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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Fiesta 2002.25 (11.2001-)

Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Cylinder Head Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Socket, Cylinder Head Bolts

303-392 (21-167)

Remover/Installer, Hose Clamp

303-397 (24-003)
Materials
Name
Specification
Engine oil
WSS-M2C912-A1 

Removal

  1. Release the fuel system pressure.
    For additional information, refer to: Fuel System Pressure Release (310-00 Fuel System - General Information, General Procedures).
  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. Remove the camshaft.
    For additional information, refer to: Camshafts (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).

  1. Detach the exhaust flexible pipe from the catalytic converter.
    • Discard the gasket and the nuts.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Using a suitable splint or wrap support the exhaust flexible pipe.

  1. Remove the exhaust manifold lower heat shield left-hand retaining bolts.

  1. Remove the exhaust manifold lower heat shield right-hand retaining bolts.
    • Remove the lower heat shield.

  1. Remove the intake manifold retaining bolt.
  1. Lower the vehicle.

  1. Disconnect the vacuum hose from the fuel pressure regulator.

  1. Disconnect the brake booster vacuum line from the intake manifold.

  1. Disconnect the positive crankcase ventilation (PCV) hose from the PCV.

  1. Disconnect the generator electrical connector.

  1. Disconnect the evaporative emissions (EVAP) hose from the EVAP valve.

  1. Disconnect the engine wiring harness electrical connector.

  1. Disconnect the EVAP valve electrical connector.

  1. Disconnect the fuel supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Using the special tool, disconnect the coolant hose from the coolant distribution assembly.

  1. Using the special tool, disconnect the coolant hose from the coolant distribution assembly.

  1. Using the special tool, detach the degas hose from the cylinder head.
    • Using the special tool, detach the degas hose from the cylinder head.

  1. Disconnect the engine coolant temperature (ECT) electrical connector.

  1. Disconnect the electronic ignition (EI) coil electrical connector.

  1. Disconnect the heated oxygen (HO2S) sensor electrical connector.
    • Detach the electrical connector from the bracket.

  1. Detach the power steering line bracket from the cylinder head.

  1. Remove the exhaust manifold upper heat shield

  1. Detach the exhaust manifold and position it to one side.
    • Discard the nuts and the exhaust manifold gasket.

  1. Remove the timing belt rear cover (engine shown removed for clarity).

  1. Detach the oil level indicator tube from the intake manifold.

  1. CAUTION:
    CAUTION:The cylinder head must have cooled to below 30°C before removal.
    CAUTION:
    CAUTION:Position the cylinder head on a soft surface.
    CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head bolts.
    • Discard the cylinder head gasket.

Installation
  1. CAUTION:
    CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole marked).
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Position the cylinder head into 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.
    • Stage 2: 30 Nm.
    • Stage 3: 90 degrees.

  1. Attach the oil level indicator tube to the intake manifold.

  1. Install the timing belt rear cover (engine shown removed for clarity).

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the nuts and bolt at this stage.
    Install the exhaust manifold.

  1. Tighten the exhaust manifold upper retaining nuts and bolt in the sequence shown in two stages.
    • Stage 1: 20 Nm.
    • Stage 2: 55 Nm.

  1. Tighten the exhaust manifold lower retaining bolts.

  1. Install the exhaust manifold upper heat shield.

  1. Attach the power steering line bracket to the cylinder head.

  1. Connect the heated oxygen (HO2S) sensor electrical connector.
    • Attach the electrical connector to the bracket.

  1. Connect the electronic ignition (EI) coil electrical connector.

  1. Connect the engine coolant temperature (ECT) sensor electrical connector.

  1. Using the special tool, connect the degas hose to the cylinder head.

  1. Using the special tool, connect the coolant hose to the coolant distribution assembly.

  1. Using the special tool, connect the coolant hose to the coolant distribution assembly.

  1. Connect the fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the evaporate emission (EVAP) valve electrical connector.

  1. Connect the engine wiring harness electrical connector.

  1. Connect the EVAP hose to the EVAP valve.

  1. Connect the vacuum hose to the fuel pressure regulator.

  1. Connect the generator electrical connector.

  1. Connect the positive crankcase ventilation (PCV) hose to the PCV.

  1. Connect the brake booster vacuum line to the intake manifold.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Install the intake manifold retaining bolt.

  1. Position the exhaust manifold lower heat shield and install the right-hand retaining bolts.

  1. Install the exhaust manifold lower heat shield left-hand retaining bolts.

  1. NOTE:
    NOTE:Install a new flexible pipe gasket and new nuts.
    Attach the flexible pipe to the catalytic converter
  1. Remove the exhaust flexible pipe support.
  1. Install the camshaft.
    For additional information, refer to: Camshafts (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
  1. NOTE:
    NOTE:Install a new oil filter.
    Change the engine oil.
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).

In-vehicle Repair|Oil Pan > < Exhaust Manifold