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Fiesta 1996 (08.1995-02.2002)

Engine - 1.8L Endura-DI (Lynx) Diesel - Cylinder Head Fiesta 1996 (08/1995-02/2002)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Installer, Valve Stem Seal

303-037 (21-007A)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060 (21-024)

303-060-05 (21-024-05)

Installer, Camshaft Seal

303-199A (21-110 A)

Installer, Valve Stem Collets

303-362 (21-156)

Pliers, Valve Stem Seal

303-390 (21-165)

Socket, Cylinder Head Temperature Sensor

303-680 (21-239)
Materials
Name
Specification
Sealer
WSK-M2G348-A5 
Hypoid oil
SQM-2C-9022-AA 
Engine oil
WSS-M2C912-A1 

Disassembly
  1. Remove the engine front lifting eye.

  1. Remove the injector nozzles and detach the glow plug wiring.

  1. Remove the glow plugs.

  1. Remove the brake vacuum pump.

  1. Using the special tool, remove the cylinder head temperature (CHT) sensor and the oil pressure switch.
    • Discard the CHT sensor.

  1. Remove the oil pressure switch.

  1. Detach the components on the right-hand side of the cylinder head.
    1. Engine lifting eye.
    1. Coolant connection.
    • Coolant hose.

  1. Remove the exhaust manifold upper retaining bolts.
    • Remove the exhaust gas recirculation (EGR) flange bolts (2 bolts).

  1. Remove the exhaust manifold lower retaining bolts.

  1. CAUTION:
    CAUTION:Loosen the nuts on the camshaft bearing caps evenly a turn at a time.
    Remove the camshaft.
    1. Remove camshaft bearing caps two and four.
    1. Loosen the nuts on the other camshaft bearing caps evenly a turn at a time.
    1. Remove the brake vacuum pump plunger.
    • Remove the bearing caps, bearing shells and the camshaft with the oil seal.
  1. NOTE:
    NOTE:Position the valve tappets in order to one side for further reuse.
    Remove the valve tappets and valve adjustment shims.

  1. Loosen the valve collets.
    • Position a socket on the valve spring seat and gently strike it with a hammer.

  1. NOTE:
    NOTE:Position the cylinder head on wooden blocks.
    Using the special tools, remove the valve springs.
    1. Using the special tools, compress the valve springs.
    1. Using the special tool, remove the valve collets.
    • Remove the valves, valve collets and the valve springs and position them in order to one side.

  1. Using the special tool, remove the valve seals.

Assembly

  1. Grind in the valves.

  1. CAUTION:
    CAUTION:Protect the grooves on the valve stems with protective sleeves.
    NOTE:
    NOTE:Only remove the protective sleeves after the valve stem oil seals have been installed.
    Coat the new valve seals with engine oil and install them.
  1. Coat the valves with hypoid oil and insert them.

  1. Install the valve springs.
    • Install the valve springs with the valve spring retainers.
    1. Using the special tool, compress the valve springs.
    1. Install the valve collets into the grooves on the valve stem.

  1. NOTE:
    NOTE:The lettering on the valve adjustment shims faces downwards.
    NOTE:
    NOTE:Coat the valve tappets and the valve adjustment shims with engine oil before installation.
    NOTE:
    NOTE:Installation sequence.
    Install the valve tappets.
  1. Insert the camshaft lower half shells and coat them with engine oil.

  1. Align the camshaft.
    • Insert the camshaft and turn it until the groove on the eccentric cam is parallel to the upper edge of the cylinder head (the larger semi-circle faces upwards).
  1. Insert the camshaft upper half shells and coat them with engine oil.

  1. Apply sealant to the bearing caps at the positions shown.

  1. NOTE:
    NOTE:The arrows on the camshaft bearing caps must point to the front of the engine.
    NOTE:
    NOTE:Tighten the camshaft bearing caps evenly a turn at a time.
    Install the camshaft.
    1. Install the brake vacuum pump plunger.
    1. Position camshaft bearing caps "1", "3" and "5" and tighten the nuts fingertight.
    1. Position the other camshaft bearing caps and tighten the nuts fingertight.

  1. NOTE:
    NOTE:Tighten the camshaft bearing caps evenly a turn at a time.
    Tighten the camshaft bearing cap retaining nuts.

  1. NOTE:
    NOTE:Coat the camshaft taper and oil seal lip with engine oil.
    Using the special tool, install the camshaft oil seal.

  1. Install the intake manifold.

  1. Tighten the exhaust manifold lower retaining bolts.

  1. Tighten the exhaust manifold upper retaining bolts.
    • Tighten the EGR flange bolts (2 bolts).

  1. Install the components on the right-hand side of the cylinder head.
    1. Engine lifting eye.
    1. Coolant connection.
    • Coolant hose.

  1. CAUTION:
    CAUTION:Install a new cylinder head temperature (CHT) sensor.
    Install the CHT sensor.

  1. Install the oil pressure switch.

  1. Install the brake vacuum pump.

  1. Install the glow plugs.

  1. NOTE:
    NOTE:Make sure that the fuel injectors are installed in their original position.
    NOTE:
    NOTE:Install new fuel injector to cylinder head sealing washers.
    NOTE:
    NOTE:Install new fuel injector retaining clamps.
    NOTE:
    NOTE:Install new fuel injector retaining clamps retaining bolts.
    Install the fuel injectors and retaining clamps.
    • Tighten the bolts in two stages.
    • 5 Nm
    • 90 degrees

  1. Install the glow plug wiring harness.

  1. Install the engine front lifting eye.

Assembly > < In-vehicle Repair|Disassembly|Engine