2007 FORD FIESTA check engine

21 1 -02-36 Power Steering 21 1 -02-36
REMOVAL AND INSTALLATION
4. Remove the front axle crossmember rear Attach the stabilizer bar link to the stabilizer
inner retaining bolt and the special tool on
bar on both sides.
both sides.
9m &~uTl~~:Twistin~ the exhaust flexible 5. Install the front axle crossmember rear inner pipe more than two degrees may cause retaining bolts on both sides.
damage resulting in failure.
N0TE:Use a pry-bar to prevent the exhaust flexible
pipe from twisting when installing the exhaust
flexible pipe to catalytic converter retaining nuts.
N0TE:lnstall a new exhaust flexible pipe to
catalytic converter gasket and retaining nuts.
Install the exhaust flexible pipe to catalytic
converter retaining nuts.
6. Lower and remove the transmission jack and
wooden block.
7. Install the engine support insulator.
8. N0TE:Use a 5 mm Allen key to prevent the
stabilizer bar link ball joint from rotating.
lo' ~CAUTION:T~~~ care when installing the
exhaust hanger insulator to prevent
damage.
N0TE:Check the exhaust hanger insulator for
damage. lnstall a new exhaust hanger insulator if
required.
2006.0 Fiesta 12/2006 G458167en
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211 -02-44 Power Steering 211 -02-44
REMOVAL AND INSTALLATION
Attach the exhaust flexible pipe to the muffler Check the exhaust hanger insulator for
and tailpipe assembly. damage. Install a new exhaust hanger
insulator
if required..
Vehicles with 1.25L, 1.4L or 1.6L engine
15. N0TE:Coat the exhaust flexible pipe studs 17' &AUTION:O~~~ bending of the exhaust
with grease.
flexible pipe may cause damage resulting
N0TE:lnstall a new exhaust flexible pipe to in failure.
catalytic converter gasket and retaining nuts. Remove the exhaust flexible pipe support
Attach the exhaust flexible pipe to the wrap
or splint.
catalytic converter.
*- AwARNING:~~~~~~~ new tie-rod end
All vehicles retaining nuts. Failure to follow this
instruction may result in personal injury.
16' AcAu~~oN:Take care when installing the NOTE:"se a 5 mm Allen key to prevent the tie-rod exhaust hanger insulator to prevent
damage. end ball joint stud from rotating.
2006.0 Fiesta iu2006 GI 05648en
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303-004 Engine System - General Information 303-00-4
DIAGNOSIS AND TESTING
Engine
Special Tool(s)
Socket, Spark Plug
303-499
I Adhesive - Loctite 243 I WSK-M2G349A7 I
Materials
1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
k.
Name S~ecification
Leaks from oil carrying
components or basic engine.
E47332
&
21211
CHECK for cracks in oil
carrying components of the
basic engine by means of a
leak test. INSTALL new
components or seals as
necessary.
2006.0 Fiesta 1212006 GI 52554en
Compression Test Adapter
303-1 052
Pliers, Valve Stem Seal
303-508
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart Symptom Possible Sources Action
Visual
Inspection Chart
Loss of oil Mechanical
- Coolant
leaks
- Oil leaks
- Fuel system leaks
- Visibly damaged or
worn parts
- Loose or missing
nuts or bolts Electrical
- Fuse(s)
- Loose
or corroded
connector(s)
- Powertrain control
module
- Damaged or worn
switch(es)
Oil leaks on components that
are
eithei coated in oil them-
selves or on components local
to them.
Internal or external leak at the
oil cooler.
Leak at the crankshaft seal.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
CHECK for evidence of oil
leaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident, INSTALL
new gaskets or components as
required.
CHECK the coolant expansion
tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
INSTALL a new crankshaft
seal.
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303-00-5 Engine System - General Information 303-00-5
DIAGNOSIS AND TESTING
Symptom
Oil consumption
Possible Sources Action
Use of the wrong type of
engine oil.
Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation or
breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty
and engine oil can enter the
combustion chamber
through the intake manifold.
Turbocharger seals (diesel
engine only).
DETERMINE the last type of
engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
CHECK if the PCV system is
operating correctly and repair
as necessary. REFER to:
Engine Emission Control (303-
08 Engine Emission Control
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 2.OL Duratec-HE (M14),
Diagnosis and Testing),
Engine Emission Control
-
Vehicles With: Vacuum
Exhaust Gas Recirculation
(EGR) Valve (303-08 Engine
Emission Control
- 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 1.6L Duratorq-TDCi (DV)
Diesel, Description and
Operation).
INSTALL a new turbocharger.
REFER to:
Turbocharger (303-04 Fuel
Charging and Controls
-
Turbocharger - I .4L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation),
Turbocharger
- I .6L Duratorq-
TDCi (DV) Diesel (303-04
Fuel Charging and Controls
- Turbocharger - I .6L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation).
2006.0 Fiesta 1212006 GI 52554en
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303-00-6 Engine System - General Information 303-00-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Damaged gaskets or mating
surfaces.
- Cylinder head gasket is
damaged or mating face are
warped.
- Valve stem oil seals are
worn and engine oil can
enter the combustion
chamber between the valve
stem and the valve stem
guide.
Piston ring or cylinder liner
wear.
Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons
- Piston rings (clearance in
groove and end gap)
- Cylinder liners
CHECK the gaskets and
mating surfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine
block mating faces. INSTALL new valve
seals.REFER
to:
Valve Seals (303-01 Engine
-
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)/l .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.3L Duratec-8V (Rocam), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
2.OL Duratec-HE (M14), In-
vehicle Repair),
Valve Seals (303-01 Engine
-
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Valve Seals (303-01 Engine
-
1.6L Duratorq-TDCi (DV)
CHECK the running surfaces
and clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
CHECK the pistons.
REFER to: Piston Inspection
(303-00 Engine System
-
General Information, General
Procedures).
CHECK the piston rings.
REFER to: (303-00 Engine
System
- General Information)
Piston Ring-to-Groove Clear- ance (General Procedures),
Piston Ring End Gap (General
Procedures).
2006.0 Fiesta 1212006 GI 52554en
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303-00-7 Engine System - General Information 303-00-7
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Coolant consumption Cooling system components.
Oil cooler.
CHECK the coooling system.
REFER to:
Engine
Cooling (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 2.OL Duratec-HE
(M14), Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.4L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing),
Engine
Cooling (303-03 Engine
Cooling - 1.6L Duratorq-TDCi
(DV)
Diesel, Diagnosis and
Testing).
INSTALL a new oil cooler.
Damaged gaskets or warped
mating faces. CHECK the cylinder head
gasket for damage. CHECK the
cylinder head for distortion. - -- - -
Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
- - - - - - - -
DETERMINE the damaged
engine
component(s) and
install new component(s) as
necessary.
Engine will not crank Battery or cables. CHECK the battery, bracket
and
cables.
REFER to: Battery (41 4-01
Battery, Mounting and
Cables, Diagnosis and
Testing).
Starter motor or cables. I CHECK the starting system.
REFER to: Starting System
(303-06 Starting System,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 52554en
I Engine cranks but will not start Fuel tank is empty. CHECK the fuel level.
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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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303-00-9 Engine System - General Information 303-00-9
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
lgnition system (petrol engines
only).
CHECK the ignition system.
REFER to:
Engine
lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine
lgnition (303-07 Engine
lgnition - 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
Incorrect valve timing. CHECK and adjust the valve
timing. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-I 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), I n-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Broken or damaged timing
beltltiming chain or
pulleylsprocket.
CHECK the timing beltltiming
chain and sprocketslpulleys.
INSTALL new components as
necessary. REFER to:
Timing
Belt (303-01 Engine -
1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-I 6V
(Sigma), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Timing Chain (303-01 Engine
- 2.OL Duratec-HE (M14), In-
vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
2006.0 Fiesta 12,2006 GI 52554en
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