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Crankshaft Rear Seal > < Exhaust Manifold

Fiesta 2002.25 (11.2001-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Cylinder Head Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Guide Studs, Cylinder Head

303-034

Gauge, Bolt Angle

303-174 (21-540)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Plate for 303-435-04

303-435-12A (21-150B)
General Equipment
Worldwide diagnostic system (WDS)
Materials
Name
Specification
Sealer
WSE-M4G323-A4 

Removal

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system is approximately 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material entering the components.
  1. Using datalogger in worldwide diagnostic system (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, 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 intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).

  1. Disconnect the brake booster vacuum line from the brake vacuum pump.

  1. CAUTION:
    CAUTION:Protect the generator with lint-free material to prevent contamination.
    Using the special tool, remove the coolant expansion tank.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Remove the CMP sensor.

  1. CAUTION:
    CAUTION:Do not remove the two screws either side of the circular cut-outs.
    Remove the catalytic converter heat shield (engine shown removed for clarity).

  1. Remove the turbocharger heat shield.

  1. Remove the camshaft housing assembly.

  1. CAUTION:
    CAUTION:Keep the camshaft roller followers in order for installation.
    Remove the camshaft roller followers.

  1. Detach the fuel pump rear bracket from the cylinder head.

  1. Detach the fuel pump bracket from the cylinder head.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Disconnect the EGR vacuum hose from the EGR valve.
Vehicles with EGR cooler
  1. Disconnect the EGR valve electrical connector.
All vehicles
  1. Detach the thermostat housing from the cylinder head.

  1. Remove the power steering pump rear retaining bolt.

  1. Detach the power steering pump from the power steering pump support bracket.

  1. Detach the power steering pump support bracket from the cylinder head.

  1. Disconnect the oil supply line from the turbocharger.

  1. Disconnect the oil return tube from the turbocharger.

  1. Detach the turbocharger from the catalytic converter.
  1. Remove the fuel injectors.
    For additional information, refer to: Fuel Injectors (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation).

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the bolts and the gasket.

Installation

All vehicles
WARNING:
WARNING:Do not smoke 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 instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material entering the components.
  1. Clean the mating faces of the cylinder head and cylinder block.
  1. Check the cylinder head for distortion.
    For additional information, refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

  1. CAUTION:
    CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked).
    Install a new cylinder head gasket.

  1. CAUTION:
    CAUTION:Install new cylinder head bolts.
    Using the special tools, install the cylinder head.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: 20 Nm
    • Stage 2: 40 Nm
    • Stage 3: 180 degrees
  1. Install the fuel injectors.
    For additional information, refer to: Fuel Injectors (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation).

  1. Attach the turbocharger to the catalytic converter.

  1. Connect the oil return tube to the turbocharger.

  1. NOTE:
    NOTE:Install new oil supply line sealing washers.
    Connect the oil supply line to the turbocharger and measure the distance to the turbocharger housing.
    • XX = 15 mm

  1. Attach the power steering pump support bracket to the cylinder head.

  1. Attach the power steering pump to the power steering pump support bracket.

  1. Install the power steering pump rear retaining bolt.

  1. Attach the thermostat housing to the cylinder head.
    • Tighten the bolts in two stages.
    • Stage 1: 4 Nm
    • Stage 2: 7 Nm
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Connect the EGR vacuum hose to the EGR valve.
Vehicles with EGR cooler
  1. Connect the EGR valve electrical connector.
All vehicles
  1. Attach the fuel pump bracket to the cylinder head.

  1. Attach the fuel pump rear bracket to the cylinder head.

  1. CAUTION:
    CAUTION:Make sure that the sealer does not enter the cylinder head blind holes.
    NOTE:
    NOTE:Do not damage the mating faces.
    Clean the mating faces of the cylinder head and the camshaft housing assembly.

  1. CAUTION:
    CAUTION:Install the camshaft housing assembly within four minutes of applying the sealer.
    Apply a 4 mm diameter bead of sealer to the cylinder head upper mating face.

  1. Install the camshaft roller followers.

  1. Using the special tools, align the camshaft housing assembly.

  1. CAUTION:
    CAUTION:Install the camshaft housing assembly bolts in two stages.
    Install the camshaft housing assembly retaining bolts.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 5 Nm
    • Stage 2: 10 Nm

  1. Install the turbocharger heat shield.

  1. Install the catalytic converter heat shield.

  1. Install the catalytic converter heat shield lower retaining bolts (engine shown removed for clarity).

  1. NOTE:
    NOTE:Turn the camshaft to align the camshaft pulley position indicator with the camshaft position (CMP) sensor if necessary.
    Install and adjust the CMP sensor.
    • XX = 1.2 mm between the CMP sensor and the camshaft pulley position indicator.
    • XX = 0.0 mm between the CMP sensor and the camshaft pulley position indicator, when a new CMP sensor is installed.

  1. Connect the CMP sensor electrical connector.

  1. Using the special tool, install the coolant expansion tank.

  1. Connect the brake booster vacuum line to the brake vacuum pump.
  1. Install the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Install the intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  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).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Crankshaft Rear Seal > < Exhaust Manifold