2007 FORD FIESTA Workshop Manual

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 3 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-01 A-I
3
GENERAL PROCEDURES
Valve Clearance Adjustment
1. Remove the valve cover. clearance.
I
General Equipment 2. Tappet thickness required = thickness of
currently installed tappet
+ the measured
For additional information, refer to Valve For additional information, refer to
Cover in this section. Specifications in this section.
3. Install the correct tappet.
*' ~AUTION:O~~Y turn the engine in the 7. NOTE:Do not install the timing belt at this normal direction of rotation.
stage.
Feeler gauges
Turn the engine until piston No. 1 is at top
Install the camshafts.
dead center (TDC).
For additional information, refer to
3. N0TE:Note down each cylinder number and
Camshafts in this section.
the valve clearances measured.
8. N0TE:Turn the camshafts to measure the
Using a suitable set of feeler gauges,
valve clearances.
measure the valve clearances.
Measure the valve clearances and repeat this
valve clearance - the required valve
procedure as necessary until all valve
clearances are within the specified tolerance.
9. Install the timing belt.
For additional information, refer to Timing
Belt in this section.
10, Install the valve cover.
For additional information, refer to Valve
Cover in this section.
4m ~CAUTION:O~I~ turn the engine in the
normal direction of rotation.
Turn the engine until each piston is at TDC
and measure the valve clearances.
5. N0TE:Only carry out the following steps
when the valve
clearance(s) require
adjustment.
For additional information, refer to
Specifications in this section.
Remove the camshafts.
For additional information, refer to
Camshafts in this section.
6. N0TE:The number on the tappet indicates
the tappet thickness.
Determine the tappet thickness required:
1. Remove the tappet and read the thickness
from the underside.
2006.0 Fiesta 1212006 GI 56806en
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303-01 A-I 4 Engine
- 1.25L Duratec-1 6V (Sigma)llm4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1 6V (Sigma) 303-01 A-I 4
IN-VEHICLE REPAIR
Crankshaft Front Seal(21 467 0)
('-
Special Tool(~) 3.
Using the special tool, remove the crankshaft
Materials
Removal
front oil seal.
Installation
21171
1. Coat the crankshaft front oil seal lip with
Engine Oil I WSS-M2C912-A1
1. Remove the timing belt.
Remover, Crankshaft Oil Seal
303-293 (2 1 -1 43)
Installer, Crankshaft Oil Seal
303-395 (21 -1 71
)
Name S~ecification clean engine oil.
2. Using the special tool, install the crankshaft
For
additional information, refer to: Timing
Belt (303-01 Engine - 1.25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma), ln-vehicle Repair). front
oil seal.
2.
Remove the crankshaft timing pulley.
3. Install the crankshaft timing pulley.
2006.0 Fiesta lu2006 G21046en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 5 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-01A-I 5
IN-VEHICLE REPAIR
4. Install the timing belt.
1 For additional information, refer to: Timing I Belt (303-01 Engine - I .25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V (Sigma)ll .6L
Duratec-1 6V (Sigma), Invehicle Repair).
2006.0 Fiesta 1212006 G21046en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-OIA-I 6 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-OIA-I 6
IN-VEHICLE REPAIR
Special Tool(s1
Compressor, Valve Spring
303-36 1 (2 1
-1 55)
Adaptor for 303-361
303-36 1 -04 (2 1 -1 55-04)
I I Adaptor for 303-361 - I
4. Remove the valve springs.
Materials Name Specification
I Engine Oil I WSS-M2C912A1 I
*' ~CAUTION:K~~~ the valve tappets in order\-
for reassembly.
Remove the valve tappets.
3. N0TE:lnset-t wooden wedges in the
combustion chamber recesses in the
cylinder head so that the valves are held in
place for removal.
Install the special tools.
I I Installer, Valve Stem Collets I
I I Pliers, Valve Stem Oil Seals I
Removal
1. Remove the cylinder head.
For additional information, refer to Cylinder
head in this section.
Compress the valve springs.
Remove the valve collets.
Remove the valve spring retainers and the
valve springs.
5. Using the special tool, remove the valve
seals.
2006.0 Fiesta 1212006 G21048en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
-01A-17 Duratec-1 6V (Sigma)/l.GL Duratec-1 6V (Sigma) 303-OIA-1 7
IN-VEHICLE REPAIR
Discard the valve seals.
6. Remove the valves.
Installation
Using the special tool, install the valve seals.
5. Using the special tool, install the valve
springs.
lnstall the valve spring retainers and the
1. Coat the valve stem with clean engine oil. valve springs.
Compress the valve springs.
2. Install the valves. Install the valve collets.
3. lnstall a valve stem mounting sleeve over
the valve
collet groove (valve shown
removed for clarity).
4m ~AUTION:T~~ valve seal for the intake
valve is green. The valve seal for the exhaust
valve is brown.
N0TE:lnset-t wooden wedges in the combustion
chamber recesses in the cylinder head so that the
valves are held in place for installation.
N0TE:lnstall new valves seals.
N0TE:Coat the valve seal lip and the valve stem
with clean engine oil.
6. Remove the special tools.
7m &AUTION:T~~ valve tappets must be
installed in their original locations.
lnstall the valve tappets.
2006.0 Fiesta 1212006 G21048en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-I 8 Duratec-16V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-I 8 - - -
IN-VEHICLE REPAIR
8. Install the cylinder head.
For additional information, refer to Cylinder
head in this section.
2006.0 Fiesta 1212006 G21048en
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Engine - 1.25L Duratec-I 6V (Sigma)ll.4L
303-01A-I 9 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-OIA-I 9
IN-VEHICLE REPAIR
Intake Manifold(21 183 0)
Removal 6. Remove the intake manifold lower retaining
bolt.
A WARNING:Do not smoke or carry lighted
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable mixtures
are always present and may ignite. Failure
to follow these instructions may result in
personal injury.
1. Release the fuel system pressure. For
additional information, refer to
Section
31 0-00 [Fuel System - General
Information].
2. Disconnect the battery ground cable. For
additional information, refer to
Section
414-01 [Battery, Mounting and 7. Disconnect the engine wiring harness
Cables]. electrical connector.
3. Remove the air cleaner. For additional
information, refer to Section
303-1 2 [Intake
Air Distribution and Filtering].
4. Detach the power steering fluid reservoir
from the bracket and position
it to one side.
5. Remove the accessory drive belt. For
additional information, refer to
Section
303-05 [Accessory Drive].
8. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV.
2006.0 Fiesta 1212006 GI 83728en
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Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A120 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 Am20
IN-VEHICLE REPAIR
9. Disconnect the brake booster vacuum line
from the intake manifold. 12. Detach the oil level indicator tube from the
intake manifold.
/'-
10. Disconnect the evaporate emission (EVAP) 13. Disconnect the temperature and manifold
hose from the EVAP valve. absolute pressure (T-MAP) sensor electrical
connector.
11. Disconnect the knock sensor (KS) electrical
connector.
14. Disconnect the throttle plate control motor
(DC-ISC) electrical connector.
2006.0 Fiesta 1212006 GI 83728en
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