
100-00-7 General Information 100-00-7 
DESCRIPTION AND  OPERATION 
Skin contact may result in frostbite. 
Instructions given  by the  manufacturer  must be 
followed. Avoid  naked lights, wear suitable 
protective gloves and  goggles. 
If  refrigerant  comes into contact with the skin  or 
eyes,  immediately rinse the affected areas with 
water.  Eyes should also be rinsed with an 
appropriate irrigation solution  and should  not be 
rubbed. SEEK MEDICAL ASSISTANCE  IF 
NECESSARY. 
Air Conditioning Refrigerant - Do  Nots 
- Do not expose refrigerant bottles  to sunlight  or 
heat. 
- Do not stand refrigerant bottles upright;  when 
filling, hold  them with the  valve downwards. 
- Do not expose refrigerant bottles to frost. 
- Do not drop refrigerant bottles. 
- Do not vent refrigerant  to atmosphere under  any 
circumstance. 
- Do  not mix  refrigerants,  for example  R12 (Freon) 
and 
R134a. 
Adhesives  and Sealers 
See also Fire,  Chemical  Materials. 
Highly  flammable,  flammable, combustible 
- 
observe No Smoking  policy. 
Generally should be stored  in No  Smoking areas. 
Cleanliness  and tidiness  in use should  be 
observed, for  example disposable paper covering 
benches; should  be dispensed from applicators 
where  possible; containers, including secondary 
containers, should  be labeled appropriately. 
Solvent-based  AdhesivesISealers - See 
Solvents 
Follow manufacturers instructions. 
Water-based  Ad hesives1Sealers 
Hot Melt Adhesives 
In the solid  state, they are safe.  In the molten state 
they  may cause burns and health hazards  may 
arise from the inhalation of toxic  fumes. 
Use appropriate protective clothing  and a 
thermostatically controlled heater with a thermal 
cut-out  and adequate extraction. 
Resin-based  AdhesiveslSealers, for 
example  Epoxide and  Formaldehyde 
Resin-based 
Mixing should be carried out  in well ventilated 
areas,  as harmful  or toxic volatile chemicals  may 
be  released. 
Skin contact with uncured resins and hardeners 
can  result  in irritation,  dermatitis, and absorption 
of toxic  or harmful chemicals through the skin. 
Splashes can  damage the eyes. 
Provide  adequate  ventilation  and avoid skin and 
eye  contact. 
Anaerobic, Cyanoacrylate (super-glues) 
and  other  Acrylic Adhesives 
Many are  irritant, sensitizing  or harmful  to the skin 
and  respiratory tract.  Some are eye irritants. 
Skin and eye contact should be avoided  and the 
manufacturers instructions followed. 
Cyanoacrylate adhesives (super-glues)  MUST NOT 
contact the skin  or eyes.  If skin  or eye tissue  is 
bonded,  cover with a clean moist pad and  SEEK 
IMMEDIATE  MEDICAL ATTENTION.  Do not 
attempt to pull tissue apart. Use  in well ventilated 
areas  as vapors  can cause  irritation  to the nose 
and  eyes. 
For two-pack  systems see Resin-based and 
lsocyanate 
AdhesivesISealers. 
lsocyanate  (Polyurethane) 
Ad 
hesives1Sealers 
See  also Resin-based Adhesives. 
Those based On polymer emulsions and rubber Individuals suffering from  asthma or respiratory 
latexes  may contain small amounts  of volatile toxic 
allergies should not work with or near these and  harmful  chemicals. Skin and eye  contact 
should be  avoided and adequate  ventilation materials 
as sensitivity reactions can  occur. 
provided during  use.  Over 
exposure  is irritating  to the eyes and 
respiratory  system. Excessive concentrations  may 
produce  effects on  the nervous system including 
2006.0 Fiesta 1212006 GI 7372en 
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100-00-1 9 General Information 100-00-1 9 
DESCRIPTION AND  OPERATION 
Standard Workshop  Practices 
Vehicle in Workshop 
When  working  on a vehicle  in the  workshop always 
make sure that: 
- the  parking  brake is applied  or the  wheels are 
securely chocked  to prevent the vehicle  moving 
forwards  or backwards. 
- the key is removed from key operated hood 
locks before  any work is carried out around  the 
front of the vehicle. 
- if  the engine  is to be  run, there  is adequate 
ventilation,  or an extraction  hose to remove 
exhaust  fumes. 
- there is adequate  room to raise the vehicle  and 
remove the  wheels, if necessary. 
- fender covers are always fitted  if any work  is to 
be  carried out  in the engine  compartment. 
- the battery  is disconnected  if working on the 
engine,  underneath the vehicle,  or if the  vehicle 
is  raised. 
Alternative Fuel - Dons 
- Do  work  on the vehicle  in a designated area, 
that  is well ventilated and with access restricted 
to qualified personnel  only. 
- Install new warning labels to their original 
locations. 
- If  possible always isolate the alternative fuel 
tank, and  run the  vehicle on  the alternative fuel 
until  it automatically switches  to its normal  fuel 
prior to taking  the vehicle into  the workshop 
service  area. 
- Only use tested and approved components  and 
pipes  when  repairing or servicing 
LPG and CNG 
systems. 
Alternative Fuel - Do Nots 
- Do not vent  off LPG fuel. 
- Do not  use shop air pressure  to force LPG fuel 
from the fuel tank. 
( A CAUTION:When electric arc welding on a - Do not use paint drying ovens above 40°C for vehicle,  always disconnect  the generator any  alternative  fuel vehicle. LPG and CNG fuel wiring  to prevent  the possibility  of a surge tanks must be removed from the vehicle prior of  current  causing damage  to the internal to being  put into  paint  drying ovens above 40°C. components  of the  generator. - Do not modify  the system  or install  new - if using welding equipment on the vehicle, a 
components that are not designed  for gas 
suitable fire extinguisher  is readily available. 
vehicles. 
Alternative Fuel 
A WARNING:When servicing the fuel system 
always follow  the recommended 
procedures.  Failure to follow these 
instructions  may result in personal  injury. 
If the  odor  of liquefied petroleum gas (LPG) or 
compressed natural gas 
(CNG) is  present in the 
air in  the workshop,  warn all persons  in the area 
to: 
- extinguish  all flames  and lighted tobacco. 
- shut  off electrical  and air powered equipment. 
- evacuate the  area. 
- ventilate the area. 
- contact  the fire control authorities. 
- remove  the vehicle to a  dedicated, ventilated 
area. 
- Do  not evacuate  fuel tanks unless there  is repair 
that requires  the removal of the  fuel tank. 
- Do not  work  on the  fuel lines  or system 
components unless  the alternative fuel has been 
evacuated and  the pressure  in the  system 
reduced  to atmospheric  or less. 
- Do not use anything other than  the specified 
leak detector  fluid to trace fuel leaks. 
Be aware  of situations that  may cause the 
LPG or I 
CNG fuel system  to vent  off fuel,  such  as: I 
- extremely hot days. 
- parking by a space  heater. 
- hoisting a vehicle  up near  a ceiling  heater. 
Only  fully trained personnel,  who are conversant 
with local  standards,  are to work on  alternative fuel 
vehicles. 
2006.0 Fiesta 1212006 GI 7373en 
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Engine Cooling - 1.3L Duratec-8V 
(Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L 
303-03A-24 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-O3A-24 
REMOVAL AND INSTALLATION 
Thermostat - 1.25L Duratec-1 6V (Sigma)/l.4L Duratec-1 6V 
(Sigma)/l .6L Duratec-1 6V (Sigma)(24 454 0) 
Special Tool(s) 4. Disconnect the heater hose from the 
I Removerllnstaller, Cooling I thermostat housing. 
Hose Clamp 
303-397  (24-003) 
Removal 
1. Drain the cooling  system. 
For  additional  information, refer  to Cooling 
System  Draining,  Filling and Bleeding  in 
this  section. 
5. Remove  the thermostat housing. 
2. Remove  the generator.  For additional 
information,  refer to Section 
414-02 
[Generator  and Regulator]. 
3. Using the special tool,  disconnect the 
radiator  lower hose from the thermostat 
housing. 
6. N0TE:The thermostat  is installed with  the 
jiggle  pin at the top. 
Remove  the thermostat. 
I I, ' 
Installation 
I. To install, reverse  the removal  procedure. 
2006.0 Fiesta 1212006 G210040en 
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303-03B-9  Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-9 
DIAGNOSIS  AND TESTING 
.Engine  Cooling 
' . Special Tool(s) 
Pressure  Tester, Cooling 
System 
303-396  (24-001 A) 
Inspection  and Verification 
1. Verify  the customer concern. 
2. Visually  inspect for  obvious signs of mechanical 
( I or  electrical  damage.  Visual 
lns~ection Chart 
I Mechanical I Electrical I 
Coolant leak(s) 
Coolant 
level 
Gasket(s) or seal(s) 
Core plug(s) 
Hose(s) or hose 
joints 
Coolant expansion 
tank cap and seal 
Coolant expansion 
tank 
Radiator 
Coolant pump 
Thermostat housing 
Heater core 
Accessory drive belt 
Coolant outlet 
connector 
Fuse(s) 
Relay(s) 
Wiring harness 
Electrical 
connector(s) 
Engine coolant 
temperature (ECT)  sensor 
Cooling  fan motor 
Powertrain control 
module (PCM) 
3.  If an obvious cause for an observed  or reported 
concern  is found,  correct the cause  (if possible) 
before proceeding to the next  step 
4.  If the  cause  is not  visually evident, verify  the 
symptom and refer  to the  Symptom  Chart. 
Symptom Chart 
Symptom  Chart 
Symptom 
Loss of coolant  Possible Sources 
Action 
Hose(s) or hose joint(s). 
Radiator. INSPECT 
the hoses and hose 
joints.  INSTALL  a new 
hose(s) 
as necessary. 
INSPECT  the radiator for leaks. 
CARRY OUT  the Pressure  Test 
Component  Test in this  section. 
INSTALL  a new  radiator  as 
necessary. 
REFER to:  Radiator (303-03 
Engine Cooling 
- 2.OL 
Duratec-H E  (M 14), Removal 
and  Installation). 
2006.0 Fiesta 1212006 G426582en 
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303-03B-17 Engine Cooling - 2.OL Duratec-HE (M14) 303=03B-17 -- 
GENERAL  PROCEDURES 
Cooling System Draining,  Filling and Bleeding(24 122 0) 
Draining 
, Special Tool(s) Allow the coolant  to drain into a suitable 
Im AWARNING:~~~~ releasing  the cooling 
system  pressure, cover  the coolant 
expansion  tank cap with  a thick  cloth to 
prevent  the possibility  of scalding. Failure 
5. Install  the radiator  lower hose. 
to  follow  this instruction  may result  in 
personal injury. 
6. Lower  the vehicle. 
Release  the cooling  system pressure  by 
slowly turning  the coolant expansion tank 
Filling and Bleeding 
cap a quarter  of a turn. 1. Fill  the coolant  expansion tank to the  MAX 
mark. 
container. 
24003 
2. Remove  the coolant  expansion  tank cap. 
3. Raise  and support  the vehicle. 
For  additional  information, refer to:  Lifting 
(1 00-02 Jacking and Lifting,  Description 
and  Operation). 
4. Using  the special  tool,  disconnect  the 
radiator lower  hose to drain  the cooling 
system. 
Removerllnstaller, Cooling 
Hose Clamp 
303-397 (24-003) 
2. N0TE:Do not allow  the engine  to reach 
normal  operating temperature. 
Start  the engine,  run the engine  briefly at 
2500 revolutions  per minute  (RPM) for 10 
seconds  to prime  the heater  circuit. 
3. Switch the  engine off. 
4. Fill the  coolant  expansion  tank 15 mm over 
the  MAX  mark. 
5. Install the coolant  expansion tank cap. 
6. Start the  engine, maintain  the engine speed 
at 
2500 RPM  for eight minutes  or until  the 
engine reaches  normal operating 
temperature. 
2006.0 Fiesta 1212006 
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303-03B-22 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-22 
REMOVAL  AND INSTALLATION 
Item Description Item Description 
I 1 coolant hose 
Removal Details 
2 
2006.0 Fiesta 1212006 G426583en 
1 
3 
Thermostat housing  to coolant expansion 
tank  and heater  core return coolant  hose 
See Removal  Detail 
Radiator lower  to thermostat housing  See 
Removal Detail 
Thermostat housing 
5. To  install, reverse the  removal procedure. 
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303-03B-23  Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-23 
REMOVAL AND  INSTALLATION 
Item 1 Thermostat housing to coolant expansion 
tank  and heater  core return  coolant  hose 
' . I. Using the special tool, disconnect the 
thermostat housing  to coolant expansion 
tank and  heater core return coolant  hose. 
Item 2 Radiator lower to thermostat  housing 
coolant  hose 
1. Using the special  tool, disconnect the 
radiator  lower to thermostat  housing coolant 
hose. 
2006.0 Fiesta 1212006 G426583en 
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303-03B-25  Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-25 
REMOVAL AND  INSTALLATION 
7. Disconnect the radiator  hose and the  heater Discard the gasket. 
hose from the coolant outlet  connector. , 
Installation 
8. Disconnect the coolant expansion tank hose 
from  the coolant outlet  connector. 1. N0TE:lnstall a new coolant outlet connector 
gasket. 
9. Disconnect  the thermostat  housing coolant 
hose  from the coolant outlet  connector.  To 
install,  reverse  the removal procedure. 
10. Remove  the coolant outlet  connector. 
2006.0 Fiesta 1212006 G421228en 
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