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Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.8L Endura-DE (Kent) Diesel - Engine Fiesta 1996 (08/1995-02/2002)
Disassembly

Special Tool(s)

Universal flange holding wrench

15-030A

Mounting bracket, engine

21-031B

Socket, cylinder head bolts

21-164

Crankshaft locking tool

21-168

Puller, crankshaft timing belt pulley

21-200

Socket, injectors

23-045

Disassembly

All Vehicles
  1. General Remarks.
    • As of 08/1995, the camshaft timing belt drive has been revised. It is not possible to renew any of the gears or the belt itself with replacement parts from previous build years.
    • If necessary, when removing coolant and ventilation hoses, For additional information, refer to Section  303-03 Engine Cooling.

  1. secure the engine to the assembly stand.
    • Attach the mounting bracket.
    • Secure the engine to the assembly stand.
  1. NOTE:
    NOTE:Escaping oil.
    Drain off the engine oil.
    Detach the oil pump with the oil filter.

  1. Remove the alternator (shown with the air conditioning compressor).
    1. Slacken and remove the drive belt.
    1. Detach the belt tensioner.
    1. Remove the alternator bolts.

  1. Remove the injection pump belt pulley.

  1. Remove the crankshaft pulley/vibration damper.
    • Immobilise the crankshaft using the ring gear.
    • Remove the bolts.

  1. Remove the timing belt upper cover.

  1. Remove the timing belt lower cover.

  1. Remove the injection pump timing belt cover.
  1. Slacken the bolt of the auxiliary shaft timing belt pulley.

  1. Remove the cylinder head cover.
    1. Detach the crankcase ventilation hoses.
    1. Remove the bolts.
Engines with automatic timing belt tensioner
  1. Remove the camshaft timing belt.
    1. Unscrew the bolt of the adjusting cam and remove the adjusting cam and the timing belt.
    1. Detach the camshaft timing belt tensioner.
    1. Undo the bolt of the camshaft timing belt pulley.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:Position a screwdriver between the camshaft timing belt pulley and the timing belt rear cover.
    Detach the camshaft timing belt pulley (continued).
    • Release the camshaft timing belt pulley from its conical seat by tapping it lightly with a light metal drift.
Engines with mechanical timing belt tensioner
  1. Remove the camshaft timing belt pulley.
    • Undo the bolts of the timing belt pulley.
    • Release the timing belt tensioner clamp bolt and slacken the timing belt.
    • Tighten the timing belt tensioner clamp bolt.
    • Remove timing belt and discard.
All vehicles
  1. Remove the injection pump timing belt.
    • Undo the bolts of the timing belt pulley.
    • Release the timing belt tensioner clamp bolt and slacken the timing belt.
    • Tighten the timing belt tensioner clamp bolt.
    • Remove timing belt and discard.

  1. WARNING:
    WARNING:The timing belt tensioner is spring-loaded.
    Remove the timing belt tensioner and the injection pump timing belt pulley.
    1. Timing belt tensioner
    1. Timing belt pulley
Engines with mechanical timing belt tensioner
  1. WARNING:
    WARNING:The timing belt tensioner is spring-loaded.
    Remove the timing belt tensioner and the camshaft timing belt pulley.
    1. Timing belt tensioner bolts
    1. Camshaft timing belt pulley bolts
All vehicles
  1. Remove the engine mounting bracket.

  1. Remove the timing belt side cover.

  1. Remove the oil dipstick tube.
  1. Detach the hose.

  1. Remove the fuel feed line.

  1. Disconnect the injection pipes and leak-off hoses.

  1. Remove the injection pump bracket.

  1. Remove the injection pump.

  1. Remove the thermostat housing, coolant hose and coolant pipe.

  1. Remove the alternator bracket.
  1. Remove the coolant pipe bracket.

  1. Remove the oil baffle.

  1. Remove injectors and heat shields. Remove the glow plugs.
    1. Injectors
    1. Glow plug wiring
    1. Glow plugs

  1. NOTE:
    NOTE:Loosening sequence
    Remove the cylinder head.
    • Take off the cylinder head and put it down on wooden blocks.
    • Remove the seal.

  1. Remove the flange of the crankshaft front timing belt pulley.

  1. Remove the auxiliary shaft timing belt pulley and oil seal housing.
      NOTE:
      NOTE:Immobilise the timing belt pulley with the old timing belt.
    1. Bolt of the auxiliary shaft timing belt pulley
    1. Bolts of the auxiliary shaft oil seal housing

  1. Remove the auxiliary shaft with the thrust plate.

  1. Remove the coolant pump.

  1. CAUTION:
    CAUTION:Only use a collet.
    Remove the crankshaft rear timing belt pulley.
    1. Fit the collet.
    1. Pull the collet back as far as the stop.

  1. Pull off the crankshaft rear timing belt pulley (continued)
    • Screw in the spindle and pull off.

  1. Remove the clutch.

  1. Remove the flywheel.

  1. Remove the crankshaft position sensor (CKP).

  1. NOTE:
    NOTE:The oil seal is integrated in the housing.
    Remove crankshaft rear oil seal housing.
  1. Remove the CKP sensor bracket.

  1. CAUTION:
    CAUTION:Remove the sump downwards so that no oil sludge or abraded particles get into the engine.
    Remove the sump.

  1. Remove the front plate.
    • Press out the crankshaft front oil seal.

  1. Remove the oil intake pipe with the bracket.

  1. CAUTION:
    CAUTION:Do not damage the piston ring zone.
    Remove the pistons.
      NOTE:
      NOTE:Put the big-end bearing caps and big-end bearing shells down in order.
    • Detach the big-end bearing caps.
    • Remove the ring of carbon around the upper edge of the cylinders using a proprietary scraper.
    • Press out the pistons with the connecting rods and big-end bearing shells.

  1. Remove the crankshaft.
    • Remove the main bearing caps.
    • Take out the crankshaft.
    • Take out the bearing shells and thrust half washers and put them down in order for re-use.

Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine