2007 FORD FIESTA air bleeding

303-01 8-1 20 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 20
INSTALLATION
57. Connect the cooling fan motor and cooling
fan resistor electrical connectors.
58. Install the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
59. Adjust the gearshift cables.
For additional information, refer to:
Gearshift Cable Adjustment (308-00
Manual
Transmission/Transaxle and
Clutch
- General Information, General
Procedures).
60. Bleed the hydraulic clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
61. Install the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and Installation).
62. Install the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (3031 2
Intake Air Distribution and Filtering,
Removal and Installation).
63. Fill and bleed 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).
2006.0 Fiesta 1212006 G451291 en
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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.
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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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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 - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
303-03A-21 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-21
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 404 0)
Removal
Vehicles built up to 0412005
Loosen the water pump pulley retaining
bolts.
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect
(414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove 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).
3. Drain the cooling system.
6. Lower the vehicle. For additional information, refer to: Cooling
System Draining, Filling and Bleeding - 1.3~ 7. Disconnect the degas hose from the coolant
Duratec-8V (Rocam)ll.25L Duratec-1 6V expansion tank.
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma) (303-03 Engine
Cooling - 1.3L DuratecdV (Rocam)ll.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma), General
Procedures).
4. Remove the crankshaft
pulley splash shield.
5m AWARNING:D~ not remove the water pump
pulley retaining bolts at this stage as the
pulley is under tension from the accessory
drive
belt. Failure to follow this instruction
may
result in personal injury. 8.
Detach the
coolant expansion tank and
secure
it to one side.
2006.0 Fiesta 1212006 GI 89080en
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Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-1 6V (Sigma)llI4L
303-03A-22 Duratec-1 6V (Sigma)lIl6L Duratec-1 6V (Sigma) 303-03A-22
REMOVAL AND INSTALLATION
9. Remove the generator.
For
additional information, refer to:
Generator
- 1.25L Duratec-1 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V
(Sigma)
(414-02 Generator and Regulator,
Removal and Installation).
10. Remove the water pump pulley.
Discard the gasket.
Vehicles built 0412005 onwards
13. Remove the timing belt.
For additional information, refer to: Timing
Belt (303-01 Engine - 1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma), ln-vehicle Repair).
11. Remove the timing belt cover (cover shown 14. Drain the cooling system,
removed for clarity). For additional information, refer to: Cooling
12' &AUTION:P~~~~~~ the timing belt and
lower cover from contamination by the
coolant.
Remove the water pump. 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)ll.25L Duratec-I 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma), General Procedures).
15. Remove the water pump and the timing
belt
tensioner.
Discard the gasket.
2006.0 Fiesta 1212006 GI 89080en
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303-03B-11 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-1 I
DIAGNOSIS AND TESTING
Symptom
The engine overheats (signs of
coolant boiling)
Possible Sources Action
Cooling system does not hold
pressure. INSPECT
the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary. INSPECT the coolant pump or
coolant pump gasket for
damage. 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).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.3L Duratec-8V
(Rocam), In-vehicle Repair). -
Air in cooling system. BLEED the cooling system.
REFER to: Cooling System
Draining, Filling and Bleeding
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
Coolant expansion tank cap or
seal(s).
CHECK the coolant expansion
tank cap for tightness and damage. INSTALL a new
coolant expansion cap as
necessary.
Coolant expansion tank. INSPECT
the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
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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