
test. This sensor output may vary between vehicles
with manual transmission and vehicles with automatic transmission and should be used for
reference only.
Volts
1.33
1.02
0.78
0.60
0.46
0.35 0.27
The LOAD display is used for reference as it is
necessary to maintain a stable load line during the
test. It is necessary to carry out the test under
normal light throttle cruise driving conditions and
average loads, typically 40% to 70% of the load
value.
OCelsius
60
70
80
90
100
110
120 '
The VSS output is used for reference but can help
to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and
can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed
which the PCM commands the engine to reach. If
the thermostat opens too early (before the correct
opening temperature has been reached), the
engine will not reach this value. When
using the WDS in data logger mode, the
signals recorded should remain within the
DEFAULT values set by the WDS.
3m AWARNING:M~~~ sure that the WDS is
placed in the vehicle so that it does not
interfere with the safe operation of the
vehicle. Do not place the WDS in the
deployment path of any air bag. Failure to
follow these instructions may result in personal injury.
N0TE:The road test is best carried out with the
aid of another technician in the vehicle to enable
the vehicle to be driven safely while the sensor
outputs are monitored within datalogger. If there
is only one technician available, the WDS can be
set up (using the
recordlcapture mode camera
icon) before leaving the workshop to record a 16
km (1 0 mile) test.
N0TE:The results from the test are more
conclusive if the engine is cold when the test is
started.
Carry out a road test.
REFER to:
RoadIRoller Testing (1 00-00 General
Information, Description and Operation).
4. Drive the vehicle at a constant throttle opening
and set speed until the ECT value settles into
a shallow rise and fall signal, close to a straight
line. This indicates that the thermostat is
functioning correctly.
N0TE:Some thermostats indicate the
temperature(s) in Celsius and Fahrenheit.
The graphic below shows the location and an
example of the opening temperature
(88OC) and
fully open temperature (1
02OC) of a thermostat.
The graphic below shows an alternative method used to show the opening temperature
(88OC) and
fully open temperature
(112OC) of a thermostat.
2006.0 Fiesta 1212006 G426582en
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303-03B-24 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-24
REMOVAL AND INSTALLATION
Coolant Outlet Connector
Removal
1. Remove the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (303-12
Intake Air Distribution and Filtering,
Removal and Installation).
2. Disconnect the spark plug wires from the
ignition coil pack.
4. Remove the ignition coil pack.
5. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling
- 2.OL Duratec-HE
(M14), General Procedures).
6. Disconnect the engine coolant temperature
3. Disconnect the ignition coil pack electrical
(ECT) sensor electrical connector.
connector.
2006.0 Fiesta 1212006 G421228en
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303-03B-26 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-26
REMOVAL AND INSTALLATION
Removal 2. Push the cooling fan motor and shroud l.
upwards and then downwards to remove.
1. Disconnect the battery ground cable. I
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
2. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 2.OL Duratec-HE
(M14), General Procedures).
3. Disconnect the cooling fan motor and
cooling fan resistor electrical connectors.
4. Remove
the air cleaner intake pipe resonator.
5. Remove the cooling fan motor and shroud.
1. Release the cooling fan motor and shroud
from the retaining brackets.
6. Disconnect the radiator upper hose.
1. Pull out the quick release spring clip.
2. Pull the radiator upper hose from the quick
release connector.
7. Disconnect the radiator degas hose from the
radiator.
Release the locking tangs.
8. Remove the radiator retainers.
2006.0 Fiesta 1212006 G457934en
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303-03B-27 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-27
REMOVAL AND INSTALLATION
I. Remove the radiator retainer locking screws.
2. Remove the radiator retainers and grommets.
9. Detach the radiator and the air conditioning
(NC) condenser from the support panel.
Om ACAUTION:S~~~~~~ the AIC condenser
by positioning it on the support panel.
Slide the
NC condenser to detach it from the
radiator
, 11. Remove the radiator. I
Installation
I. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G457934en
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Fuel Charging and Controls - 1.25L
Duratec-1 6V (Sigma)llI4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma)
SPECIFICATIONS
General Specifications
I Maximum idle increase for high generator load I I00 rpm I
Condition
Regulated fuel pressure
l~ir conditioning idle upspeed at low ambient temperatures I 100 rpm I
Specification
380 kpa (55 psi)
I Air conditioning idle upspeed at high ambient temperatures I 150 rpm I
I Power steering idle speed upspeed I 50 rpm I
Toraue S~ecifications
Description Nm I b-ft Ib-in
I Throttle body retaining bolts I 10 1 - I 89 I
I Fuel pressure regulator retaining bolts I 10 I - I 89 I
I Fuel injection supply manifold retaining bolts I 15 I 11 I - I
2006.0 Fiesta 1212006 GI 46265en
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Fuel Charging and Controls - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-I 6V
303-04A-4 (Sigma)ll.GL Duratec-1 6V (Sigma) 303-04A-4
REMOVAL AND INSTALLATION
Throttle Body(23 198 0)
Removal 2. N0TE:Do not press the accelerator pedal
during the initialization period as this will
1. Disconnect the air cleaner outlet pipe from
prevent the complete initialization of the
the throttle body. throttle body.
2. Remove the throttle body retaining bolts. Turn
the ignition key to position
II and wait
for one minute to
initialize the throttle body.
3. Turn the ignition key to the OFF position.
3. Disconnect the throttle body electrical
connector and remove the throttle body.
I nin
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 GI 46266en
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