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In-vehicle Repair|Disassembly > < Cylinder Head

Fiesta 1996 (08.1995-02.2002)

Engine - 1.3L Endura-E (HCS) - Engine Fiesta 1996 (08/1995-02/2002)
Removal

Special Tool(s)

Separator, ball joint

211-020 (13-006)

Engine lifting bracket

303-122 (21-068A)

Remover/installer, coolant hose clip

303-397 (24-003)

Remover, drive halfshaft

308-237 (16-087)

Remover, drive halfshaft

308-256 (16-089)
General Equipment
9 mm twist drill
Assembly stand
Hydraulic jib crane
Retaining straps
Engine lifting eye order no.: 6630411
Engine lifting eye, finis code: 6009618
Assembly plugs for differential
Materials
Name
Specification
Cable ties
 
Coolant
ESDM-97B49-A 
Power steering hydraulic fluid
ESPM-2C-166-H 
Brake fluid (DOT 4)
SAM-6C9103-A 
Transmission fluid
WSD-M2C200-C 

Removal

All Vehicles
NOTE:
NOTE:If necessary, when removing coolant and ventilation hoses, use removal tool 303-397.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Open the coolant expansion tank.
  1. Drain off the coolant. For additional information, refer to Section  303-03 Engine Cooling.

  1. Disconnect the intake pipe from the air cleaner.

  1. Disconnect the intake pipe from the throttle body.

  1. Remove the battery.
    • Remove the retaining clip.
    • Unclip the wiring brackets.

  1. Remove the battery box.

  1. Disconnect the plug of the heated exhaust gas oxygen sensor (HO2S).

  1. Detach the accelerator cable.
    1. Unclip the accelerator cable.
    1. Detach the clip.
    1. Unhook the accelerator cable.

  1. Detach the upper coolant hose from the thermostat housing.
    • Unclip the high-tension leads and lay them to one side.

  1. Disconnect the alternator plug.

  1. Disconnect the coolant hose to the heat exchanger (quick-release fitting).

  1. Detach the coolant hose at the top right of the radiator.
Vehicles with mass air flow (MAF) sensor
  1. Disconnect the plugs and remove the vacuum lines.
    1. Two plugs (engine wiring loom)
    1. Brake servo vacuum line
    1. Evaporative emission control valve (EVAP) vacuum line
    • Unclip the wiring bracket.
Vehicles with temperature/manifold absolute pressure (T-MAP) sensor
  1. Separate the connectors and pull off the vacuum hoses.
    1. Engine wiring loom plug
    1. Vacuum line - fuel pressure control
    1. Vacuum hose - evaporative emission purge solenoid (EVAP)
    1. Brake servo vacuum line
    1. T-MAP sensor connector
All vehicles
  1. Pull out the plug of the engine coolant temperature sensor (ECT sensor).

  1. NOTE:
    NOTE:To detach the hose, first detach the oil filler cap, and install it again afterwards.
    Detach the hose from the oil filler cap.

  1. Disconnect the starter motor plug.
    1. Disconnect the connector.
    1. Unclip the wiring.

  1. Disconnect the ground cable from the transmission.

  1. Disconnect the speedometer drive cable.

  1. Disconnect the plug of the vehicle speed sensor (VSS).
    • Unclip the connector from the bulkhead.

  1. Remove the drive belt cover at top.

  1. Remove the drive belt.
    • Slacken the tensioning pulley with a 15 mm ring spanner and remove the drive belt.

  1. NOTE:
    NOTE:Collect any escaping power steering fluid.
    Disconnect the feed hose and pressure pipe from the power steering pump.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Disconnect the plug of the fan motor thermo switch.

  1. Remove the drive belt cover at the bottom.

  1. Disconnect the coolant hose from the coolant pump.

  1. Remove the lower radiator cover.
  1. Detach the radiator crossmember on the bottom left-hand side.

  1. Lift out the air guide with the fan motor (push-fit at the top and bottom).
Vehicles with air conditioning
  1. Remove the air conditioning compressor.
    1. Disconnect the electromagnetic clutch plug.
    1. Remove the bolts.
    • Tie up the compressor with wire.
All vehicles
  1. Disconnect the exhaust system.

  1. Detach the shift rod and gearshift stabilizer from the transmission.
    1. Detach the shift rod.
    1. Detach the gearshift stabilizer and tie it up with wire.

  1. Remove the engine roll restrictor.

  1. Detach the suspension lower arm and the left-hand track rod.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees, and the outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Escaping oil.
    Press the left-hand front drive halfshaft out of the transmission, swivel it backwards and tie it up.

  1. Remove the front drive halfshaft center bearing.
Vehicles built up to 12/1996 and vehicles for non-European markets
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees, and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After releasing the front drive halfshaft, immediately insert suitable auxiliary plugs into the differential to prevent it turning.
    Detach the right-hand front drive halfshaft from the transmission.
    • Release the right-hand front drive halfshaft from the transmission with a light tap.
Vehicles built from 01/1997 for European markets
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees, and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After removing the front drive halfshaft, immediately insert suitable auxiliary plugs into the differential to prevent it turning.
    Withdraw the right-hand front drive halfshaft from the transmission.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees, and the outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Do not damage the gaiters of the drive halfshaft.
    Tie up the right-hand front drive halfshaft towards the front.

  1. Disconnect the starter motor.
  1. Lower the vehicle.
  1. Disconnect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. NOTE:
    NOTE:Watch out for escaping brake fluid.
    Detach the clutch hydraulic pipe.
    1. Pull out the retaining clip and disconnect the pipe.
    1. Push the pipe out of its guide.
  1. Preparatory measures for removing the engine and transmission assembly.
    • Raise the vehicle so that the assembly stand fits under the engine. For additional information, refer to Section  100-02 Jacking and Lifting.
    • Position the assembly stand and wooden blocks underneath the engine and transmission assembly.
    • Lower the vehicle until the engine and transmission assembly rests on the wooden blocks.

  1. Secure the engine to the assembly stand with a retaining strap.

  1. Detach the rear engine mounting bracket from the transmission.
    • Unscrew the three nuts.
    • Pull out the transmission breather.

  1. Detach the front engine mounting bracket from the transmission.
  1. Raise the vehicle slowly until engine and transmission assembly comes free.

  1. Attach the left-hand engine lifting eye.
    • Unscrew the lower nut from the exhaust manifold (cylinder no. 4) and screw it on again with the engine lifting eye.
    • Engine lifting eye, finis code: 6009618

  1. NOTE:
    NOTE:Enlarge the right-hand hole to a=10 mm.
    Modify the right-hand engine lifting eye.
    • Engine lifting eye order no.: 6630411

  1. Attach the right-hand engine lifting eye.

  1. Mount the Special Tool.
    • Raise the special tool with a workshop hoist so that it takes the strain.
    • Take off the retaining strap.
  1. Position the engine and transmission assembly so that only the transmission is on the assembly stand.
    • Support the transmission on wooden blocks and secure it with a retaining strap.

  1. Remove the heat shield.

  1. Detach the catalytic converter from the exhaust manifold.

  1. Remove the catalytic converter.

  1. Detach the front engine mounting bracket.

  1. Detach the rear engine mounting bracket.

  1. Remove the starter motor bolt.

  1. Remove the starter motor.
    1. Unscrew the bolt and take off the retaining plate.
    1. Remove the starter motor.

  1. Remove the left-hand flange bolts.

  1. Remove the right-hand flange bolts.
    • Remove the cover from the crankshaft position sensor (CKP sensor).
    • Remove the catalytic converter bracket.

  1. Unscrew the upper flange bolts.
    • Place the cable guide to one side.
    • Separate the transmission from the engine.
    • Take out the adapter plate over the flywheel.

In-vehicle Repair|Disassembly > < Cylinder Head