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Ford 2007 WQ Fiesta, Repair Manual

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Ford 2007 WQ Fiesta Repair Manual Download Page 501

Summary of Contents for 2007 WQ Fiesta

Page 1: ...921140 151 Set ISBN 1 921140 16X Volume 1 ISBN 1 921140 178 Volume2 ISBN 1 921140 186 Volume3 O 2007 Ford Motor Company of Australia Ltd RegisteredOffice CAMPBELLFIELD VICTORIA A B N 30 004 116223 Re...

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Page 3: ...ystem General lnformation Power Steering Steering Linkage Steering Column Steering Column Switches Engine Engine System General lnformation Engine 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l GL D...

Page 4: ...ge Center 413 08 Warning Devices 413 09 Parking Aid 413 13 Battery and Charging System Charging System General Information 414 00 Battery Mounting and Cables 414 01 Generator and Regulator 414 02 lnfo...

Page 5: ...art of this publicationmay be reproduced stored in a data processing system or transmitted inanyform electronic mechanical photocopy recording translation or by any other meanswithout prior permission...

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Page 7: ...UP General Information SECTION TITLE PAGE Service Information General Information 100 00 Identification Codes 100 01 Jacking and Lifting 100 02 Noise Vibration and Harshness 100 04 0562005 2006 0 Fies...

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Page 9: ...Drum Brake 206 02 Front Disc Brake 206 03 Rear Disc Brake 206 04 Parking Brake and Actuation 206 05 Hydraulic Brake Actuation 206 06 Power Brake Actuation 206 07 Anti Lock Control 206 09A Anti Lock Co...

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Page 11: ...l 3L Duratec 8V Rocam ll 25LDuratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 303 08A Engine Emission Control2 0L Duratec HE M14 303 088 IntakeAir Distributionand Filtering 303 12 Evap...

Page 12: ...ystem General Information 3 1 0 0 0 Fuel Tank and Lines 310 01 Acceleration Controll 3L Duratec 8V Rocam ll 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 310 02A Acceleration C...

Page 13: ...413 09 ParkingAid 413 13 Battery and Charging System Charging System General Information 14 00 Battery Mounting and Cables 41 4 01 Generator and Regulator 414 02 lnformationand EntertainmentSystems I...

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Page 15: ...2 1 1 Handles Locks Latches and Entry Systems 501 14 Wipers and Washers 501 16 Bumpers 501 19 Safety Belt System 50I 2OA Supplemental Restraint System 50I 2OB Body Repairs General Information 501 25...

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Page 17: ...Bags Air Conditioning Refrigerant Adhesives and Sealers Antifreeze Asbestos Battery Acids Brake and Clutch Linings and Pads Brake Fluids Polyalkylene Glycols Brazing Chemical Materials Chlorofluoroca...

Page 18: ...iton Welding Warning Symbols on Vehicles White Spirit Standard Workshop Practices Vehicle in Workshop Alternative Fuel Alternative Fuel Do s Alternative Fuel Do Nots Towing the Vehicle Connecting a Sl...

Page 19: ...This manualisstructuredintogroups and sections with specific system sections collectedtogether under their relevant group A group covers a specific portion of the vehicle The manual is divided into fi...

Page 20: ...exclusively for graphics and icons with or without captions and the DETAILSIRESULTSIACTIONScolumn provides directionto another test step or specific corrective actions The boxed numbers indicatethe or...

Page 21: ...for voltmeters and ohmmeters If multiple measurementsare made in a single graphic the test leads are drawn with a solid line until the test lead splits to indicatethe multiple measurements at which po...

Page 22: ...de This material is hermeticallysealed in the module and is completely consumed during deployment No attempt should be made to open an air bag inflator as this will lead to the risk of exposureto Sodi...

Page 23: ...ve clothing and a thermostatically controlled heater with a thermal cut out and adequate extraction Resin based AdhesiveslSealers for example Epoxideand Formaldehyde Resin based Mixingshould be carrie...

Page 24: ...om coolant antifreeze glycol when heated Avoid breathingthese vapors Antifreeze may be absorbed through the skin in toxicor harmfulquantities Antifreeze ifswallowed can befatal and MEDICALATTENTION SH...

Page 25: ...alonsare depleting the upper ozone layer which filters out harmful ultraviolet radiation Decreasedfiltration of ultraviolet radiation may result in increases in skin cancer cataracts and immunesystem...

Page 26: ...re notfrayed kinked cut cracked or otherwise Fibre damaged Make sure that electrical equipmentand flexes do See also Dusts not come into contact with water Used in noise and sound insulation Make sure...

Page 27: ...ate toxic and harmfulfumes Smoking nakedflames or the use of electrical equipmentduring foaming operationsand until vapors mists have cleared should not be allowed Any heat cutting of cured foams or p...

Page 28: ...rdto health that can lead to personal injury illness or even death If a leak is detected under no circumstances attempt to seal the leak by tightening the unionlconnection untilthe fuel in the system...

Page 29: ...matitis may be irritant or allergic in nature Risks are higherwhere prolongedor repeatedskin contactwith afluid may occur These fluids are used for vehicle initial fill and service purposes This sub s...

Page 30: ...s as lubricants or for any applicationwhere appreciableskincontact is likely to occur EnvironmentalPrecautions Burning used engine oil in small space heaters or boilers can be recommended only for uni...

Page 31: ...ene xylene trichloroethane 2006 0 Fiesta1212006 Used in cleaning and dewaxing materials paints plastics resins and thinners Some may be highlyflammable or flammable Skin contact will degrease the skin...

Page 32: ...and the affected area washed down using wire wool and a limewater calcium hydroxide solution to neutralizethe acid before disposing of the decomposed Viton residue and final cleaning of the area After...

Page 33: ...e engine BEFORE ANY WELDING OR CUTTING TAKES runningor the ignitionswitchedon See Electric PLACE ON VESSELS WHICH HAVE Shock in this subsection CONTAINED COMBUSTIBLE MATERIALS FOR EXAMPLE BOILING OR S...

Page 34: ...icinity due to the presenceof highlyflammable or explosive liquids or vapors See Fire in this subsection 6 Displayingthis symbol normally in conjunction with 5 above warn ofthe presenceof potentially...

Page 35: ...ns above 40 C for vehicle always disconnect the generator any alternativefuel vehicle LPG and CNG fuel wiring to preventthe possibilityof a surge tanks must be removedfrom the vehicle prior of current...

Page 36: ...e vehicle can be transported on a jumper cables do not touch each other or low loader or a trailer ground against the vehicle body at any time while the cables are attached to the Connectin a Slave Ba...

Page 37: ...engine compartment do not usea steam cleaner or a powerwasher to clean the engine compartment Blowing dirt off with compressedair Removalof dry dust using vacuum equipment This method must always be...

Page 38: ...urers instructions If in doubt about any substance particularly a solvent DO NOT use it A CAUTI0N lf in doubt about the suitability of any proprietary solvent or sealer for a particular application co...

Page 39: ...umspeed of 25 kmlh 15 mileslh Never operate at high engine speed or with the acceleratorpedalat full travelwhilst the engine is cold With the ignition switched off check that the parking brake is appl...

Page 40: ...ay result in personal injury Foradditional information referto Health and Safety Precautions 100 00 General Information DescriptionandOperation CAUTIONS A Avoid braketesting on busy roads where it may...

Page 41: ...1 I SECTION 100 01 ldentificationCodes VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE DESCRIPTIONAND OPERATION Identification Codes 100 01 2 VIN an example of VIN shown 100 01 3 Vehicle Certification...

Page 42: ...ed on the right hand B pillar The codes through the windshield or in the engine stamped or printed on the VIN plate during compartmentwhere it is stamped onto the productionenablethe precisedetailsof...

Page 43: ...rerIdentifier VIN Position 12 Month of manufacture VIN Position 5 and 6 ConstantX I Codes I World Manufacturer VIN Position 7 and 8 Product source company and assembly plant I WFO I Ford WerkeAG Germa...

Page 44: ...f Code J Model FiestaIFusion VIN Position 12 Month of Manufacture Year of Manufacture 2002 3 4 5 6 7 VIN Positions 13 to 17 Vehicle Serial Number Five Digit Number 2003 2004 2005 2006 2007 February Ma...

Page 45: ...deltype I Item Description 1 10 1Door combination I I 11 IExhaustemission level codes I 1 1 2 1Body color codes I 1 13 1Interiortrim codes I 1 14 1Transaxle final drive ratio I 1 15 1Transaxle codes I...

Page 46: ...alue Diesel only Number I JC3 I door van Fiesta I Smoke Value ltem 8 Model Body or Type I JD3 I door Fiesta I Code I JHI I 5 door Fiesta I Model Body or Type I JU2 I 5 door Fusion I ltem 10 Door Combi...

Page 47: ...denotesthe original modelyear of the color s introduction O1 colorintroduction in 2000 modelyear Code AT BR DC DM FB FC FP FT GM HH IW JH LM MI MT NM QB QL QM QZ Q2 Interior Trim Dogtooth Mamara Blue...

Page 48: ...Speed ManualTransaxle iB5 I A I 1 3L Duratec 8V Rocam 60PS I B C ltem 16 EngineCodes I H I 1 6L Duratorq TDCi DV Diesel 90PS I 5 Speed ManualTransaxle iB5 Automated Shift Manual 4 Speed Automatic Tra...

Page 49: ...01 9 DESCRIPTION AND OPERATION 2006 0 Fiesta1212006 G413286en Code 4 5 6 N P Q R S T Drive Right handdrive Left handdrive Right handdrive Left handdrive Right handdrive Left handdrive Right hand driv...

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Page 51: ...100 02 1 Jacking and Lifting 100 02 1 SECTION 100 02 Jacking and Lifting VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE DESCRIPTIONAND OPERATION Jacking 100 02 2 Lifting 100 02 5...

Page 52: ...le must be lifted on a soft surface the supporting forces must be spread by using a suitable base under the jack Place a wheel chock againstthe wheel oppositethejack Failure to follow these instructio...

Page 53: ...jack or a lifting platform special adapters with locating plates must be used Description Rocker panel moulding left handside shown Front cover Rear cover A In order to preventdamage to the chassis an...

Page 54: ...r jacking points 2006 0 Fiesta1212006 GI 67070en Item I 2 3 Description Adapter with locating plate and rearjacking point viewing angle from belowthe vehicle Adapter with locating plate and rearjackin...

Page 55: ...ting 100 02 5 DESCRIPTIONAND OPERATION Lifting A WARNING Only raise the vehicle at the A CAUTI0N Place blocks underneaththe specified lifting points hoist points if a two column hoist is used 2006 0 F...

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Page 57: ...eveloping 100 04 2 Do Not Cure the Symptom and Leavethe Cause 100 04 2 Be Positive the Cause is Found 100 04 2 Diagnostic Charts 100 04 2 DIAGNOSISAND TESTING Noise Vibration and Harshness NVH 100 04...

Page 58: ...tion It is a way of lookingat systems improbable Certainfailures in a system can be that are not functioning the way they should and improbable but still happen finding out why Also it is knowing how...

Page 59: ...ormingcertain tests before others Elimination of checking huge portions of a system by performing simple tests Certainty of narrowing down the search to a small portionbefore performingin depthtesting...

Page 60: ...utlined in General Procedures Alwaysfollow each step exactlyand makenotes to recall importantfindings later driveline It is important therefore that an NVH concern be isolated into its specific area s...

Page 61: ...mental and must be considered normal The roadtest and customer interview if available provideinformationneededto identifythe condition and give direction to the correct starting point for diagnosis 1...

Page 62: ...stablish a route that will be used for all NVH diagnosis road tests The road selected should be reasonably smooth level and free of undulations unless a particular condition needsto be identified A sm...

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Page 64: ...be present from new X Lock stop impact knock a Parkingat lockstop Must be presentfrom new Mechanicalknock power assisted steering PAS off b Parking between lock stops engine OFF Must be present from n...

Page 65: ...emperature is the same as described at the customer interview 4 All evaluations must take place in a relatively quiet location 5 The heating air conditioning AIC fan and radio must beturned off during...

Page 66: ...ine rpm changes Particularly annoying at lower engine speed 2006 0 Fiesta1212006 G37349en PossibleSources Power steering lines Incorrect powersteering fluid Power steering pump Action CHECK the routin...

Page 67: ...00 Power Steering System Flushing 1 8L Duratec HE M14 1 8L Duratec SCi M14 2 OL Duratec HE M14 General Procedures Power Steering System Flushing 3 OL Duratec SE VE6 2 5L Duratec VE VE6 3 OL Duratec ST...

Page 68: ...iss occurs while turning betweenthe steering lock stops all steering angles Noise does not change with engine rpm and is worse at high operating temperatures N0TE Engine speed at idle holdingthe steer...

Page 69: ...rs at steering condition with engine off very high efforts Tolerances in the steering gear components Test Condition Action REFER to Steering System REFERto Steering System 211 00 Diagnosisand Testing...

Page 70: ...gear design no quality issue High power steering pump flow rate by design Power Steering Toc Toc Noise 1 Turnthe steeringwheelfrom leftto rightabruptly changing direction Test Condition 2 Drive the ve...

Page 71: ...ompon ents such as steering wheel and the steering column shroud 2006 0 Fiesta1212006 G37349en Steeringwheel to shroud interfer ence Steering column bearing Foreign material in contact with the steeri...

Page 72: ...sure allcomponents removed It may not always be necessaryto follow the chart have been installed to its conclusion Carry out only the pinpointtest PINPOINTTEST A SHAKE AND VIBRATIONWHILE DRIVING TEST...

Page 73: ...DETAILSIRESULTSIACTIONS B1 CHECK THE AIR CLEANER Check the condition of the air cleaner mounts inlet tube outlet tube resonatorsand all other components associated with the air induction systemfor cor...

Page 74: ...ratec SE VE6 2 5LDuratec VE VE6 3 OL Duratec ST VE6 Removal and Installation Accessory Drive Belt 2 OL Duratorq DilTDDi Puma Diesell2 0L Duratorq TDCi Puma Diesel12 2L Duratorq TDCi Puma Diesel Remova...

Page 75: ...new components as necessary ROAD TEST as necessary C2 CHECK THE ENGINE COOLING RADIATOR rnCheck the engine cooling radiator mountings and bushingsfor security and condition Check the radiator installa...

Page 76: ...sary No INSTALLnew powertrainldrivetrain mounts as necessary ROAD TEST as necessary PINPOINTTEST D WHEEL END VIBRATION ANALYSIS TEST CONDITIONS DETAILSIRESULTSIACTIONS Dl INSPECTTHE WHEELS AND TIRES I...

Page 77: ...OL Duratorq DiITDDi Puma Diesel12 0L Duratorq TDCi Puma Diesel Vehicles With 5 Speed Automatic Transaxle 5F31J 204 01 Front Suspension Removal and lnstallation Wheel Hub 204 02RearSuspension Removal a...

Page 78: ...ition II ChecktheN Csystemcomponentsfor noiseby turning the N C system on and off Is the N C system causing the noise Yes INSPECTthe N C system REFER to 412 00 ClimateControlSystem General Informa tio...

Page 79: ...rt the powertrainldrivetrainin an approximate positionand height N0TE Make sure that the right hand mount and left hand insulator align over the studs on the powertrainand drivetrain to allow the fixi...

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Page 81: ...TION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 204 00 2 DIAGNOSISAND TESTING Suspension System 204 00 4 Inspectionand Verification 204 00 4 Symptom Chart 204 00 4 Pinpoint Tests 204 00...

Page 82: ...1 0 50 Toe ink 0 35 Caster angle 0 30 Toe in 0 10 Degreesand minutes 0 65 3 1Toeink1 0 0 50 Toe ink 0 17 Decimaldegrees 1 25 Camber angle Degreesand minutes Decimaldegrees Total toe Degrees and minute...

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Page 84: ...Tire pressure s Symptom Chart before proceedingto the next step 4 Ifthe cause is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Drift left or right Possib...

Page 85: ...Information Steering System Diagnosis and Testing Steering System 1 6L Duratorq TDCi DV Diesel Diagnosis and Testing Suspension lower arm ball joint CARRY OUT the Ball Joint lnspectioncomponenttest in...

Page 86: ...test in this procedure CHECK and INSTALL new suspension components as necessary REFERto Front Strut and Spring Assembly 204 01 Front Suspension Disas sembly and Assembly CHECK and INSTALL new suspensi...

Page 87: ...nformation General Proced ures Wheels and tires CHECKthe tires BALANCEor INSTALL new tires as neces sary I Incorrectwheel alignment I ADJUST the wheel alignment REFERto Specifications 204 00 Suspensio...

Page 88: ...onditions Adequate grip should always be maintained oh the steering wheel Failureto follow these instructions may result in personal injury N0TE The following conditions must be met when evaluating th...

Page 89: ...HE LEFT HANDWHEEL AND TlRE ASSEMBLIES Raiseand supportthe vehicle REFERto 100 02 Jacking and Lifting Jacking Descriptionand Operation Lifting Descriptionand Operation Swap the front left handwheel and...

Page 90: ...TALL NEW TIRES Raiseand supportthe vehicle REFERto 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation Swap the front right handwheel and tire assembly with...

Page 91: ...ension Specifications Specifications 204 02 Rear Suspension Specifications No GO to B2 B2 INSPECTTHE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS N0TE Make sure that the oil is not from a...

Page 92: ...ON BUSHINGS I lnspect the suspension bushingsfor excessive wear or damage Are the bushingsworn or damaged Yes INSTALL new components as necessary REFERto Front Stabilizer Bar Bushing 204 01 Front Susp...

Page 93: ...enwear Is there uneven tire wear Yes REFER to the symptom chart No GO to B8 B8 INSPECTTHE STRUTAND SPRINGASSEMBLYAND REARSUSPENSIONSPRINGINTERFACE Loosenthe strut and spring assemblies and shock absor...

Page 94: ...ut and Spring Assembly 204 01 Front Suspension Disassemblyand Assembly Inspectthe shock absorbertop mountfor wear or damage Carry out the Strut or Shock Absorber Testing componenttest in this procedur...

Page 95: ...rfor signs of oil weepage or leaks Make sure that the oil is not from another source Weepage deposits a thin film of oil on the strut and spring assembly or shock absorber is normally noticed due to a...

Page 96: ...al information refer to Brake Jacking Description and Operation Lifting Description and Operation 2 Check for loose front wheel bearings by rocking the wheels at the top and bottom 3 Spin the wheel qu...

Page 97: ...kwise direction 1 Centralizethe steering and lock it in position to adjust the toe setting For additional information refer to Specifications 204 00 Specifications 2 Loosen the tie rod end locknuts 3...

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Page 99: ...DIAGNOSISAND TESTING Front Suspension PAGE REMOVALAND INSTALLATION Front Stabilizer Bar Bushing 14 754 0 204 01 6 Lower Arm 14 706 0 204 01 7 Front Stabilizer Bar 14 752 0 204 01 9 Wheel Knuckle 14 3...

Page 100: ...ng bolts I 48 I 35 I I Tie rod end retaining nut Stabilizer bar clamp retaining bolts Stabilizer bar to connecting link retaining nut Fb wer arm front retaining bolt I 70 48 ILower arm rear clamp reta...

Page 101: ...ion position If the wheel bearing were to be installed incorrectlythen this would cause failure of the ABS A newly developed Mc Phersonfront suspension with L shaped lower arms is used These lower sus...

Page 102: ...eparate routes for independentlydeflecting the spring andshock absorberforces intothe body This reducesthe level of noisetransmitted from the road surface Rear rubber mounting The correct installation...

Page 103: ...204 01 5 Front Suspension 204 01 5 DIAGNOSIS AND TESTING Front Suspension REFER to Section 204 00 SuspensionSystem General Information 2006 0 Fiesta1212006 GI 7395en...

Page 104: ...s Foradditionalinformation referto Stabilizer Bar in this section Installation 1 CAUTIONS A D O not lubricatethe stabilizer bar bushings A T h e stabilizer bar bushings must be positionedwith the slot...

Page 105: ...to prevent damage Detachthe lower arm balljoint from the wheel knuckle Removethe heat shield 3 Removethe crossmember outer retaining bolt 4 Removethe lower arm Installation 1 N0TE Do not fully tighte...

Page 106: ...ction 204 00 Suspension System knuckle General Information Attach the lower arm balljoint to the wheel knuckle 5 Install the wheel and tire For additional information referto Section 204 04 wheels and...

Page 107: ...k itin position 2 Detach the steering column shaft from the steering gear pinion Discard the retaining bolt 3 Raise and support the vehicle For additional information refer to Jacking 100 02 Jacking a...

Page 108: ...e stabilizer bar 7 Using a suitable transmission jack and a clamp retaining bolts at this stage wooden block support the crossmember Installthe stabilizer bar clamp on bothsides 8 Removethe crossmembe...

Page 109: ...ossmember retaining bolt to locate the special tools Install the special tools on both sides AUTION W I tightening the crossmember retaining bolts makesure the crossmember does not move Installthe cro...

Page 110: ...justment 204 00 Suspension System General Information General Procedures 15 N0TE Use a 5 mmAllen key to prevent the balljoint from rotating Attach the stabilizer bar connecting link to the stabilizer...

Page 111: ...re For additional information refer to Wheel andTire 204 04WheelsandTires Removal and Installation 4 N0TE Make a note of the position of the brake hose to aid installation Detach the brake hose from t...

Page 112: ...the wheel knuckle All vehicles A U T I O N L thetie rod end retaining nut in place to protect the ball joint stud Loosen the tie rod end retaining nut k AuTl N rotect the balljoint seal using a soft...

Page 113: ...Using the special tool remove the wheel knuckle 12 Remove thewheel knuckle to suspension strut pinch bolt Installation 13 N0TE Support the halfshaft The innerjoint must not be bent more than 18 degre...

Page 114: ...chbolt must be installed from the rear of the wheel knuckle instruction may result in personal injury N0TE Use a 5 mm Allen key to preventthe ball joint stud from rotating Attach the tie rod end to th...

Page 115: ...additional information refer to Wheel prevent damage to the brakehose A and Tire 204 04Wheels and Tires Removal and Installation A M a k e sure the brake hose retaining clip 12mTighten the wheel hub...

Page 116: ...204 01 18 REMOVALAND INSTALLATION 14 Check the toe setting and adjust as necessary For additional information refer to Specifications 204 00 Suspension System General Information Specifications 2006...

Page 117: ...erto Section 204 04wheels and Tires 2 N0TE Make a note of the position of the brake hose to aid installation Detach the brake hose from the brake hose support bracket 5 Removethe brake disc Removethe...

Page 118: ...mbly Removethe strut and spring assembly Installation CAUTIONS A Makesure the heat shield is installed to prevent damage to the balljoint The lower arm pinch bolt must be installed from the rear of th...

Page 119: ...3 A InstallerIAligner Crankshaft Rear Oil Seal 303 172 03 21 102 03 Removal I Removethe wheel knuckle For additional information refer to Wheel Knuckle in this section 2 N0TE When removing the wheel h...

Page 120: ...ring Make sure the wheel speed sensor ring is clean A Avoid any contact betweenthe wheel speedsensor ring anda magneticsurface 1 CAUTIONS n a k e sure the wheel bearing is installed into the wheel knu...

Page 121: ...ve as a complete assembly Disassembly Disassemblethe strut and spring assembly I Removethe thrust bearing retaining nut AWARNING T spring is under extreme 2 Removethe top mount tension care must be ta...

Page 122: ...204 01 24 DISASSEMBLY AND ASSEMBLY 7 Remove the insulator pad Assembly To assemble reversethe disassembly procedure C A U T I O N T ends of the spring must locate correctly in the spring seats 2006 0...

Page 123: ...ICLE APPLICATION 2006 0 Fiesta CONTENTS SPECIFICATIONS Specifications DESCRIPTIONAND OPERATION Rear Suspension DIAGNOSISAND TESTING Rear Suspension REMOVALAND INSTALLATION Rear Shock Absorber Spring B...

Page 124: ...5 1 92 I I Nm 115 Idrum brakes I I I I Beam axle retaining bolts Wheel spindle retaining bolts Vehicles with rear Wheel spindle retaining bolts Vehicles with rear disc brakes Ib ft 85 IWheel hub retai...

Page 125: ...ear suspension is a semi independent In addition the diameter of the longitudinal suspension The track has been increased by 71 membershas been increasedto increasestability mm to 1444 mm andto reduce...

Page 126: ...s Mc Phersonsuspension struts with separatespringand shock absorberelements This resultsin morespace inthe area ofthe suspension strut turrets thus increasingthe volume of the luggagecompartment Inadd...

Page 127: ...204 02 5 Rear Suspension 204 02 5 DIAGNOSISAND TESTING Rear Suspension I REFERto Section 204 00 Suspension System General Information 2006 0 Fiesta1212006 GI 7411en...

Page 128: ...nal information referto Section 204 04 Wheels and Tires 2 Detachthe fender splash shield from the fender 3 Using a suitable transmission jack support the beam axle 4 Detachthe shock absorber from the...

Page 129: ...4 Installthe wheel and tire For additional information referto Section 204 04 Wheels and Tires 5 N0TE The final tightening of the shock absorber lower mounting bolt should be carried outwhenthevehicle...

Page 130: ...llation 2 m A t h e r i n g i s n d e r e x t r e m e tension care must be taken at all times Failureto follow this instructionmay result installed and the spring ends butt correctly against the upper...

Page 131: ...204 02 9 Rear Suspension 204 02 9 REMOVAL AND INSTALLATION Tighten the shock absorber lowermounting bolt 2006 0 Fiesta1212006 G89135en...

Page 132: ...refer to Wheel andTire 204 04 WheelsandTires Removal 6 Remove the brake dIIlm and wheel spindle and Installation assembly on both sides 3 Detach the rear wheel speed sensor and brake hose retaining b...

Page 133: ...parking brake cable from the beam axle on both sides 11 Removethe rear wheel speed sensor For additionalinformation refer to Rear Wheel Speed Sensor 206 09 Anti Lock Control Removaland Installation I...

Page 134: ...axle on both sides componentsshould becarriedoutwhen thevehicle I I weight is on the road wheels 1 Using a suitable transmission jack locate the beam axle 2 N0TE Do not fully tighten the beam axle re...

Page 135: ...n both sides 9 Attach the parking brake cable to the beam axle bracket on both sides 10 Installthe brake disc shield For additional information refer to Brake Disc Shield 206 04 Rear Disc Brake Remova...

Page 136: ...etaining bracket to the beam Foradditional information referto Parking axle on both sides Brake Cable Adjustment Vehicles With Installthe retaining bolt Rear Drum Brakes 206 05 Parking Brake and Actua...

Page 137: ...4 Removethe wheel spindle Vehicles with rear disc brakes 5 Removethe brake disc For additional information refer to Brake Disc 206 04 Rear Disc Brake Removaland Installation For additional information...

Page 138: ...REMOVALAND INSTALLATION 7 Detachthe wheel speed sensor from the wheel spindle I 8 Remove the wheel spindle Installation N0TE lnstall a new wheel hub retaining nut 1 To install reversethe removal proce...

Page 139: ...ith rear disc brakes i Removal CAUTI0N The brake drum and hub assembly removal in this procedure is for 5 Removethe brake disc For additional information refer to Brake Disc 206 04Rear Disc Brake Remo...

Page 140: ...el bearing brake disc shown is not knocked damaged and keptfree from metal fragments A r o t e c t the face of the wheel speed sensor ring with a non ferrous flat block to prevent damage A a k e sure...

Page 141: ...akes 6 CAUTIONS A A v o i d impact on the wheel speed sensor ring A M a k e sure the wheel speed sensor ring is clean A A v o i d any contact between the wheel speed sensor ring and a magnetic surface...

Page 142: ...Tool s Bushing 205 342 15 110 1511002 General Eaui ment Adapter for 205 342 205 342 02 15 110 02 ITransmissionjack I Removal I Raise and support the vehicle For additional information refer to Jacking...

Page 143: ...sufficientlyto gain 1 N0TE lnstall a new trailing arm bushing access to the trailing arm bushing N0TE Alignthe mark on the bushinghousingwith 7 Mark the bushing housingadjacentto the the locating tan...

Page 144: ...e fabricated spacer set the beam axle bracket to the installation setting 4 N0TE Final tightening of the trailing arm bushing retaining nut and bolt must be carried out at the installation setting Ins...

Page 145: ...ls and Tires VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 204 04 2 DIAGNOSISAND TESTING Wheels and Tires 204 04 3 Inspection and Verification 204 04 3 Symptom Chart 20...

Page 146: ...e S ecifications Description Wheel nuts I Maximum lateral runout I 0 3 I 0 6 I Wheel and Tire Assembly RunoutSpecifications I Maximum radial runout I 0 3 I 0 5 I Nm 90 Description 2006 0 Fiesta1212006...

Page 147: ...rrecttoe settingsor worn strutswill cause severe cupping or scalloped tire wear on non drivenwheels Severelyincorrecttoe settingswill also cause other unusualwear patterns Tire Vibration Diagnosis A t...

Page 148: ...h the contact betweenthe tire andthe road surface Symptom Chart Symptom PossibleSources Action Tire s show excess wear on edge of tread I Vehicle overloaded I CORRECT as necessary I Tire s under infla...

Page 149: ...eels and Tires Specifications Specifications Wheel and Tire Removal and Installation Damagedwheel I INSPECTthe wheel rims for damage BALANCE the wheel and tire assemblies Using a suitable dial indicat...

Page 150: ...section of the tire appearsto waver while being rotated the tire bead may not be correctly seatedonthe wheel REMOVE the tire and CLEAN the bead seat areas on both wheel and tire Excessivelateral or r...

Page 151: ...y REFERto 204 04 Wheels and Tires Specifications Specifications Wheel and Tire Removal and Installation CAUTION Do not permit lubricantto get on cone sets of stud holes or on cone angle of wheel nuts...

Page 152: ...emovethe wheel and tire assembly Installation A W A R N I N G R the corrosion or dirt from the mounting surfaces of the wheel wheel hub brakedrum or brakedisc as this may causethe wheel nuts to loosen...

Page 153: ...05 04 3 Driveshafts 205 04 3 DIAGNOSISAND TESTING Front Drive Halfshafts 205 04 4 Inspectionand Verification 205 04 4 Symptom Chart Front Drive Halfshafts 205 04 4 REMOVALAND INSTALLATION Front Halfsh...

Page 154: ...t 1 259 A1 1 Toraue S ecifications Outer constant velocity CV joint boot ConstantVelocity CV Joint Boot Capacities Inner constant velocity CV joint boot Description ILower arm balljoint pinch bolt nut...

Page 155: ...tall a new boot on the outerjoint it isfirst necessaryto removethe driveshaft andthen disassemblethe innerjoint A specialservice kit is available in service for this purpose consisting of the inner an...

Page 156: ...ive halfshaft assembly INSPECTand REPAIR as necessary REFERto Section 204 00 Suspension System General Information 1 206 00 Brake System General Information I 211 00 Steering System General Informatio...

Page 157: ...ide CHECK for worn bushingsor bent components front stabil izer bar front suspensionlower arm REPAIRor INSTALLnew as necessary REFERto Section 204 01 Front Suspension REFERto Halfshaft LH 1Halfshaft R...

Page 158: ...eering fluids supplied to Ford contain additives which may cause skin irritation or other skin reactions after contact WSD M2C200 C 2 ACAUTION a socket to loosen the wheel hub retaining nut to prevent...

Page 159: ...to Healthand Safety Precautions 100 00 General Information Descriptionand Operation See Transmission Fluids Using a suitable tire lever remove the halfshaft Discardthe snap ring Allow the oilto drain...

Page 160: ...axle ACAUTION M sure the halfshaft is completely installed into the wheel hub Using the special tool install the halfshaft 3 N0TE lnstall a new wheel hub retaining nut N0TE Do not fully tighten the wh...

Page 161: ...y top mount retaining nuts Vehicles with manual transaxle 9 With the vehicle on a level surface fill the transaxlewith transmission fluid untilthe oil level is just below the bottom of the filler hole...

Page 162: ...Removal I Loosen the strut and spring assembly top mount retaining nuts by three turns 5m A C A U T I O N S the halfshaft Theinner joint must not bebent morethan 18degrees The outer joint must not be...

Page 163: ...not be bent more than 45degrees Attach the halfshaft to the intermediate shaft 3 N0TE Do not damage the inner constant velocity CV joint boot N0TE Make surethatthe intermediateshaft mating surface for...

Page 164: ...and Installation lorn AUTION U a socket to tighten the wheel hub retainingnutto prevent damage 7m AUTION M sure that the heat shield is installed to prevent damage to the ball joint Install the heat s...

Page 165: ...FrontDriveHalfshafts Removal and Installation 2 Remove the intermediate shaft center bearing cap 1 Remove and discard the locknuts 2 Detachthe heatshieldfrom the bearingcap 3 Removeanddiscardthe cente...

Page 166: ...t RH 205 04Front DriveHalfshafts Removal and Installation Vehicles with manualtransaxle 4 With the vehicle on the level surface fillthe transaxle with transmission fluid untilthe oil level isjust belo...

Page 167: ...V joint housing and discard the grease I IInstaller Extension Housing I BushingIOilSeal 308 046 16 0 16 Materials Name Specification 1Grease IWSS M1C259A1 I 4 Remove and discard the spider circlip Rem...

Page 168: ...N0TE Make sure that the inner constant Install the spider circlip velocity CV joint boot is installed to the marks on the halfshaft Installthe inner CVjoint boot ACAUTION T total amount of grease in t...

Page 169: ...7 N0TE lnstall a new CV joint boot retaining clamp N0TE Makesurethatthe CVjoint bootisclamped at the measured postion Usinga specialtool installthe CVjoint boot retaining clamp 8 Installthe right han...

Page 170: ...uction may result not exceed 85 grams in damage to the outer CV joint Apply grease to the outer CVjoint boot Removethe inner CVjoint boot For additional information refer to Inner Constant Velocity CV...

Page 171: ...joint boot retaining clamp Using the special tool install the inner CV joint boot retaining clamp 4 N0TE lnstall a new outer CVjoint boot retaining clamp Using the special tool install the outer CV j...

Page 172: ......

Page 173: ...ION 2006 0 Fiesta CONTENTS DESCRIPTIONAND OPERATION Brake System Overview DIAGNOSISAND TESTING Brake System Inspectionand Verification Road Test Pinpoint Tests ComponentTests Brake System Check Brake...

Page 174: ...es without ABS are equipped with brake pressure reduction valves for the rear wheel brakes They are located in the corresponding brake circuits at the brake master cylinder Vehicles with ABS do not ne...

Page 175: ...t of weight shifted to the low set of wheels on this type of road Once the route is establishedand consistently used the road surface variable can be eliminated from the test results Before a road tes...

Page 176: ...brake adjust ment PERFORM a parking brake cable adjustment REFERto 206 05 Parking Brake and Actuation Parking Brake Cable Adjust ment Vehicles With Rear Drum Brakes General Procedures Parking Brake C...

Page 177: ...h system for leaks including brake fluid in the brake booster Leaking brake master cylinder primary piston cup INSTALLa new brake master cylinder REFER to 206 06 Hydraulic Brake Actuation Brake Master...

Page 178: ...FER to Brake Shoes 206 02 Drum Brake Removaland Installa tion BrakePads 206 03FrontDisc Brake Removaland Installa tion Brake Pads 206 04 Rear Disc Brake Removaland Installa tion Loosecaliper mounting...

Page 179: ...inder piston cups or scored cylinder bore INSTALLa new brake master cylinder REFER to 206 06 Hydraulic BrakeActuation Brake Master Cylinder RHD Removal and lnstallation Brake Master Cylinder LHD Remov...

Page 180: ...oes or brake pads pedal force INSTALLnew brakeshoes or brake pads REFER to Hydraulicsystem Incorrecttire pressures Tires worn Glazedorworn brakeshoes or brake pads Brake booster GO to PinpointTest F I...

Page 181: ...ads Brake booster Brake booster Brake master cylinder GO to Pinpoint Test H GO to Pinpoint Test I ADJUSTthe brake lightswitch PERFORM a brake booster functional test REFERto the componenttests INSTALL...

Page 182: ...es GO to A3 No INFLATEthe tires to the correct pressure INSTALLnewtires if excessively worn TEST the system for normal operation A3 BRAKE SHOE OR BRAKE PADSAND LINING INSPECTION Inspectthe brake shoes...

Page 183: ...t wheel Read the pressure at right hand rear wheel Doesthe pressuregauge read between4692 5164 kPa 680 750 psi at the right hand rear wheel Yes INSPECTthe brake calipers and INSTALL new componentsas r...

Page 184: ...on TEST the system for normal operation No INSTALLa new left hand rear brake pressure control valve BLEED the brake system REFERto 206 00 Brake System General Information Brake System Bleeding General...

Page 185: ...ING SWITCH OR WIRING I IrnIgnition switch in position II I Removethe brake master cylinder reservoir filler cap or switch Allow the float to rest at its lowest point Does the brake warning indicator i...

Page 186: ...necessary REFERto Brake Drum 206 02 Drum Brake Removaland Installation BrakeShoes 206 02DrumBrake Removaland Installation Brake Pads 206 04 Rear Disc Brake Removal and lnstallation Brake Disc 206 04 R...

Page 187: ...e brake master cylinder reservoir fluid level Is the fluid level acceptable Yes GO to D3 NO CHECK the brake master cylinder reservoir sealing pointsfor leaks REFER to the brake master cylinder compone...

Page 188: ...akeCableAdjustment VehiclesWith Rear Disc Brakes General Procedures If the condition still exists BLEEDthe brake system REFERto 206 00 Brake System General Information Brake System Bleeding General Pr...

Page 189: ...er Cylinder LHD Removaland Installation ADD fluid and BLEEDthe brake system REFER to 206 00 Brake System General Information Brake System Bleeding General Procedures Brake System Pressure Bleeding Gen...

Page 190: ...tem for normal operation No GO to E3 E3 PERFORMA BRAKE MASTER CYLINDER BYPASSTEST Test for a brake master cylinder bypass Refer to the componenttests Was a concern found Yes INSTALLa new brake master...

Page 191: ...rvoirfluid level Is the fluid level OK Yes GO to F3 No CHECK the brake master cylinder reservoir sealing points REFERtothe componenttests ADD fluid and BLEED the brake system REFERto 206 00 Brake Syst...

Page 192: ...ut loose Yes INSTALLa newfront wheel hub retaining nut REFER to Specifications 204 01 Front Suspension Specifications Do not reusethefrontwheel hubretaining nut TEST the system for normal operation No...

Page 193: ...s as necessary TEST the system for normal operation No GO to G4 GO to Pinpoint Test G 164 CHECK PRESSURECONSCIOUS REDUCINGVALVE RIGHT HAND REAR I rnInstallpressuregauges in the left hand front and rig...

Page 194: ...psi at the lefl hand rear wheel Yes TEST the brake booster Go to PinpointTest I No INSTALLa new left hand rear brake pressure control valve BLEED the brake system REFERto 206 00 Brake System General...

Page 195: ...ion No CHECK the front brake disc s for thickness variances REFER to Specifications 206 03 Front Disc Brake Specifications INSTALLnew components as necessary TEST the system for normal operation PINPO...

Page 196: ...eeding General Procedures TEST the systemfor normal operation PINPOINT TEST J EXCESSIVE BRAKE PEDAL EFFORT TEST CONDITIONS DETAILSIRESULTSIACTIONS J1 CHECK BRAKEAPPLICATION With the engineoff applyand...

Page 197: ...ectthe vacuum hose from the brake booster check valve Run the engine at idle Check the supply with a vacuum gauge Is the vacuum pressure above 40 5 kPa 12 in Hg with the brake boosternon operational Y...

Page 198: ...hicles With 4 Speed Automatic Transmission AW81 40 Vehicles With Automated Gearshift Removal and Installation Brake Pedal RHD Removal and Installation TEST the system for normal operation 157 CHECK BR...

Page 199: ...noise present Yes GO to K2 No Vehicle OK K2 CHECK PUSH ROD ALIGNMENT Check the brake booster push rod alignment and travel Is the push rod OK Yes BLEEDthe brakesystem REFERto 206 00 Brake System Gene...

Page 200: ...BrakeActuation Brake Booster LHD Removaland lnstallation Brake Booster RHD Removaland lnstallation TEST the system for normal operation No REPAIR or INSTALLnew brake pedal bush ings REFER to 206 06 H...

Page 201: ...will tend to move downward under constant foot pressure If no motion is felt the vacuum booster system is not functioning 4 Removethe vacuum hose from the brake booster Intake manifoldvacuum should b...

Page 202: ...cttire pressures grease or fluid on the brake shoes and linings damaged brake shoes and linings incorrectly adjusted parking brake or damaged or contaminated brake pressure control valves The brake pe...

Page 203: ...external leak may occur at the master cylinder reservoir cap because of incorrect positioning of the gasket and cap Repositionthe cap and gasket Type 2 An externalleak mayoccur atthe reservoir mounti...

Page 204: ...alled after bleeding the brake N0TE Make sure that the vehicle is standing on a level surface line s This will prevent corrosion to the bleednipple Failureto followthis instruction Bleeding may result...

Page 205: ...e affected area must be immediatelywasheddownwith coldwater brakefluid from the hydraulic control unit I N0TE Make sure that the vehicle is standing on a level surface N0TE The systemconsistsof separa...

Page 206: ......

Page 207: ...TIONS Specifications 206 02 2 Drum Brake Specification 206 02 2 DESCRIPTIONAND OPERATION Drum Brake 206 02 3 Overview 206 02 3 DIAGNOSISAND TESTING Drum Brake REMOVALAND INSTALLATION Brake Drum 122750...

Page 208: ...I 36 mm I New brake drum nominaldiameter Worn brake drum discard diameter 1worn brake shoe lining discard thickness I Imm I 203 mm 204 mm I When the discard diameterlthickness has been reached install...

Page 209: ...uipped with an automatic adjuster which adjusts the brake shoes towards the brake drum when lining wear occurs The adjustment mechanism is equipped with a bi metallic strip which prevents undesired ad...

Page 210: ...the bi metallicstrip If the heat exceeds a critical point the bi metallic strip bends upwards into the correspondingniband preventsfurther adjustment After the brake has cooled again the bi metallic s...

Page 211: ...206 02 5 Drum Brake 206 02 5 DIAGNOSISAND TESTING Drum Brake REFER to Section 206 00 Brake System General Information 2006 0 Fiesta1212006 GI 7465en...

Page 212: ...emovethe wheel and tire For additional 1 CAUTION Rotatethe drum tentimesin information referto Section 204 04 Wheels the opposite direction when tightening the and Tires wheel hub retaining nut to pre...

Page 213: ...e shoe adjuster 2 Loosen the parking brake cable adjustment nut to the end of the thread SAM 1C1024 A Discard the retaining clip 6 Removethe brake drum 7 Removethe hold down springs 3 Releasethe parki...

Page 214: ...e brakeshoeadjuster is fully released N0TE lnstall a new parking brake cable retaining clip To install reverse the removal procedure Apply greasetothe brakeshoeadjusterstrut Clean the backing plate an...

Page 215: ...twork the affected area must be immediatelywasheddown with coldwater 1 Removethe brake shoes For additional information refer to Brake Shoes in this section 2m ACAUTION C the brake tube to prevent flu...

Page 216: ...tional information refer to Wheel Cylinder in this section 2 Detach the parking brake cable from the backing plate I Depressthe retaining clip 2 Detachthe cable 3 Removethe brake backing plate Using a...

Page 217: ...ION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 206 03 2 Front Disc Brake Specification 206 03 2 DESCRIPTIONAND OPERATION Front Disc Brake 206 03 3 Overview 206 03 3 DIAGNOSISAND TESTING...

Page 218: ...5 20 Worn brake disc discard thickness Vehicles with 2 OL Duratec HE Maximum brake disc thickness variation IWorn brake pad discard thickness Vehicles with 2 OL Duratec HE I 2 0 I 23 0 025 I When the...

Page 219: ...ston floating caliper 3 4 5 The front disc brakesare the same on all vehicles irrespectiveof the vehicle specifications 1 2 Retaining spring clip Brake pads Brake caliper Pleasereferto the General Spe...

Page 220: ...206 034 Front Disc Brake 206 03 4 DIAGNOSISAND TESTING Front Disc Brake REFER to Section 206 00 Brake System General Information 2006 0 Fiesta1212006 G I7475en...

Page 221: ...caliper anchor plate A CAUTI0N If brake fluid is spilt on the paintwork the affected area must be 1 Remove the brake caliper retaining bolt immediately washed downwith coldwater covers if equipped 2 R...

Page 222: ...n installing the brake caliper to prevent damage to the brake hose A a k e surethatthe brakehoseiscorrectly located inthe brake hosesupport bracketto prevent damage to the brake hose A a k e sure that...

Page 223: ...to Wheel andTire 204 04WheelsandTires Removal I Removethe brake caliper retaining bolt and Installation covers if equipped 2 Remove the brake caliper retaining clip 2 Removethe brake caliper retaining...

Page 224: ...removal procedure Apply greasetothe brake pad contact points 2 Bleedthe brake system For additional information refer to 206 00 Brake System General Information Brake System Bleeding General Procedure...

Page 225: ...SPECIFICATIONS Specifications 206 04 2 Brake Disc Specification 206 04 2 DESCRIPTIONAND OPERATION Rear Disc Brake 206 04 3 DIAGNOSISAND TESTING Rear Disc Brake 206 04 5 REMOVALAND INSTALLATION Brake...

Page 226: ...10 15 Worn brake disc discardthickness Maximumbrake disc thickness variation IBrake caliper piston diameter I 34 I 8 0 02 I When the discard thickness has been reached installa new brakedisdbrake pad...

Page 227: ...Hub and Disc BrakeAssembly Item Description Item Description I 1 IBeam axle 2 3 Iplate assembly 2006 0 Fiesta1212006 G427693en 5 Brakediscshield Brake caliper and brake caliper anchor 4 Wheel hub reta...

Page 228: ...ar Disc Brake 206 04 4 DESCRIPTIONAND OPERATION Brake Caliper and BrakeCaliperAnchor PlateAssembly r 3 1Brake caliper I Item Description 2006 0 Fiesta1 2 0 0 6 G427693en 1 2 Brake caliper anchor plate...

Page 229: ...206 04 5 Rear Disc Brake 206 04 5 DIAGNOSISAND TESTING Rear Disc Brake REFER to Brake System 206 00 Brake System General Information Diagnosis and Testing 2006 0 Fiesta1212006 G427694en...

Page 230: ...th coldwater ESD M6C57 A 1 Releasethe parking brake 2 Removethe wheel and tire For additional information refer to Wheel andTire 204 04Wheels andTires Removal and Installation 3 Detach the brake hose...

Page 231: ...er piston 2 N0TE Make sure that the brake pad contact pointsare clean andfreefrom contamination To install reverse the removal procedure 3 Fully depress and release the brake pedal 4 Check the fluid l...

Page 232: ...the brake caliper A CAUTI0N If brake fluid is spilt on the paintwork the affected area must be immediatelywashed downwith coldwater I Releasethe parking brake 2 Remove the wheel and tire For addition...

Page 233: ...brake caliper piston 2 N0TE Make sure that the brake pad contact points arecleanandfreefrom contamination To install reverse the removal procedure 3 Bleed the brake system For additional information r...

Page 234: ...rake hose from the brake hose support bracket 4a A U T I O N S the brakecaliper and brake caliper anchor plate assembly to preventload being placedonthe brakehose Detach the brake caliper and brake ca...

Page 235: ...rmation refer to Brake Disc 206 04RearDisc Brake Removaland Installation 2 Detach the wheel speed sensor from the wheel spindle 3 Removethe wheel spindle and wheel hub assembly 4 Removethe brake disc...

Page 236: ......

Page 237: ...206 05 5 Inspectionand Verification 206 05 5 Symptom Chart 206 05 5 Pinpoint Tests 206 05 5 GENERAL PROCEDURES Parking Brake Cable Adjustment Vehicles With Rear Drum Brakes 12 662 0 206 05 9 Parking B...

Page 238: ...Brake and Actuation 206 05 2 SPECIFICATIONS Torque Specifications IParking brake control retaining nuts I 24 I 18 I I Description Nm Ib ft Ib in Parking brake cable adjustment nut 4 35 2006 0 Fiesta12...

Page 239: ...RIPTIONAND OPERATION Parking Brake Overview 2006 0 Fiesta1212006 G250946en Item Description Item Description 1 2 6 7 Handbrake lever Handbrake adjusting nut Sleeve connection Rear handbrake cable 3 4...

Page 240: ...The two handbrakecables underneaththe vehicle are bothconnectedvia a threaded pieceand a nut to the equaliser and therefore the front handbrake cable They are connectedto the rear handbrake cables via...

Page 241: ...obviouscause for an observed or reported concern isfound correctthe cause if possible before proceedingto the next step 4 If the concern is not visually evident verify the symptom and refer to the Sy...

Page 242: ...s GO to A3 No INSTALL new brake shoes or pads REFERto BrakeShoes 206 02DrumBrake Removaland Installation I Brake Pads 206 04 Removaland Installa tion TEST the system for normal operation A3 CHECK FOR...

Page 243: ...en the parking brake cable tension Rotatethe rear wheels by hand Did the rear wheels turn freely Yes INSTALL a new parking brake control REFERto Parking Brake Control 206 05 Removal and Installation T...

Page 244: ...edbythe disconnected parking brake Did the wheel turn freely Yes INSTALLa new parking brake control lever on the rear drum brakes or caliper assembly on rear disc brakes REFERto BrakeShoes 206 02Drum...

Page 245: ...ve stages Stage 1 Raisethe parkingbrake controlfour notches Stage 2 Tighten the adjustment nut until increasedtorque is detected Stage 3 Operate the parking brake control firmly ten times Stage 4 Loos...

Page 246: ...tage I Raiseand releasethe parkingbrake control and check that it returnsto the fully releasedposition Ifthe parking brakecontrol does notfully release repeatthe adjustment procedure Stage 2 Rotatethe...

Page 247: ...e actuating levers and the stops when added together is between 0 5 mm and 2 0 mm left hand parking brake actuating lever shown 3 Releasethe parking brake 4 Make sure that the parking brake cable is c...

Page 248: ...05 12 Parking Brake and Actuation 206 05 12 GENERAL PROCEDURES 11 Install a new parking brake cable adjustment nut retainingclip 12 Installthe parkingbrakecontroltrim panel 2006 0 Fiesta1212006 G45889...

Page 249: ...ration Lifting Description and Operation 3m C A U T I O N T care when removing the 6 Detach the parking brake cable from the exhaust hanger insulators to prevent damage beam axle on both sides Detach...

Page 250: ...able Installation ACAUTION T care when installingthe exhaust hanger insulators to prevent damage N0TE Check the exhaust hanger insulatorsfor damage Install new exhaust hanger insulators if required To...

Page 251: ...ction of the exhaust system heat shield from the floor pan 6 Detach the parking brake cable from the brake caliper on both sides I Pull back the parking brake actuating lever 2 Disconnectthe parkingbr...

Page 252: ...he parking brake cable from the floor pan on both sides 11 Removethe parking brake cable Installation ACAUTION T care when installingthe exhaust hanger insulators to prevent damage N0TE Check the exha...

Page 253: ...stallation 2 Disconnect the parking brakewarning I To install reverse the removal procedure indicator switch electrical connector 2 Adjust the parking brake For additional information refer to Parking...

Page 254: ...I...

Page 255: ...NTENTS PAGE SPECIFICATIONS Specifications 206 06 2 DESCRIPTIONAND OPERATION Hydraulic Brake Actuation Vehicles Built Up To 01 2004 206 06 3 Brake pedal 206 06 3 DIAGNOSISAND TESTING Hydraulic Brake Ac...

Page 256: ...em Super DOT4 brake fluid I Description I Nm I Ib ft I Ib in I Specification ESD M6C57 A IBrake master cylinder brake tube unions I 17 I 13 I I IBrake master cylinder retaining nuts I 25 I 18 I I Pres...

Page 257: ...safety device which uncouplesthe brake pedalfrom the brake master cylinder in the event of a severe frontal collision to reduce injuries to the feet of the driver As a result the pressure acting from...

Page 258: ...cut through The connection point of the brake pedal is released and no more force can be transmitted The complete pedal unit is mounted via a bore in The carrier plate ofthe pedal is uncoupledfrom the...

Page 259: ...206 06 5 Hydraulic Brake Actuation 206 06 5 DIAGNOSIS AND TESTING Hydraulic Brake Actuation REFERto Section 206 00 Brake System General Information 2006 0 Fiesta1212006 GI7506en...

Page 260: ...the stowage compartment 3 Releasethe clip 2 Detachthe brakeboosteractuating rodfrom the brake pedal accelerator pedal shown removed for clarity I Depressthe clip 2 Removethe brakeboosteractuatingrod...

Page 261: ...e brake pedal 6 Remove the brake pedal bushings Installation Im ACAUTION D notdropor knockthe brake pedal Failureto follow this instructionwill cause damage to the brake pedal decoupler mechanism if e...

Page 262: ...information refer to Section 414 01 Battery Mounting and Cables 3 Remove the windshield wiper motor assembly For additional information refer to Section 501 16 Wipers and Washers 4m AUTION T brake fl...

Page 263: ...s Disconnect the clutch master cylinder feed hose from the brake fluid reservoir 12 Removethe brake master cylinder and brake fluid reservoir assembly Installation A CAUTI0N Make sure the brake master...

Page 264: ......

Page 265: ......

Page 266: ...ower BrakeActuation 206 07 2 SPECIFICATIONS Torque Specifications IBrake master cylinder retaining nuts I 25 I 18 I I Description Brake booster retaining nuts 2006 0 Fiesta1212006 28531 en Nm 25 Ib ft...

Page 267: ...m is available j as an option depending on market and vehicle variant Function In normal braking situations the brake servo with EBA operates in the same way as a conventional brake servo unit This me...

Page 268: ...07 4 Power Brake Actuation 206 07 4 DESCRIPTIONAND OPERATION Item Descri tio on I 1 IRelativetravel distance I r 2 b o n t r o housing I 1 3 Valvepiston I Normal braking 2006 0 Fiesta1212006 G I63289...

Page 269: ...ription I 1 IRelativetravel distance I 1 2 1Disc valve I 1 3 1Key I If the activation threshold level is exceeded because of an emergency braking situation i e the relativetravel distance ofthe valve...

Page 270: ...is occurs the controlhousingtogetherwith the valve piston move back into the rest position The key is pressedagainstthe stoponthe vacuum cylinder and bythis the locksleeve isslid backinto its rest pos...

Page 271: ...206 0717 Power BrakeActuation 206 07 7 DIAGNOSIS AND TESTING Power Brake System REFER to Section 206 00 Brake System General Information 2006 0 Fiesta1212006 G I7519en...

Page 272: ...lip 5 Remove the brake booster Discard the gasket Installation 1 WARNINGS A D O not installan Emergency BrakeAssist EBA brake booster to a vehicle that is not equipped with the Anti lock Brake System...

Page 273: ...OVALAND INSTALLATION N0TE On vehicles equipped with EBA the brake booster is identified by a white sticker showing a large letter A N0TE lnstall a new brake booster gasket To install reversethe remova...

Page 274: ......

Page 275: ...D TESTING Anti Lock Control 206 09A 7 Inspection and Verification 206 09A 7 REMOVALAND INSTALLATION Hydraulic Control Unit HCU Vehicles Built Up To 0512004 206 09A 8 Hydraulic Control Unit HCU Vehicle...

Page 276: ...I ISuper DOT4 brake fluid Hydrauliccontrol unit HCU to support bracket retaining bolts IWheel speed sensor retaining bolts I 9 I I 80 I HCU support bracket retaining bolts Brake tube to HCU unions IAn...

Page 277: ...d driving stability in extreme Electronic brake force distribution is integrated in the software of the ABS control unit which electronicallyregulatesand optimisesthe pressure applied to the wheel bra...

Page 278: ...the inlet valves are open and the outlet valves are closed The valve block also contains the low pressure reservoir and sound damping chambers Pump motor Inthe eventof anABS interventionthe pump moto...

Page 279: ...medium size vehicles Compared to the MK20ABS system it has been possibleto reduce the size of the hydraulic and electric components e g hydraulic valves and solenoids and the housing As a result the...

Page 280: ...tedon the stub axle The registeredwheel speed is converted into a digital square wave signal by the electronics integrated in the sensor and is then transmitted to the ABS control unit Data Link Conne...

Page 281: ...s signs of mechanical or electrical damage Visual Inspection Chart I Mechanical I Electrical I 3 If an obvious causefor an observed or reported concern isfound correctthe cause if possible before proc...

Page 282: ...tion refer to Section 206 06 Hydraulic BrakeActuation 2 Detach the engine wiring harness electrical connector from the wheelhouse assembly 3 CAUTIONS ap the braketubes to prevent fluid loss or dirt in...

Page 283: ...om the bulkhead 10 Remove the HCU and ABS module 7 Raiseand supportthe vehicle Foradditional information referto Section 100 02 Jacking 12 Remove the HCUto ABS module retaining and Lifting bolts 8 Rem...

Page 284: ...6 09A 10 Anti Lock Control 206 09A 10 REMOVAL AND INSTALLATION 2 Bleedthe brake system For additional information refer to Section 206 00 Brake System General Information 2006 0 Fiesta1212006 G I83774...

Page 285: ...5 CAUTIONS h a p the brake tubes to prevent fluid loss or dirt ingress n p l u g the hydraulic control unit HCU ports to prevent fluid loss or dirt ingress Left hand drive vehicles N0TE Make a note o...

Page 286: ...and socket to prevent dirt and fluid ingress Disconnect the ABS module electrical connector I Depressthe lockingtangs 2 Releasethe retainer 8 Raiseandsupport thevehicle Foradditional information refer...

Page 287: ...U Installation 1 To install reversethe removal procedure 2 Bleed the brake system For additional information refer to 206 00 Brake System General Information Brake System Bleeding General Procedures B...

Page 288: ...tion refer to Section 206 06 Hydraulic BrakeActuation 2 Detach the engine wiring harness electrical connector from the wheelhouse assembly 4m CAUTIONS 3 CAUTIONS ap the braketubes to prevent fluid los...

Page 289: ...trical connector 11 Detachthe HCUandABS moduleassembly from the support bracket 7 Raiseandsupport thevehicle Foradditional information referto Section 100 02 Jacking 12 Removethe HCU to ABS module ret...

Page 290: ...6 09A 16 Anti Lock Control 206 09A 16 REMOVAL AND INSTALLATION 2 Bleed the brake system For additional information refer to Section 206 00 Brake System General Information 2006 0 Fiesta1212006 G327317...

Page 291: ...06 06 Hydraulic BrakeActuation Removaland Installation 3 CAUTIONS ap the brake tubes to prevent fluid loss or dirt ingress A p l u g the hydraulic control unit HCU ports to prevent fluid loss or dirt...

Page 292: ...tubes from the bulkhead 7m AUTION C the anti lock brakesystem ABS module electrical connector and socket to prevent dirt and fluid ingress Disconnect the ABS module electrical connector 1 Depressthe l...

Page 293: ...dule Installation I To install reversethe removal procedure 2 Bleedthe brake system For additional information refer to 206 00 Brake System General Information Brake System Bleeding General Procedures...

Page 294: ...Detachthe wheel speed sensor from the wheel spindle on both sides Vehicles with rear disc brakes 3 Detachthe wheel speed sensor from the wheel spindle on both sides 4 Detachthe wheel speed sensor wiri...

Page 295: ...sfrom the wheel speed sensor 1 support bracket Discardthe retaining clips 8 Detachthe wheel speed sensor wiring harnessfrom the beam axle on both sides 9 Remove the rear wheel speed sensor Installatio...

Page 296: ...kes 2 Removethe dust cap Installation All vehicles 1 CAUTIONS A M a k e sure the wheel speed sensor ring 3 Removethe brake disc is not knocked damaged and kept free from For additional information ref...

Page 297: ...eel hub retaining nut to prevent damage to the wheel bearing Vehicles with rear drum brakes 5 CAUTIONS A A v o i d any impact on the wheel speed sensor ring A M a k e sure the wheel speed sensor ring...

Page 298: ...electrical connector from the wheelhouse assembly 2 Disconnectthe wheelspeedsensorelectrical connector 5 N0TE Make surethat allopenings aresealed N0TE Note the position of the component before removal...

Page 299: ...6 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 206 09B 2 DIAGNOSIS AND TESTING Anti Lock Control Traction Control 206 09B 3 REMOVALAND INSTALLATION Rear Wheel Speed Sensor Ring 12 788 0 206 09...

Page 300: ...alers and Adhesives I I Specifications I ISuper DOT4 brakefluid IESD M6C57 A 1 Torque S ecifications Hydraulic control unit HCU support bracket retaining bolts 2006 0 Fiesta1212006 G89252en HCU retain...

Page 301: ...Control 206 09B 3 DIAGNOSIS AND TESTING Anti Lock Control Traction Control REFERto Section 206 09A Anti Lock Control I 206 09B Anti Lock Control Traction Control I 206 09C Anti Lock Control StabilityA...

Page 302: ...4 REMOVALAND INSTALLATION Rear Wheel Speed Sensor Ring l2 788 0 For additional information refer to Section 206 09A Anti Lock Control I 206 098 Anti Lock Control Traction Control 1 206 09C Anti Lock C...

Page 303: ...REMOVALAND INSTALLATION Rear Wheel Speed Sensor l2 785 0 Removal I For additional information referto Section 206 09A Anti Lock Control I 206 09B Anti LockControl Traction Control 1 206 09C Anti Lock...

Page 304: ...moval 1 N0TE The traction control function is only availableonvehiclesequippedwiththe MK60 anti lock brake system ABS and the stability assist program Foradditionalinformation referto Hydraulic Contro...

Page 305: ...le Removal 1 N0TE The traction control function is only availableonvehiclesequippedwith the MK60 anti lock brake system ABS and the stability assist program Foradditional information referto Stability...

Page 306: ......

Page 307: ...Specifications 206 09C 2 DIAGNOSISAND TESTING Anti Lock Control Stability Assist 206 096 3 REMOVALAND INSTALLATION Hydraulic Control Unit HCU 206 09C 4 Rear Wheel Speed Sensor 12 785 0 206 09C 7 Yaw...

Page 308: ...support bracket retaining bolts I 20 I 15 I I Hydrauliccontrol unit HCU to support bracket retaining bolts Brake tube to HCU unions I 18 I 13 I I 9 Wheel speed sensor retaining bolts I 9 I I 80 I Stab...

Page 309: ...Assist 206 096 3 DIAGNOSIS AND TESTING Anti Lock Control Stability Assist I REFERto Section 206 09A Anti Lock Control I 206 09B Anti Lock Control Traction Control 1 206 09C Anti Lock Control Stability...

Page 310: ...refer to Section 206 06 Hydraulic BrakeActuation 2 Detach the engine wiring harness electrical connector from the wheelhouse assembly 3 CAUTIONS h a p the brake tubes to preventfluid loss or dirt ingr...

Page 311: ...e bulkhead 10 Removethe HCU and stability assist 7 Raiseandsupport the vehicle Foradditional information referto Section 100 02 Jacking 12 Removethe HCUto stability assist module and Lifting retaining...

Page 312: ...Anti Lock Control Stability Assist 206 09C 6 REMOVAL AND INSTALLATION 2 Bleed the brake system For additional information refer to Section 206 00 Brake System General Information 2006 0 Fiesta1212006...

Page 313: ...EMOVALAND INSTALLATION Rear Wheel Speed Sensor l2 785 0 Removal 1 For additional information refer to Section 206 09A Anti Lock Control 1 206 09B Anti Lock Control Traction Control 1 206 09C Anti Lock...

Page 314: ...ethe yaw rate sensor and accelerometer assembly 3 Removethe B pillartrim panel Foradditional 1 Disconnectthe electricalconnector information referto Section 501 05 Interior 2 Removethe bracket retaini...

Page 315: ...the correct bolts are used for the yaw rate sensor and accelerometer assembly Failureto follow this instruction will result in damaged threads A Makesure the correct bolts are used for the yaw rate s...

Page 316: ...additional information referto Section 501 20A Safety Belt System I501 20B Supplemental Restraint System Installation AWARNING T stability assist program must be re configured following installation F...

Page 317: ...OVAL AND INSTALLATION Rear Wheel Speed Sensor Ring l2 788 0 Removal 1 For additional information referto Section 206 09A Anti Lock Control I 206 098 Anti Lock Control Traction Control 1 206 09C Anti L...

Page 318: ...er to Section 206 06 Hydraulic BrakeActuation 2 Detach the engine wiring harness electrical I connector from the wheelhouse assembly 4 CAUTIONS 3 CAUTIONS h a p the braketubes to prevent fluid loss or...

Page 319: ...or 11 Detachthe HCUandstability assist module assembly from the support bracket 7 Raiseandsupport thevehicle Foradditional information referto Section 100 02 Jacking 12 Removethe HCUto stability assis...

Page 320: ...Anti Lock Control Stability Assist 206 096 14 REMOVALAND INSTALLATION 2 Bleedthe brake system For additional information refer to Section 206 00 Brake System General Information 2006 0 Fiesta1212006...

Page 321: ...G Steering System 211 00 5 Principles of Operation 211 00 5 Inspectionand Verification 211 00 5 Components Tests 211 00 14 Steering Gear Checks After a Collision 211 00 18 GENERAL PROCEDURES Power Ste...

Page 322: ...ulicfluid vehicles with 1 6L Duratorq TDCi DV Diesel I Description I Meters I Specifications WSA M2C195 A WSS M2C204 A2 IWall to wall vehicles with 2 OL Duratec HE M14 I 11 65 I IMaximum allowable ste...

Page 323: ...211 00 3 Steering System General Information 211 00 3 DESCRIPTIONAND OPERATION Steering System Overview 2006 0 Fiesta1212006 G202090en...

Page 324: ...I 1 2 1Additional cooling loop I Independentof the equipment level all vehicles haveconventionalpower assistedrackand pinion steering with an additional cooling loop The steering gear is suppliedwith...

Page 325: ...es due to the extra load on the engine imposed by the power steering pump have a power steering pressure PSP switch The switch which is normallyclosed sends a signal to the powertrain control module P...

Page 326: ...system I REFERto BrakeSystem 206 00 Brake System General Information Diagnosis and Testing CARRY OUT the steering linkage component test REFER to Steering Linkage Component Test in this procedure CAR...

Page 327: ...ectwheel alignment CHECK the wheel alignment and adjust if necessary REFERto 204 00 Suspension System General Information Specifications Specifications FrontToeAdjustment General Procedures Wheels and...

Page 328: ...t is highllow Looseor worn accessorydrive belt CHECK the accessory drive belt REFER to 303 05 Accessory Drive Power Steering Pump Belt 1 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma Vehicles With Air...

Page 329: ...re Line 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma l 6L Duratec 16V Sigma Vehicles Without Air Conditioning Removal and lnstallation Power Steering Pumpto Steering Gear Pressure Line 1 3L Duratec...

Page 330: ...eering linkage component test REFERto Steering Linkage Component Test in this procedure Worn power steering pump INSTALLa new powersteering pump REFERto 211 02 Power Steering Power Steering Pump 1 3L...

Page 331: ...ise Check Excessive noise REFERto Noise Vibration and Harshness NVH 100 04 Noise Vibration and Harsh ness Diagnosisand Testing Powersteeringoperationnoise Power steering fluid aeration BLEEDthe power...

Page 332: ...moval and Installation Power Steering Pumpto Steering Gear Pressure Line I 3L Duratec 8V Rocam Removal and Installation Power Steering Pumpto Steering Gear Pressure Line I 4L Duratorq TDCi DV Diesel R...

Page 333: ...s With Air Condi tioning Removaland Installa tion Power Steering Pump 1 25L Duratec I6V Sigma l 4L Duratec I6V Sigma l GL Duratec I6V Sigma Vehicles Without Air Condi tioning Removaland Installa tion...

Page 334: ...s necessary REFERto Specifications 211 04 Steering Column Specifications Loosesteering column to steering gear pinion retaining bolt CHECK and INSTALL a new steering column to steering gear pinion ret...

Page 335: ...FER to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation 3m ACAUTION T prevent damage to the steering linkage turn the steering wheel to move the steering...

Page 336: ...0 SupplementalRestraintSystem Removaland Installation 3 Removethe driver air bag modulewiring harnessfrom the driver air bag module REFERto Driver Air Bag ModuleWiring Harness 501 20 Supplemental Rest...

Page 337: ...DriverAir Bag Module 501 20 counterclockwise SupplementalRestraintSystem Removaland Ifany movement isfelt installa newsteering installation column REFERto SteeringColumn 211 04Steering Column Removal...

Page 338: ...steering pump reliefvalve are acceptable is greater than 0 5 mm install a new steering Itemsto be observedwhen checkingthe steering gear STEERING GEAR HOUSING I Raise and support the vehicle REFERto L...

Page 339: ...ring lock stop I 6 Check for power steering fluid leaks at the steering gear housing and the power steering line connectionsto the steering gear If there is a power steering fluid leak at the steering...

Page 340: ...0TE Do not start the engine at this stage N0TE Make sure that the power steering fluid in the power steering fluid reservoir does not fall belowthe MINmark as air couldenterthe system Slowly turn the...

Page 341: ...d until the power steering fluid in the power steering fluid reservoir stops dropping 4 Check the power steering fluid level Fill the power steering fluid reservoir to the MAX mark with the appropriat...

Page 342: ...or leaks Using the special tools bleedthe power steering system in the following sequence 1 Startthe engine and slowly turn the steering wheel from lock to lock once then turn the steeringwheel to the...

Page 343: ...teering fluid sensor electrical connector reservoir return hose into a suitable container 5 Lower the vehicle until the wheels are clear of the floor to allow the steering wheel to be rotated from loc...

Page 344: ...the special tool install the spark plugs 9 N0TE When filling the power steering fluid reservoir makesure that the powersteering fluid is clean and not agitated prior to use The fluid should be poured...

Page 345: ...cedures Power Steering System Bleeding General Procedures 17 Raise and support the vehicle For additional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Desc...

Page 346: ...ark plug wires ES21202 I N0TE Cap the powersteering fluid reservoir to prevent fluid loss or dirt ingress Socket Spark Plug 303 499 Using the special tool disconnect the steering gear to power steerin...

Page 347: ...steering fluid must be pouredslowly intothe powersteeringfluid reservoirto minimize the possibility of aeration While cranking the engine turn the steering wheel from lock to lock With the aid of ano...

Page 348: ...at the steering fluid is clean and not agitated prior to use The steering fluid must be poured slowly into the power steering fluid reservoir to minimize the possibility of aeration The steering fluid...

Page 349: ...0 Power Steering Pump 2 OL Duratec HE M14 Power Steering Pumpto SteeringGear PressureLine 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma Vehicles With Air Conditioning 13 440 0...

Page 350: ...ith 1 3L Duratec 8V Rocam Power steering lineto power steering pump union vehicles with 1 4L Duratec I6V Sigma 1 6L Duratec 16V Sigma or 2 OL Duratec HE M14 Power steering lineto power steering pump u...

Page 351: ...ut Steering column shaft to steering gear pinion retaining bolt Exhaustheatshieldto steeringgear retaining bolts Exhaustflexible pipe to muffler and tailpipe assembly retaining nuts vehicles with I 6L...

Page 352: ...21I 02 4 Power Steering 211 02 4 DIAGNOSISAND TESTING Power Steering REFER to Section 211 00 Steering System General Information 2006 0 Fiesta1212006 G I7571en...

Page 353: ...ouse assembly and position itto one side 1 Removethe retaining bolt 4 Removethe accessory drive belt 2 Releasethe retaining clip For additional information refer to Power Steering Pump Belt 1 4L Durat...

Page 354: ...r from the power steering pump Usingthe specialtool disconnectthe power steering linefrom the power steering pump pressureadapter Allow the fluid to drain into a suitable container Installation 1 N0TE...

Page 355: ...ng i To install reverse the removal procedure 3 Fill and bleed the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Information Ge...

Page 356: ...Duratec 16V Sigma Vehicles Without Air Conditioning 303 05 Accessory Drive RemovalandInstallation 2 Disconnectthe powersteeringfluid reservoir return hose quick releasecoupling from either the power s...

Page 357: ...l and bleed the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Information General Procedures IPower Steering System Bleeding 21...

Page 358: ...r to HeadlampAssembly 417 01 Exterior Lighting Removaland Installation 2 Removethe accessory drive belt For additional information refer to Accessory Drive Belt 2 OL Duratec HE M14 303 05Accessory Dri...

Page 359: ...er steering fluid reservoir return line See Removal Detail Power steering fluid reservoir retaining bolts Power steering pump pulley See Removal Detail See Installation Detail 6 To install reversethe...

Page 360: ...power steering fluid loss or dirt ingress Using the special tool disconnect the steering gear to power steering fluid reservoir return linefrom the powersteering fluid reservoir Allow the power steeri...

Page 361: ...r steering pumpto steering gear pressureline I union and installthe Teflon seal Item 4 Power steering pump pulley I Usingthe special tool install the power steering pump pulley Item 3 Power steering f...

Page 362: ...ank from the wheelhouse assembly and position itto one side I Removethe retainingbolt 2 Releasethe retaining clip Detachthe powersteering line bracketsfrom the cylinder head 4 Raise and support the ve...

Page 363: ...E Note the positionofthe power steering line to aid installation Detach the power steering line from the steering gear Left hand drive vehicles 7 Detach the steering gear return hose from the pressure...

Page 364: ...being installed pushthe new line into the new union until it clips into place 4 To install reverse the removal procedure 5 Fill and bleed the power steering system For additional information refer to...

Page 365: ...formation refer to Jacking 100 02 Jacking and Lifting Description and Operation I N0TE Notethe positionofthe powersteering I Lifting 100 02 Jacking and Lifting line to aid installation Description and...

Page 366: ...onnect the power steering pressure line to aid installation PSP switch electrical connector Detach the power steering line bracket from the steering gear Left hand drive vehicles 7 Detach the steering...

Page 367: ...s being installed pushthe new line intothe new union until it clips into place 4 To install reverse the removal procedure 5 Fill and bleed the power steering system For additional information refer to...

Page 368: ...opening panel Transmissionjack 1 Removethe right hand headlamp assembly 5 N0TE Make sure that the roadwheels are in For additional information refer to the straight ahead position 4 Removethe battery...

Page 369: ...taining bolt 6 Detach the steering column shaft from the steering gear pinion 7 Removethe accessory drive belt For additional information refer to Accessory Drive Belt 2 OL Duratec HE M14 303 05Access...

Page 370: ...etail See InstallationDetail I I e e Removal Detail I 5 Power steering pump to steering gear pressure line See Removal Detail See lnstallation Detail 3 10 To install reverse the removal procedure Powe...

Page 371: ...s or dirt ingress Item 4 Power steering pump to steering gear pressureline bracketto intakemanifold retaining bolt 1 Raiseandsupportthe vehicle For additional information refer to 100 02 Jacking and L...

Page 372: ...aid installation Detach the power steering pump to steering gear pressure line from the steering gear 5m AUTION O bending of the exhaust flexible pipe may cause damage resulting in failure damage res...

Page 373: ...des 13 Detachthe steering gear to power steering fluid reservoir return line from the power steering pump to steering gear pressure line 9 Remove the engine support insulator 10 Using a transmission j...

Page 374: ...rvoir return line to the power 1 Installnew power steering lines O ring seals steering pumpto steering gear pressure line 2 Connect the power steering lines to the 4 N0TE Use the front axle crossmembe...

Page 375: ...pport insulator front axle crossmember rear outer retaining bolts make sure that the front axle crossmember does not move Install the front axle crossmember front retaining bolt and the front axle cro...

Page 376: ...e than two degrees may cause damage resulting in failure N0TE Use a pry barto preventthe exhaustflexible pipe from twisting when installing the exhaust flexible pipe to catalytic converter retaining n...

Page 377: ...al and Installation Pump Item 1 Power steering pump pulley 1 N0TE This step is only required if installing a new power steering pump to steering gear pressure line Push the new power steering pump to...

Page 378: ...columnshaftto steering gear pinion retaining bolt P p 205524 24003 Alignment Pins Subframe 205 524 Removerllnstaller Hose Clamp 303 397 General Equipment Transmission jack 3 Removethe front wheels and...

Page 379: ...retaining nut See Removal Detail 3 I Isteering gear retaining bolt I Item Description Steering gear heat shield See Removal Detail See Installation Detail 4 Steeringgear to power steering fluid reser...

Page 380: ...urn linefrom the powersteering fluid reservoir Allow the power steering fluid to drain into a container Item 2 Steering gear to power steering fluid reservoir return line support bracketto generator r...

Page 381: ...twisting when removingthe catalytic converterto mufflerandtailpipeassembly retaining nuts Removethe exhaust flexible pipeto catalytic converter retaining nuts 4 N0TE Use a 5 mm Allen key to prevent t...

Page 382: ...Rotatethe power steering lines clamp plate Allow the power steering fluid to drain into a container 9 Detach the steering gear to power steering fluid reservoir return line from the power steering pum...

Page 383: ...mber 2 Connect the power steering lines to the steering gear valve body 1 Rotatethe power steering lines clamp plate 2 Installthe power steering lines clamp plate retaining bolt 3a AUTION W I tighteni...

Page 384: ...pipefrom twisting when installingthe exhaust flexible pipe to catalytic converter retaining nuts N0TE lnstall a new exhaust flexible pipe to catalytic converter gasket and retaining nuts Install the e...

Page 385: ...ger insulator A U T I O N O bending of the exhaust flexible pipe may cause damage resulting in failure Removethe exhaust flexible pipe support wrap or splint Ifem 3 Steeringgear heat shield 1 Attach t...

Page 386: ...ure that the roadwheels are in the straight ahead position Materials Centralizethe steering and lock itin position return hose quick release coupling 2 Detach the steering column shaft from the steeri...

Page 387: ...ve the exhaust hanger insulator Vehicles with 2 OL engine 9 Detach the exhaust flexible pipe from the catalytic converter Discardthe exhaustflexible pipeto catalytic converter gasket and retaining nut...

Page 388: ...engine support insulator using a soft cloth to prevent damage Usingthe special tool detach the tie rod end from the wheel knuckle on both sides 1 Releasethe tie rod end 2 Removeand discardthe tie rod...

Page 389: ...power steering lines from the steering gear valve body 1 Remove the retaining bolt 2 Rotate the clamp plate Allow the fluid to drain into a suitable container Discard the O ring seals 17 Using a trans...

Page 390: ...t axle 2 Install a new steering gear bulkhead floor crossmember retaining bolts makesure that seal the crossmember does not move 3 Install the steering gear Install the front axle crossmember retainin...

Page 391: ...ust flexible pipe studs with grease N0TE lnstall a new exhaust flexible pipe to catalytic converter gasket and retaining nuts Attach the exhaust flexible pipe to the 10 Attach the power steering lines...

Page 392: ...pipe may cause damage resulting N0TE lnstall a new exhaust flexible pipeto in failure catalytic converter gasket and retaining nuts Remove the exhaust flexible pipe support Attach the exhaust flexibl...

Page 393: ...to the steering gear pinion 23 Fill and bleed the power steering system Foradditional information referto 211 00 Steering System General Information Power Steering System Filling General Procedures Po...

Page 394: ...steering gear to power steering fluid cooler return hose quick releasecoupling from either the power steering fluid cooler or the power steering reservoir return hose 1 Pressthe power steering fluid...

Page 395: ...0TE Make sure that the collar on the hose is fully inserted into the quick release coupling N0TE Check the power steering lines to steering gearvalve bodyO ringsealsfor damageorfatigue 8 N0TE Note the...

Page 396: ...angs 2 Disconnectthe power steering fluid cooler hose quick release coupling Allow the fluid to drain into a suitable container 3 Removethe radiator splash shield 4 Lower the vehicle 5 Removethe power...

Page 397: ...gear body Secure the steering gear in a vise Materials 3 Installthe steering gear gear insulator bushing on both sides Installation 14037 1 Lubricate the steering bushing with Rubber For additional i...

Page 398: ......

Page 399: ...CTION 211 03 Steering Linkage VEHICLE APPLICATION 2006 0 Fiesta CONTENTS SPECIFICATIONS Specifications DIAGNOSIS AND TESTING Steering Linkage REMOVALAND INSTALLATION Tie Rod End 13 273 0 Steering Gear...

Page 400: ...ering Linkage 211 03 2 SPECIFICATIONS Torque Specifications s l lb ft Ib in ITie rod to steering gear I 110 I 81 I 1 c I ie rod end locknut ITie rod end retaining nut 1 48 I 35 I I 2006 0 Fiesta121200...

Page 401: ...211 03 3 Steering Linkage 211 03 3 DIAGNOSISAND TESTING Steering Linkage REFER to Section 211 00 SteeringSystem General Information 2006 0 Fiesta1212006 GI7594en...

Page 402: ...ve the tie rod endrn nut in place to protect the balljoint stud Removethe tie rod end N0TE Use a 5 mm Allen key to preventthe ball joint stud from rotating Loosen the tie rod end locknut and the tie r...

Page 403: ...e ball joint stud from rotating Attach the tie rod end to the wheel knuckle 1 Tighten the retaining nut 2 Tighten the locknut 3 Install the wheel and tire For additional information refer to Section 2...

Page 404: ...ion 2 Removethe tie rod end locknut 3 N0TE Make sure the tie rod is clean before removing the steering gear boot Removethe steering gear boot 2 Usinga suitable pairof pincers install a new steering ge...

Page 405: ...7 Steering Linkage 211 03 7 REMOVALAND INSTALLATION 4 Install the tie rod end locknut 5 Install the tie rod end For additional information referto Tie Rod End in this section 2006 0 Fiesta1212006 GI 0...

Page 406: ...d the steering gear boot 1 Removethe steering gear For additional information refer to Section 211 02 Power Steering 2 N0TE Make a note of the number of turns usedto remove the tie rod end Name S ecif...

Page 407: ...vise and using a suitable pipe wrench remove the tie rod Installation 1 Using the special tool install the tie rod 4 N0TE Make sure the steeringgear boot outer clamp is located over the recess in the...

Page 408: ...211 03 10 Steering Linkage 211 03 10 REMOVAL AND INSTALLATION 6 Install the steering gear For additional information refer to Section 211 02 Power Steering 2006 0 Fiesta1212006 G91976en...

Page 409: ...ng Column VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 211 04 2 DIAGNOSISAND TESTING Steering Column REMOVALAND INSTALLATION Steering Wheel 13 524 0 Steering Column 13...

Page 410: ...SPECIFICATIONS Torque Specifications Description Nm Ib ft lb in Steering wheel retaining bolt ISteering column retaining nuts I 24 I 18 I I Steering column shaft to steering gear pinion retaining bol...

Page 411: ...21I 04 3 Steering Column 211 04 3 DIAGNOSISAND TESTING Steering Column REFER to Section 211 00 SteeringSystem General Information 2006 0 Fiesta1212006 G91977en...

Page 412: ...information refer to Driver Air Bag Module 501 20 Supplemental Restraint System Removal and Installation 2 N0TE Make sure that the roadwheels are in the straight ahead position Centralizethe steering...

Page 413: ...e clip 3 Detachthe audio control switch from the steering column lowershroud if equipped Using a thin bladedscrewdriver releasethe locking tang 4 Removethe audio control switch if equipped 5 N0TE Turn...

Page 414: ...sition PATS transceiver windshield Centralizethe steeringand lock it inposition wiperlwasher switch and clockspring electrical connectors Depressthe locking tangs 8 Detach the steering column shaft fr...

Page 415: ...s instructionmay result in personal injury A a k e sure that the steering column lockingleveris inthe lockedposition Failure to follow this instructionmay result in personal injury Anstall new steerin...

Page 416: ...etaining screw A C A U T I O N M sure the clockspringis not allowed to rotate Secure in the central positionwith a piece of suitable tape Removethe multifunctionswitches 1 Depressthe lockingtangs 2 Li...

Page 417: ...driver depressthe detent Right handdrive vehicles 7 Removethe ignition lock cylinder 1 Insertand turn the ignition key to position 1 2 Usinga thin bladedscrewdriver depressthe detent on both sides Ass...

Page 418: ......

Page 419: ...211 05 1 Steering Column Switches 211 05 1 SECTION 211 05 Steering Column Switches VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE REMOVALAND INSTALLATION Ignition Switch 36 424 0 211 05 2...

Page 420: ...trol switch if equipped Disconnectthe electrical connector N0TE Turn the steeringwheel to accessthe steering column upper shroud retaining clips Detach the steering column upper shroud from the steeri...

Page 421: ...211 05 3 Steering Column Switches 211 05 3 REMOVALAND INSTALLATION Depressthe lockingtangs Installation 1 To install reversethe removal procedure 2006 0 Fiesta1212006 G I05656en...

Page 422: ......

Page 423: ...re 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 16V Sigma l 4L Duratec 16V Sigma l 6L...

Page 424: ...303 00 2 Engine System General Information 303 00 2 Exhaust Manifold Cleaning and Inspection 303 00 52 Bearing Inspection 303 00 2 Valve Seat Inspection 303 00...

Page 425: ...DESCRIPTIONAND OPERATION Enaine Engineltransmissioncombinations Item Description I 1 I1 3L Duratec 8V engine I 1 2 1 1 411 6L Duratec 16V engine I 1 3 11 4L DuratorqTDCi turbodiesel engine I 1 4 1iB5...

Page 426: ...art Symptom Chart Symptom PossibleSources Action Visual InspectionChart Loss of oil Mechanical Coolant leaks Oil leaks Fuel system leaks Visibly damaged or worn parts Looseor missing nuts or bolts Ele...

Page 427: ...r as necessary REFERto Engine EmissionControl 303 08 Engine EmissionControl 1 3L Duratec 8V Rocam l 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l 6L Duratec 16V Sigma Diagnosisand Testing Engine Emis...

Page 428: ...matingfaces INSTALLnewvalve seals REFER to Valve Seals 303 01 Engine 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma l 6L Duratec I6V Sigma In vehicle Repair Valve Seals 303 01 Engine 1 3L Duratec 8V...

Page 429: ...q TDCi DV Diesel Diagnosis and Testing INSTALLa new oil cooler Damaged gaskets or warped matingfaces CHECK the cylinder head gasketfor damage CHECKthe cylinder head for distortion Cracks or fractures...

Page 430: ...sand Testing INSTALLa new fuel filter REFER to 310 01 Fuel Tank and Lines FuelFilter 1 4LDuratorq TDCi DV Diesel Removal and Installation FuelFilter I 6LDuratorq TDCi DV Diesel Removaland Installation...

Page 431: ...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 Broke...

Page 432: ...l Charging and Controls 303 04 Fuel Charging and Controls 1 6L Duratorq TDCi DV Diesel Diagnosis and Testing Engine intake air system CHECK the intake air system REFER to lntake Air Distribu tion and...

Page 433: ...t damaged CHECK and adjust the valve timing REFERto Timing Belt 303101 Engine I 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma In vehicle Repair Timing Chain 303 01 Engine 1 3L...

Page 434: ...vehicle Repair Noisy running misfiring back firing or knocking Incorrectfuel DETERMINEwhichtype offuel was last put in the tank note the country specific fuel specifications Valve timing incorrect ti...

Page 435: ...n vehicle Repair Valve ClearanceAdjustment 303 01 Engine 2 OL Duratec HE M14 General Procedures Hydraulic Lash Adjuster 303 01 Engine I 4L Duratorq TDCi DV Diesel In vehicle Repair Camshaft 303 01 Eng...

Page 436: ...rly established Ifthe oil leakcannot beidentifiedclearlyby avisual inspection carry out an ultraviolet UV test Ultraviolet UV Testing 1 Clean the engine and transmission with a suitable cleaning fluid...

Page 437: ...DCi DV biesel 1 Remove the air cleaner REFERto Air Cleaner 1 4L Duratorq TDCi DV Diesel 303 12 IntakeAir Distributionand Filtering Removal and Installation 4 Detachthe exhaustgas recirculation EGR tub...

Page 438: ...lug bore N0TE Operate the starter motor until the reading on the compressiontester stops rising 1QCarry out the measurement in accordance with the instructions supplied with the measuring device on ev...

Page 439: ...l related components Highly flammable mixtures are always 1 6 Attach the EGR tube to the EGR cooler if present and can ignite Failure to follow equipped these instructions may result in personal injur...

Page 440: ...per cover 8m CAUTION DO not disconnect the fuel injection pump electrical connectors and crank the engine Disconnectthe fuel injector electrical connectors 9 Detachthe exhaust gas recirculation EGR co...

Page 441: ...ed compression tester into the glow plug bore N0TE Crank the engine with the starter motor until the readingon the compressiontester stops rising 13 Carry out the measurement on all cylinders followin...

Page 442: ...2 Installthe radiator undershield 23 Installthe engine undershield Z Lowerthe vehicle 2 5 Resetthe PCM fault memory I Openthe centraljunction box CJB and remove the fuel pump relay N0TE The enginewill...

Page 443: ...n throttle untilthe readingon the compressiontester stops rising 7 Carry out the measurement in accordancewith the instructionssupplied with the measuring device on every cylinder using a suitable com...

Page 444: ...isconnectingthem Pull on the connector and not on the cable 5 Disconnectthe spark plug connectors N0TE The engine will start runfor a few seconds and then stop 6 Removethe spark plugs 2 Start the engi...

Page 445: ...l and Installation 13 Usingworldwidediagnosticsystem WDS clear the fault codes from the PCM Measure the compression ressure Engine 2 OL Duratec HE PMI 1 Openthe centraljunction box CJB and remove the...

Page 446: ...rk plugs N0TE Operate the starter motorwith wide open throttle until the pointer on the measuringdevice stops rising 7 Carry out the measurementin accordance with the instructionssupplied with the mea...

Page 447: ...auge connector and position it to N0TE Measure the oil pressure at the specified allow readingfrom above engine speed 5 Lower the vehicle I Raise and support the vehicle REFERto 100 02 Jacking and Lif...

Page 448: ...the oil pressure switch 3 Attach the oil pressure gauge with the oil pressure gauge connector 4 N0TE Measure the oil pressureat the specified engine speed Measure the oil pressure at an oil temperatur...

Page 449: ...Sigma Duratec 16V N0TE The oil pressuredependsonvarious factors enginespeed oiltemperature oilviscosity extent of oil filter contamination N0TE Measure the oil pressure at the specified engine speed...

Page 450: ...h with adhesive I Q Installthe oil pressure switch 1 1 Connect the oil pressure switch electrical connector to the oil pressure switch I2 Lower the vehicle Measurethe oil pressure Engine 1 3L Duratec...

Page 451: ...cking Descriptionand Operation Lifting Descriptionand Operation 8 Detachthe oil pressure gauge and connector from the oil pressure switch bore 9 Coat the oil pressure switch with sealant adhesive I Q...

Page 452: ...eswitch 6 N0TE OiI pressureat 2000 rpm 3 5 bar Measure the oil pressure 7 Raise and support the vehicle REFER to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Op...

Page 453: ...connector to the oil pressureswitch 12 Lower the vehicle Valve train analysis static engineoff Removethe valve cover Checkall componentsofthe valvetrainfor damage andwear Makesurethat only original c...

Page 454: ...iameter of the camshaft journals Usinga micrometer measure the diameter at 90 degrees intervalsto determine if the journals are out of round Measureattwo different pointsonthejournal to determine if t...

Page 455: ...om engine oil and dirt Position on a width of plastigage on the bearing cap Insert the camshaft without lubrication into the cylinder head Position a plastigage strip which should be equal to the widt...

Page 456: ...mshaft is to specification Usinga Dial Indicator Gauge measure the end play Slide the camshaft in both directions Read and notethe maximumand minimumvalues on the Dial lndicator Gauge Endplay maximumv...

Page 457: ...eral Information 303 00135 GENERAL PROCEDURES Camshaft Surface lnspection I I Inspect the camshaft lobesfor pitting or damage in the active area Minor pitting is acceptable outside the active area 200...

Page 458: ...eral Information 303 00 36 GENERAL PROCEDURES Camshaft Lobe Lift 1 Determinethe cam lift Usinga micrometermeasurethe cam intwo directions The difference between the two measurementsis the cam lift 200...

Page 459: ...IMicrometer I 1 Measurethe diameter of the main bearing journals and the big end bearingjournals Repeatthe measurementwith the micrometer offset by 90 in order to determine any eccentricitywhich may...

Page 460: ...al Equipment IDial indicator I IDial indicator fixture I 1 Determinethe end float Place on the dial indicator and bracket Determinethe end float by raisingthe crankshaft with the aid of a screwdriver...

Page 461: ...que however the bearing shells should not be installed Measurethe cylinder bore with an internal micrometer Carry out the measurementsin different directions and at different heightsto determine ifthe...

Page 462: ...se any aggressive cleaningfluid or a wire brush to cleanthe piston Carry out a visual inspection Cleanthe pistonskirt pinbush ringgrooves and crown and check for wear or cracks Ifthere are signs of we...

Page 463: ...e Diameter 1 N0TE The piston and piston pin form a matched pair Do not mix up the components Measurethe diameterof the pistonpin bore Measure the diameter in two directions If the values are not to sp...

Page 464: ...nformation 303 0042 GENERAL PROCEDURES Piston Diameter General Equipment IMicrometer I 1 N0TE Mark the piston to make sure the piston is installed correctly Using a Micrometer measurethe piston diamet...

Page 465: ...Gap CAUTION DO notmix upthe pistonrings Installthe piston rings in the same position and location Take the pistonringand usea pistonwithout rings to push the piston ring about 30 mm into the cylinder...

Page 466: ...arance General Equipment IFeeler Gauge I I N0TE The piston ring must protrudefrom the piston groove To determinethe piston ringclearance insertthe FeelerGauge right to the back of the groove behindthe...

Page 467: ...n Pin Diameter I N0TE The piston and piston pin are a matched pair Do not mix up the components Measurethe piston pin diameter Measurethe diameter in two directions If the values are not to specificat...

Page 468: ...00 46 GENERALPROCEDURES Connecting Rod Large End Bore 1 Measurethe bearing bore in two directions The difference is the connectingrod bore out of round Verifythe out of roundandthe bearing bore is wit...

Page 469: ...General Information 303 00 47 GENERALPROCEDURES Valve Stem Diameter I Using a micrometer measurethe diameter of the valve stems Ifthe measurementsare notto specification install a new valve 2006 0 Fi...

Page 470: ...ation 303 00 48 GENERAL PROCEDURES Flywheel Inspection 1 Inspect the flywheel If there is evidence of the following install a new flywheel 1 Cracks 2 Worn ring gear teeth 3 Chipped or cracked ring gea...

Page 471: ...in the Diagnosis and Testing procedure For additional information refer to 308 00 ManualTransmission Transaxle and Clutch General Information Manual Transmission and Clutch Vehicles With MT 75 Diagnos...

Page 472: ...CEDURES Cylinder Head Distortion General Equipment 1Straight edge I 1 Usinga straight edge and feeler gauge measurethe cylinder head distortion Measurethe matingface distortion Refer to Specifications...

Page 473: ...ROCEDURES Cylinder Block Distortion 1 Using a Straight Edge and a Feeler Gauge measurethe cylinder blocWcylinderhead distortion Measurethe mating face distortion Ifthe value is not to specification re...

Page 474: ...anifold Cleaning and Inspection I Inspect the cylinder headjoining flanges of the exhaust manifoldfor evidenceof exhaust gas leaks 2 Inspect the exhaust manifoldfor cracks damaged gasket surfaces or o...

Page 475: ...earingsfor the following defects 1 Cratering fatigue failure 2 Spot polishing incorrect seating 3 Imbedded dirt engine oil 4 Scratching dirty engine oil 5 Base exposed poor lubrication 6 Both edges wo...

Page 476: ...PROCEDURES Valve Seat Inspection General Equipment IValve seat width scale 1 Measurethe width of the valve seat Measurethe valve seatwidth usingthe Valve seat width scale If the value is not to speci...

Page 477: ...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 DESCRIPTIONAND OPERATION Engine 303 01A...

Page 478: ...ar Seal 21 468 4 303 01 Engine 303 01A 70 Engine Vehicles With Automatic Transaxle 303 01A 82 DISASSEMBLY Engine 21 1348 303 01A 95 DISASSEMBLYAND ASSEMBLY OF SUBASSEMBLIES Cylinder Head 21 1656 303 0...

Page 479: ...70 PS 55 kW 75 PS m e p e r i s s i b l e engine speed intermittent I 6175 rpm I IIdle speed I 750 rprn I IMaximumoil consumption I 0 5Ll1OOOkm I Engine Data 1 4L I Description Code FXJAIFXJB IFiring...

Page 480: ...Capacity 1 25U1 4L I Service fill including oil filter EFLI0 I 3 80 I Description Initialfill includingoil filter Service fill includingoil filter EFL500 I Service fill excluding oil filter I 3 50 I L...

Page 481: ...r block 1 6L ICylinder bore diameter class 2 I 79 010 79 020 I Description mm Cvlinder head IPiston diameter class 1 uncoated I 71 875 71 885 I Cylinder bore diameter class 3 Crankshaft end float Pist...

Page 482: ......

Page 483: ...retaining bolts Water pump pulley retaining bolts Oil pump to cylinder block retaining bolts Oil panto cylinder block retaining bolts Oil level indicator tube bracket retaining bolt Engine oil drain p...

Page 484: ...gine coolant temperature ECT sensor I 18 I 13 I I IExhaust manifold studs I 10 I I 89 I Positivecrankcaseventilation PCV cover retaining 1bolts Fuel rail to intake manifold Knock sensor KS retaining b...

Page 485: ...lledon Focusvehicles underthe have also been changed The pistons and piston name of the Zetec SE engine rings have been modified The cylinder headcover Details of this engine have been modified The is...

Page 486: ...t a belt tensioner WDS diagnosis CD 817 Instrumentcluster engine indicator lamp Engine management Sequential multi portfuel injection SFI temperature and manifoldabsolute pressure T MAP sensor in conj...

Page 487: ...in the camshaft timing belt pulleys are now made of reinforced plastic The design has also been changed in the process A The basic procedurefor installing the camshaft timing belt pulleys remainsthe s...

Page 488: ...25L Duratec 16V Sigma ll 4L 303 01A I2 Duratec 16V Sigma ll 6L Duratec 16V Sigma 303 01A I2 DIAGNOSISAND TESTING Enaine REFERto Section 303 00 Engine System General Information 2006 0 Fiesta1212006 G...

Page 489: ...measure the Using a suitable set of feeler gauges valve clearances measure the valve clearances Measurethevalve clearances and repeatthis valve clearance the requiredvalve procedure as necessary until...

Page 490: ...ip with Engine Oil IWSS M2C912 A1 1 Removethe timing belt Remover CrankshaftOilSeal 303 293 21 143 Installer Crankshaft Oil Seal 303 395 21 171 Name S ecification clean engine oil 2 Usingthe special t...

Page 491: ...a l GLDuratec 16V Sigma 303 01A I5 IN VEHICLE REPAIR 4 Install the timing belt 1 For additional information refer to Timing I Belt 303 01 Engine I 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L D...

Page 492: ...order for reassembly Removethe 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 t...

Page 493: ...tall the valve collets 3 lnstall a valve stem mounting sleeve over the valve collet groove valve shown removed for clarity 4m A U T I O N T valve seal for the intake valve is green The valve seal for...

Page 494: ...16V Sigma ll 4L 303 01A I 8 Duratec 16V Sigma ll 6LDuratec 16V Sigma 303 01A I 8 IN VEHICLE REPAIR 8 Installthe cylinder head For additional information refer to Cylinder head in this section 2006 0 F...

Page 495: ...em pressure For additional information refer to Section 310 00 Fuel System General Information 2 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting...

Page 496: ...ld 12 Detachthe oil level indicator tube from the intake manifold 10 Disconnectthe evaporateemission EVAP 13 Disconnect the temperature and manifold hose from the EVAPvalve absolutepressure T MAP sens...

Page 497: ...lectrical 17 Disconnectthe fuel injector electrical connector connectors and position it with the engine i wiring harnessto one side 16 Detach the generatorfrom the engine 1 Removethe bolts 2 Removeth...

Page 498: ...20 Disconnectthefuel return line quick release coupling For additional information refer to Section 310 00 Fuel System General Information 21 Detach the fuel line from the intake manifold and positio...

Page 499: ...nifold 4 N0TE lnstall new injector O ring seals 1 N0TE lnstall new intake manifold gaskets N0TE Coat the 0 rina sealswith clean enaine oil Installthe intake manifold V Installthe fuel supply manifold...

Page 500: ...ionalinformation referto Section 310 00 Fuel System General Information 7 Attach the fuel line to the intake manifold Installthe cable tie 8 Connectthe fuel injector electrical connectors 9 Connectthe...

Page 501: ...eratorelectricalconnector 12 Connect the throttle plate control motor DC ISC electrical connector 13 Connect the temperature and manifold absolutepressure T MAP sensor electrical connector 14 Attach t...

Page 502: ...ctrical connector 20 Install the intake manifold lower retaining bolt and the generator bracket retaining bolts 18 Connectthe positive crankcaseventilation PCV hose to the PCV 21 Install the accessory...

Page 503: ...4L 303 01A 27 Duratec 16V Sigma ll 6LDuratec 16V Sigma 303 01A 27 IN VEHICLE REPAIR 24 Connect the battery ground cable For additional information refer to I Section 414 01 Battery Mountingand Cables...

Page 504: ...Mounting and Cables 2 Remove the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 3 Disconnect the spark plug electrical connectors and detach the w...

Page 505: ...spark plugelectricalconnectors and attach the wires to the valve cover 3 Install the air cleaner For additional information refer to Section 303 12 Intake Air Distributionand Filtering 4 Connect the b...

Page 506: ...3 508 21 211 IEngineoil IWSS M2C912A1 I Materials Removal 1 Remove the camshafts Name Specification For additional information refer to Camshafts in this section 2 Removethe engine rear lifting eye 3m...

Page 507: ...Using the special tool install the valve seal Discard the valve seals 3 Remove the mounting sleeve 4 Using the special tool install the valve springs lnstallthe valve spring retainerandthe valve spri...

Page 508: ...IN VEHICLE REPAIR 6m A C A U T I O N T valve tappets must be installed in their original locations Installthe valve tappets 7 Installthe engine rear lifting eye 8 Installthe camshafts For additional i...

Page 509: ...ts indicated on the I Remove the timing belt camshaft bearing cap no 1andto the mating surface of the cylinder head For additional information refer to Timing Belt 303 01 Engine 1 25L Duratec 16V Sigm...

Page 510: ...ehicle Repair of the camshaft bearing caps are in contact with the cylinder head Stage 2 7 Nm Stage 3 45 degrees 4 Adjust the valve clearances For additional information refer to Valve Clearance Adjus...

Page 511: ...a new camshaft seal For additional information refer to Timing Belt 303 01 Engine 1 25L Duratec 16V N0TE Coat the camshaftjournals and camshaft Sigma ll 4L Duratec 16V Sigma ll 6L seal with clean engi...

Page 512: ...ining bolts at this stage Make sure the camshaft pulleys turn on the camshafts N0TE lnstall new camshaft pulley retaining bolts Installthe camshaft timing pulleys 3 Installthe timing belt For addition...

Page 513: ...IWooden block I Materials Name S ecification High Temperature Grease Removal All vehicles 1 Removethe valve cover For additional information refer to Valve Cover 303 01AEngine 1 25L Duratec 16V Sigma...

Page 514: ...pump pulley 6 Removethe timing belt cover retainingbolts 9 Detachthe coolant expansion tank from the bracket and position it to one side 1 Removethe timing beltuppercover retaining bolts 10 Disconnect...

Page 515: ...l tool removethe spark directly on the oil pan plugs Placethe trolley jack with a wooden block under the engine and raise it slightly until the engine front mount is free from strain 13 Removethe engi...

Page 516: ...lt tensioner with the special tool Vehicles built 0912003 onwards 20 Removethe timing belt Detensionthe timing belt and lockthe timing belt tensioner with the special tool Discardthe timing belt Disca...

Page 517: ...belt N0TE lnstall the timing belt beginningwith the crankshafttiming pulleyworking counterclockwise Install the timing belt 6 Measuring the depth of the threaded hole in the crankshaft Depth of the th...

Page 518: ...wards 10 Tension the timing belt Tension the timing belt by turning the tensioner counterclockwiseuntilthe arrow points at the mark and tighten the bolt I AWARNING D not removethe special tool until t...

Page 519: ...t a l l a hose order no E890438S to the special tool studs to prevent damage to the camshaft pulleys 17 Remove the special tool ADO nottighten the camshaft pulley bolts 18 N0TE Only turn the engine i...

Page 520: ...sing the special tool install the spark plugs Apply grease to the spark plug threads 24 Install the engine front mount bracket Tighten the bolts in the indicated order in three stages Stage 1 Handtigh...

Page 521: ...not tighten the coolant pump pulley retaining bolts at this stage lnstall the coolant pump pulley I 33 lnstall the accessory drive belt 29 Connectthe generator electrical connector For additional info...

Page 522: ...pulley retaining bolts 35 Install the valve cover For additional information refer to Valve Cover 303 01A Engine 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma In vehicle Repa...

Page 523: ...r Distributionand Filtering Removal and Installation 3 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 4m ACAUTION bendin...

Page 524: ...lower heat shield left hand retaining bolts 11 Disconnect the heatedoxygen H02S sensor electrical connector 12 Disconnect the catalyst monitor sensor electrical connector 9 Removethe exhaust manifold...

Page 525: ...romthe bracketand positionitto oneside 15 Detachthe coolant expansiontank from the bracket and position it to one side 16 Installthe special tools 17 Removethe enginefront mount 18 Usingthe specialtoo...

Page 526: ...Removethe exhaust manifold Discardthe gasket Installation 1 N0TE lnstall a newexhaust manifold gasket Attach the exhaust manifold to the cylinder head 2 Lower the vehicle 3 N0TE lnstall a newexhaust...

Page 527: ...the engine 10 Attach the coolant expansion tank to the bracket 8 N0TE lnstall new engine front mount retaining nuts 11 Attach the powersteeringfluid reservoirto Install the engine front mount the bra...

Page 528: ...lator electrical connector retaining bolt 15 Raise and support the vehicle 19 Attach the exhaust system insulatorsto the For additional information refer to Lifting exhaust brackets 1 00 02 Jacking an...

Page 529: ...For additional information refer to Air Cleaner 1 25L Duratec 16V Sigma llm4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 303 12 Intake Air Distribution and Filtering Removal and Installation 24 Connec...

Page 530: ...neral Procedures and Operation 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling 1 4L Duratorq TDCi DV Diesel General 7...

Page 531: ...d 9 Remove the intake manifold retaining bolt 10 Lower the vehicle 12 Disconnectthe brake booster vacuum line from the intake manifold 13 Disconnectthe positive crankcase ventilation PCV hose from the...

Page 532: ...ess electrical connector 17 Disconnect the EVAPvalve electrical connector For additional information refer to Quick Release Coupling 310 00 Fuel System GeneralInformation GeneralProcedures I9 Disconne...

Page 533: ...al connector I I assembly 25 Disconnect the heatedoxygen H02S 22 Using the special tool detach the degas sensor electrical connector hose from the cylinder head Detachthe electrical connector from the...

Page 534: ...position 31 CAUTIONS it to one side A h e cylinder head must have cooled to Discard the nuts and the exhaust manifold below 30 C before removal gasket A o s i t i o n the cylinder head on a soft surfa...

Page 535: ...head intothe two guide sleeves Using the special tool install the cylinder head Tighten the cylinder head bolts in the sequence shown in three stages Stagel 15Nm Stage 2 30 Nm Stage 3 90 degrees 3 Ins...

Page 536: ...ing linebracketto the cylinder head TIE0030694 6 Tightenthe exhaust manifoldlowerretaining g Connect the heatedoxygen H02S sensor bolts electrical connector Attachthe electricalconnectorto the bracket...

Page 537: ...connect the degas 15 Connect the fuel return line quick release hose to the cylinder head coupling 13 Usingthe special tool connect the coolant hose to the coolant distribution assembly For additiona...

Page 538: ...n EVAP 20 Connectthe vacuum hose to the fuel valve electrical connector pressure regulator 18 Connectthe engine wiring harness 21 Connectthe generatorelectricalconnector electrical connector 22 Connec...

Page 539: ...talytic and Operation converter 25 Installthe intake manifold retaining bolt 29 Removethe exhaust flexible pipe support 26 Position the exhaust manifold lower heat 30 Install the camshaft shield and i...

Page 540: ...from the cylinder block Using the special tool remove the oil pan Installation 1 CAUTIONS n h e oil pump gasket projects over the cylinder block sealing surface and must not Removal be damaged I Rais...

Page 541: ...nstall a new drain plug if I within a further 5 minutes necessary Apply a 3 4 mm diameter bead of sealant to Install the oil drain plug the oil pan flange 6 Fill the engine with engine oil 4 N0TE Alig...

Page 542: ...itioning AIC compressor from the cylinder block and positionitto one side 4 Removethe oil pan For additional information refer to Oil Pan in this section 5 Detachthe oil pick uptube from the oil pump...

Page 543: ...engine shown removedfor clarity 7 Installthe timing belt 3 N0TE lnstall a new crankshaftfront oil seal For additional information refer to Timing Usingthe specialtool installthe crankshaft Belt in thi...

Page 544: ...nd lnstallation 2 Using the special tool remove the flywheel Discardthe bolts LockingTool Flywheel 303 393 21 168 Gauge BoltAngle 303 174 2 1 540 Installation All vehicles 4 Remove the crankshaft rear...

Page 545: ...xle 5 N0TE Position of location stud for the flexplate NOTE lnstall new flexplate retaining bolts Using the special tool install the flexplate Tighten the bolts in the sequence shown in two stages Veh...

Page 546: ...General Procedures 2 Removethe air cleaner For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling 1 4L Duratorq TDCi DV Diesel General Procedures 3 Dra...

Page 547: ...Fuel System GeneralInformation GeneralProcedures 8 Disconnectthe fuel supply line quick release coupling For additional information refer to Quick Release Coupling 310 00 Fuel System GeneralInformati...

Page 548: ...ensor coolant hosefrom the coolant distribution electrical connector housing I 17 Disconnectthe powersteering pressure 14 Usingthe specialtool disconnectthe hose PSP switch electricalconnector from th...

Page 549: ...orate emission EVAP hosefrom the EVAPvalve 23 Disconnect the generator electrical connectors 21 Detachthe brake boostervacuum linefrom the intake manifold 24 Removethe right handheadlampassembly For a...

Page 550: ...Disconnectthe enginecoolant temperature 30 Detachthe power steering line from the ECT electrical connector power steering pump mounting bracket 28 Disconnect the electronic ignition El coil 31 Disconn...

Page 551: ...r 34 Disconnect the N C high pressure cut off 37 Disconnect the reversing lamp switch switch electrical connector electrical connector 35 Disconnect the oil pressure switch electrical connector 38 Dis...

Page 552: ...er the steering pump Discard the nuts and the gasket Allow the fluid to drain into a suitable container 41 Removethe accessory drive belt For additional information refer to 45 Usingthe special tool d...

Page 553: ...from the retaining brackets shown 2 Push the coolingfan motor and shroud Removethe heat shield upwards and then downwards to remove I I 51 CAUTIONS 48 Usingthe special tool disconnect the Asupport th...

Page 554: ...er must not be bent more than 18 degrees The outerjoint must not be bent morethan 45 degrees A D O not damage the halfshaft oil seal N0TE Plug the transaxle to prevent oil lossor dirt ingress Detach t...

Page 555: ...the clutch slave cylinder supply line Removethe spring clip Vehicles without automated gearshift 58 ACAUTION brake fluid is spilt on the paintwork the affected area must be immediately washed down wit...

Page 556: ...locks support the engine and transaxle assembly 65 Raisethe vehicle and remove the engine and transaxle assembly 66 Usingthe special tool attach the engine 62 Removethe battery tray support bracket an...

Page 557: ...Sigma llm4L Duratec 16V Sigma ll 6LDuratec I6V Sigma REMOVAL 68 Removethe transaxle right hand retaining bolt 69 Removethe transaxle lowerretaining bolts 70 Removethe transaxle from the engine 2006 0...

Page 558: ...sult in personal injury Certain Transmission and Power Steering fluids supplied to Ford contain additives which may cause skin irritation or other skin reactions after contact For additional informati...

Page 559: ...g 310 00 Fuel System General Information General Procedures 8 Disconnect the fuel supply line quick release coupling For additional information refer to Quick Release Coupling 310 00 Fuel System Gener...

Page 560: ...hosefromthe EVAPvalve coolant hose from the coolant distribution housing 14 Detachthe brakeboostervacuum linefrom the intakemanifold 17 Disconnectthe heated oxygen HOZS sensor electrical connector 15...

Page 561: ...wiring harness PSP switch electrical connector electrical connector I 20 Detachthe power steering line support 23 Disconnectthe EVAP electrical connector bracket from the cylinder head 24 Disconnectth...

Page 562: ...ethe right handheadlampassembly 30 Removethe enginewiring harnesssupport For additional information refer to brackets HeadlampAssembly 417 01 Exterior Lighting Removal and Installation 27 Disconnectth...

Page 563: ...axle 35 Disconnectthe transmission range TR sensor electrical connector 33 Disconnectthe transaxle breather hose 36 Detachthe selector lever cable from the transaxle 34 Disconnectthe transaxle wiring...

Page 564: ...fer to Health and Safety Precautions 100 00 General Information Description and Operation See Transmission Fluids Allow the fluid to drain into a suitable container For additional information refer to...

Page 565: ...e N C compressor clutch 45 Detach the exhaust flexible pipe from the electrical connector catalytic converter Discard the nuts and the gasket 46 Remove the accessory drive belt For additional informat...

Page 566: ...l Information Description and Operation See Transmission Fluids Allow the fluid to drain into a suitable container 52 Disconnect the power steering line from the steering pump For additional informati...

Page 567: ...cooling fan motor and shroud upwards and then downwards to remove Asupport the halfshaft The innerjoint 56 Using the special tool disconnect the must not be bent more than 18 degrees coolant hose from...

Page 568: ...e to preventfluid loss or dirt ingress 62m ACAUTION D not support the engine For additional information refer to Health and directly on the oil pan Safety Precautions 100 00 GeneralInformation N0TE Us...

Page 569: ...hicle and remove the engine and transaxle assembly 67 Removethe starter motor 68 Removethe torque converter retaining nuts Rotate the torque converterto gain access to the remaining nuts Discardthe nu...

Page 570: ...Duratec 16V Sigma l 6L Duratec 16V Sigma REMOVAL 70 Removethetransaxle lowerretainingbolts 71m A W A R N I N G M sure the torque converter remainsinthe converter housing Removethe transaxle from the e...

Page 571: ...7 Socket Cylinder Head Bolt 303 392 21 167 MountingBracketfor 303 435 303 435 06 21 031B I ISocket Spark Plug Special Tool s Adapter for 205 047 303 633 21 227 0 0 0 ES21212 LockingTool Timing Belt Te...

Page 572: ...at Discardthe gasket shield left hand retaining bolts 3 Removethe exhaust manifold lower heat shield right hand retaining bolts 4 Removethe exhaust manifold upper heat shield 5 Removethe exhaust manif...

Page 573: ...engine to the mounting stand 11 Removethe oil pressureswitch 9 Drain the engine oil 12 Removethe generator Allow the oilto drain intoa suitablecontainer 13 Removethe coolant pump pulley 10 Using a sui...

Page 574: ...ISASSEMBLY 14 Removethe timing belt upper cover 15 Removethe engine front mount bracket 16 Remove the fuel supply and return lines 17 Disconnectthe spark plug electrical connectorsand detach the wires...

Page 575: ...ming belt 20 Set the crankshaft to approximately 20 tensioner degrees before TDC 24 Slacken the timing belt tensioner and 21 Usingthe special tool lock the crankshaft remove the timing belt 22 Removet...

Page 576: ...ool Discard the timing belt r Ii Tension the timing belt tensioner by pulling 30 Removethe timing belt tensioner the timing belt and lock it with the special tool Discardthe timing belt 28 Removethe t...

Page 577: ...n 36 Detachthe oil level indicator andtube from the intake manifold Detachthe knock sensor KS electrical connectorfrom the oil level indicatortube Remove the camshafts 37 Remove the intake manifold lo...

Page 578: ...SASSEMBLY Usingthe special tool remove the cylinder head Discardthe gasket 39mACAUTION D not damage the coolant pump impeller Removethe coolant pump Discardthe gasket Discardthe gasket 41 Remove the K...

Page 579: ...e PanmDonotuseachiselorscrewdriverfor 47 Removetheclutchdiscandpressureplate removal For additional information refer to Clutch N0TE Tighten the lock nut againstthe oil pan and Disc and Pressure Plate...

Page 580: ...DISASSEMBLY All vehicles Removethe special tools 50 Remove the crankshaft position CKP sensor 51 Removethe CKP sensor bracket 52 Removethe crankshaft rear seal carrier Discardthe crankshaft rear seal...

Page 581: ...manifold Discard the O ring seals absolute pressure T MAP sensor electrical connector 2 Disconnect the throttle plate control motor DC ISC electrical connector 3 Disconnect the fuel injector electric...

Page 582: ...3 NOTE Installa new coolant distribution Discard the O ring seal housinggasket Assembly 1 N0TE A new cylinder head is supplied without exhaust manifoldstuds Installthe exhaust manifoldstuds if necessa...

Page 583: ...fold 9 Connectthe throttle plate control motor DC ISC electrical connector 6 N0TE lnstall newfuel supply manifoldO ring seals 10 Connect the temperature and manifold Install the fuel supply manifold a...

Page 584: ...racket Engine 303 1 22 2 1 068A 21068A I 1Alignment Plate Camshaft I 21540 Socket Cylinder Head Bolt Gauge BoltAngle 303 174 2 1 540 I ILocking Tool Flywheel I Special Tool s Installer Crankshaft Seal...

Page 585: ...e 243 IWSK M2G349 A7 I Gasket Eliminator Sealant i All vehicles High Temperature Grease 1 Attach the cylinder block short block to the mounting stand ESD M1C220 A Installthe special tools 4 Install th...

Page 586: ...tion refer to Clutch Disc and Pressure Plate 308 01 Clutch All vehicles Removal and Installation 10 N0TE lnstall a new oil pump gasket 7 Removethe special tool from the flywheel Installthe oil pump Ve...

Page 587: ...1 fl f ELE0013938 Usingthe special tool install the crankshaft front seal 16 N0TE Align the oil panso that the cylinder block is flush with the oil pan on the 14 C A U T I O N T crankcase may be dama...

Page 588: ...e switch threads 19 C A U T I O N T knock sensor KS cable must not touch the cylinder head or the PCV cover Positionthe KS cable at approximately the 10 o clock position lnstall the KS 20 N0TE lnstall...

Page 589: ...0TE Position the cylinder head onto the two guide sleeves Using the special tool install the cylinder head Tighten the cylinder head bolts in the sequence shown in three stages Stage 1 15 Nm Stage2 30...

Page 590: ...fts and camshaft bearing caps Tighten the camshaft bearing cap retaining boltsinthe sequenceshown inthree stages Stage 1 One half turn on each bolt until all of the camshaft bearing caps are in contac...

Page 591: ...emove the blanking plug and install the special tool Carefully turn the crankshaft against the I special tool 40 Measuring the depth of the threaded hole in the crankshaft Depth of the threaded 42 mm...

Page 592: ...belt tensioner 45 Installthetiming belttensioner andtension the timing belt Installthe bolts finger tight Tension the timing belt by turning the tensioner clockwise until the arrow points in line wit...

Page 593: ...or may damage the timing belt tensioner Installthe timing belt tensioner 49 Tension the timing belt Removethe special tool All vehicles 50 CAUTIONS nlnstall a hose order no E890438S to the special too...

Page 594: ...ne 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma General Procedures 59 Usingthe special tool install the spark plugs Apply grease to the spark plug threads 60 N0TE lnstall th...

Page 595: ...nectors 63 Install the timing belt upper cover and attach the wires to the valve cover I 62 Installthe engine front mount bracket Tighten the bolts in the indicated order in three stages Stage 1 Handt...

Page 596: ...ness 69 Removethe special tools 70 N0TE lnstall a newexhaust manifoldgasket and new exhaust manifold retaining nuts N0TE Do not fully tighten the nuts and bolt at this stage Install the exhaust manifo...

Page 597: ...2 Tighten the exhaust manifold lower 75 Install the exhaust manifold lower heat retaining bolts shield left hand retaining bolts I 73 Install the exhaust manifold upper heat shield 74 Install the exha...

Page 598: ...e 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 instruction...

Page 599: ...e compartment Carefully lower the vehicle 8 N0TE lnstall new engine front mount retaining nuts I N0TE Do not tighten the engine front mount retaining bolts and nuts at this stage Install the engine fr...

Page 600: ...than 18 degrees The outerjoint must not be bent morethan 45 degrees A D O not damage the halfshaft oil seal A a k e sure the snap ring is correctly seated N0TE lnstall a new snap ring Attach the left...

Page 601: ...ing pump 18 Install the cooling fan motor and shroud 21 Connect the power steering line to the 1 Push the cooling fan motor and shroud steering pump upwards and then downwardsto install 2 Installthe c...

Page 602: ...nkshaft position CKP electrical connector sensor electrical connector 25 Install the accessory drive belt 29 Connect the oil pressure switch electrical For additional information refer to connector Ac...

Page 603: ...he spring clip iscorrectlyseated Connect the clutch slave cylinder supply line Installthe spring clip 34 N0TE Do not install the air cleaner at this stage Adjust the gearshift cable Foradditional info...

Page 604: ...r cover 39 Connect the clutch slave cylinder supply line Installthe spring clip 40 Bleed the hydraulic clutch system For additional information refer to Clutch System Bleeding Vehicles With Automated...

Page 605: ...tor 46 Installthe engine wiring harness support 49 Connect the generator electrical brackets connectors Connect the engine ground cable 50 Connect the air conditioning AIC 47 Connect the electronic ig...

Page 606: ...ical connector 55 Connectthe powersteering pressure PSP switch electrical connector f 53 Connectthe evaporativeemission EVAP 56 Connectthe catalyst monitor sensor electrical connector electrical conne...

Page 607: ...se 59 Usingthe special tool connect the coolant coupling hose to the coolant distribution housing For additional information refer to Quick 60 Attach the brake booster vacuum line to the intake manifo...

Page 608: ...dule the intake manifold PCM electrical connector Install the cable tie For additionalinformation refer to PowertrainControl Module PCM 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16...

Page 609: ...m i 1 Foradditionalinformation referto Cooling System Draining Filling and Bleeding 1 25L Duratec 16V Sigma ll 3L Duratec 8V Rocam ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 303 03A Engine Coolin...

Page 610: ...engine flange dowels tobacco or open flame of any type when Installthe transaxle to the engine working on or near any fuel related components Highlyflammable vapors are 3 Install the transaxle lower...

Page 611: ...ting Description and Operation 9 Position the engine and transaxle assembly 5 Install the transaxle right hand retaining in the engine compartment bolts Carefully lower the vehicle 6 N0TE lnstall newt...

Page 612: ...t more than 18 degrees The outer joint must not be bent more than 45 degrees A D O not damage the halfshaft seal N0TE lnstall a new center bearing cap and locknuts ASupport the halfshaft The innerjoin...

Page 613: ...connectthe coolant hoseto the distribution pipe 19 Connectthe coolingfan motorandcooling fan resistorelectrical connectors 17 Usingthe specialtool connectthe coolant hose to the radiator 20 Usingthe s...

Page 614: ...starter motor solenoid cables 22 Attach the power steering line support bracket to the engine block 26 Connect the crankshaft position CKP sensor electrical connector 23 N0TE lnstall new exhaust flan...

Page 615: ...electrical connector 32 Install the accessory drive belt For additional information refer to Accessory Drive Belt 1 4L Duratec 16V Sigma ll GL Duratec 16V Sigma Vehicles With Air Conditioning 303 05 A...

Page 616: ...cooler line 39 Attach the selector lever cable retaining to the transaxle bracket to the transaxle 37 Connect the vehicle speed VSS sensor 40 Attach the selector lever cable to the electrical connecto...

Page 617: ...ange TR 45 Connect the turbine shaft speed TSS I sensor elecrtrical connector sensor electrical connector 43 Connectthe transaxle wiring harness 46 Attach the ground cable to the transaxle electrical...

Page 618: ...49 Connect the electronic ignition El coil 53 Connect the knock sensor KS electrical electrical connector connector 50 Connect the engine coolant temperature 54 Connect the EVAP electrical connector E...

Page 619: ...itor sensor electrical connector electrical connector i 56 Attach the powersteering lineto the power 59 Connectthe heatedoxygen H02S sensor steering pump mounting bracket electrical connector 57 Attac...

Page 620: ...oolant distribution housing 64 Attach the coolant expansion tank to the bracket 62 Attach the brake booster vacuum line to 65 Usingthe specialtool connect the degas the intake manifold hose to the cyl...

Page 621: ...Sigma ll GL Duratec 16V Sigma 303 14 Electronic EngineControls Removal and Installation 72 Install the air cleaner For additional information refer to Air Cleaner 1 25L Duratec 16V Sigma ll 4L Durate...

Page 622: ......

Page 623: ...nder Head Cylinder Block PAGE DESCRIPTIONAND OPERATION Engine 303 018 8 DIAGNOSISAND TESTING Engine GENERAL PROCEDURES Valve ClearanceAdjustment IN VEHICLE REPAIR Intake Manifold 21 183 0 Crankshaft F...

Page 624: ...303 01B 2 Engine 2 OL Duratec HE M14 303 01B 2 ASSEMBLY Engine 21 1348 303 018 INSTALLATION Engine 303 01B I1I...

Page 625: ...il consumption Viscosity ambient temperature Recommendedengine oil 4 0 0 w 20 C to over 40 C I Ford Formula S I ACEA A3lB3 I SAE 5W 30 below 20 C to over 40 C IIf other types of engine oil are used th...

Page 626: ...ce I 0 035 0 080 I Description Camshaftjournal diameter ICamshaft endplay I 0 09 0 24 I mm 24 97 0 01 Camshaft lobe lift intake Camshaft lobe lift exhaust Piston Dimensions 8 8 7 7 Description Cranksh...

Page 627: ...t a 10 IGenerator upper retaining bolt I 25 I 18 I I ICoolant plugs 4 to cylinder head I 75 I 55 I I 89 Hood latch lever retaining bolts Crankshaft pulley retaining bolts Coolant expansiontank retaini...

Page 628: ...I 15 I I Oil filter adaptor retaining bolts Positivecrankcase ventilation housing retaining bolts IThermostat housing retaining bolts I 10 I I 89 I 21 25 IOil pump retaining bolts I a I I I 25 10 IOi...

Page 629: ...g bolts Air conditioning AIC compressor retaining bolts Engine rear mount retaining nut Enginefront mount studs to front cover Enginefront mount retaining bolts Enginefront mount retaining nuts Strut...

Page 630: ...ine For the Fiesta ST the engine is available with the following specification 2006 0 Fiesta1212006 G461395en r k 2 OL Duratec HE M14 engine Engine code Displacement Maximum power output Maximumtorque...

Page 631: ...uns very quietly and is also maintenance free Cvlinder head Item Description 1 2 The engine managementfor the 2 OL Duratec HE M14 is provided by a Visteon system Item Description Exhaustcamshaft Camsh...

Page 632: ...pairsto the valve 2 gear Item Description I 1 IExhaust camshaft sprocket 1 2 ITiming chain I 1 3 1Intake camshaft sprocket I 1 4 I i m i n chain guide I 1 5 1Crankshaftsprocket I 1 6 1Hydraulictiming...

Page 633: ...Crankshaftfront seal I 1 3 1Silicone sealant for sealing at bores I 4 Silicone sealant for sealing engine front I Icover The camshaft drive is sealed with an aluminum engine front cover The crankshaft...

Page 634: ...forms a unit with the rotor for indicatingthe crankshaft position It is secured to the crankshaft by the contact pressure of the retaining bolt free to turn on the seat on the crankshaft The crankshaf...

Page 635: ...or The rotor pump works very evenly can produce high pressures and is therefore fundamental for optimum engine lubrication Item Description I 1 ICrankshaftsprocket I 1 2 1Oil pump chain tensioner I 1...

Page 636: ...ngbolt I 1 2 1Oil cooler I 1 3 1Oil filter I 1 4 1Oil pressure switch I 1 5 1Oil filter adapter retainingbolts I 1 6 1Oil filter adapter gasket I 1 7 1Oil filter adapter I Item Description 1 3 Oil coo...

Page 637: ...303 01B 15 Engine 2 OL Duratec HE M14 303 01B I5 DIAGNOSISAND TESTING I REFER to Section 303 00 Engine System General Information 2006 0 Fiesta1212006 G37449en...

Page 638: ...nal information refer to Battery Disconnect 414 01 Battery Mounting and Cables General Procedures Silicone Sealant 2 Removethe air cleaner WSE M4G323 A4 For additional information refer to Air 5 Disco...

Page 639: ...acket 10 Remove the valve cover 8 Usingthe special tool disconnect the spark 11 CAUTION Only rotate the crankshaff in plug electrical connectors the normal direction of rotation Rotatethe crankshaft u...

Page 640: ...Removethe valve tappet and read the thickness from the underside 2 Valve tappet thickness required thickness of currently installed valve tappet the measured valve clearance the required valve clearan...

Page 641: ...stallthe positive crankshaftventilation valve support bracket PCV hose 24 Install the air cleaner retaining bracket 27 Attach the engine wiring harnessto the valve cover 1 Clip the engine wiring harne...

Page 642: ...dditional information refer to Air Cleaner 2 OL Duratec HE M14 303 12 IntakeAir Distributionand Filtering Removal and Installation 29 Connectthe battery ground cable Foradditionalinformation referto B...

Page 643: ...val and Installation 3 Remove the right hand headlamp 6 Disconnect the generator electrical connectors For additional information refer to Headlamp Assembly 417 01 Exterior Lighting Removal and Instal...

Page 644: ...hthe powersteeringsupply linefrom the intake manifold 15 Disconnectthe manifoldabsolute pressure MAP sensor electrical connector 1 11 Lower the vehicle 12 Detachthe engine wiring harnessfrom the valve...

Page 645: ...onnector 18 Disconnect the throttle body electrical 21 Removethe hoodlatch lever retainingbolt connector 22 Detach the hood latch from the radiator 19 Disconnectthe knocksensor KS electrical grille op...

Page 646: ...ion PCV hose from the intake manifold 24 Remove the oil level indicator and oil level indicator tube 27 Remove the intake manifold Installation 1 N0TE lnstall new gaskets if necessary To install rever...

Page 647: ...emovedfor clarity 2 Remove the crankshaft pulley retaining bolt and the special tool Discardthe crankshaft pulley retaining bolt 1 Remove the crankshaft pulley 3 Installthe crankshaft pulley For addit...

Page 648: ...l I Disconnect the battery For additional information refer to Battery Disconnect 414 01 Battery Mounting and Cables General Procedures 2 Remove the air cleaner For additional information refer to Air...

Page 649: ...emovethe EVAP valve bracket PCV hose from the valve cover 8 Usingthe special tool disconnectthe spark 5 Disconnectthe camshaft positionsensor plug electrical connectors CMP sensor electrical connector...

Page 650: ...ntil piston no 1is approx 45 degrees before TDC Usingthe special tool removethe crankshaft pulley 14 Remove the crankshaft front seal For additional information refer to Crankshaft Front Seal 303 01 E...

Page 651: ...ve the cylinder block lower blanking plug and install the special tool 2 Installthe crankshaft front seal For additional information refer to 8 N0TE Only rotate the crankshaft in the Crankshaft FrontS...

Page 652: ...w crankshaft pulley bolt Counterholdthe crankshaft pulleyusingthe specialtools and tighten the crankshaft pulley bolt Tighten the bolt in two stages Stage 1 I00 Nm Stage 2 90 degrees 13 Lowerthe vehic...

Page 653: ...l tool 19 N0TE Only rotate the crankshaft in the normal direction of rotation 21 Lower the vehicle 22 N0TE Hthe special tool cannot beattached correct the valve timing Check the position of the camsha...

Page 654: ...ration Usea suitable screwdriverunderthe bootto 25 Removethe M6x 18 mm bolt allow air to escape 26 Removethe special tool 29 N0TE lnstall a new boot clamp Usingasuitable grip wrench installthe inner C...

Page 655: ...for clarity 1 Installthe CKP sensor bolts 2 Removethe tool Install the valve cover Tighten the bolts in the sequence shown 35 Using the special tool install the spark plugs Install the drive belt 36 U...

Page 656: ...take pipe 2 Clip on the enginewiring harnessbracket at the intake pipe 3 Installthe air cleaner retainer 4 Connectthe power steering fluid return line to the retaining clip 42 Installthe air cleaner F...

Page 657: ...ditional information refer to Camshafts 303 01 Engine 2 OL Duratec HE M14 In vehicle Repair 2 Using the special tool apply 7 to 10 bar of compressed air into the cylinder 3 Remove the valve tappets an...

Page 658: ...s N0TE Cover the valve collet groove on the valve stem with a protective sleeve For additional information refer to Camshafts 303 01 Engine 2 OL Usingthe specialtool installthevalve seals Duratec HE M...

Page 659: ...Duratec HE M14 In vehicle Repair 2 Using the special tools remove the valve springs Compress the valve spring Removethe valve collets Releasethe valve spring Removethe valve spring retainer and the va...

Page 660: ...the valve springs lnstallthe valve spring retainerandthe valve spring Compress the valve spring Install the valve collets Releasethe valve spring 4 Removethe special tools 5 lnstallthe cylinder head F...

Page 661: ...ting and Cables General Procedures 2 Remove the air cleaner For additional information refer to Air Cleaner 2 OL Duratec HE M14 303 12 Intake Air Distribution and Filtering Removal and Installation 3...

Page 662: ...trical connectors 1 6 Removethe air cleaner retaining bracket 9 Using the special tool remove the spark plugs 7 Remove the evaporative emission EVAP valve support bracket 10 Remove the valve cover 11...

Page 663: ...and Operation 13 Disconnect the crankshaft position CKP sensor electrical connector 14 Disconnect the generator electrical connectors Unclipthe wiring harness 16 N0TE Only rotate the crankshaft in th...

Page 664: ...rning 21 ACAUTION T detensionthetimingchain makesure the timing chain tensioner N0TE Using a suitable piece of wire preventthe ratchet is in the released position timing chain and the sprocket from dr...

Page 665: ...2 N0TE Do not tighten the camshaft sprocket retaining bolt at this stage Attach the intake camshaftsprocket together with the timing chain to the intake camshaft and insert the intake camshaft 3 CAUT...

Page 666: ...upper blanking plug 12 Raise and support the vehicle For additional information refer to 100 02 Jacking and Lifting I I Jacking Description and Operation 9 N0TE Only rotate the crankshaft inthe Lifti...

Page 667: ...ol 19 N0TE lf it is not possibleto install the special tool correct the valve timing Usingthe special tool check the positionof the camshafts 16 N0TE Only rotate the crankshaft in the normal direction...

Page 668: ...ing Description and Operation Lifting Description and Operation 22 Removethe crankshaft pulleysecuring bolt N0TE Make surethatthe intermediateshaftmating surface for the CVjoint boot is clean ELE00219...

Page 669: ...shown I I 30 Connect the crankshaft position CKP I I sensor electrical connector 34 Using the special tool install the spark plugs 31 Install the accessory drive belt For additional information refer...

Page 670: ...e engine wiring harnessto the intake manifold 2 Clipthe enginewiring harnessbracketto the intake manifold 3 lnstall the air cleaner retaining bracket 4 Clip the power steering return line to the engin...

Page 671: ...er to 100 02 Jacking and Lifting For additional information refer to Battery Jacking Description and Operation Disconnect 414 01 Battery Mounting and Lifting Description and Operation Cables General P...

Page 672: ...oil pan drain plug seal for damage Install a new drain plug and seal if required lnstall the drain plug 10 Loosen the transaxle right hand retaining bolts approximately 10 mm 11 Loosen the transaxle...

Page 673: ...stallthe transaxle lower retaining bolts the oil pan and the engine front cover with cleaner 2 Apply a 3 mm bead of sealant to the oil pan 3 N0TE lnstall the oil pan within 10 minutes of applying the...

Page 674: ...Install the oil level indicatortube lower sequence shown retaining bolt f 8 Tighten the transaxle lower retaining bolts 11 Tighten the transaxle left hand retaining bolts 9 Install the engine support...

Page 675: ...additional information refer to Air Cleaner 2 OL Duratec HE M14 303 12 IntakeAir Distribution and Filtering Removal and Installation 17 Connect the battery Foradditional information refer to Battery D...

Page 676: ...o Timing Chain 303 01 Engine 2 OL Duratec HE M14 Invehicle Repair 2 Remove the oil pan For additional information refer to Oil Pan 303 01 Engine 2 OL Duratec HE M14 Invehicle Repair 3 Remove the oil p...

Page 677: ...Nm 2 N0TE Do not tighten the oil pump sprocket retaining bolt at this stage lnstall the oil pump chain 1 lnstallthe oil pump chain and the oil pump sprocket 2 lnstallthe oil pump sprocket retaining bo...

Page 678: ...ator Oil Pan 303 428 21 179 Removal 1 Removethe oil level indicator and oil level indicator tube upper retaining bolt 2 Remove the clutch disc and pressure plate For additional information refer to Cl...

Page 679: ...t rear seal carrier 9 Removethe oil pan retaining bolts Installation Irn AUTION DO not removethe the installationsleeve before installation N0TE A new crankshaft rear seal carrier is supplied preassem...

Page 680: ...y a 3 mm bead of sealant to the oil pan 7 Tighten the oil pan retaining bolts in the sequence shown 4 N0TE lnstall the oil pan within 10 minutes of applying the silicone sealant and tighten the retain...

Page 681: ...lts For additional information refer to Clutch Disc and Pressure Plate 308 01 Clutch Removal and installation 14 Install the oil level indicator and oil level indicator tube upper retaining bolt Tight...

Page 682: ...to Crankshaft Pulley 303 01 Engine 2 OL Duratec HE M14 Invehicle Repair 2 Remove the timing cover lower bolts 7 Support the engine with a vehicle jack 8 Remove the front engine mount Discardthe front...

Page 683: ...er 3 mm 3 Install the timing cover engine shown installation removedfor clarity Tighten the bolts in the sequence shown 1 Cleanthe sealing surfaces of the timing Tighten bolts Ito 8 to a torque of 10...

Page 684: ...n bolts 20 to 22 to a torque of 48 Nm 5 Installthe coolant pump pulley 4 Install the multi groovebelt idler pulley 6 N0TE lnstall new front engine mount nuts Installthe front engine mount 7 Installthe...

Page 685: ...B 63 IN VEHICLE REPAIR 9 Connect the CKP sensor electrical connector 10 Install the crankshaft belt pulley For additional information refer to Crankshaft Pulley 303 01 Engine 2 OL Duratec HE M14 In ve...

Page 686: ...Cleaner 2 OL Duratec HE M14 303 12 IntakeAir Distributionand Filtering Removal and Installation 2 Remove the components in the order indicated in the following illustration s and table s 2006 0 Fiest...

Page 687: ...is stage Loosenthe exhaust manifold outer retaining nuts by two turns engine shown removed for clarity i 5 Removethe exhaust flexible pipe For additional information refer to Exhaust Flexible Pipe 2 O...

Page 688: ...lly tighten the exhaust manifold outer retaining nuts at this stage Loosely install the exhaust manifold outer retaining nuts Item 4 Exhaust manifold retaining nuts I Install the exhaust flexible pipe...

Page 689: ...on 2 Detension the timing chain 1 Unlock the timing chain tensioner ratchet 2 Apply pressureto the timing chain guide 3 Fixthe timing chaintensionerwith a suitable pin punch 3 N0TE Hold the camshafts...

Page 690: ...camshafts Installthe camshaft sprockets Installthe timing chain 4 Tension the timing chain Apply pressureto the timing chain and removethe securing pin 5 N0TE Hold the camshafts by the hexagon with an...

Page 691: ...components Highlyflammable vapors are always present and may ignite Failure to 7 Using the special tool disconnect the follow these instructions may result in coolant hose from the EGR valve personal...

Page 692: ...mp return 13 Removethe exhaust manifold lower heat line support bracket shield engine shown removedfor clarity 11 Removethe generatorupper retaining bolt 14 Removethe exhaust manifold retaining nuts e...

Page 693: ...Discardthe gasket Discard the bolts Installation Stage3 45Nm Stage 4 90 degrees Stage 5 90 degrees 3 Install the valve tappets 4m A U T I O N W in several stages evenly tighten the camshaft bearing c...

Page 694: ...ral Procedures 6 Connect the engine coolant temperature ECT sensor electrical connector 7 Using the special tool connect the coolant hoses to the coolant outlet connector 8 Connectthe exhaust gas reci...

Page 695: ...g Jacking Description and Operation Lifting Description and Operation 13 lnstall the generator upper retaining bolt 18 lnstallthe exhaust manifoldsupport bracket retaining bolts 19 Fill and bleed the...

Page 696: ...on refer to Battery Tray 2 OL Duratec HE M14 414 01 Battery Mounting and Cables Removal and Installation 3 Loosenthe strut and spring assembly top mount nuts by three turns on both sides 4 Removethe r...

Page 697: ...coolingfan motor and shroud 1 Releasethe cooling fan motor and shroud from the retaining brackets 2 Pushthe cooling fan motor and shroud 13 Disconnectthe brake boostervacuum line upwards and then dow...

Page 698: ...ewiring harnessbracket electrical connector I 19 Detachthe power steering high pressure 16 Disconnectthe catalyst monitor sensor line retaining bracketfrom the transaxle electrical connector 20 Remove...

Page 699: ...ar to power steering fluid reservoir return line from the power Disconnectthe clutch slave cylinder supply steering fluid reservoir line Remove the spring clip Allow the powersteering fluid to drain i...

Page 700: ...p pulley For additional information refer to Quick Discardthe power steering pump pulley Release Coupling 310 00 Fuel System Generalinformation General procedures 29 Detachthe powersteering pumptostee...

Page 701: ...fshaft seal is not damaged A p l u g the transaxle to prevent oil loss or dirt ingress Removethe halfshaft and intermediate shaft assembly Allow the oilto drain intoa suitable container 38 CAUTIONS As...

Page 702: ...ector cable from the selector levers 2 Turn the abutment sleeve clockwise and detach the cables from the bracket 44 N0TE Use securing straps to secure the engine and the transaxle on the workshop tabl...

Page 703: ...g harnessfrom the retaining bracket 47 Raise and support the vehicle and remove the engine and transaxle assembly For 51 Removethe transaxle lower retaining bolts additional information refer to 100 0...

Page 704: ...atec HE M14 303 01B 82 REMOVAL 52 Remove the transaxle right hand retaining bolts 53 Remove the transaxle left hand retaining bolts 54 Removethetransaxleupperretainingbolts 55 Removethe transaxle 2006...

Page 705: ...pter for 205 072 205 072 02 15 03OA 02 LockingTool Flywheel 303 254 21 135 Mounting Plate for 303 435 06 303 435 11A 21 146D Socket Spark Plug 303 499 21 202 Pliers Valve Stem Seal 303 508 21 211 I IR...

Page 706: ...engine to 3 Remove the exhaust manifold lower heat the mounting stand shield 7 Remove the special tool 4 Disconnect the crankshaft position CKP sensor electrical connector 8 Drainthe engine Allow the...

Page 707: ...ressureswitch electrical connector 10 Detachthe engine wiring harness bracket from the intake manifold 13 Disconnectthe fuel injector electrical connectors 11 Disconnectthe knocksensor KS electrical c...

Page 708: ...e electrical connector sensor electrical connector f 16 Disconnect the electronic ignition El 19 Disconnectthethrottle body TB electrical electrical connector connector 17 Disconnectthe enginecoolant...

Page 709: ...e intake manifold Discardthe gasket 25 Removethe oil level indicator and oil level 22 Disconnectthe manifoldabsolutepressure indicatortube MAP sensor electrical connector 26 Remove the intake manifold...

Page 710: ...efrom the intake manifold 30 Using the special tool remove the spark plugs 31 Remove the valve cover 28 Removethe evaporativeemission EVAP valve support bracket 32 Using the special tool disconnectthe...

Page 711: ...power steering pump 36 Removethe coolant pump pulley 34 Removethe accessorydrive belttensioner 37 Using the special tools preventthe crankshaftpulleyfrom rotatingand remove the crankshaft pulley 35 R...

Page 712: ...e timing chain f 41 Remove the timing chain guides I Unlockthe timing chain tensioner ratchet 2 Apply pressureto the timing chain guide 42 Remove the timing chain tensioner 3 Lock the timing chain ten...

Page 713: ...ove the oil pump chain tensioner 47 Remove the front friction washer if equipped Discardthe friction washer 45 Usingthe specialtools loosenthe oil pump sprocket retaining bolt 46 Removethe oil pump ch...

Page 714: ...sequence shown N0TE Working in several stages release each camshaft bearing cap retaining bolt two turns at a time Remove the camshaft bearing caps Removethe camshafts ACAUTION K the valve tappets in...

Page 715: ...parator 60 Remove the flywheel Discardthe bolts 57 Removethe oil filter adapter Discard the gasket 61 Remove the special tool 62 Remove the oil pan 58 Removethe clutch disc and pressure plate For addi...

Page 716: ...303 01B 94 Engine 2 OL Duratec HE M14 303 01B 94 DISASSEMBLY Discardthe seal carrier 64 Removethe oil pump 2006 0 Fiesta1212006 G451309en...

Page 717: ...1 IStraight edge I Materials Name Specification ISilicone Sealant IWSE M4G323 A4 I IHypoid Gear Oil ISQM 2C9002 AA I Assembly 1 Install the oil pump Tighten the bolts in the sequence shown in two sta...

Page 718: ...pan within 10 minutes of applying the sealant and tighten the retaining bolts within a further 5 minutes Apply a 3 mm beadof sealant to the oil pan 9 Tighten the flywheel bolts Tighten the bolts in th...

Page 719: ...ilter adapter gasket lnstall the oil filter adapter 13 lnstall the crankcase vent oil separator 16 N0TE lnstall a new coolant pump O ring lnstall the coolant pump 17 N0TE lnstall new cylinder head bol...

Page 720: ...dead center TDC 19 Install the valve tappets 20m l l n s t a l l the camshafts approximately at valve overlap position on cylinder No 4 Install the camshafts Working inseveral stages evenly tightenth...

Page 721: ...sprocket retaining bolt 24 N0TE lnstall a new front friction washer lnstallthe front friction washer 27 lnstall the oil pump chain tensioner 25 lnstallthe oil pump chain I lnstall the oil pump chain a...

Page 722: ...l the camshaft sprockets Installthe timing chain 32 Tension the timing chain Apply pressure to the timing chain and remove the securing pin 33mACAUTION H I each camshaft by the hexagon with an open en...

Page 723: ...vethe cylinder block lower blanking 36 Install the engine front cover plugfrom the cylinder block and installthe special tool Tighten the bolts in the sequence shown Tighten bolts 1 through 8 to 10 Nm...

Page 724: ...pulley securing bolt finger tight Installthe crankshaft pulley onto the crankshaftandsecurethe crankshaftpulley to the front cover using a M6 x 18 mm bolt 41 N0TE lnstall a new crankshaft pulley reta...

Page 725: ...two revolutions special tool correct the engine timing 46 Installthe special tool Usingthe special tool check the positionof the camshafts 47 N0TE Only rotate the crankshaft in the normal direction of...

Page 726: ...r blanking plug9 54 N0TE When installinga new crankshaft pulley or enginefront cover the crankshaft position CKP sensor must be aligned usingthe alignmenttool suppliedwith the new component N0TE Do no...

Page 727: ...quence shown 58 1nstall the accessory drive belt tensioner 61 Install the evaporative emission EVAP valve support bracket 59 Apply a small bead of sealant to the areas as shown 62 Using the special to...

Page 728: ...nectors PCV hose to the intake manifold 64 Installthe power steering pump 67 Install the intake manifold 65 Using the special tool install the coolant 68 Install the oil level indicator tube and oil h...

Page 729: ...electrical connectorto the intake manifold 70 Installthe exhaustmanifoldlower retaining bolts 73 Connectthe intakemanifoldrunnercontrol IMRC electrical connector 71 Connectthe manifold absolute pressu...

Page 730: ...ation electrical connector EGR valve electrical connector 76 Connectthe engine coolanttemperature 79 Connectthe camshaft position CMP ECT sensor electrical connector sensor electrical connector 77 Con...

Page 731: ...he engine i ASSEMBLY 82 Connect the knock sensor KS electrical 86 Remove the special tools connector 87 Installthe generator 83 Attach the engine wiring harness bracket to the intake manifold 84 Fill...

Page 732: ...ASSEMBLY 88 Connectthe crankshaft position CKP 91 Connectthe generatorelectricalconnector sensor electrical connector 89 Install the exhaust manifold lower heat shield 90 Install the exhaust manifold...

Page 733: ...or near any fuel related components Highlyflammable vapors are always present and may ignite Failure to follow these instructions may result in personal injury 1 N0TE Using suitable retainingstraps se...

Page 734: ...ne mounts 7 lnstall the starter motor 8 lnstall the wiring harness retaining bracket Attach the wiring harnessto the retaining bracket 10 N0TE Do nottighten the engine rear mount retaining nuts at thi...

Page 735: ...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 h e inner CV joint must not be bent more...

Page 736: ...sing the special tool attach the right hand halfshaft and intermediate shaft assembly to the transaxle Removethe specialtool beforefully installing the halfshaft 21 N0TE lnstall a new intermediate sha...

Page 737: ...aining nut 25 Install the air cleaner resonator support 29 Tighten the engine front mount retaining bracket nuts and retaining bolts 26 Lower the vehicle 30 Connect the fuel supply line 27 Tighten the...

Page 738: ...lley Using the special tool install a new O ring 35 Install new power steering fluid reservoir seal onto the power steering pump to O ring seals steering gear pressure line union 1 Push the O ring sea...

Page 739: ...38 Attach the steering gear to power steering 41 Connect the reversing lamp switch fluid reservoir return line support bracket electrical connector to the generator 42 Lower the vehicle 39 Connect th...

Page 740: ...atalyst monitor sensor line retaining bracketto the transaxle electrical connector 45 Install the engine wiring harness bracket 48 Connect the power steering pump switch electrical connector 46 Connec...

Page 741: ...e EVAP valve 3 Pushthe EVAPvalve onto the support bracket 52 Usingthe specialtool connect the coolant hose to the coolant outlet connector 54 Install the right hand headlamp assembly For additional in...

Page 742: ...hydraulic clutch system For additional information refer to Clutch System Bleeding 308 00 Manual Transmission Transaxle and Clutch GeneralInformation GeneralProcedures 61 Installthe battery tray For...

Page 743: ...03A 4 Components 303 03A 5 DIAGNOSISAND TESTING Engine Cooling 303 03A 8 Inspection and Verification 303 03A 8 j Symptom Chart 303 03A 8 Component Tests 303 03A 46 GENERAL PROCEDURES Cooling System D...

Page 744: ...no other additive is in the coolant Cooling System Refill Capacities Approximate percentage of antifreeze by volume Description I Radiator pressuretest I 138 20 I Liters Cooling System PressureSpecifi...

Page 745: ...ng 1 3L Duratec 8V Rocam ll 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll GLDuratec 16V Sigma SPECIFICATIONS 2006 0 Fiesta1212006 G I46257en Description Thermostat housing retaining bolts Nm 10 Ib...

Page 746: ...ec 16V Sigma l 6L Duratec 16V Sigma DESCRIPTIONAND OPERATION Engine Cooling 1 4L Duratec I6V Sigma l 6L Duratec 16V Sigma Overview 2006 0 Fiesta1212006 GI 79022en Description Item Description I 4 5 6...

Page 747: ...RIPTION AND OPERATION Components Coolant pump The coolant pump is secured to the engine block at the timing gear end Item Description It is driventhrough a pulley b the accessory drive 2006 0 Fiesta12...

Page 748: ...303 03A 6 DESCRIPTIONAND OPERATION Thermostat and thermostat housing Item Description Thethermostatandthermostat housingare located 2006 0 Fiesta1212006 GI 79022en I 1 IThermostat housing 2 3 on the s...

Page 749: ...ERATION Water outlet housing Coolant Temperature ECT sensor Item Description The water outlet housingis locatedon the cylinder head nearest the transmission 1 2 Among other things it is used to mount...

Page 750: ...ead temperature CHT sensor Powertrain control module PCM 3 Ifan obviouscausefor an observedor reported Inspectionand Verification concernisfound correctthe cause if possible before proceedingto the ne...

Page 751: ...p 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 303 03 Engine Cooling 1 3L Duratec 8V Rocam l 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma Removal and...

Page 752: ...r tightness If OK I CARRY OUT the Coolant ExpansionTank Cap Pressure Test ComponentTest in this section INSPECTthe seal face on the coolant expansiontank for damage INSTALLa new coolant expansiontank...

Page 753: ...l 25L Duratec I6V Sigma l 4L Duratec 16V Sigma l 6L Duratec I6V Sigma Removaland Installation Water Pump 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 303 03 Engine Cooling 1...

Page 754: ...ooling System Draining Fillingand Bleeding 1 3L Duratec 8V Rocam l 25L Duratec 16V Sigma l 4L Duratec I6V Sigma l 6L Duratec 16V Sigma 303 03 Engine Cooling 1 3L Duratec 8V Rocam l 25L Duratec 16V Sig...

Page 755: ...cam l 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma General Proced ures CHECK the coolant condition If the coolant is in poor condi tion drain and refillwith new coolant REFER...

Page 756: ...igma l 4L Duratec 16V Sigma l GL Duratec 16V Sigma 303 03 Engine Cooling 1 3L Duratec 8V Rocam l 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l GL Duratec 16V Sigma Removal and Installation CARRY OUT...

Page 757: ...instrument cluster engine temperature gauge REFER to lnstrument Cluster Vehicles Built Up To 1012005 413 01 lnstrument Cluster Diagnosis and Testing I lnstrument Cluster Vehicles Built From 1012005 41...

Page 758: ...iator if necessary REFERto Radiator 303 03 EngineCooling 1 3L Duratec 8V Rocam l 25L Duratec I6V Sigma l 4L Duratec I6V Sigma ll 6L Duratec I6V Sigma Removaland Installation CoolantExpansionTank Cap P...

Page 759: ...iseduringthe warm up cycleand laterduringthe normallightthrottle cruise test Thissensoroutput mayvary betweenvehicles with manualtransmission and vehicles with automatictransmission and should be used...

Page 760: ...C for athermostat that hasan 88OCvalue The signal value will then fall as cooler coolant enters the engine Ifthe ECTvalue fails to maintain a constantvalue and falls back to lower figures typically be...

Page 761: ...sethe coolingsystem pressure by slowly turning the coolant expansion tank cap a quarter of a turn 2 Fillthe coolant expansiontank until coolant is expelled from the radiator bleed point or stabilizesa...

Page 762: ...Engine Cooling 1 3L Duratec 8V Rocam ll125LDuratec I6V Sigma ll14L Duratec 16V Sigma l 6L Duratec 16V Sigma GENERAL PROCEDURES 9 Switch the engine off 2006 0 Fiestaiz1 006 GI 46259en...

Page 763: ...03 12 IntakeAir Distributionand Filtering Removal and Installation 3 Drain the cooling system 6 Lower the vehicle For additional information refer to Cooling System Draining Filling and Bleeding 1 3 7...

Page 764: ...3 01 Engine 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma ln vehicle Repair 11 Removethe timing belt cover covershown 14 Drain the cooling system removed for clarity For addi...

Page 765: ...303 03A 23 Duratec 16V Sigma l 6L Duratec 16V Sigma 303 0349 23 REMOVALAND INSTALLATION 16 Removethe timing belt tensioner from the water pump Installation 1 N0TE lnstall a new water pump gasket To i...

Page 766: ...ng Hose Clamp 303 397 24 003 Removal 1 Drainthe coolingsystem For additional information refer to Cooling System Draining Fillingand Bleedingin this section 5 Removethe thermostat housing 2 Removethe...

Page 767: ...ooling 1 3L Duratec 8V Rocam ll 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma Il GLDuratec 16V Sigma REMOVAL AND INSTALLATION Make sure the rubber seal is located correctly I I 2006 0 Fiesta1212006 G2...

Page 768: ...ion referto Section 414 01 Battery Mountingand Cables 5 Usingthe special tool disconnect the 2 Drainthe cooling system radiator upper hose For additional information refer to Cooling System Draining F...

Page 769: ...radiatorretainersand grommets 8 Detachthe radiator and the air conditioning NC condenser from the support panel 9m A U T I O N S U O the condenser by positioning it on the support panel SlidetheN Ccon...

Page 770: ......

Page 771: ...nt 303 038 7 Changing Coolant 303 038 7 Fail safe Cooling 303 038 8 DIAGNOSISAND TESTING Engine Cooling 303 038 9 Inspection and Verification 303 038 9 Symptom Chart 303 038 9 Component Tests 303 038...

Page 772: ......

Page 773: ...oling I I System Overview Item Description I 1 ICoolant outlet connector I 1 2 1Exhaustgas recirculation EGR valve I 1 3 1Cooling fan motor I 1 4 1Radiator I Item Description 1 5 1Oil cooler I 1 6 ITh...

Page 774: ...ON Components Coolant Pump Description The coolant pump is of a conventionaldesign and is driven by the water pump pulley and accessory drive belt It is driven througha pulley by the accessorydrive be...

Page 775: ...tat Housing Item Description Thethermostatandthermostat housingare located 2006 0 Fiesta1212006 G421219en I 1 IThermostat housing 2 on the side of the engine block and cannot be servicedas a separate...

Page 776: ...Connector I 1 ICoolant outlet connector I 1 2 1Enginecoolanttemperature ECT sensorI 1 3 1Coolant outlet connector gasket I The coolant outlet connector is locatedon the cylinder head above the transmi...

Page 777: ...ld be checked through the neck of the expansiontank with a hydrometer The acceptable range of specific gravity sg of correctly balancedfluids is between 1 06 and 1 07kg l which representsa coolantconc...

Page 778: ...ched off and the temperature continues to rise the malfunction indicator lamp MIL is illuminated This indicates to the driver that the engine is approachingcritical limits and should stop At this poin...

Page 779: ...ector Fuse s Relay s Wiring harness Electrical connector s Engine coolant temperature ECT sensor Cooling fan motor Powertrain control module PCM 3 Ifan obvious causefor an observedor reported concern...

Page 780: ...aks CARRYOUT the PressureTest Component Test in this section INSTALL a new thermostat housing and thermostat housing gasket as necessary REFERto ThermostatHousing 303 03 Engine Cooling 2 OL Duratec HE...

Page 781: ...g 2 OL Duratec HE M14 Removal and Installation INSPECTthe engine cylinder head cylinder block and cylinder head gasket REFERto Cylinder Head 303 01 Engine 1 3L Duratec 8V Rocam In vehicle Repair Air i...

Page 782: ...fications drain and refill with new coolant REFERto Cooling System Draining Fillingand Bleeding 303 03 Engine Cooling 2 OL Duratec HE M14 General Procedures INSPECTthe radiatorgrillefor air restrictio...

Page 783: ...r Removal and Installation Thermostat CARRY OUT the Thermostat Test ComponentTest in this section INSTALLa new ther mostathousingandthermostat housing gasket as necessary REFERto Thermostat Housing 30...

Page 784: ...he possibility of coolant scalding Failureto follow this instruction may result in personal injury 1 Removethe coolant expansiontank cap 2 Use water to clean the area of the rubber seal and pressure r...

Page 785: ...lculatedidlespeed which the PCM commands the engine to reach If the thermostat opens too early beforethe correct opening temperature has been reached the engine will not reach this value When using th...

Page 786: ...er ingress The temperatureshould riseto approximately90 C for athermostatthat hasan 88OCvalue The signal value will then fall as cooler coolant enters the engine If the ECTvalue fails to maintaina con...

Page 787: ...ansion tank to the MAX mark container 24003 2 Removethe coolant expansion tank cap 3 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description an...

Page 788: ...lncrease the engine speedto 4000 RPMfor five seconds 9 Decreasethe engine speedto 2500 RPMfor three minutes 10 lncreasethe engine speedto 4000 RPMfor five seconds 11 Decreasethe engine speed to 2500 R...

Page 789: ...System Draining Filling and Bleeding 303 03 Engine Cooling 2 OL Duratec HE M14 General Procedures 2 Removethe crankshaft pulleysplash shield 4 Remove the accessory drive belt For additional informatio...

Page 790: ...Duratec HE M14 303 03B 20 REMOVAL AND INSTALLATION Item Description 1 2 6 To install reverse the removal procedure Coolant pump pulley Coolant pump retaining bolts 3 4 2006 0 Fiesta1u2oos G421227en Co...

Page 791: ...in the cooling system I For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling 2 OL Duratec HE M14 General Procedures Hose Clamp 303 397 For additional...

Page 792: ...tem Description I 1coolant hose Removal Details 2 2006 0 Fiesta1212006 G426583en 1 3 Thermostathousingto coolant expansion tank and heater core return coolant hose See Removal Detail Radiator lower to...

Page 793: ...and heater core return coolant hose I Using the special tool disconnectthe thermostat housing to coolant expansion tank and heater core return coolant hose Item 2 Radiator lower to thermostat housing...

Page 794: ...Removaland Installation 2 Disconnect the spark plug wires from the ignition coil pack 4 Removethe ignition coil pack 5 Drain the cooling system For additional information refer to Cooling System Drain...

Page 795: ...coolant outlet connector Installation 8 Disconnectthe coolant expansiontank hose from the coolant outlet connector 1 N0TE lnstall a newcoolant outlet connector gasket 9 Disconnect the thermostat housi...

Page 796: ...Filling and Bleeding 303 03 Engine Cooling 2 OL Duratec HE M14 General Procedures 3 Disconnect the cooling fan motor and cooling fan resistor electrical connectors 4 Removethe air cleaner intakepiper...

Page 797: ...orretainersandgrommets 9 Detachthe radiator and the air conditioning NC condenserfrom the support panel OmA C A U T I O N S the AIC condenser by positioning it on the support panel SlidetheN C condens...

Page 798: ......

Page 799: ...gma l 6L Duratec I6V Sigma VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 303 04A 2 DIAGNOSISAND TESTING Fuel Charging and Controls 303 04A 3 Principles Of Operation 303...

Page 800: ...ng idle upspeed at low ambienttemperatures I 100 rpm I Specification 380 kpa 55 psi IAir conditioning idle upspeed at high ambient temperatures I 150 rpm I IPower steering idle speed upspeed I 50 rpm...

Page 801: ...2 Visually inspectfor obvious signs of mechanical or electrical damage Visual Inspection Chart I Mechanical I Electrical I Fuel leak s Blockedor contamin ated fuel filter Fuel rail Vacuum line s Throt...

Page 802: ...ll 1 Disconnectthe air cleaner outlet pipe from preventthe complete initializationof the the throttle body throttle body 2 Removethe throttle body retaining bolts Turn the ignition key to position I I...

Page 803: ...tor can be disconnected information refer to Section 303 12 Intake the throttle body electrical Air Distribution and Filtering connector 2 Disconnect the spark plug wires from the ignition coil 6 Disc...

Page 804: ...4L Duratec 16V Sigma ll 6L Duratec 16V Sigma REMOVAL AND INSTALLATION 8 Disconnectthe fuel injector electrical connectors and remove the fuel charging wiring harness Installation I To install reverse...

Page 805: ...these instructions may result in personal injury 5 Disconnectthe fuel injector electrical connectors and positionthe wiring harness to one side 1 Releasethe fuei system pressure For additional informa...

Page 806: ...or are identified by a white band Fuel return line connectors are red or are identified by a red band Disconnect the fuel return line from the fuel injection supply manifold For additional information...

Page 807: ...ors are always present and can ignite Failure to follow these instructions may result in personal injury A This procedure involves fuel handling Be prepared for fuel spillage at all times and always o...

Page 808: ......

Page 809: ...PECIFICATIONS Specifications 303 04B 2 DESCRIPTIONAND OPERATION Fuel Charging and Controls 303 048 3 DIAGNOSISAND TESTING Fuel Charging and Controls 303 04B 5 Principles of Operation 303 04B 5 Inspect...

Page 810: ...Fuel Charging and Controls 2 OL Duratec HE M14 SPECIFICATIONS Torque Specifications IFuel injection supply manifold retaining bolts I 25 I 18 I I Description 2006 0 Fiesta1212006 G37518en...

Page 811: ...ctly into the fuel injection supply manifold and are retained by the 3 fuel injector retaining clips Sealing betweenthe The fuel injectionsupply manifoldis retainedto the engine by two bolts The fuel...

Page 812: ...y also gives inputs back to the Item Description The signal from the PCM is used to control a DC The throttle butterfly position is controlled by a signal from the PCMwhich receivesan input from the a...

Page 813: ...some major internal changes to the fuel supply and delivery system Some earlier vehicles used an Ethanol mixture called Ethanol E l5 This fuel was madeupof 15 Ethanoland 85 gasoline At this mixture ra...

Page 814: ...the only differance bothfuel pump modules have different Fuel composition monitoring fuel level sensor resistor card values The quantity of Ethanol E85 in relationto the quantityof unleadedfuel contai...

Page 815: ...maintain correct operating conditions Fuel rail The throttle body on Ethanol E85 vehicles is the same as non Ethanol E85 variants This is a fully electronic controlled and monitoredcomponent The PCMad...

Page 816: ...ncern 2 Visually inspectfor obvioussigns of mechanical or electrical damage Visual lnspectionChart I Mechanical I Electrical I Fuel leak s Vacuum line s Gasket s Seal s Fuel injector s Throttle body F...

Page 817: ...h Check the fuel system pres sure REFERto Fuel System Pres sure Check 310 OOA General Procedures RESETthe IFS switch Fuellines damagedor blocked INSPECTthe fuel lines INSTALLnew componentsas necessary...

Page 818: ...ures Fuel system leak CHECK the system for fuel leak s REPAIRthe systemas necessary Fuel system restriction INSPECTthe fuel system INSTALL new componentsas necessary TEST the system for normal operati...

Page 819: ...pression TEST the engine cylinder compression Enginestarts but immediately stops Air cleaner element blocked INSTALLa new air cleaner element CKP sensor Carry out a full engine diagnosis using the gui...

Page 820: ...3 04C Removal and Installation Low fuel system pressure Check the fuel system pres sure RE FERto Fuel System Pres sure Check 310 OOA General Procedures I Fuelfilter blocked I INSTALL a new fuel filter...

Page 821: ...trol 2 OL Duratec HE M14 Diagnosis and Testing Carry out a full engine diagnosis using the guided diagnostic menu in WDS Engine ignition REFERto Engine lgnition 303 07B Diagnosis and Testing Brakes bi...

Page 822: ...old 303 04C Removaland Installation I Fuel filter blocked I INSTALL a new fuel filter I REFERto Engine Emission Control 303 08 Engine Emission Control 2 OL Duratec HE M14 Diagnosis and Testing I Vehic...

Page 823: ...ctors CLEAN the fuel injectors or INSTALLa newset of injectors as required only after the checks have been carried out ECT sensor Carry out a full engine diagnosis using the guided diagnostic menu in...

Page 824: ...303 04C Removaland Installation REFER to Engine Emission Control 303 08 Engine Emission Control 2 OL Duratec HE M14 Diagnosis and Testing I CKP sensor Carry out a full engine diagnosis usingthe guided...

Page 825: ...ctors CLEAN the fuel injectors or INSTALLa new set of injectors as requiredonly after the checks have been carried out Fuel rail fuel pressuresensor Carry out a full engine diagnosis using the guided...

Page 826: ...ors CLEANthe fuel injectors or INSTALLa new set of injectors as requiredonly after the checks have been carried out INSTALL a new fuel rail REFERto Fuel Injection Supply Manifold 303 04C Removal and I...

Page 827: ...ALL a new fuel filter INSPECTthe fuel injectors CLEAN the fuel injectors or INSTALLa new set of injectors as required only after the checks have been carried out INSTALL a new fuel injection supply ma...

Page 828: ...d out INSTALLa new fuel rail REFER to Fuel Injection Supply Manifold 303 046 Removaland Installation Low fuel system pressure Check the fuel system pres sure REFER to Fuel System Pres sure Check 310 O...

Page 829: ...edcylinder headgasket REMOVEthe cylinder head INSPECTthe cylinder head gasket and cylinder bores for wear or damage REFERto CylinderHead 303 01C In vehicle Repair Low engine oil level CHECK the engine...

Page 830: ...ents KS Fuel injectors Carry out a full engine diagnosis using the guided diagnostic menu in WDS INSPECTthe fuel injectors CLEAN the fuel injectors or INSTALLa newset of injectors as required only af...

Page 831: ...gnostic menu in WDS Fuel injectors INSPECTthe fuel injectors CLEAN the fuel injectors or INSTALLa new set of injectors as required only after the checks have been carried out PCM calibration Using WDS...

Page 832: ...iningclip Air cleaner intake pipe Item 2 Air cleaner intake pipe See InstallationDetail Throttle body gasket Air cleaner outlet pipe retainingclip Air cleaner outlet pipe retainingclip Air cleaner out...

Page 833: ...he air 1 Detachthe air cleaner outlet pipe resonator cleaner outlet pipe Installation Details Ifem 7 Throttle body N0TE Do not fully tighten the throttle body retaining bolts at this stage I Installea...

Page 834: ...ging and Controls 2 OL Duratec HE M14 REMOVAL AND INSTALLATION Fuel Injectors 23455 0 1 Removethe fuel injectionsupply manifold For additional information refer to Fuel InjectionSupply Manifold inthis...

Page 835: ...uctions may result in personal injury 1 Releasethe fuel system pressure For additional information refer to Fuel System Pressure Release 310 00 Fuel System General Information General Procedures 2 Dis...

Page 836: ...bolts Fuel rail A Do not smoke or carry lighted tobacco or open flame of any type when working on 11 Removal Details 1 12 1Fuel injectors Item 1 Fuel charging wiring harness retaining clip Fuel injec...

Page 837: ...m General Information General Procedures Item 6 Fuel charging wiring harness retaining clip 1 Detach the fuel charging wiring harness retainingclip from the fuel rail retainingbolt Item 10 Fuel inject...

Page 838: ......

Page 839: ...5 5 Inspection and Verification 303 05 5 Accessory Drive Belt Concerns 303 05 5 Symptom Chart 303 05 10 Component Tests 303 05 16 REMOVAL AND INSTALLATION Accessory DriveBelt 1 4L Duratec 16V Sigma l...

Page 840: ...sory drive belt idler pulley retaining bolt Accessory drive bracketassembly retaining bolts Accessory drive belt tensioner retaining bolts lb ft 18 Torque Specifications vehicleswith I 4L Duratorq TDC...

Page 841: ...nditioning 1 3 1Generator I not need a tensioning pulley Re tensioningis not required 1 4 1Power steering pump I 1 5 1Air conditioning compressor I Vehicles without air conditioning have one drive bel...

Page 842: ...engine Item Description I 1 IAccessory drive belt 1 1 2 1Power steering pump pulley I 1 3 1Coolant pump pulley I 1 4 1Air conditioning AIC compressor pulley I 1 5 1Crankshaft pulley I 1 6 1Accessory d...

Page 843: ...ot consideredto be a failure of the belt Only if the crackis deep enough to reach the bottomof the grooveto exposethe cord or any chunksarefound to be missingfrom the belt is the belt condition consid...

Page 844: ...lt I 4L Duratorq TDCi DV Diesel 303 05Accessory Drive Removal and Installation REFER to Accessory Drive Belt 1 6L Duratorq TDCi DV Diesel 303 05Accessory Drive Removal and Installation REFER to Access...

Page 845: ...ve Removal and Installation I Accessory Drive Belt 1 6L Duratorq TDCi DV Diesel 303 05Accessory Drive Removal and Installation 1Accessory Drive Belt 2 OL Duratec HE M14 303 05 Accessory Drive Removal...

Page 846: ...new belt REFERto Accessory Drive Belt I 3L Duratec 8V Rocam 303 05 Accessory Drive Removaland Installation 1Accessory Drive Belt I 4L Duratec I6V Sigma ll 6L Duratec 16V Sigma Vehicles With Air Condi...

Page 847: ...303 05 9 Accessory Drive 303 05 9 DIAGNOSISAND TESTING 4 Check the accessory drive belt for fraying 1 No fraying new belt Not considered a concern No action required 2006 0 Fiesta1212006 G346263en...

Page 848: ...mptom Chart Symptom Chart 5 High amount of fraying with cord cuts INSTALLa new accessory drive belt f REFER to Accessory Drive Belt 1 3L Duratec 8V Rocam 303 05Accessory Drive Removal and lnstallation...

Page 849: ...not the accessory drive system If a noise is not apparent the cause is the accessory drive system CHECK where the noise is coming from Use a stethoscopeor other listening deviceto determinethe source...

Page 850: ...mp Belt 1 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma Vehicles With Air Conditioning 303 05 Accessory Drive Removal and Installation 1Accessory Drive Belt I 4L Duratec 16V Sigma ll 6L Duratec I6V Sig...

Page 851: ...and Installa tion I Power Steering Pump Belt 1 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma Vehicles With Air Conditioning 303 05 Accessory Drive Removal and Installation I Accessory Drive Belt 1 4L...

Page 852: ...y drive belt tensioner as neces sary REFER to Accessory Drive Belt Tensioner 1 6L Duratorq TDCi DV Diesel Vehicles With Air Condi tioning 303 05 Removaland Installation 1Accessory Drive Belt Tensioner...

Page 853: ...Installation I Accessory Drive Belt I 6L Duratorq TDCi DV Diesel 303 05 Accessory Drive Removaland Installation I Accessory Drive Belt 2 OL Duratec HE M14 303 05 Accessory Drive Removal and Installati...

Page 854: ...hardwarefor correct installation and tighten as necessary TEST the system for normal operation CHECK the extent of the fraying by referring to the illus trations shown in the Visual lnspection sectio...

Page 855: ...cessory drive belt tensioner as necessary REFER to Accessory Drive Belt Tensioner 1 6L Duratorq TDCi DV Diesel Vehicles With Air Conditioning 303 05 Removaland Installation REFER to Accessory Drive Be...

Page 856: ...ional information referto Section 100 02 Jacking and Lifting 2 Detachthe power steering line and remove the crankshaft pulleysplash shield 3 lnstallthe installationtool supplied in the parts kit to th...

Page 857: ...nting bracket direction of rotation N0TE Guide the accessory drive belt onto the pulleys as the engine is rotated Turn the engine until the paint mark is at the 8 o clock position 9 N0TE Only turn the...

Page 858: ...ock position 18 Removethe installationtool from the crankshaft pulley 19 N0TE Only turn the engine in the normal direction of rotation Turn the engine through 360 degrees 20 Checkthat the power steeri...

Page 859: ...thevehicle Foradditional information referto Section I 00 02 Jacking and Lifting 2 Detachthe power steering line and remove the crankshaft pulleysplash shield 3 lnstallthe installationtool suppliedin...

Page 860: ...nting bracket direction of rotation N0TE Guide the accessory drive belt onto the pulleysas the e ngineis rotated Turn the engine untilthe paint mark is at the 8 o clock position 9 N0TE Only turn the e...

Page 861: ...rive belt is correctly positioned in the grooves of the pulleys Repeat the installation procedure if the accessory drive belt is misaligned Discard the installationtool 13 Removethe belt guide tool fr...

Page 862: ...le Foradditional information referto Section 100 02 Jacking and Lifting 2 Detachthe power steering line and remove the crankshaft pulleysplash shield 3 Installthe power steering pump belt I Installthe...

Page 863: ...Only turn the engine in the normal direction of rotation Turn the engine through 360 degrees 1 8 Check that the power steering pump belt is correctly positionedin the grooves of the pulleys i Repeatt...

Page 864: ...tethe accessory drive belt tensioner For additional information refer to Battery counterclockwise Disconnect 414 01 Battery Mountingand 2 Removethe accessory drive belt Cables eneral procedures 2 Rais...

Page 865: ...ations vehicles with 1 4LDuratorq TDCi DV 1 6L Duratorq TDCi DV Diesel engines Torque Specifications vehicles with 2 OL Duratec HE M14 engine DESCRIPTIONAND OPERATION Starting System Starting system D...

Page 866: ......

Page 867: ...CM The solenoid is supplied with voltage The solenoid engagesthe starter motor pinion with the flywheel ring gear The solenoid applies battery current to the starter The starterturnsthe crankshaft unt...

Page 868: ...4 If the cause is not visually evident verify the The engine does not crank the relay does not click symptom and refer to the Symptom Chart Possible Sources Action Battery REFER to Charging System 414...

Page 869: ...REFER to 303 06 Starting System StarterMotor 1 3LDuratec 8V Rocam l 25L Duratec I6V Sigma l 4L Duratec 16V Sigma l 6L Duratec 16V Sigma Removaland Installation Starter Motor 1 4L Duratorq TDCi DV Die...

Page 870: ...2 No GO to A3 1 2 CHECK THE VOLTAGE DROP I Measure the voltage betweenstarter motor terminal 30 component side and the battery positive terminal Is the voltage less than 0 5 volts Yes GO to A4 No CLEA...

Page 871: ...tery 1 ground terminal Is the resistance less than 0 5 ohms Yes INSTALLa new starter motor REFER to Starter Motor 1 3L Duratec 8V Rocam l 25L Duratec 16V Sigma l 4L Duratec 16V Sigma ll 6L Duratec 16V...

Page 872: ...1 circuit 50 BB16 GYIBK harnessside Is the resistance less than 5 ohms Yes INSTALLa new ignition switch REFER to lgnition Switch 211 05 Steering ColumnSwitches Removaland Installation TEST the system...

Page 873: ...pin 2 circuit 91S BB16 BWRD harnesssideand PCMC343 pin F30 91S BBI6 BWRD harness side Is the resistance less than 5 ohms Yes CHECK the PATS system REFERto WDS No REPAIR the circuit TEST the system fo...

Page 874: ...valand Installation 1Batteryto Starter Motor Solenoid Cable 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 414 01 Battery Mounting and Cables Removaland Installation Test the sy...

Page 875: ...mation refer to Section 414 01 Battery Mounting and Cables 2 Raiseandsupportthevehicle Foradditional information referto Section 100 02 Jacking and Lifting 3 Disconnectthe ignition switchto starter mo...

Page 876: ...r to Battery For additional information refer to Lifting Disconnect 414 01 Battery Mounting and 100 02 Jacking and Lifting Description Cables General Procedures and Operation 3 Remove the components i...

Page 877: ...cables See RemovalDetail See Installation Detail Installation Details Item 1 Starter motor electrical connectors Item 3 Starter motor 1 N0TE Clean the electrical connectors before 1 N0TE Clean the ma...

Page 878: ......

Page 879: ...ition 303 07A 1 SECTION 303 07A Engine Ignition VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 303 07A 2 DIAGNOSISAND TESTING Engine Ignition 303 07A 3 Inspection and Ve...

Page 880: ...Engine Ignition SPECIFICATIONS Description 53 ISpark plugs I 15 I 11 I I 2006 0 Fiesta12 2006 1 4 8 2 1 8en...

Page 881: ...trical damage Visual InspectionChart I Mechanical I Electrical I 3 Ifan obviouscausefor an observedor reported concern isfound correctthe cause if possible before proceedingto the next step Spark plug...

Page 882: ......

Page 883: ...03 07B 1 SECTION 303 07B Engine Ignition 2 OL Duratec HE M14 VEHICLE APPLICATION 2006 0 Fiesta CONTENTS SPECIFICATIONS Specifications PAGE DIAGNOSISAND TESTING Engine Ignition 303 07B 3 Inspection and...

Page 884: ...Engine Ignition 2 OL Duratec HE M14 SPECIFICATIONS Torque Specifications Description Ignition coil pack retaining bolts 2006 0 Fiesta1212006 G421398en ISpark plug s Nm 6 12 lb ft lb in 53 9...

Page 885: ...sfire 3 Ifan obviouscausefor an observedor reported concernisfound correctthe cause if possible before proceedingto the next step 4 If the cause is not visually evident verify the symptom and refer to...

Page 886: ......

Page 887: ...l 6L Duratec I6V Sigma VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 303 08A 2 DESCRIPTIONAND OPERATION Engine Emission Control 303 08A 3 Positive CrankcaseVentilation...

Page 888: ...ol 1 3L Duratec 8V Rocam llI25L Duratec 16V Sigma llI4L Duratec 16V Sigma l 6L Duratec 16V Sigma SPECIFICATIONS Torque Specifications Description Crankcasevent oil separator retaining bolts 2006 0 Fie...

Page 889: ...6V Sigma DESCRIPTIONAND OPERATION Engine Emission Control Positive CrankcaseVentilation PCV 1 3L Duratec 8V Overview Side view Item Description 2006 0 Fiesta1212006 G I67099en Item Description From Ev...

Page 890: ...of the cylinder head cover The crankcasegases are sucked bythe PCVvalve into the intake manifold The PCV valve is opened by the vacuum in the intake manifold The amount of crankcase gases depends on t...

Page 891: ...r and in the PCV oil separator in order to preventthe oil from being sucked in and burned housing The PCVvalve is locatedinthe PCVoil separator The amount of crankcase gases depends on the engine spee...

Page 892: ...ase ventilation PCV valve PCV separator Symptom Chart Symptom Excessivecrankcase pressure 4 If the cause is not visually evident verify the symptom and refer to the Symptom Chart Oil in the air intake...

Page 893: ...ve the intake manifold For additional information refer to Section 303 01A Engine 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma llm6L Duratec 16V Sigma I303 01B Engine 1 4L Duratorq TDCi DV Diesel I...

Page 894: ......

Page 895: ...0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 303 088 2 DESCRIPTIONAND OPERATION Engine Emission Control 303 088 3 DIAGNOSISAND TESTING Engine Emission Control 303 088 6 Inspection and Verific...

Page 896: ...SPECIFICATIONS Toraue Specifications I Description I Nm I Ib ft I Ib in I IExhaustgas recirculation EGR valve bolts I 25 I 18 I I 2006 0 Fiesta12 2006 G37567en EGR valve outlet tube union Crankcaseve...

Page 897: ...intake manifold by the EGR valve Exhaustgas recirculation EGR valve 3 a measuredquantity of exhaust gas to be directed The EGR valve is controlled by an input from the back to the intake manifold The...

Page 898: ...s of a valve mounted inthe crankcasevent oil separator attachedto the cylinder block and connects the valve cover to the air cleaner 1 4 2006 0 Fiesta1212006 G37563en Positivecrankcaseventilation PCV...

Page 899: ...AND OPERATION E57308 i Item Description I I 1 PCV hose to valve cover connector I Underfull throttle conditions the crankcasevapor flows from the valve cover intothe air cleaner through the PCV hose 2...

Page 900: ...next step 4 If the concern is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Symptom Possible Sources Action I Poor engine performance EGR valve Usi...

Page 901: ...amaged engine components REFER to Section 303 01A Engine 1 25L Duratec I6V Sigma l 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 1 303 01B Engine 1 4L Duratorq TDCi DV Diesel 1 303 01C Engine 1 3L Dura...

Page 902: ...ntake tube System Draining Filling and Bleeding 24003 303 03 Engine cooling 2 01 Duratec HE M14 General Procedures 4 Usingthe special tool disconnect the 2 Removethe air cleaner outlet pipe radiator u...

Page 903: ...l 2 OL Duratec HE MI41 REMOVALAND INSTALLATION I Item Description I 1 IEGR valve electrical connector I I 1EGR valve coolant hose See Removal Detail 6 To install reversethe removal procedure 2006 0 Fi...

Page 904: ...1 4L Duratorq TDCi DV Diesel I303 01C Engine 1 3L Duratec 8V Rocam I303 01D Engine 2 OL Duratec HE M14 1 303 01E Engine 1 6L Duratorq TDCi DV Diesel 2 Disconnectthe positivecrankcaseventilation PCV h...

Page 905: ...ibution and Filtering 1 4L Duratec 16V Sigma l 6L Duratec 16V Sigma lntake manifold lntakeAir Distribution and Filtering 2 OL Duratec HE M14 2 OL Duratec HE M14 engine DIAGNOSIS AND TESTING lntakeAir...

Page 906: ...diesel engine Air cleaner outlet hose retainingclip vehicleswith 1 6L Duratorq TDCi DV diesel engine Nm 4 Air cleaner intakepipeduct retainingbolts vehicles with I 6L Duratorq TDCi DV diesel engine Ch...

Page 907: ...reased but the pipes are of equal length on all cylinders This has resulted in increased torque in the lower engine speed range and a reduction in noise levels I 1 IMountingfor the throttle valve unit...

Page 908: ...tem Descri tion I 1 IIntake manifold I 1 2 1lntake manifoldtuning valve solenoid I 1 3 lntake manifoldtuning valve I 1 4 1 lntake manifoldtuning valve solenoid to intake manifoldvacuum pipe Item Descr...

Page 909: ...303 12 5 IntakeAir Distributionand Filtering 303 12 5 DESCRIPTIONAND OPERATION Air intake system 2006 0 Fiesta12 2006 G421936en...

Page 910: ...et Air cleaner housing Air cleaner pipe retainingclamps 6 7 1 9 1Air cleaner intake pipe resonator I Air cleaner intake pipe Air cleaner intake pipe resonator isolators 1 10 1Air cleaner intake pipe d...

Page 911: ...leswith 1 6L Duratorq TDCi DV Diesel engine Charge air cooler intake hose Vehicles with 1 6L Duratorq TDCi DV Diesel engine Charge air cooler outlethose Vehicles with I 6L Duratorq TDCi DV Diesel engi...

Page 912: ...Turbocharger Vehicles with Duratorq TDCi DV Diesel engine or 1 6L Duratorq TDCi DV Diesel engine Vehicles with 1 4L Duratorq TDCi DV Diesel engine REFERto Turbocharger 303 04 Fuel Charging and Control...

Page 913: ...DV Diesel engine Charge air cooler blocked Vehicleswith 1 6L Duratorq TDCi DV Diesel engine INSPECTthe chargeair cooler pipes for damage INSTALLa new charge air cooler pipe s as necessary INSPECTthe c...

Page 914: ...and Controls 303 04 Fuel Char ging and Controls 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l 6L Duratec I6V Sigma Diagnosis and Testing Vehicles with I 4L Duratorq TDCi DV Diesel engine REFERto Fu...

Page 915: ...Vehicles with 1 4L Duratorq TDCi DV Diesel engine REFERto Turbocharger 303 04 Fuel Charging and Controls Turbocharger 1 4L Duratorq TDCi DV Diesel Removaland Installa tion Vehicles with 1 6L Duratorq...

Page 916: ...sconnectthe air cleaner outlet pipe and 1 N0TE Locatethe rearisolatorsontothe rear the positivecrankcaseventilation PCV hose mounting pegs and push down from the air cleaner To install reversethe remo...

Page 917: ...ach the air cleaner outlet pipe from the throttle body 1 Detach the PCV hose from the air cleaner 5 6 7 Air cleaner outlet pipe retaining clip Air cleaner outlet pipe See Removal Detail Air cleaner in...

Page 918: ...A U T I O N M sure the air cleaner is removedfrom the air cleaner mountingsin a vertical direction Failureto follow this instruction may cause damage to the air cleaner and air cleaner mountings Detac...

Page 919: ...AGE DESCRIPTIONAND OPERATION Evaporative Emissions 303 13 2 Overview 303 13 2 DIAGNOSISAND TESTING Evaporative Emissions 303 13 3 Inspectionand Verification 303 13 3 REMOVALAND INSTALLATION Evaporativ...

Page 920: ...EVAP solenoid I 1valve 1 6 1To the intake manifold I The EVAPcollectionsystempreventsfuel vapours from reachingthe atmosphere To achieve this the fuel vapours are led from the fuel tank into the activ...

Page 921: ...echanical I Electrical I Vacuum line s Evaporativeemis sion EVAP system canister EVAP system hose s EVAP system canister purge valve I Fuse s I I Wiring harness Electrical connector s 3 Ifan obviousca...

Page 922: ...lways present and may ignite Failureto follow these instructions may result in personal injury A This procedure involves fuel handling Be preparedfor fuel spillage at all times and alwaysobservefuel h...

Page 923: ...ect thefuel tank vent pipefrom the 7 Remove the fuel tank support strap rear evaporative emission canister For retaining bolts additional information refer to Section 310 00 Fuel System General Inform...

Page 924: ...flammable vapors are always present and may ignite Failure to follow these instructions may result in personal injury A h i s procedure involves fuel handling Be preparedfor fuel spillage at all times...

Page 925: ...erview 2 OL Duratec HE M14 Engine Components DIAGNOSISAND TESTING Electronic Engine Controls 303 14 14 Principles of Operation 303 14 14 MIL Code List 303 14 17 Inspectionand Verification 303 14 21 RE...

Page 926: ...r KS retaining bolt I 20 I 15 I I 47 47 ICamshaft position CMP sensor retaining bolt I 10 I I 89 I 53 89 35 35 Cylinder head temperature CHT sensor Crankshaft position CKP sensor retaining bolt IEngin...

Page 927: ...n referto CrankshaftPosition CKP Sensor 1 6L Duratorq TDCi DV Diesel 303 14 ElectronicEngineI I Controls Removaland Installation I Torque Specifications vehicles with 2 OL Duratec HE M14 eng 35 53 I D...

Page 928: ...14 4 Electronic Engine Controls 303 14 4 DESCRIPTIONAND OPERATION Electronic Engine Controls 1 25L Duratec 16V Sigma lAL Duratec I6V Sigma l GL Duratec 16V Sigma Overview 2006 0 Fiesta1212006 G204204...

Page 929: ...5 DESCRIPTIONAND OPERATION Item Description Item Description 2006 0 Fiesta1212006 G204204en I 1 ITemperature and ManifoldAbsolute 2 3 1Knock Sensor KS pressure T MAP sensor Throttle Position TP senso...

Page 930: ...1Inertia fuel shut off switch I Battery Powertrain Control Module PCM 18 19 1 21 1Fuel Pump Driver Module FPDM I Data Link Connector DLC Fuel Pump FP relay 1 22 1Fuel injectors I 23 Evaporativeemissi...

Page 931: ...spindle by means of the gear set Standby function Ifa fault developsinthe throttle control unit TCU a standby function is carried out This standby function allows a slight opening of the throttle flap...

Page 932: ...PCM Ifwhen the APP sensor has failed the BPP is operated the engine will be controlledto run at idle speed by the PCM In order that the engine power output can be matched to that required by the driv...

Page 933: ...wer maximumtorque 80 Nm if both potentiometersfail the enginewill runwith reduced power maximumtorque 55 Nm This warning may also be indicated if the engine does not start The cause may be a poor stat...

Page 934: ...303 14 10 ElectronicEngine Controls 303 14 10 DESCRIPTIONAND OPERATION Electronic Engine Controls 2 OL Duratec HE M14 System Overview 2 OL Duratec HE M14 Engine 2006 0 Fiesta1212006 G422229en...

Page 935: ...from the MAPTsensor is usedto modifythe ignition and fuel delivery 1 12 1Accelerator pedal position APP sensor 1 13 1Clutch pedal position CPP switch 1 14 1Brake pedal position BPP switch CMP sensor 1...

Page 936: ...ationsbetweenthe PCM and other control units for example the stability assist and the instrument cluster includingthe DLC for diagnosis of the system take place on the controller area network CAN Inta...

Page 937: ...rating mode Accelerator pedal position APP sensor The PCMrequiresthe pedal positionfrom theAPP sensor in order to regulatethe poweroutput of the engine accordingto the driver requestfor power The APP...

Page 938: ...llowing elements Warm up Cycle C The warm up cycle is an operationthat consists of key on engine start and a coolant temperature increaseof 22 C exceeding71O C on completion Drive Cycle A drive cycle...

Page 939: ...HT Sensor Heated Oxygen Sensor H02S Catalyst Monitor Sensor Charge Air Temperature Sensor Knock Sensor KS Throttle Position TP Sensor Vehicle Speed Sensor VSS Boost PressureSensor Cam Crank PhasingSen...

Page 940: ...efunctionality of the EGRsystem is checked by comparing either the MAP sensor output or EGR valve lift potentiometeroutput dependingupon application with expected values Diagnostic Requirements Vehicl...

Page 941: ...puts Px7xx for transmission Px8xx for transmission Px9xx category to be determined PxOxx category to be determined When a concern occurs the actions taken include storage of the relevant informationan...

Page 942: ...I Cylinder No 3 injector circuit open circuit I Fuel system error HClCO emissions Cylinder No I injector circuit open circuit PO202 I PO204 I Cylinder No 4 injector circuit open circuit I Cylinder No...

Page 943: ...Evaporative mission canister purge valve low voltage I I 1 PO459 1 Evaporative mission canister purge valve high voltage I I PO460 I Fuel tank level malfunctionfrom instrument cluster I 3 I VSS signa...

Page 944: ...1 PO694 1 Cooling fan 2 control circuit high voltage I I PI500 I Vehicle speed sensor VSS output circuit malfunction I PO704 P I000 Generatorcommand malfunction I Clutch switch implausiblesignal EOBD...

Page 945: ...key transponder PATS received invalid format of key codefrom ignition key transponder PATS transceiver module signal is not received PATS immobilizer antenna not connected PATS immobilizerchallenge r...

Page 946: ...odule 418 537 29 0 16 1 Removethe battery tray connector For additional information refer to Battery Tray 414 01 Removaland Installation 2 Positionthe PCMonthe batterytray support panel 4m ACAUTION M...

Page 947: ...period as this will preventthe complete initializationof the throttle body Turn the ignitionkey to position I 1and wait for one minuteto initializethe throttle body 6 Turn the ignitionkey to the OFF p...

Page 948: ...additional information refer to Battery Tray 414 01 Removal and Installation 2 Raise and support the vehicle For additional information refer to Lifting 1 00 02 Jacking and Lifting Description and Op...

Page 949: ...Detail See Installation Detail PCM retaining bolts See Removal Detail 1 5 1PCM retaining bracket I Item Descri tion 1 6 1PCM mounting bracket I 1 I removalDetail 9 To install reversethe removal proced...

Page 950: ...shear bolts PCM retaining bolts Drill a 8 mm hole in the PCM security shield shear bolts and removethe PCM security Item 7 PCM shield I Removethe PCM from the PCM retaining bracket Item 2 PCM securit...

Page 951: ...nfiguration information sensor electrical connector and detach the using the programmable modules installation wiring harness from the retaining clip routine prior to commencingthe removal of the PCM...

Page 952: ...il 1 3 1PCM retaining bracket I 1 4 1PCM mounting bracket I Removal Details Item Description I ISee Removal Detail I 4 To install reverse the removal procedure N0TE lf a new PCM is being installedconn...

Page 953: ...Controls 303 14 29 REMOVALAND INSTALLATION Item 2 PCM retaining bolts I Supportthe PCMand PCM retainingbracket while removingthe PCM retaining bolts 1 Removethe PCM from the PCM retaining bracket 200...

Page 954: ...Removethe exhaust manifold heat shield 2 Disconnect the ignition coil pack electrical connector 23050 3 Detachthe ignition coil pack and position it to one side Socket FuelInjector 22mm 310 063 23 050...

Page 955: ...e Controls 303 14 31 REMOVALAND INSTALLATION cannot be damaged by heat or moving components and will not cause a noise vibration or harshness NVH issue 1 To install reverse the removal procedure 2006...

Page 956: ...e crankshaft pulleyclockwiseuntil A 0 n l y turn the crankshaft pulley in the normaldirectionof rotation the crankshaft pulleytiming bolt M6 x 18 I Raise and support the vehicle mm can be installedthr...

Page 957: ...electrical connector 2 Installation Details ISee Installation Detail Item 3 CKP sensor 2 Align the CKP sensor with the crankshaft 1 Install the CKP sensor alignment tool to the pulleysensor ring CKP...

Page 958: ...34 Electronic Engine Controls 303 14 34 REMOVALAND INSTALLATION Item 2 CKP sensor retaining bolts I Install the CKP sensor retaining bolts 2 Removethe CKP sensor alignmenttool 2006 0 Fiestaiz1 006 423...

Page 959: ...refer to Intake 1 Manifold 303 01Engine 2 OL Duratec HE M14 Invehicle Repair 3 Removethe components in the order indicated in the following illustration s and table s Item Description Item Description...

Page 960: ...note of the position of the KS and hose retaining clip and position it to one when installed make sure it is positioned in the same position side Installation Details ltem 3 KS NOTE Prior to installi...

Page 961: ...ody Internal gearshift mechanism Fluid circuit IdentificationTags Type plate Transmission Ranges and Power Flow Transmission ratio and power flow route 1st gear Transmission ratio and power flow route...

Page 962: ...ssion Fluid Level Check 307 01 k Transmission Fluid Drain and Refill 307 01 53 IN VEHICLE REPAIR Transmission Range TR Sensor 307 01 55 Halfshaft Seal LH 307 01 58 Halfshaft Seal RH 307 01 59 Turbine...

Page 963: ...nut I 25 I 18 I I ITorque converter retaining nuts I 27 I 20 I I lb in Item IStarter motor retaining bolts I 47 I 35 I I IEngine and transaxle rear mount retainingbolt I 80 I 59 I I Nm ILower arm to...

Page 964: ...Speed Automatic Transmission AW81 40 SPECIFICATIONS Transmissionrange TR sensor to selector shaft 7 locking nut ITransmissionrange TR sensor retaining bolts I 5 I I 44 I IManualshift lever retaining...

Page 965: ...Automatic Transmission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Automatic Transaxle Transmission cross section 2006 0 Fiesta1212006 380521 en...

Page 966: ...nverter Clutch TCC Item Description I 1 ITorque converter housing and impeller I 1 2 1Turbine wheel 1 1 4 1Transmission input shaft I F l G w i t h roller type one way clutch The torque converter hydr...

Page 967: ...Item Description It sucks up transmission fluid from the oil pan 1 2 3 2006 0 Fiesta1212006 G380521en Fluid pump housing 4 buildsupthe oil pressureandthen supplies it under high pressureto the main co...

Page 968: ...The output always flows through the annulus 6 2006 0 Fiesta1212006 380521 en Short planet gear Transmission input shaft The differenttransmission ratios are selected by actuatingand releasingthe indi...

Page 969: ...ed with three clutches and five brakes The brakes are three multi plate brakes and two one way sprag clutches The clutches serve to transmit the torque from the transmission input shaft to certain com...

Page 970: ...way clutch I 1 3 12nd 4th gear brake I 1 4 11st gear one way clutch 1 5 1Reversegear brake I 1 6 13rd14thgear clutch Item Description 1 8 1Output wheel planetary gearset I 1 7 1Fromthe torque converte...

Page 971: ...brake 4th gear brake Reverse gear brake 1st gear one way clutch 2nd gear one way clutch Only in selector lever position2 Only in selector lever position 1 Transmissioninput shaft to planet gear carrie...

Page 972: ...put wheel intermediategear stage The differential assembly transmits the torque via the halfshaftsto the front wheels In addition the manual selector slide in the main control body provides a hydrauli...

Page 973: ...llyvia the selector lever when the selector lever position P is engaged Accordingly the differential is blockedvia the intermediateshaft and the vehicle is secured and The movement of the selector lev...

Page 974: ...enoid valves and main control body I 1 3 IClutches and brakes I 1 4 1Planetary gearset 1 5 1Fluid pump I 1 6 1Oil pan I 1 7 1Fluidcooler I Item Description 1 8 ITorque converter I I A IElectricactuati...

Page 975: ...smission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Item Description I H ITo the fluid cooler I i 2006 0 Fiesta1212006 G380521en F G Lubrication To the tor...

Page 976: ...In addition the serial number is also stamped on I 1 IFord part number the transmission housing 2 2006 0 Fiesta1212006 G380522en 3 1Stamped serial number Serial number G Month of manufacture July Ser...

Page 977: ...n AW81 40 DESCRIPTIONAND OPERATION I production line 1 12345 Serial number 2006 0 Fiesta12 2006 G380522en Code letter part of the serial number A B C D E F G H J K L M Month of manufacture January Feb...

Page 978: ...ansmission Transaxle Vehicles With CSpeed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transmission Ranges and Power Flow Transmission ratio and power flow route 1st gear 2006 0 Fiesta12120...

Page 979: ...king The short planet gears 8 are driven by the small sun gear inthe opposite directionof rotationto the output from the engine The short planetgears drive the long planetgears 9 in the same direction...

Page 980: ...Automatic TransmissionlTransaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transmission ratio and powerflow route 2nd gear 2006 0 Fiesta1212006 G380528en...

Page 981: ...ngine The short planet gears drive the long planetgears 9 in the same direction of rotation as the output from the engine The long planet gears are supported by the large sun gear which is being held...

Page 982: ...atic TransmissionlTransaxle Vehicles With CSpeed Automatic 307 01 22 Transmission AW81 40 307 01 22 DESCRIPTIONAND OPERATION Transmission ratio and power flow route 3rd gear 2006 0 Fiesta1212006 G3805...

Page 983: ...on the other hand from the transmissioninputshaft via the 3rdl4thgear clutch 17 to the planet gear carrier 6 As the drive is transmitted to two components simultaneously there are no relative movemen...

Page 984: ...Automatic TransmissionlTransaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transmission ratio and power flow route 4th gear 2006 0 Fiestalu2006 G380528en...

Page 985: ...is transmitted from the torque converter I to the transmission input shaft 2 and via the 3rdl4th gear clutch 17 to the planet gear carrier 6 The large sun gear 15 is held by the 4th gear brake 16 the...

Page 986: ...Automatic Transmission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transmission ratio and power flow route reverse gear 2006 0 Fiesta12 2006 G380528en...

Page 987: ...ssion input shaft 2 and via the r reversegear clutch 18 to the largesun gear 15 The planet gear carrier 6 is held by the reverse gear brake 7 The large sun gear drives the long planet gears 9 inthe op...

Page 988: ...Automatic Transmission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transaxle Electronic Control System Overview 2006 0 Fiesta1212006 G380530en...

Page 989: ...n Range TR sensor I 1 9 1Starter inhibit relay I 1 10 1Backup lamp relay I 11 Transmission Fluid Temperature TFT I Isensor 1 12 loverdrive switch I 1 13 1Driver s side door ajar switch I 1 14 1Solenoi...

Page 990: ...or pedal position and the vehicle speed For kick down acceleratorpedal presseddown at least 95 the next lowest gear is selected as long as the engine speed allows it All gearshift timings are set by t...

Page 991: ...ture reachesa temperature of around 135 C the transmission controlemploys a shift patterndesignedto prevent a further increase in the transmissionfluid temperature When the transmission fluid temperat...

Page 992: ...ch is disengaged and a brake is engaged simultaneously In order to control the synchronizedswitching of the two components as exactly as possible the shifl timing solenoid valve is actuatedaccordingly...

Page 993: ...the shifttiming solenoidvalve as a result of which Transmission input speed the actuating pressuredoes not reachthe reverse Vehicle speed gear clutch or the reverse gear brake The following are actua...

Page 994: ...o 3rd gear Selector lever position 2 If the selector lever is moved to position 1 at higherspeedsthan are permittedforfirst gear then the transmissioncontrol delays the downshift until the vehicle spe...

Page 995: ...depressed This signal is transmitted via the CAN databus to the transmission control unit The transmission control unit uses this signal for Gearshift control Engagementof the TCC Accelerator pedal p...

Page 996: ...I I Actuation of the overdrive indicator lamp I The overdrive indicator lamp is located on the instrument panel The MIL warning lamp is actuated by the Thetransmission control unitsends a warningtone...

Page 997: ...Torque reductionwhen pulling away Consequences of signal failure No TCC no torque reduction no shift timing adaptation no 4th gear The OSS sensor is a Hall sensor It is mechanicallyconnectedvia a gea...

Page 998: ...is actuated by the PCMvia the TR sensorwhen the selector lever is in the positions P or N Inselectorleverposition R the backup lamp relay is also actuated via the TR sensor The transmission control u...

Page 999: ...during shifts from 3rd to 4th gear Shift timing adaptation during shifts from 4th to 3rd gear Overheating protection mode Consequencesof signal failure NoTCC no shift timing adaptation no 4th gear The...

Page 1000: ...oncontrol unit transmits the warning tone request via the CAN databus to the instrument cluster The instrument cluster passes this request on to the GEM which then generates a warning tone Consequence...

Page 1001: ...o precisely SSB On Off Off On control the timing of the engagement and disengagementof the I st3rd gear clutch In addition it is also used to prevent engagement of reverse gear if the driver moves the...

Page 1002: ...ption The starter inhibit relay is located in the central 1 Starter inhibit relay junction box CJB Inthe selectorleverpositions P and Nu a ground N0TE The enginecannot bestarted ifthe electrical signa...

Page 1003: ...r lock solenoid in all selector lever a result positions except P 1 Consequences of signal failure backup lamps inoperative Backup lamp relay Selector lever lock solenoid lock solenoid is actuated by...

Page 1004: ...gnition key can be turned to 0 and removed from the ignition lock In all other selector lever positionsthe ground connection is made via the selector lever lock solenoid The locking pin of the solenoi...

Page 1005: ...mechanism Transaxle fluid leaks Damagedtransaxle casing I DiagnosticTrouble Code Chart Fuse s Electrical connector s DiagnosticTrouble Code Charts Symptom Possible Sources Action I A207 Checksum erro...

Page 1006: ...ressurecontrolsolenoid Circuit s REFERto WDS PO972 Shift solenoidA performance Shift solenoid A open circuit Circuit s Internal mechanical hydraulic failure REFER to WDS REFERto WDS PO974 Shift soleno...

Page 1007: ...sting each of the following ranges I D DRIVE and R REVERSE rmovethe 1 Connect the special tools to the line pressure selector lever to N NEUTRAL and run the engine at I000 rpm for approximately test p...

Page 1008: ...axle at normal operating temperatures 50 C to 80 C A Apply the parking brake firmly while N0TE Prolonged use of this procedure may set carrying out each stall test DTC PO712 After carryingout the stal...

Page 1009: ...ime between moving the selector Recordthe time lag and refer to the time lag lever from IN NEUTRAL to ID DRIVE or IN chart NEUTRAL to R REVERSE With the parking 2 If the time lag is not within specifi...

Page 1010: ...ND TESTING Test Results Lowerthan specification in N NEUTRAL to R REVERSE Possible Source Pressurecontrol solenoid inoperative Pressureregulator valve sticking Reverseclutch failure slipping First and...

Page 1011: ...ids 1 N0TE Make sure that the transmission is not in emergency operation mode Connect the worldwide diagnostic system WDS to the data link connector DLC indicator Automatic transmission lfluid AWARNIN...

Page 1012: ...le Vehicles With CSpeed Automatic 307 01 52 Transmission AW81 40 307 01 52 GENERAL PROCEDURES 8 Install the transmissionfluid level indicator 9 Switch the engine off 10 Disconnectthe WDS from the DLC...

Page 1013: ...uids Install the drain plug 1 Raise and support the vehicle WSS M2C924 A For additional information refer to Jacking 100 02 Jacking and Lifting Description and Operation ILifting 100 02 Jacking and Li...

Page 1014: ...information refer to Specifications 307 01 Automatic Transmission Transaxle Vehicles With 4Speed Automatic Transmission AW81 40 Specifications 7 Check the transmissionfluid level For additional infor...

Page 1015: ...2 Jacking and Lifting Description and Operation Removethe manual shift lever automatic I Lifting 100 02 Jacking and Lifting transaxle shown removedfor clarity Description and Operation 3 Disconnect th...

Page 1016: ...g retaining bolts can be reused three times washer pointer to the N NEUTRAL Check the retaining bolts and install new position scribed on the TR sensor body bolts if necessary N0TE Do nottightenthe TR...

Page 1017: ...nt rotational torque being by moving the transmission selector lever transmitted to the TR sensor and shift through all gear ranges mechanism Installthe manual shift lever automatic transaxle shown re...

Page 1018: ...reactions after contact Installation Foradditional information referto Health and Safety Precautions 100 00 General Information Descriptionand Operation See Transmission Fluids Using the special tool...

Page 1019: ...utions 100 00 General Information Description and Operation See Transmission Fluids Remover Halfshaft Seal 308 208 16 074 1 Removethe right hand halfshaft 2 Installthe right hand halfshaft For additio...

Page 1020: ...sor Removal 1 Disconnect the turbine shaft speed TSS sensor electrical connector 2 Remove the TSS sensor Installation 1 N0TE lnspect the O ring seal for damage Install a new O ring seal if necessary N...

Page 1021: ...l N0TE Apply a light coat of petroleumjelly to the 1 Disconnectthe vehicle speed sensor VSS O ring seal before installation electrical connector 2 Removethe VSS heat shield 3 Remove the VSS Installati...

Page 1022: ...hich may cause skin irritation or other skin reactions after contact For additional information refer to Health and Safety Precautions 100 00 General Information Description and Operation See Transmis...

Page 1023: ...round cablefrom the transaxle mount nuts by three turns on both sides 8 Disconnect the turbine shaft speed TSS 5 Detachthe engine ground cable from the sensor electrical connector transaxle 9 Disconne...

Page 1024: ...isconnect the transmission range TR 15 Detachthe selector lever cable retaining sensor electrical connector bracket from the transaxle and position it to one side 12 Disconnectthevehicle speedsensor V...

Page 1025: ...21 Detach the exhaust flexible pipe from the 18 Removethe accessory drive belt cover catalytic converter Discardthe nuts and the gasket 19 Removethe engine support insulator 22m A U T I O N L thetie...

Page 1026: ...not be bent more than 18degrees The outerjoint must not be bent morethan 45 degrees A D O not damage the halfshaft seal N0TE Plug the transaxle to preventoil loss or dirt ingress For additional inform...

Page 1027: ...ilure to follow this instruction may result in personal injury 31 Removethe engine and transaxle rear A CAUTI0N Plug the transmission fluid mount cooler feed and return linesto preventfluid loss or di...

Page 1028: ...ngine and transaxle rear mount retaining bracket 37 Removethe transaxle lower retaining bolts 34 Raise and support the vehicle 38 N0TE Secure the transaxlewith a securing strap to the transmission jac...

Page 1029: ...I O N T torque converter must Usingthe transmission jack and remove the remain at the correct installation depth transaxle during the entire installation N0TE Secure the transmissionwith the securing...

Page 1030: ...olts I 4 Install the transaxle right hand retaining 10 Install the starter motor bolts 11 Lower the vehicle 5 Removethe wooden block 12 Installthe engine andtransaxle rear mount 6 Removethe securing s...

Page 1031: ...0TE lnstall newengine rear mount retainingnuts For additional information refer to Lifting Install the engine rear mount retaining nuts 15 Remove the special tools 100 02 Jacking and Lifting Descripti...

Page 1032: ...s N0TE Use a 5 mm Allen key to preventthe ball A D O not damage the halfshaft seal joint stud from rotating A a k e sure the snap ring is correctly Attach the right handtie rodendtothe wheel seated kn...

Page 1033: ...cket to the transaxle 27 Connectthe ignitionswitch to starter motor 30 Attach the selector lever cable to the solenoid and battery to starter motor solenoid cables manual shift lever 31 Adjust the sel...

Page 1034: ...saxle breather hose 33 Connectthe vehicle speed sensor VSS electrical connector 34 Connectthe transmission range TR sensor electrical connector 35 Connect the transaxlewiring harness electrical connec...

Page 1035: ...ining nut 40 Attach the engine ground cable to the 43 Installthe battery tray support bracket transaxle 44 Tighten the strut and spring assembly top 41 Tighten the engine rear mount outer mount retain...

Page 1036: ...Removaland Installation 48 Installthe air cleaner For additional information refer to Air Cleaner 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll GL Duratec 16V Sigma 303 12 IntakeAir Distribution...

Page 1037: ...oling Vehicles With 4 Speed Automatic Transmission AW81 40 VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 307 02 2 DESCRIPTION AND OPERATION Transaxle Cooling 307 02 3 C...

Page 1038: ...nd Operation See Transmission Fluids A WARN1NG Refer to the Material Safety Data Sheets for the Automatic Transmission Fluid E AW Failure to follow this instruction may result in personal injury Certa...

Page 1039: ...uid cooler is positioned in front item Description of the radiator I 1 IQuick releasecoupling The quick release couplings are colour codedto The bumper needs to be disassembled in order to prevent the...

Page 1040: ...ingress For additional information refer to Health and Safety Precautions 100 00 General Information Description and Operation See Transmission Fluids Information andOperation NOTE Mark the position o...

Page 1041: ...oler lines are installed in the correct positions To install reverse the removal procedure 2 Check the transmission fluid level and top up with clean automatic transmission fluid if necessary For addi...

Page 1042: ...f the feed and return lines to aid installation Detach the transmission fluid cooler lines from the transmission I Pushthe transmissionfluid cooler line quick release connectortoward the transmission...

Page 1043: ...cooler lines are installed in the correct positions To install reverse the removal procedure 2 Check the transmission fluid level and top up with clean automatic transmission fluid if necessary For ad...

Page 1044: ......

Page 1045: ...HICLE APPLICATION 2006 0 Fiesta CONTENTS SPECIFICATIONS Specifications DESCRIPTIONAND OPERATION External Controls Selector lever cable GENERAL PROCEDURES Selector Lever Cable Adjustment PAGE REMOVALAN...

Page 1046: ...les With 4Speed Automatic Transmission AW81 40 SPECIFICATIONS Lubricants Fluids Sealers and Adhesives I ltem 1 Specification 1Grease I S MlC1021 A Torque Specifications Selector lever assembly 9 80 De...

Page 1047: ...Automatic Transmission Transaxle External Controls VehiclesWith 4 SpeedAutomatic Transmission AW81 40 DESCRIPTIONAND OPERATION External Controls Selector lever cable 2006 0 Fiesta1212006 G357360en...

Page 1048: ...lector levercable isclippedonto a ball head on the selector lever At the transmission end it is clipped onto the ball head on the selector shaft lever The cable is moved in an axial direction by opera...

Page 1049: ...ng and Lifting Description mechanism locking clip fully and Operation 3 Releasethe selector lever cable adjustment 1 mechanism locking clip 6 Lower the vehicle 7 Start the engine and movethe selector...

Page 1050: ...switch electricalconnector selectorleverassembly shown removedfor clarity 3 Removethe brake shift interlockactuator 1 Removethe bolt 2 Removethe knob 3 Removethe brakeshift interlock actuator Installa...

Page 1051: ...ehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 Removethe exhaust front hanger insulator 4 Detachthe exhaust heatshieldfrom the floor panel 5...

Page 1052: ...r lever cable locking pin and detachthe selector lever cableoutersleeve 4 Attach the selector levercableto the selector lever 11 Removethe selector lever cable grommet 12 Removethe selector lever cabl...

Page 1053: ...9 Clip the selector lever cable into the right hand side of the bracket 13 Attach the selector cable to the retaining clip 10 Attach the exhaust heat shield to the floor panel 14 Adjust the selector l...

Page 1054: ...n selector lever 1 Shift the selector lever to the P PARK position 2 Detachthe selector lever cable 3 Pullthe selector lever cable locking pin and detachthe selector lever cable outersleeve 3 Disconne...

Page 1055: ...VALAND INSTALLATION 1 Shift the selector lever to the P PARK position 2 Attach the selector lever cable outer sleeve 3 Attach the selector lever cable 4 Install the floor console 5 Adjust the selector...

Page 1056: ...to TransmissionSelector Lever Knob inthis section 2 Removethe selector lever bezel selector lever assembly shown removedfor clarity Unclipthe bezel Unclipthe lamp Installation 1 Installthe selector l...

Page 1057: ...console 2 Disconnectthe overdrive OID switch electricalconnector selectorleverassembly shown removed for clarity 3 Remove the selector lever knob Remove the bolt i Installation 1 Install the selector...

Page 1058: ...Disassembly N0TE Use vice jaw protectorsfor all work to be done in the vice 1 Disconnectthe overdrive OID switch electrical connector Assembly 1 To assemble reversethe disassembly procedure Coatall sl...

Page 1059: ...NTS PAGE SPECIFICATIONS Specifications 308 00 2 Clutch Dimensions 308 00 2 DIAGNOSISAND TESTING Manual Transaxle and Clutch 308 00 3 Inspectionand Verification 308 00 3 Gear shifting concerns 308 00 3...

Page 1060: ...res 1 fluid 10 15 mm belowthe loweredge of the fluid filler plug 2 3 Description Pedaltravel Worn clutch disc discard thickness Clutch disc diameter 1 25Ll1 4L Duratec 16V Sigma Clutch disc diameter 1...

Page 1061: ...saxle concerns can be considered in three main areas 2 Clean the transaxle and the adjacent areas carefully and road test the vehicle engine speed check if the noise also occurs in 3 Ifan obviouscause...

Page 1062: ...nformation General Procedures GO to Pinpoint Test C INSTALLa newclutchdisc and pressure plate REFER to Clutch Disc and Pressure Plate 308 01 Clutch Removaland Installa tion CHECK the crankshaft end pl...

Page 1063: ...Engine or transaxle is in contact with the chassis or body REFER to PowertrainIDriv etrain Mount Neutralizing 100 04 Noise Vibration and Harshness General Proced ures Engine and transaxle out of alig...

Page 1064: ...amage SEAL the transaxle with sealant REFERto Transaxle 308 03 ManualTransmis sion rransaxle Assembly PINPOINT TEST A CLUTCH SLIPPAGE TEST CONDITIONS DETAILSIRESULTSIACTIONS Al TEST CLUTCH SLIPPAGE Lo...

Page 1065: ...hydraulicfluid Yes CHECK the engine and transaxle for leaks INSTALL new components as necessary TEST the system for normal operation No INSTALL a new clutch disc and pressure plate REFER to Clutch Di...

Page 1066: ...hydraulicfluid Yes CHECK the engine and transaxle for leaks INSTALL new components as necessary TEST the system for normal operation No GO to B3 B3 CHECK THE CLUTCH DlSC AND PRESSURE PLATE rnVisually...

Page 1067: ...d pressure plate REFERto ClutchDiscand PressurePlate 308 01 Clutch Removaland Installation Isthe clutchdisc and pressureplatecontamin ated with oil or hydraulicfluid Yes CHECK the engine and transaxle...

Page 1068: ...al Procedures PINPOINT TEST D EXCESSIVE NOISE TEST CONDITIONS IDl STATIC CHECK I Depress and releasethe clutch pedal Isthe noise apparentwhen the clutch is oper ated Yes LUBRICATEthe clutch and brake...

Page 1069: ...arshift cables cover Vehicles built up to 0812003 4 Releasethe selector cable adjuster locking insert gearshift cable box shown removed for clarity Press down the orange colored clip Vehicles built 08...

Page 1070: ...is available this can be used to bleed the clutch system followingthe methodbelow The maximum pressure must not exceed 1 5 bar N0TE The clutch control system is self venting The components are arrange...

Page 1071: ...ch pedal wait two seconds then carefully engage reverse gear If there are any abnormal noises or reversegear is difficultto engage repeatthe clutchsystem bleedingprocedure 18 Initialize the door windo...

Page 1072: ......

Page 1073: ...LICATION 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 308 01 2 DESCRIPTIONAND OPERATION Clutch 308 01 3 Self adjusting clutch 308 01 3 DIAGNOSISAND TESTING Clutch 308 01 6 REMOVALAND INST...

Page 1074: ...308 01 2 Clutch 308 01 2 SPECIFICATIONS Torque Specifications I Item Clutch pressure plate retaining bolts 2006 0 Fiesta1212006 GI13195en Nm 29 Ib ft 21 Ib in...

Page 1075: ...he self adjusting clutch has the following advantagesover conventionallydesignedclutches lower releaseforces which remain constant overthe service lifeand thus ensure highdriving comfort throughout th...

Page 1076: ...the inner tongues forms the bearingfor the main Belleville washer Thesensing Bellevillewasher isdesignedto deliver a slightly greater opposingforce under normal conditions than the maximum required re...

Page 1077: ...ingring ramp ring arrangedaroundthe circumference immediately compensates for the air gap To do this springs pressthe adjusting ring and therefore the ramp against the main Belleville washer This resu...

Page 1078: ...308 01 6 Clutch 308 01 6 DIAGNOSISAND TESTING Clutch REFERto ManualTransaxle and Clutch 308 00 Diagnosisand Testing 2006 0 Fiesta1212006 GI 8068en...

Page 1079: ...6V Sigma ll 6L Duratec 16VTi VCT sigma m val 9 2 nCAUTION Tighten the clutch pressure Transaxle 1 8L Duratec HE M14 Removal plate retaining bolts finger tight and then 2m AUTION LOOS the clutch pressu...

Page 1080: ...Removethe special tool 4 Install the transaxle For additional information refer to 308 03A Manual Transmission Transaxle Vehicles With 5 Speed ManualTransaxle iB5 Transaxle 1 6L Duratec 16V Sigma ll...

Page 1081: ...ta CONTENTS PAGE SPECIFICATIONS Specifications 308 02 2 DESCRIPTIONAND OPERATION Clutch Controls 308 02 3 Overview 308 02 3 Function 308 02 4 DIAGNOSISAND TESTING Clutch Controls 308 02 5 REMOVAL AND...

Page 1082: ...hesives Specificat I ions 1 High temperaturegrease I Clutch slave cylinder retaining bolts I 10 I I 89 I Torque Specifications 1 Clutch master cylinder retaining bolts I 8 I I 71 I Item I Pedal pivot...

Page 1083: ...PERATION Clutch Controls Overview Description Item Description 2006 0 Fiesta1212006 G281360en 5 6 4 Pressure line Slave cylinder with choke assembly The hydraulic clutch is supplied from a separate Ma...

Page 1084: ...ndthe flywheel iscreated again A spring inthe slave cylinder ensures preload on the release bearing The release bearing is always touching the pressure plate becauseof this preload The extra travelcau...

Page 1085: ...308 02 5 Clutch Controls 308 02 5 DIAGNOSIS AND TESTING Clutch Controls REFERto ManualTransaxle and Clutch 308 00 Diagnosis and Testing 2006 0 Fiesta1212006 GI8080en...

Page 1086: ...Ci DV Diesel Removal 2 Clean any grease and foreign material from the input shaft 3 CAUTIONS Alf brakefluid isspilt onthe paintwork the affected area must be immediately washed down with cold water A...

Page 1087: ...Remove the air cleaner For additional hose from the brake fluid reservoir information refer to 303 12 Intake Air Distribution and Filtering Push the clip to releasethe clutch master cylinder supply ho...

Page 1088: ...ster cylinder 1 Removethe clutch pedal returnspring 2 Detachthe clutch master cylinder actuating rod from the clutch pedal Installation 9 N0TE Remove the clutch master cylinder and the clutch pedal as...

Page 1089: ...inder and the hose to the clutch master cylinder clutch pedal assembly Installthe clutchmastercylindersupply hose I Rotatethe clutch master cylinder and the retaining clip I I retainingclip I I clutch...

Page 1090: ...tion Battery Tray 2 OL Duratec HE M14 414 01 Battery Mounting and Cables Removal and Installation 9 Connect the two vacuum hoses Attach the vacuum hosesto the battery clamp clip Right hand drive vehic...

Page 1091: ......

Page 1092: ...Manual Transmission Transaxle INSTALLATION Transaxle 1 25L Duratec 16V Sigma l 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 16 114 0 308 03 62 Transaxle 2 OL Duratec HE M14 16 114 0 308 03 69...

Page 1093: ...1 4L DieselI1 6L Diesel First gear Second gear Third gear Fourthgear Fifth gear Reverse gear Final drive Reauiredshim thickness I Description I mm I I r i n g shim I 3 8 I IShim availability in incre...

Page 1094: ...e retaining nuts Wiring harness retaining bracket retaining nut Powersteeringhigh pressureline retainingbracket retaining bolt Lower arm balljoint to the wheel knuckle retaining nut Engine rear mount...

Page 1095: ...Transaxle i General The iB5 manualtransmission is a two shaft 1st and 2nd gears are double synchronised transmission There is no need to change the oil All gear wheels are helical toothed synchronise...

Page 1096: ...ction 2006 0 Fiesta1212006 G281365en Item Description Item Description I 2 3 4 6 7 8 9 5th gear housing Transmission side housing halves Breather Hydraulicclutch connection Slave cylinder with integra...

Page 1097: ...ATION lnput shaft Item Description Item Description 1 2006 0 Fiesta1212006 G281365en 1 2 3 4 5 6 7 8 9 10 11 Ball bearing lnput shaft Reverse gear idler I st gear wheel Reverse gear wheel 2nd gear whe...

Page 1098: ...r wheel I 1 4 11stgear double synchronisation I 1 5 1 Synchroniser I stl2nd gear with reverse gear wheel 1 6 12ndgear double synchronisation I Item Description 1 7 12ndgearwheel I 1 8 13rdgear wheel I...

Page 1099: ...onised 1 5 1Synchroniserhub I 3 4 2006 0 Fiesta1212006 G281365en The effective synchronisation surface for double synchronisation is almost twice that of simple svnchronisation Because of this the wee...

Page 1100: ...differential pinion gears mounted on a spindle and the axle halfshaft pinion gears which connect to the front wheel axle halfshaftsthrough helical gearing The axle halfshaftpiniongears can revolvearo...

Page 1101: ...gear selector shaft I 1 7 1Selector interlock I 5 6 Itern Descri tion Snap ring Shift rod 5th gearlreverse gear 1 8 1Selector shaft I 1 9 1Guide sleeve I The shift locking bush preventstwo gears from...

Page 1102: ...g bush prevents transferredatthe transmissionto the selectorshaft access to other gear combinations which can turn in its bearing Shift locking bush 4 2006 0 Fiesta1212006 G281365en the selector shaft...

Page 1103: ...ector boss both move vertically together As this happens the selector shaft is guided by a After the gear pairto be shifted has beenselected pin in the selector gate the shift movementtakes place The...

Page 1104: ...ctor cable is transferred to is moved backwards The selector boss engages inthe 5th gearlreversegear shift rod which inturn 5 6 the selector shaft which can turn in its bearing 2006 0 Fiestala2006 G28...

Page 1105: ...308 03 15 ManualTransmissionlTransaxle 308 03 15 DESCRIPTIONAND OPERATION Power transmission in the individualgears 2006 0 Fiesta1212006 G281365en...

Page 1106: ...308 03 16 Manual Transmission Transaxle 308 03 16 DESCRIPTIONAND OPERATION r 2006 0 Fiesta1212006 G281365en...

Page 1107: ...smission Transaxle 308 03 17 DIAGNOSISAND TESTING Manual Transaxle REFERto Manual Transaxle and Clutch 308 00 ManualTransmission Transaxleand Clutch General Information Diagnosisand Testing 2006 0 Fie...

Page 1108: ...nor overheating possiblythrough excessive pre load lnstall a new bearing and new seals if necessary Check the bearing is correctly lubricated 3 Check whether the ends of the taper rollers are worn awa...

Page 1109: ...blue colour caused by overheating yellowor brownis normal due to excessive pre load or inadequate lubrication Installa new bearing new seals and check other components as necessary 7 Checkthe surface...

Page 1110: ...l isjust below the bottom of the filler hole Installer Drive Pinion Seal 205 115 I5 058 Remover HalfshaftSeal 308 208 16 074 2 Install the left hand halfshaft For additional information refer to Front...

Page 1111: ...l 16018 2 Installthe right hand halfshaft 2 Using the special tool remove the halfshaft seal Remover Drive Pinion Seal 205 078 I 5 048 Installer HalfshaflSeal 308 039 16 018 Discardthe seal Name Speci...

Page 1112: ...hevehicle Foradditional information refer to 100 02 Jacking Descriptionand Operation Lifting Descriptionand Operation 2 Disconnectthe vehicle speed sensor VSS electrical connector 3 Removethe VSS I Re...

Page 1113: ...56 16 089 1Transmissionjack I Removal All vehicles 1 Remove the air cleaner For additional information refer to Air Cleaner 1 25L Duratec 16V Sigma ll 4L Duratec 16V Sigma ll 6L Duratec 16V Sigma 303...

Page 1114: ...bracket Vehicles with automated gearshift from the transaxle 10 Removethe gearshift actuator cover 7 Removethe front wheels and tires 1 1 Disconnectthe gearshift actuator electrical For additional inf...

Page 1115: ...s spilt on the paintwork the affected area must be All vehicles immediately washeddown with coldwater 16 Removethe accessory drive belt cover Disconnectthe clutch slave cylinder supply line Removethe...

Page 1116: ...alfshaft oil seal N0TE Plug the transaxle to preventoil loss or dirt N0TE PIug the transaxle to prevent oil loss or dirt ingress ingress Using the special tool detach the left hand Detachthe halfshaft...

Page 1117: ...the affected area must be immediatelywashed downwith coldwater Disconnect the clutch slave cylinder supply line Removethe spring clip 25 Disconnectthevehicle speedsensor VSS electrical connector if e...

Page 1118: ...sembly 30 Removethe engine and transaxle rear 33 Removethe transaxle right handretaining mount retaining bracket bolts 31 Removethe transaxle lowerretainingbolts 34 Removethe transaxle left hand retai...

Page 1119: ...308 03 29 Manual Transmission Transaxle 308 03 29 REMOVAL 35 Usinga suitabletransmissionjack remove the transaxle 2006 0 Fiesta1212006 GI I3290en...

Page 1120: ...IRetainingstrap I Adapter for 303 290A 303 290 06 21 140 06 ITransmissionjack I Removal 1 Removethe air cleaner For additional information refer to Air Cleaner 2 OL Duratec HE M14 303 12 Intake Air D...

Page 1121: ...t the reversing lamp switch electrical connector 7 Remove the front wheels and tires 11 Removethe gearshift cables cover For additional information refer to Wheel andTire 204 04Wheels andTires Removal...

Page 1122: ...emovethe left hand halfshaft For additional information refer to Front Halfshaft LH 205 04 Front Drive Halfshafts Removal and Installation 16 Removethe right hand halfshaft For additional information...

Page 1123: ...saxle rear mount retaining bracket 22 Remove the engine and transaxle rear mount Discardthe nuts 25 Raise and support the vehicle For additional information refer to 100 02 Jacking and Lifting Jacking...

Page 1124: ...4 REMOVAL Usinga suitable transmissionjack support the transaxle 30 Usinga suitabletransmissionjack remove the transaxle 28 Removethe transaxle right handretaining bolts 29 Removethe transaxle left ha...

Page 1125: ...35 21 187 Mounting Bracket EngineIDifferential 205 329 15 105A Special Tool s I IInstaller Extension Housing I I IRemover Input Shaft Fifth I General Equipment IBlanking plugs 1Drift I CAUTIONS Use vi...

Page 1126: ...snap ring J 4 Removethe vehicle speed sensor VSS if 7m Remove the gearshift cable equipped 1 Remove the retaining pin 2 Pull out the VSS 5 Removethe selector mechanism cover 6 Remove the gearshift le...

Page 1127: ...ning bolts of the fifth gear synchroniserassembly 11 Usingthe specialtool removethe fifth gear housing cover 12 Removethe fifth gear synchroniser assembly the selector fork and the fifth gear I Remove...

Page 1128: ...ts 17 Removethe fifth gear housinggasket the snap rings and the blankingplug 1 Remove and discard the gasket 2 Removethe output shaft snap ring 3 Removethe input shaft snap ring Only removethe reversi...

Page 1129: ...fferential assembly and the 1 Removeand discardthe selector shaft guide permanent magnet sleeve lower snap ring 2 Remove the selector shaft guide sleeve 22 N0TE lnstall a rubber band to the second sel...

Page 1130: ...e special tool in the Removethe rollers and the roller cage from transaxle housing grooves the output shaft roller bearing 1 Usingthe special tool removethe differential I 28m AUTION O I use the speci...

Page 1131: ...third and fourth gear 1 Remove and discard the small snap ring 2 Installthe output shaft snap ring 3 Using a suitable two leg puller removethe ball bearing Discard the output shaft snap ring and the b...

Page 1132: ...irst gear as an assembly Removethe first and reversegear the gear synchronizer and synchronizer assembly 1 Removeand discard the snap ring 2 Removethe first and second gear synchronizerclutch and the...

Page 1133: ...at them with clean transmission oil before assembly 3 N0TE lnstall a newoutput shaft bearing cone snap ring N0TE lnstall a new output shaft bearingcone Install the output shaft bearing cone Evenly hea...

Page 1134: ...output shaft lnstallthe second gear synchronizer assembly 1 Outer synchronizer ring 2 Synchronizercone 3 Inner synchronizer ring 4 Second gear 5 Snap rings 7 Third gear synchronizerassembly 1 Third g...

Page 1135: ...he third gear 2 lnstallthe snap ring 9 N0TE lnstall a new snap ring N0TE lnstall a new ball bearing N0TE lnstall the ball bearing with the annular groove facing outwards Using the special tool and a s...

Page 1136: ...Disassembly 1 Using a suitable two leg puller remove the ball bearing 1 Installthe input shaft snap ring 2 Removethe ball bearing Discardthe input shaft snap ring and the ball bearing I Coat all comp...

Page 1137: ...308 0347 Manual Transmission Transaxle 308 03 47 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Usingthe special tool and a suitable press install the ball bearing 2006 0 Fiesta12 2006 G21537en...

Page 1138: ...ntialtaper roller bearings I Installthe special tool 2 Removethe differentialtaper roller bearings 1 Rotatethe differential pinionsapproximately 90 degrees in the differential case and remove them 2 R...

Page 1139: ...e ring gear to the differential case 1 I Discardthe ring gear bolts 2 lnstallthe two differential pinions plastic thrust elements and using a suitable drift install the pin and snap ring 3 lnstallthe...

Page 1140: ...thand reversegear selector shaft guide 1 6 1Reversegear selector lever return sleeve sleeve 1 7 1Reversegear selector lever I Disassembly 1 Remove the selector mechanism 8 9 1 Fifth and reverse gear s...

Page 1141: ...308 03 51 ManualTransmission Transaxle 308 03 51 DISASSEMBLYAND ASSEMBLY OF SUBASSEMBLIES 4 Selector plate 2006 0 Fiesta1212006 Gl8lllen...

Page 1142: ...I IInstaller Extension Housing I 1press I 16031 IDial indicator gauge I Installer lnput Shaft Snap Ring 308 076 16 031 IMagnetic stand for dial indicator gauge Seneral Equipment IBlanking plugs I IM8...

Page 1143: ...l the oil funnel 2 lnstall the output shaft roller bearing 3 Usingthe special tool installthe differential bearing cup 4 lnstall the fifth and reversegear selector shaft and the shift lock 1 lnstall t...

Page 1144: ...lthe snap rina Insertthe inputshaft to a depth of I approximately50 mm and move it slightly to one side Insertthe output shaft to the levelofthe input shaft and engagethe gear wheels lnstallthe input...

Page 1145: ...nthe dial indicatorgauge by a minimum of 1 mm tool 16 N0TE Carry out the measuring procedure Installthe blanking plugs threetimesandcalculatethe averagevalue Installthe bolts Turn the transaxle 180deg...

Page 1146: ...le Adjustingshim 3 80 mm 0 73 mm 0 14 mm 4 42 mm 0 25 mm Thethicknessofthe adjustingshim becomes 0 2 mm rounded down from 0 25 mm 18 Separate the transaxle housing lnstallthe blanking plugs Turn the t...

Page 1147: ...lts instructionmay cause damage to the fifth 23 N0TE lnstall new input and output shaft snap rings gear housing Turn the snap rings to the position shown Raise the and shafts lightly 27 NOTE lnstall n...

Page 1148: ...aft interlock mechanism Apply sealant to the thread 30 Mountthe transaxle onthe mountingstand 31 N0TE lnstall a new fifth gear snap ring Install the fifth gear snap ring 1 Installthe snap ring onto th...

Page 1149: ...etaining pin lnstallthe snap ring 36 Apply sealer evenly to the inside edge of the fifth gear housing mating face 37 lnstall the fifth gear housing cover 38 lnstall the selector lever lnstallthe bello...

Page 1150: ...the input shaft oil seal 1 lnstall the snap ring 2 lnstall the protective cap if equipped Position the input shaft oil seal TIE 43 lnstall the selector mechanism cover 46m CAUTION DOnot apply grease...

Page 1151: ......

Page 1152: ...2114002 I I I General Equipment Retainingstrap ITransmissionjack I Materials Name Specification Installation Manualtransmission 1fluid All vehicles I CAUTIONS WSD M2C200 C se suitable retaining straps...

Page 1153: ...7 Installthe engine and transaxle rear mount retaining bracket 12 N0TE lnstall new exhaust flange nuts and a new exhaust flange gasket Attach the exhaust flexible pipe to the 8 Lower the vehicle catal...

Page 1154: ...ediate shaft to the transaxle 14 ACAUTION brake fluid is spilt on the paintwork the affected area must be immediatelywashed down with coldwater N0TE Make surethe springclip iscorrectlyseated Connect t...

Page 1155: ...aft to the transaxle 20mACAUTION M surethatthe heatshield is installedto prevent damage to the ball joint N0TE The lower arm pinch bolt must be installed from the rear of the wheel knuckle 22 Installt...

Page 1156: ...es with automated gearshift 25 Connect the gearshift actuator electrical connector colored grey 26 Connect the gearshift actuator electrical connector colored black 28 Connect the clutch slave cylinde...

Page 1157: ...he starter motor retaining nuts 31 Lower the vehicle 35 Tighten the engine rear mount center 32 Tighten the strut spring assembly top retaining nut mount nuts on both sides 36 Install the batterytray...

Page 1158: ...hicles 41 Install the battery tray For additional information refer to Section 414 01 Battery Mounting and Cables 42 With the vehicle on a level surface fill the transaxle untilthe oil level isjust be...

Page 1159: ...290A 303 290 05A 21 140 05A Adapter for 303 290A 303 290 06 21 140 06 ITransmissionjack I Materials Name Specification Installation 1 CAUTIONS A s e suitable retainingstraps to secure the transaxle on...

Page 1160: ...10 N0TE Do nottighten the engine rear mount retaining nuts at this stage N0TE lnstall newenginerearmount retainingnuts Install the engine rear mount 5 Removethe retaining strap 6 Removethe transmissi...

Page 1161: ...ft RH 205 04 Front Drive N0TE Make sure the springclip iscorrectlyseated Halfshafts Removal and Installation Connect the clutch slave cylinder supply 17 lnstall the left hand halfshaft line For additi...

Page 1162: ...and turn the abutment sleeves electrical connector counterclockwise I I 24 Install the starter motor 21 Attach the gearshift cables to the selector levers 22 Install the gearshift cables cover 25 Ins...

Page 1163: ...axle retaining nuts I 28 Installthe transaxle upper retaining bolts 31 Tighten the engine rear mount center retaining nut 29 Install the engine wiring harness bracket 32 Install the battery tray suppo...

Page 1164: ...h system For additional information refer to Clutch System Bleeding 308 00 Manual Transmission Transaxle and Clutch GeneralInformation GeneralProcedures 36 Installthe battery tray Foradditional inform...

Page 1165: ...ON 2006 0 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications 308 06 2 DESCRIPTIONAND OPERATION External Controls 308 06 3 DIAGNOSISAND TESTING External Controls 308 06 5 Inspection and Verification 30...

Page 1166: ...ontrols SPECIFICATIONS Torque Specifications IGearshift mechanismto floor assembly I 9 I I 80 I Description Shift and selector cable bushing 2006 0 Fiesta1212006 GI 8149en Nm 9 Exhaustflange bolts Gea...

Page 1167: ...Manual Transmission Transaxle External Controls DESCRIPTIONAND OPERATION External Controls 2006 0 Fiesta1212006 GI 63328en...

Page 1168: ...ed with the gear lever Inthe internalgearshift mechanism this axial movement translates into the selection of the shift slot The shift cable is also moved in an axial direction when a gear is selected...

Page 1169: ...ction Gearshift cables incorrectly adjusted Gearshift lever damaged Selectormechanismdamaged Gearshift cables damaged ADJUST the gearshift cables REFERto Gearshift Cable Adjustment Vehicles With 5 Spe...

Page 1170: ...s from the transaxle Is the gearshift lever difficult to operate Yes Install new gearshift cables REFERto Gearshift Cables 308 06 Manual Transmission TransaxleExternalControls Removaland Installation...

Page 1171: ...gearshift lever 4 Removethe gearshift lever front retaining bolts 5 Removethe gearshift lever Removethe bolts Installation 1 To install reverse the removal procedure 3 Detach the gearshift cables from...

Page 1172: ...Distribution and Filtering 3 Raiseandsupport the vehicle Foradditional information referto Section 100 02 Jacking and Lifting 4 Removethe exhaust front hanger insulator 5 Detachthe exhaustheatshieldf...

Page 1173: ...to the vehicle interior 10 Lower the vehicle 11 Remove the air distribution channel 12 Cut the floor covering and the sound deadening material to gain access to the gearshift cable bushing Installatio...

Page 1174: ...t and turn the abutment sleeves counterclockwise 6 Attach the exhaust heat shield to the floor panel Slide the heat shield forwards 8 Attach the gearshift cables to the retaining clip 9 Attach the sel...

Page 1175: ...rnal 308 06 11 Controls 308 06 11 REMOVALAND INSTALLATION 12 Adjust the gearshift cables For additional information refer to Section 308 00 i ManualTransmission Transaxleand Clutch General Information...

Page 1176: ......

Page 1177: ...ENTS PAGE SPECIFICATIONS Specifications 309 00 2 DESCRIPTIONAND OPERATION Exhaust System 309 00 4 Exhaust system 1 31 1 41and 1 61petrol engines and 1 41diesel engines 309 00 4 REMOVAL AND INSTALLATIO...

Page 1178: ...ews Vehicles with I 4L diesel engine Turbocharger heat shield lower retaining bolts Vehicles with I 4L diesel engine Catalytic converter heat shield retainingscrews Vehicles with I 6L diesel engine Ex...

Page 1179: ...Description Exhaustflexible pipeto front mufflerpipe heatshield retaining bolts Vehicles with 1 6L engine Exhaustflexible pipeclamp retainingnut Vehicles with diesel engine Rear muffler clamp retaini...

Page 1180: ...TIONAND OPERATION Exhaust System Exhaustsystem 1 31 1 41and 1 61 petrolengines and 1 41diesel engines Description Item Description 2 Servicingclamp 3 Front muffler I D 11 41DuraTorqTDCi I I 1 IFlexibl...

Page 1181: ...ERATION All exhaust systems are single part systems The final mufflercan be renewedseparately inservice 1 In this case the pipe needsto be cut through and the new final muffler needsto be secured with...

Page 1182: ...tional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation CAUTION bending of the exhaust flexible pipe may cause damage resulting in 3...

Page 1183: ...terto muffler andtailpipe N0TE Discard the catalytic converterto exhaust assembly retaining clamp flexible pipe gasket N0TE Discard the catalytic converter to muffler and tailpipe assembly clamp retai...

Page 1184: ...andsupportthe vehicle Foradditional information referto I 00 02 Jacking and Name Specification I 1 Liftinn Lifting Descriptionand Operation Grease ISA M1C9107 A 2 Removethe components in the order ind...

Page 1185: ...haust Im A u l N T w i s t i n the exhaust flexible flexible pipe may cause damage resulting in pipemorethan2 degreesmaycause damage failure resulting in failure Support the exhaust flexible pipe with...

Page 1186: ...lexible pipeto catalytic converter retaining nuts Item3 Exhaustflexiblepipeto exhaustmanifold retaining nuts Im CAUTION bending of the exhaust flexible pipe may cause damage resultingin failure Remove...

Page 1187: ...G Fuel System 1 3L Duratec 8V Rocam ll 25L Duratec I6V Sigma 2 0L Duratec HE M14 1 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 310 00 2 Inspection and Verification 310 00 2 GENERAL PROCEDURES Fuel Sys...

Page 1188: ...ical or electrical damage Fuel level Fuel leak s Fuel line s Fuel filter if equipped Fuel tank Fuel tank filler pipe Fuel filler cap Visual lnspectionChart Electrical connector s Wiring harness Inerti...

Page 1189: ...structions may result in personal injury A h e fuel system remains pressurized for a longtime after the ignition is switched off The fuel pressure must be released before attempting any repairs Failur...

Page 1190: ...ow these instructions may result in personal injury A The fuel system remains pressurizedfor a longtime after the ignition is switched off The fuel pressure must be relieved before attempting any repa...

Page 1191: ...ick release coupling CAUTI0N Fuel injection equipment is locking tang manufactured to very precise tolerances 2 Push the clip through the fuel line quick andfine clearances Itisthereforeessential rele...

Page 1192: ...8 Releasethe fuel linequick releasecoupling 4 b VUE0014718 Press the fuel line quick release coupling Pressthe fuel line quick release coupling locking release collar buttons and pull the fuel line t...

Page 1193: ...pe when working on or near any fuel relatedcomponents Highlyflammable vapors are always present and can ignite Failureto follow these instructions may result in personal injury A This procedure involv...

Page 1194: ...oupling Insert the fuel line quick release coupling secondary locking tang into the fuel line AUTION M sure the fuel line clicks into place when installing the line To make quick release coupling sure...

Page 1195: ...ease coupling before the locking tang is locked lnstall the fuel line quick release coupling 1 lnstallthe fuel line quick release coupling lockingtang 2 Rotate the fuel line quick release coupling loc...

Page 1196: ...ons may result in personal injury This procedure involves fuel handling Be preparedfor fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may...

Page 1197: ...pressure 9 Releasethe fuel system pressure For additional information refer to Fuel System Pressure Release 310 00 Fuel System General Information General Procedures 10 Disconnect the WDS pressurelvac...

Page 1198: ...ation 310 00 12 GENERAL PROCEDURES 15 Installthe air cleaner assembly For additional information refer to Air Cleaner 2 OL Duratec HE M14 303 12 IntakeAir Distributionand Filtering Removal and Install...

Page 1199: ...AND OPERATION Fuel Tank and Lines 1 25L Duratec I6V Sigma l 4L Duratec 16V Sigma l 6L Duratec I6V Sigma 310 01 3 Overview 310 01 3 DIAGNOSISAND TESTING Fuel Tank and Lines REMOVALAND INSTALLATION Fuel...

Page 1200: ...in I Fueltank support strap retaining bolts I 25 I 18 I Fueltank filler pipe retaining bolts I 9 I I 80 I Fuel pump module lockingring All except vehicles with diesel engine Fuellevelsensor lockingrin...

Page 1201: ...ly so that no more fuel can be supplied Non returnvalve Evaporative Emission EVAP system Fuel pump unit 1 7 1Fuel filter I It is located behind a cover on the right hand A pillar in the footwell next...

Page 1202: ...4 DESCRIPTIONAND OPERATION Care must betaken on installation that the arrows on the fuel tank and the fuel pump unit point at each other Ifthe alignmentiswrong then the fuel levelshown may be incorre...

Page 1203: ...Rocam l 25L Duratec 16V Sigma Z OL Duratec HE M14 1 4L Duratec 16V Sigma l 6L Duratec 16V Sigma 310 00 Fuel System General Information Diagnosisand Testing Vehicles with diesel engine REFERto FuelSys...

Page 1204: ...bservefuel handling precautions Failure to follow these instructions may 4 Removethe floor panel crossmember 5 Detachthe exhaust system from the center exhaust hanger insulator result in personal inju...

Page 1205: ...to the pipes N0TE Make note of the positionsof the retaining clampsto makesure they are positionedin exactly the same positionswhen installing Disconnectthe fuel tank filler pipe and the fuel tank ven...

Page 1206: ...les 13 C A U T I O N W lowering the fuel tank make sure that excessive strain is not placed on the fuel lines and electrical connectors Partially lower the fuel tank Vehicles with diesel engine 15 Dis...

Page 1207: ...ation All exce t vehicles with diesel engine 21 ACAUTION M sure that the float or V 17 Disconnect the evaporative emissions canister pipe Squeezethe clip to release the pipe 18 Removethe evaporativeem...

Page 1208: ...sensor 1 Removethe locking ring 2 Removethe O ring seal Discardthe O ring seal 3 Liftthe sensor from the fuel tank Make sure the fuel lines are connected in the correctfuel flow direction Fuelsupply l...

Page 1209: ...11 REMOVALAND INSTALLATION Fuel Pump Module 23 534 0 Removal I Removethe fuel pump module For additionalinformation referto FuelTank in this section Installation I To install reversethe removalproced...

Page 1210: ...01 Battery Mounting and Cables 2 Drain the fuel tank For additional information refer to Section 310 00 Fuel System General Information 3 Raiseandsupport the vehicle Foradditional information referto...

Page 1211: ...resentand can ignite Failureto follow these instructionsmay result in personal injury A This procedure involvesfuel handling Be preparedfor fuel spillage at all times and always observefuel handlingpr...

Page 1212: ...01 14 REMOVAL AND INSTALLATION Fuel Level Sensor Removal 1 Removethe fuel level sensor Foradditionalinformation referto FuelTank in this section Installation I To install reversethe removal procedure...

Page 1213: ...connectors ACAUTION DO not touch the fuel level I resistor card surface with tools or hands 1 i Failure to follow this instruction may result I in damage to the fuel level resistor card 4 Using needl...

Page 1214: ...with diesel engine 4 N0TE lnstall a newfuel levelsensor gasket Install the fuel level sensor Foradditional information referto FuelTank 310 01 Fuel Tank and Lines Removal and InStallation All except v...

Page 1215: ...igma l 4L Duratec I6V Sigma lm6L Duratec 16V Sigma VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE DESCRIPTIONAND OPERATION Acceleration Control 310 02A 2 1 3L Duratec 8V 310 02A 2 1 4Ll1 6L Duratec 1...

Page 1216: ...ne There are two different throttle bodies depending on the power of the variant Becausethe throttleflap openingangle is different the way in which the cable is controlled at the throttleflap varies s...

Page 1217: ...dule circuit Description B Area B electronic throttle body to PCM I Icircuit I 1 IAccelerator pedal I The system consists primarily of two circuits connected to the PCM The two circuits are the accele...

Page 1218: ...eans that the concern may lie between the componentand the PCM All wiring and electrical connectors should be checked before a new component is installed Also note that general vehicle electrical issu...

Page 1219: ...non electronicaccelerator control related DTCs and rectify them first Check area B see system overview and if no failure is found install a new PCM PCM Related Codes The PCMcontinuously monitorsall t...

Page 1220: ...nical Electrical Symptom Chart I Be aware that installing new system related componentswithout these DTCswill not improve Symptom Chart Vehicles With 1 3L Engine Symptom PossibleSources Powertraincont...

Page 1221: ...incorrectly installed INSTALLa new accelerator pedal Accelerator pedal does not return freely I Throttle body CHECK the accelerator pedal for correct installation Damagedaccelerator pedal REFER to WDS...

Page 1222: ......

Page 1223: ...N 310 02B Acceleration Control 2 OL Duratec HE M14 VEHICLE APPLICATION 2006 0 Fiesta CONTENTS PAGE DESCRIPTIONAND OPERATION Acceleration Control 310 02B 2 DIAGNOSISAND TESTING Acceleration Control 310...

Page 1224: ...3 Accelerator pedal Tsensors requested and torque converts To achieve the signals the driver into arequested driver The accelerator pedal incorporatestwo sensors torque the PCMcontrolsthe positionof t...

Page 1225: ...owered up the throttle plate sits open at approximately 8 degreesfrom the closed in bore position This position also referred to as the default position is maintainedwithin thethrottle body bytwo inte...

Page 1226: ...Symptom Chart Symptom Possible Sources Action Accelerator pedal is hard to depress or has a roughlraspy or sticky feel Adjacent hardware wiring harness s trim s carpet or mat s incorrectly installed H...

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