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Содержание 2007 WQ Fiesta

Страница 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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Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 172: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 206: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 236: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 254: ...I...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 264: ......

Страница 265: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 274: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 306: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 398: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 418: ......

Страница 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...

Страница 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...

Страница 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...

Страница 422: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 482: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 622: ......

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 770: ......

Страница 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...

Страница 772: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 798: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 808: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 838: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 866: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 878: ......

Страница 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...

Страница 880: ...Engine Ignition SPECIFICATIONS Description 53 ISpark plugs I 15 I 11 I I 2006 0 Fiesta12 2006 1 4 8 2 1 8en...

Страница 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...

Страница 882: ......

Страница 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...

Страница 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...

Страница 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...

Страница 886: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 894: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 909: ...303 12 5 IntakeAir Distributionand Filtering 303 12 5 DESCRIPTIONAND OPERATION Air intake system 2006 0 Fiesta12 2006 G421936en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 965: ...Automatic Transmission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Automatic Transaxle Transmission cross section 2006 0 Fiesta1212006 380521 en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 980: ...Automatic TransmissionlTransaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transmission ratio and powerflow route 2nd gear 2006 0 Fiesta1212006 G380528en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 988: ...Automatic Transmission Transaxle Vehicles With 4 Speed Automatic Transmission AW81 40 DESCRIPTIONAND OPERATION Transaxle Electronic Control System Overview 2006 0 Fiesta1212006 G380530en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1044: ......

Страница 1045: ...HICLE APPLICATION 2006 0 Fiesta CONTENTS SPECIFICATIONS Specifications DESCRIPTIONAND OPERATION External Controls Selector lever cable GENERAL PROCEDURES Selector Lever Cable Adjustment PAGE REMOVALAN...

Страница 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...

Страница 1047: ...Automatic Transmission Transaxle External Controls VehiclesWith 4 SpeedAutomatic Transmission AW81 40 DESCRIPTIONAND OPERATION External Controls Selector lever cable 2006 0 Fiesta1212006 G357360en...

Страница 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...

Страница 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...

Страница 1050: ...switch electricalconnector selectorleverassembly shown removedfor clarity 3 Removethe brake shift interlockactuator 1 Removethe bolt 2 Removethe knob 3 Removethe brakeshift interlock actuator Installa...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1072: ......

Страница 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...

Страница 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...

Страница 1075: ...he self adjusting clutch has the following advantagesover conventionallydesignedclutches lower releaseforces which remain constant overthe service lifeand thus ensure highdriving comfort throughout th...

Страница 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...

Страница 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...

Страница 1078: ...308 01 6 Clutch 308 01 6 DIAGNOSISAND TESTING Clutch REFERto ManualTransaxle and Clutch 308 00 Diagnosisand Testing 2006 0 Fiesta1212006 GI 8068en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1091: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1105: ...308 03 15 ManualTransmissionlTransaxle 308 03 15 DESCRIPTIONAND OPERATION Power transmission in the individualgears 2006 0 Fiesta1212006 G281365en...

Страница 1106: ...308 03 16 Manual Transmission Transaxle 308 03 16 DESCRIPTIONAND OPERATION r 2006 0 Fiesta1212006 G281365en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1119: ...308 03 29 Manual Transmission Transaxle 308 03 29 REMOVAL 35 Usinga suitabletransmissionjack remove the transaxle 2006 0 Fiesta1212006 GI I3290en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1141: ...308 03 51 ManualTransmission Transaxle 308 03 51 DISASSEMBLYAND ASSEMBLY OF SUBASSEMBLIES 4 Selector plate 2006 0 Fiesta1212006 Gl8lllen...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1151: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1167: ...Manual Transmission Transaxle External Controls DESCRIPTIONAND OPERATION External Controls 2006 0 Fiesta1212006 GI 63328en...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1176: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1222: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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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