2007 FORD FIESTA contents

21 1-03-1 Steering Linkage 21 1=03-I
SECTION 211 -03 Steering Linkage
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
............................................ Specifications..
DIAGNOSIS AND TESTING
........................................................................\
....................................... Steering Linkage..
REMOVAL AND INSTALLATION
Tie Rod End
........................................................................\
.......................... (1 3 273 0)
Steering Gear Boot ........................................................................\
................. (1 3 134 0)
........................................................................\
................................... Tie Rod (1 3 263 0)
PAGE
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21 1-04-1 Steering Column 21 I -04-1
SECTION 211 -04 Steering Column
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications.. ........................................................................\
............................................ 2 1 1 -04-2
DIAGNOSIS AND TESTING
Steering Column ........................................................................\
.........................................
REMOVAL AND INSTALLATION
Steering Wheel ........................................................................\
....................... (1 3 524 0)
Steering Column ........................................................................\
................. (1 3 542 0)
DISASSEMBLY AND ASSEMBLY
Steering Column ........................................................................\
..................... (1 3 543 4)
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21 1-05-1 Steering Column Switches 21 1-05-1
SECTION 211 -05 Steering Column Switches
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
REMOVAL AND INSTALLATION
Ignition Switch ........................................................................\
........................ (36 424 0) 2 1 1 -05-2
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303-00-1 Engine System = General Information 303-00-1
SECTION 303-00 Engine System . General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
DESCRIPTION AND
OPERATION
Engine
........................................................................\
......................................................... 303-00-3
Engineltransmission combinations ........................................................................\
........ 303-00-3
DIAGNOSIS AND TESTING
........................................................................\
.......................................................... Engine
. Engine Oil Leaks ........................................................................\
........................................
Ultraviolet (UV) Testing ........................................................................\
...............................
Measure the compression pressure ........................................................................\
...........
.............. Measure the compression pressure (Engine . 1.4L Duratorq-TDCi (DV) Diesel)
Measure the compression pressure (Engine
. 1.6L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine . 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V
........................................................................\
......... (Sigma)ll . 6L Duratec-I 6V (Sigma))
Measure the compression pressure (Engine
. 1.3L Duratec-8V (Rocam)) ........................
Measure the compression pressure (Engine . 2.OL Duratec-HE (M14)) .............................
. Measure the oil pressure (Engine 1.4L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.6L Duratorq-TDCi (DV) Diesel) ...............................
Measure the oil pressure (Engine . 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V
........................................................................\
......... (Sigma)/l . 6L Duratec-1 6V (Sigma))
. Measure the oil pressure (Engine 1.3L Duratec-8V (Rocam)) .........................................
. Measure the oil pressure (Engine 2.OL Duratec-HE (M14)) ...............................................
Valve train analysis . static (engine off) ........................................................................\
......
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
........................................................................\
..........
Camshaft Bearing Journal Clearance ........................................................................\
.........
Camshaft End Play ........................................................................\
.....................................
Camshaft Surface Inspection ........................................................................\
.....................
........................................................................\
...................................... Camshaft Lobe Lift
Crankshaft Main Bearing Journal Diameter
........................................................................\

Crankshaft End Play ........................................................................\
...................................
Cylinder Bore Taper ........................................................................\
....................................
Piston Inspection ........................................................................\
........................................
Piston Pin to Bore Diameter ........................................................................\
.......................
Piston Diameter ........................................................................\
..........................................
Piston Ring End .Gap ........................................................................\
...................................
............................................ ................................... Piston Ring-to-Groove Clearance ......
Piston Pin Diameter ........................................................................\
.....................................
Connecting Rod Large End Bore ........................................................................\
................
Valve Stem Diameter ........................................................................\
..................................
Flywheel Inspection ........................................................................\
....................................
............................................... Flywheel Inspection - Vehicles With: Dual Mass Flywheel
Cylinder Head Distortion ........................................................................\
.............................
Cylinder Block Distortion ........................................................................\
.............................
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303-01 A-I Engine
. 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I
6V (Sigma)ll . 6L Duratec-1 6V (Sigma)
303-01 A-I
SECTION 303-01A Engine . 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)/l . 6L Duratec-1 6V
(Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
.............................................. Specifications
Engine Data
. 1.25L ........................................................................\
................................
Engine Data . I . 4L ........................................................................\
..................................
Engine Data . 1.6L ........................................................................\
..................................
Oil pressure ........................................................................\
.............................................
Engine Oil Capacity . - 1.25Ll1.4L ........................................................................\
............
Engine Oil Capacity - 1.6L ........................................................................\
......................
Valve Clearance - 1.25LlI . 4L ........................................................................\
..................
Valve Clearance - 1.6L ........................................................................\
............................
Cylinder block - 1.25L ........................................................................\
.............................
Cylinder block - 1.4L ........................................................................\
...............................
........................................................................\
............................... Cylinder block - 1.6L
........................................................................\
.......................................... Cylinder head
Piston
-1.25L ........................................................................\
...........................................
Piston -1.4L ........................................................................\
.............................................
Piston - l.6L ........................................................................\
............................................
PAGE
DESCRIPTION AND OPERATION
........................................................................\
......................................................... Engine 303-01A-9
........................................................................\
.................... 1.4Ll1.6L Duratec 16V engine 303-01A-9
DIAGNOSIS AND TESTING
........................................................................\
......................................................... Engine 303-01A-12
GENERAL PROCEDURES
........................................................................\
....................... Valve Clearance Adjustment 303-01 A-I 3
IN-VEHICLE REPAIR
Crankshaft Front Seal ........................................................................\
......... (21 467 0)
Valves ........................................................................\
..................................... (21 21 5 4)
Intake Manifold ........................................................................\
....................... (21 183 0)
Valve Cover ........................................................................\
............................ (21 141 0)
Valve Seals ........................................................................\
............................. (21 238 0)
Camshafts ........................................................................\
........................ (21 284 0)
Camshaft Seal ........................................................................\
................... (21 288 0)
Timing Belt ........................................................................\
.......................... (21 304 0)
Exhaust Manifold ........................................................................\
.................... (21 187 0)
Cylinder Head ........................................................................\
...................... (21 163 0)
Oil Pan ........................................................................\
............................. (21 154 0)
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303-01 B-I Engine -- 2.OL Duratec-HE (M14) 303-01 B-1
SECTION 303-01 B Engine . 2.OL Duratec-HE (M14)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
........................................................................\
.............................................. Specifications
Engine Data
........................................................................\
............................................
Engine Oil ........................................................................\
...............................................
........................................................................\
............................................... Oil system
Engine Oil Capacity
........................................................................\
................................
Valve Dimensions ........................................................................\
...................................
Camshaft Dimensions ........................................................................\
.............................
Crankshaft Dimensions ........................................................................\
...........................
Piston Dimensions ........................................................................\
..................................
Cylinder Head ........................................................................\
.........................................
Cylinder Block ........................................................................\
.........................................
PAGE
DESCRIPTION AND OPERATION
Engine ........................................................................\
......................................................... 303-01 8-8
DIAGNOSIS AND TESTING
Engine ........................................................................\
.........................................................
GENERAL PROCEDURES
........................................................................\
....................... Valve Clearance Adjustment
IN-VEHICLE REPAIR
Intake Manifold ........................................................................\
................. (21 183 0)
Crankshaft Front Seal ........................................................................\
............. (21 467 0)
Crankshaft Pulley ........................................................................\
................... (21 5720)
Valve Seals ........................................................................\
....................... (21 238 0)
Valves ........................................................................\
................................. (21 2154)
Camshafts ........................................................................\
.......................... (21 284 0)
Oil Pan ........................................................................\
................................. (21 154 0)
Oil Pump ........................................................................\
.............................. (21 714 0)
Crankshaft Rear Seal ........................................................................\
.......... (21 468 4)
Engine Front Cover ........................................................................\
............. (21 148 0)
Exhaust Manifold ........................................................................\
........................................
Timing Chain ........................................................................\
........................ (21 314 0)
Cylinder Head ........................................................................\
....................... (21 163 0)
REMOVAL
Engine ........................................................................\
.........................................................
DISASSEMBLY
Engine ........................................................................\
................................ (21 134 8)
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Engine Cooling - I .3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llm4L
303-03A-1 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-03A-I
i
SECTION 303-03A 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)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................\
....................................... 303-03A-2
DESCRIPTION AND OPERATION
Engine Cooling - 1.4L Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) ......................... 303-03A-4
Overview..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-4
Components..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-5
DIAGNOSIS AND TESTING
Engine Cooling ........................................................................\
........................................... 303-03A-8
Inspection and Verification
........................................................................\
...................... 303-03A-8
j Symptom Chart ........................................................................\
........................................... 303-03A-8
Component Tests..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03A-4 6
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding - I .3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V (Sigma)/l.GL
Duratec-1 6V (Sigma). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 122 0) 303-03A-19
Draining
........................................................................\
...................................................... 303-03A-19
Filling and Bleeding
........................................................................\
.............................. 303-03A-19
REMOVAL AND INSTALLATION
Water Pump - 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-1 6V (Sigma). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 404 0) 303-03A-21
Thermostat
- 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma) ........................................................................\
........... . (24 454 0) 303-03A-24
Radiator
........................................................................\
.................................. (24 254 0) 303-03A-26
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303-03B-1 Engine Cooling -- 2.OL Duratec-HE (M14) 303-03B-1
SECTION 303-03B Engine Cooling . 2.OL Duratec-HE
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications
........................................................................\
.............................................. 303-038-2
DESCRIPTION AND OPERATION
Engine Cooling
........................................................................\
...................................... 303-038-3
System Overview
........................................................................\
.................................. 303-038-3
........................................................................\
............................................... Components 303-038-4
........................................................................\
....................................................... Coolant 303-038-7
........................................................................\
....................................... Changing Coolant 303-038-7
Fail-safe Cooling
........................................................................\
........................................ 303-038-8
DIAGNOSIS AND TESTING
........................................................................\
........................................... , Engine Cooling 303-038-9 ........................................................................\
.......................... , Inspection and Verification 303-038-9
Symptom Chart ........................................................................\
........................................... 303-038-9
........................................................................\
........................................ Component Tests 303-038-1 3
GENERAL PROCEDURES
.............................................. Cooling System Draining. Filling and Bleeding (24 1 22 0) 303-038-1
7
Draining
........................................................................\
...................................................... 303-038-1 7
Filling and Bleeding
........................................................................\
.................................... 303-038-1 7
REMOVAL AND INSTALLATION
Coolant Pump
........................................................................\
....................... (24 404 0) 303-038-19
Thermostat Housing
........................................................................\
................................ 303-038-21
Coolant Outlet Connector
........................................................................\
........................... 303-038-24
........................................................................\
.................................. Radiator (24 254 0) 303-038-26
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