2007 FORD FIESTA air condition

303-01 B-77 Engine - 2.OL Duratec-HE (M14) 303-01 B-77
REMOVAL
21. Disconnect the reversing lamp switch Detach the steering gear to power steering
electrical connector. fluid
reservoir return line support bracket
from the generator.
22m CAUTION:^^ brake fluid is spilt on the 25s Using the special tool, disconnect the paintwork, the affected area must be
immediately washed down with cold water. steering
gear to power steering fluid
reservoir return line from the power
Disconnect the clutch slave cylinder supply
steering fluid reservoir.
line.
Remove the spring clip. Allow
the power steering fluid to drain into a
suitable container.
23. Disconnect the air conditioning low 26. Remove the power steering fluid reservoir.
pressure switch connector.
24. N0TE:Note the position of the steering gear 27m &AUTION:C~~ the power steering fluid
to power steering fluid reservoir return line reservoir
to prevent power steering fluid
support bracket to aid installation. loss
or dirt ingress.
2006.0 Fiesta 12/2006 G451290en
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303-01 B-I 13 Engine - 2.OL Duratec-HE (M14) 303-01 B-113
INSTALLATION
12. Remove the securing straps. 17.
Attach the gearshift cables to the bracket
13. Raise and support the vehicle. For and
turn the abutment sleeves
( additional information, refer to: (I 00-02 counterclockwise.
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
14. Install the engine support insulator.
15. Attach the air conditioning (NC)
compressor to the cylinder block. 18.
Attach the gearshift cables to the selector
levers.
19. CAUTIONS:
A~he inner CV joint must not be bent
more than 23 degrees. The outer CV joint
must not be bent more than 45 degrees.
16. Connect the
NC high pressure switch n~ake sure that the halfshaft seal is not
electrical connector. damaged.
n~ake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring.
Using the special tool, attach the left-hand
halfshaft to the transaxle.
2006.0 Fiesta 1212006 ~451291 en
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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 - 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)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
REMOVAL AND INSTALLATION
2. Remove the radiator retainers and grommets.
8. Detach the radiator and the air conditioning
(NC) condenser from the support panel.
9m &AUTION:SU~~O~~ the condenser by
positioning it on the support panel.
Slide the
NC condenser to detach it from the
radiator
130. Remove the radiator.
Installation
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 ~210041 en
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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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Engine Cooling - 2.OL Duratec-HE (M14)
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
I Accessory drive belt. CHECK the condition of the
accessory drive belt.
REFER to: Accessory Drive
(303-05 Accessory Drive,
Diagnosis and Testing).
Cooling fan.
CHECK the operation of the
I cooling fan. REFER to WDS.
Engine. INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head
(303-
01 Engine - I .3L Duratec-8V
(Rocam), I n-vehicle Repair).
The engine does not reach
normal operating temperature. CHECK the ECT sensor.
I REFER to WDS.
Temperature gauge. CHECK the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (41 3-01 lnstrument
Cluster, Diagnosis and
Testing)
I lnstrument Cluster - Vehicles
Built From:
1012005 (41 3-01
lnstrument Cluster, Removal
and Installation).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
REFER to: Thermostat Housing (303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation).
Component Tests
Pressure Test
A WARNING:When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to
- prevent the possibility of coolant scalding.
Failure to follow this instruction may result
in personal injury.
N0TE:lf the coolant expansion tank cap is rotated
counterclockwise by 1 12 a full turn, the pressurized
coolant will be vented to the underside of the
coolant expansion tank cap.
1. Remove the coolant expansion tank cap.
2. Install the special tools 303-396 and 303-396-01
to the coolant expansion tank.
3. Pressurize the system to the coolant expansion
tank cap release pressure.
REFER to: Specifications (303-03 Engine
Cooling
- 2.OL Duratec-HE (M14),
Specifications).
2006.0 Fiesta 1212006 G426582en
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303-03B-15 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-15
DIAGNOSIS AND TESTING
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
1 OO°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:
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
1.33
1.02
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
60
70
80
90
100
110
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.
N0TE:The results from the test are more
conclusive if the engine is cold when the test is
started.
Carry out a road test.
REFER to:
RoadIRoller Testing (1 00-00 General
Information, Description and Operation).
4. Drive the vehicle at a constant throttle opening
and set speed until the ECT value settles into
a shallow rise and fall signal, close to a straight
line. This indicates that the thermostat is
functioning correctly.
N0TE:Some thermostats indicate the
temperature(s) in Celsius and Fahrenheit.
The graphic below shows the location and an
example of the opening temperature
(88OC) and
fully open temperature (1
02OC) of a thermostat.
The graphic below shows an alternative method used to show the opening temperature
(88OC) and
fully open temperature
(112OC) of a thermostat.
2006.0 Fiesta 1212006 G426582en
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