2007 FORD FIESTA coolant system

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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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
procarmanuals.com

Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
303-03A-I I Duratec-1 6V (Sigma)/lI6L Duratec-I 6V (Sigma) 303-03A-1 I
DIAGNOSIS AND TESTING
Symptom
The engine overheats (signs of
coolant boiling)
Possible Sources Action
Cooling system does not hold
pressure.
Radiator. CARRY
OUT the Coolant
Expansion Tank Cap Test
Component Test in this section.
INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
INSPECT the water pump or
water pump gasket for damage.
INSTALL a new water pump or
water pump gasket as neces-
sary.
REFER to: Water Pump
- 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling
- 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V
(Sigma)ll.4L Duratec-
16V
(Sigma)/l .6L Duratec-
16V (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), Removal and
Installation).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine
- 1.25L Duratec-
16V
(Sigma)/l.4L Duratec-
1 6V
(Sigma)/l .6L Duratec-
16V (Sigma), In-vehicle
Repair).
INSPECT the radiator for
blockage or damage. 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)ll.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation).
2006.0 Fiesta 1212006 GI 46258en
procarmanuals.com

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-I 2 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-12
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
2006.0 Fiesta 1212006 Gl46258en
Air in system.
Coolant expansion tank cap or
seal.
Coolant expansion tank.
BLEED the cooling system.
REFER to:
Cooling System
Draining,
Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), General Proced-
u res)
.
CHECK the coolant expansion
tank cap for tightness. If OK,
CARRY OUT the
Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.
procarmanuals.com

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.
procarmanuals.com

Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-16 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-16
DIAGNOSIS AND TESTING
Component Tests
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.
Install the special tools to the coolant expansion
tank.
3. Pressurize the system to the
coolant expansion
tank cap
release pressure.
REFER to: Specifications (303-03 Engine
Cooling - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma),
Specifications).
4. Observe the
cooling system pressure tester
gauge reading for
approximately two minutes.
The pressure
should not drop during this time.
If the system holds pressure, proceed to step
6.
If the system does not hold pressure, check
it
thoroughly for coolant leaks.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and
fill and bleed the cooling system as
necessary.
REFER to:
Cooling System Draining, Filling and
Bleeding - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma) (303-03
Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V
(Sigma), General Procedures).
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 - 1.3L
Duratec-8V (Rocam)/l.25L Duratec-I 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-I 6V (Sigma), 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. l-
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
make sure the pressure test reading is
repeatable and within acceptable gauge reading
limits of the coolant expansion tank cap.
5.
If the pressure test gauge readings are not
within the
acceptable gauge reading limits,
INSTALL a new coolant expansion tank cap.
6. Recheck the system by repeating steps 3 and
4 at least twice.
Thermostat Test
Radiator Leak Test, Removed From Vehicle
A CAUTI0N:Radiator internal pressure must
not exceed
130 kpa (20 psi) or damage may
result.
1. 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) sensort
CHT - cylinder head temperature (CHT) sensori
LOAD - engine load
VSS - vehicle speed sensor (VSS)
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - I .3L Duratec-8V
(Rocam)llm25L Duratec-1 6V (Sigma)ll.4L
303-03A-17 Duratec-1 6V (Sigma)/lm6L Duratec-1 6V (Sigma) 303-03A-17
DIAGNOSIS AND TESTING
RPM - engine speed
i 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
I A I Thermostat opens I
B Thermostat settles into a cyclic open and
I I closure pattern
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
100°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:
Volts
OCelsius
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
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
80
90
100
11 0
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.
2006.0 Fiesta 1212006 GI 46258en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-19 Duratec-1 6V (Sigma)lll6L Duratec-I 6V (Sigma) 303-03A-19
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding - 1.3L Duratec-8V
I (Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l.6L Duratec-1 6V (Sigma)(24 122 0)
Draining 5. Install the radiator drain plug.
la AWARNING:~~~~ releasing the cooling 6. Lower the vehicle.
system pressure, cover the coolant
expansion tank cap with a thick cloth to
Filling and Bleeding
prevent the possibility of scalding. Failure 1. Remove the radiator bleed plug (if equipped). to follow this instruction may result in
personal injury.
Release the cooling system pressure by
slowly turning the coolant expansion tank
cap a quarter of a turn.
2. Fill the coolant expansion tank until coolant
is expelled from the radiator bleed point or
stabilizes at the MAX mark (whichever occurs
first).
3. Install the radiator bleed plug (if equipped). 2. Remove the coolant expansion tank cap. 4. Fill the coolant expansion tank to the MAX 3. Raise and support the vehicle.
mark (if necessary).
For additional information, refer to: Lifting
(1 00-02 Jacking and Lifting, Description
and Operation).
4. Drain the cooling system.
Allow the coolant to drain into a suitable
container.
5.
Start and run the engine at 3000 revolutions
per minute (RPM) for two minutes.
6. Fill the coolant expansion tank completely.
7. Install the coolant expansion tank cap.
8. Start and run the engine at 3000 RPM for
another two minutes.
2006.0 Fiesta 1212006 G146259en
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