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In-vehicle Repair|Removal > < Timing Belt

Fiesta 1996 (08.1995-02.2002)

Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L - Cylinder Head Fiesta 1996 (08/1995-02/2002)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205–072 (15-030A)

Lifting Bracket, Engine

303–122 (21-068A)

Gauge, Bolt Angle

303–174 (21-540)

Pliers, Valve Shim

303–196 (21-107)

Alignment Plate, Camshaft

303–376 (21-162B)

Socket, Cylinder Head Bolt

303–392 (21-167)

Installer, Crankshaft Seal

303–395 (21-171)

Compressor, Belt Tensioner

303–429 (21-180)

Socket, Spark Plug

303–499 (21-202)

Timing Peg, Crankshaft TDC

303–507 (21-210)

Installer, Crankshaft Vibration Damper

303-510 (21-214)

Pliers, Spark Plug Connector

303-622 (21-226)

Locking Tool, Crankshaft

303-748 (21-259)
Materials
Name
Specification
Sealer, camshaft bearing cap
WSK-M2G348-A2 
Never Seez
ESE-M1244-A 
Engine oil
WSS-M2C912-A1 
Coolant
ESDM-97B49-A 
Silicone grease, spark plugs
ESE-M1C171–AA 
Lubricant (spark plug threads - Never Seez)
ESE-M1244–A 

Removal

All vehicles
  1. General note:
    • If necessary, use remover 303-397 when removing coolant hoses and vent hoses.
  1. Release pressure in fuel system.
    For additional information, refer to: Fuel System Pressure Release (310-00 Fuel System - General Information, General Procedures).
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. CAUTION:
    CAUTION:When the engine is hot there is a risk of scalding.
    Open the coolant expansion tank.

  1. Slacken and remove the drive belt.
  1. Detach the heat shield from the catalytic converter.

  1. Remove the coolant pump pulley and the drive belt idler pulley.

  1. Remove the crankshaft pulley/vibration damper.
Vehicles with air conditioning
  1. Loosen the bolts and pull the power steering pump back by 10 mm.
All vehicles
  1. Remove the bolts from the timing belt covers.
    1. Timing belt upper cover.
    1. Timing belt lower cover.
  1. Remove the lower cover.

  1. Drain the coolant.
    • Reinstall the drain plug after draining.
  1. Lower the vehicle.
  1. Remove the battery
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Remove the battery tray.
    1. Detach the wiring bracket.
    1. Remove the bolts.

  1. Remove the intake hose.
  1. Disconnect the fuel lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
Vehicles with 1.25l engine
  1. Detach the accelerator cable.
    • Detach the clips and unhook the accelerator cable.
Vehicles with 1.4l or 1.6l engine
  1. Detach the accelerator cable.
    1. Detach the clip.
    1. Twist out of the bracket.
All vehicles
  1. Detach / separate the connectors.
    1. Throttle position (TP) sensor.
    1. EI ignition coil.
    1. Engine coolant temperature (ECT) sensor
    1. Detach the engine wiring harness connector.

  1. Detach / separate the connectors.
    1. Camshaft position (CMP) sensor.
    1. Heated oxygen (HO2S) sensor.

  1. Detach the coolant hose from the coolant outlet housing.

  1. Detach the coolant hoses.
    1. From the coolant outlet housing.
    1. To the coolant expansion tank.

  1. Detach the vacuum hoses from the throttle body.
    • Brake servo.
    • Fuel pressure regulator.
    • EGR valve (if present).

  1. Detach the vacuum hoses from the exhaust gas recirculation valve (EGR valve) (if present).

  1. Remove the exhaust manifold heat shield.

  1. Detach the exhaust manifold from the catalytic converter.
Vehicles built up to 07/1998
  1. Remove the generator.
    1. Detach the connector.
    1. Disconnect the lead.
    1. Remove the three bolts.
Vehicles built from 08/1998
  1. Remove the generator and lay it to one side.
    1. Detach the connector.
    1. Disconnect the positive cable.
    1. Detach the studs.
All vehicles
  1. Remove the three lower intake manifold bolts from the cylinder block and detach the oil dipstick tube.
Vehicles built up to 01/2001
  1. Remove the cover plate from the cylinder head cover.
    1. Unclip the fuel pipes.
    1. Detach the positive crankcase ventilation hose (PCV hose).
    1. Unclip the carbon canister vacuum pipe bracket.
    1. Remove the bolts.

  1. CAUTION:
    CAUTION:Do not pull on the cable when detaching the spark plug connector. If necessary, detach the connector from the ignition coil to avoid bending the cable. Turn the spark plug connector slightly before detaching it in order to loosen the seal.
    CAUTION:
    CAUTION:Detach the spark plug connector in line with the spark plug axis.
    CAUTION:
    CAUTION:Do not damage the cylinder head cover gasket as this cannot be renewed separately.
    Remove the cylinder head cover vertically upwards.
    1. Detach the spark plug connectors. Use special tool 303-622 for angled spark plug connectors.
    1. Remove three bolts of the timing belt upper cover.
    1. Remove the nuts.
Vehicles built from 01/2001
  1. Detach the PCV hose and the fuel supply and return lines from the cylinder head cover.

  1. CAUTION:
    CAUTION:Do not pull on the cable when detaching the spark plug connector. If necessary, remove the ignition coil plug to avoid bending the cable. Turn the spark plug connector slightly before removing it, to loosen the seal.
    CAUTION:
    CAUTION:Detach the spark plug connector in line with the spark plug axis.
    Disconnect the spark plug electrical connectors and unclip the wires from the cylinder head cover.

  1. Remove the cylinder head cover.
All vehicles
  1. Position a trolley jack with a wooden support underneath the oil pan and jack it up slightly to take the load off the front engine mounting.

  1. NOTE:
    NOTE:Support the engine with a trolley jack and wooden block.
    Detach the front engine mounting bracket.
  1. Remove the timing belt upper cover.
Vehicles built up to 07/1998
  1. Remove the front engine mounting bracket.
Vehicles built from 08/1998
  1. Remove the front engine mounting bracket (shown with engine removed).
Timing belt tensioner up to build month 03/97
  1. NOTE:
    NOTE:When re-using the timing belt, mark the running direction.
    Slacken and remove the timing belt.
    • Compress the timing belt tensioner using the special tool.
Timing belt tensioner from build month 04/97
  1. NOTE:
    NOTE:When re-using the timing belt, mark the running direction.
    Slacken and remove the timing belt (shown with engine removed).
    • Loosen the bolt.
Timing belt tensioner from build month 03/98
  1. NOTE:
    NOTE:When re-using the timing belt, mark the running direction.
    Slacken and remove the timing belt (shown with engine removed).
    • Detach the bolts.
All vehicles
  1. CAUTION:
    CAUTION:Counterhold using the special tool.
    Remove the camshaft timing pulleys.
    • Discard the timing pulley bolts.

  1. Remove the spark plugs with the special tool.

  1. NOTE:
    NOTE:Loosening sequence.
    NOTE:
    NOTE:Keep the bearing caps in order for reassembly. The identification numbers are located on the outside of the camshaft bearing caps.
    Remove the camshafts.
    • Loosen the camshaft bearing cap bolts one turn at a time until the camshaft is released.
    • Detach the camshaft bearing caps.
    • Detach the camshaft oil seal.
Vehicles built up to 01/2001
  1. NOTE:
    NOTE:Keep the valve tappets and adjusting shims in order for reassembly.
    Remove the valve tappets and adjusting shims using the special tool.
Vehicles built from 01/2001
  1. NOTE:
    NOTE:Keep the valve tappets in order for reassembly.
    Remove the valve tappets using the special tool.
All vehicles
  1. Detach the timing belt cover bracket from the cylinder head (two bolts).

  1. Remove the three lower intake manifold bolts and detach the oil dipstick tube.
  1. Disconnect the fuel lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. CAUTION:
    CAUTION:The cylinder head must cool to below 30 degrees C prior to removal.
    CAUTION:
    CAUTION:Place the cylinder head on a soft surface.
    NOTE:
    NOTE:Loosening sequence.
    Detach the cylinder head using the special tool.

  1. Lift the cylinder head from the cylinder block and put it down on a soft surface.
    • Remove the cylinder head gasket.

Installation

All vehicles
  1. NOTE:
    NOTE:Ensure that all mating faces are clean.
    Set the crankshaft to approx. 25 mm before TDC.
    Place the cylinder head on the cylinder block.
    • Fit a new gasket.

  1. NOTE:
    NOTE:Tightening sequence.
    NOTE:
    NOTE:The cylinder head is located by two guide sleeves.
    NOTE:
    NOTE:Used cylinder head bolts can be reused.
    Install the cylinder head using the special tool.
    • Ensure that the mating faces are clean.
    • Fit a new cylinder head gasket.
    • Install the cylinder head, tightening in three stages in the sequence indicated.
    • 1st stage: 15 Nm.
    • 2nd stage: 30 Nm.
    • 3rd stage with special tool 303-174: 90 degrees.
Vehicles built from 01/2001
  1. NOTE:
    NOTE:Install each valve tappet in the location from which it came.
    Install the valve tappets.
    • If necessary, change the tappet to adjust the valve clearance.
      For additional information, refer to: Valve Clearance (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
Vehicles built up to 01/2001
  1. NOTE:
    NOTE:Install the valve tappets with adjusting shims in the locations from which they came.
    Install the valve tappets and adjusting shims.
    • If necessary, change the particular adjusting shim to adjust the valve clearance.
      For additional information, refer to: Valve Clearance (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
All vehicles
  1. Install the three lower intake manifold bolts and attach the oil dipstick tube.
Vehicles built up to 07/1998
  1. Install the front engine mounting bracket.
Vehicles built from 08/1998
  1. Install the front engine mounting bracket.
  1. Move the timing belt upper cover into the installation position.

  1. Install the front engine mounting.

  1. Attach the catalytic converter to the exhaust manifold.
  1. Install the exhaust manifold heat shield.

  1. Install the timing belt cover bracket.
  1. Remove the trolley jack.

  1. NOTE:
    NOTE:The identification numbers are located on the outside of the camshaft bearing caps.
    Apply sealer to the areas shown on camshaft bearing cap no. 1 and to the opposite surface on the cylinder head.

  1. CAUTION:
    CAUTION:Install the camshaft with none of the cams at full lift.
    NOTE:
    NOTE:The exhaust camshaft has an additional cam for the camshaft position (CMP) sensor.
    Install the camshafts.
    • Before installation, lubricate the camshafts and camshaft bearings with engine oil.

  1. Identification numbers on the camshaft bearing caps.
    1. Begins with I1 at the timing belt end for intake-side camshaft bearing caps.
    1. Begins with E1 at the timing belt end for exhaust-side camshaft bearing caps.
  1. NOTE:
    NOTE:Tightening sequence.
    Fit the camshaft bearing caps and tighten the bolts in three stages.
    • 1st stage: Tighten the bolts evenly half a turn at a time until the camshaft bearing caps contact the cylinder head.
    • 2nd stage: 6 Nm.
    • 3rd stage: 15 Nm.
  1. Check the valve clearance and correct if necessary.

  1. Press in a new camshaft oil seal using the special tool.

  1. Turn the camshafts to TDC of cylinder no. 1.
    • Turn the camshafts at the hexagon with an open-ended spanner until the special tool can be inserted.

  1. CAUTION:
    CAUTION:Counterhold using the special tool.
    NOTE:
    NOTE:Use new camshaft pulley bolts.
    Install the camshaft timing pulleys so that it is still just possible to turn them on the camshafts.

  1. NOTE:
    NOTE:Marked running direction on re-used timing belt.
    Fit the timing belt.
    • Fit the timing belt working counter-clockwise from the crankshaft timing pulley.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Install the timing belt lower cover.

  1. NOTE:
    NOTE:Use the bolt removed from the crankshaft pulley/vibration damper.
    Install the crankshaft pulley/vibration damper using the special tool.

  1. Remove the blanking plug and install the special tool.
    • Carefully turn the crankshaft until the crank web contacts the special tool.

  1. NOTE:
    NOTE:Use a new bolt.
    Install the crankshaft pulley/vibration damper bolt.
    • Tighten the bolts in two stages.
    • 1st stage: 40 Nm
    • 2nd stage: 90 degrees

  1. Remove the special tool.

  1. Attach the special tool.
    • Carefully turn the crankshaft until the crank web contacts the special tool.
Timing belt tensioner up to build month 03/97
  1. Tension the timing belt.
    • Slacken the special tool.
Timing belt tensioner from build month 04/97
  1. Tension the timing belt (shown with engine removed).
    • Using a 6 mm Allen key, turn the eccentric counter-clockwise until the arrow is in line with the center of the window.
      NOTE:
      NOTE:Do not turn the eccentric when tightening it. Counterhold using an Allen key.
    • Tighten the bolt.
Timing belt tensioner from build month 03/98
  1. Tension the timing belt (shown with the engine removed)
    • Using an 8mm Allen key, tension until the pointer is positioned exactly in the center of the square recess.
    • Tighten the bolts.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulleys against special tool 303-376.
    NOTE:
    NOTE:Do not turn the crankshaft and the camshaft.
    Tighten the bolts of the camshaft timing pulleys.
  1. Remove special tool 303-376.

  1. Remove the special tool.

  1. NOTE:
    NOTE:If special tool 303-507 cannot be screwed in, turn the crankshaft back counter to the direction of engine rotation by about 20 degrees.
    Check the valve timing.
    • Turn the crankshaft two revolutions in the direction of engine rotation and set it to TDC.
    • Screw in special tool 303-507.
    • Carefully turn the crankshaft in the direction of engine rotation until the crank web contacts the special tool.
    • Use special tool 303-376 to check TDC position.
    • Remove special tools 303-376 and 303-507.

  1. NOTE:
    NOTE:Only if special tool 303-376 cannot be inserted.
    Set the valve timing.
    • Screw in the special tool.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulley against special tool 303-376.
    NOTE:
    NOTE:Only if special tool 303-376 cannot be inserted.
    Set the valve timing.
    • Loosen the camshaft timing pulley of the affected camshaft, counterholding using the special tool.
    • Turn the camshaft at the hexagonal section using an open-ended spanner until special tool 303-376 can be inserted.
    • Tighten the camshaft timing pulley; the crankshaft must remain at TDC.
    • Remove special tool 303-376 and unscrew special tool 303-507.
    • Check the valve timing again in accordance with the previous step.

  1. Install the blanking plug in the timing peg bore.

  1. NOTE:
    NOTE:Apply lubricant to the spark plug threads.
    Install the spark plugs using the special tool.

  1. Install the bolts of the timing belt cover.
    • Timing belt upper cover.
Vehicles with air conditioning
  1. Tighten the power steering pump bolts.
All vehicles
  1. Install the coolant pump pulley and the drive belt idler pulley.

  1. Fit and tension the drive belt.
Vehicles built up to 07/1998
  1. Install the generator.
    1. Three bolts.
    1. Attach the cable.
    1. Attach the connector.
Vehicles built from 08/1998
  1. Install the generator.
    1. Attach the connector.
    1. Attach the cable.
    1. Tighten the studs.
All vehicles
  1. Install the vacuum hoses on the EGR valve (if present).

  1. Connect the vacuum hoses to the throttle body.
    • Brake servo
    • Fuel regulator
    • EGR valve (if present)

  1. Attach the coolant hoses.
    1. Heater hose to coolant outlet housing.
    1. Hose to coolant expansion tank.

  1. Attach the coolant hose to the coolant outlet housing.

  1. CAUTION:
    CAUTION:Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Push on the spark plug connector keeping it in line with the spark plug.
    NOTE:
    NOTE:Coat the inside of the spark plug connectors with silicone grease to a depth of 5 - 10 mm.
    Install the cylinder head cover.
    1. Attach the nuts and tighten in two stages.
    • 1st stage: 3 Nm.
    • 2nd stage: 10 Nm.
    1. Push on the spark plug connectors until they engage.
    1. Install three bolts of the timing belt upper cover.

  1. Install the cover plate of the cylinder head cover.
    1. Install the bolts.
    1. Install the PCV hose.
    1. Clip in the carbon canister vacuum pipe bracket.
    1. Clip on the fuel pipes.
Vehicles built from 12/2000
  1. CAUTION:
    CAUTION:Check the cylinder head cover gasket for damage and install a new one if necessary.
    Attach the cylinder head cover.
    • Screw in bolt no. 1 finger tight.
    • Tighten bolt nos. 2 to 13 in the sequence shown.

  1. CAUTION:
    CAUTION:Use suitable blunt object to avoid damaging the spark plug connector seal. Coat the inside of the spark plug connector with silicone grease to a depth of 5 - 10 mm.
    Connect the spark plug electrical connectors and clip the wires to the cylinder head cover.

  1. Install the PCV hose and the fuel supply and return lines on the cylinder head cover.
All vehicles
  1. Attach the connector.
    1. CMP sensor.
    1. HO2S.

  1. Attach the connectors.
    1. TP sensor.
    1. EI ignition coil.
    1. ECT sensor.
    1. Attach the engine wiring harness connector.

  1. Install the cylinder head cover plate.
    1. Tighten the bolts.
    1. Attach the crankcase breather hose and close the wiring harness cover.
    • Screw on the oil filler cap.
Vehicles with 1.25l engine
  1. Attach the accelerator cable.
    • Hook in the accelerator cable and secure it to the bracket with the clip.
Vehicles with 1.4l or 1.6l engine
  1. Attach the accelerator cable.
    1. Attach the clip.
    1. Screw the cable into the bracket.
All vehicles
  1. Connect the fuel lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the intake hose.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Drain the engine oil.
    • Install the oil drain plug with a new seal.

  1. Install the battery tray.
    1. Attach the cable bracket.
    1. Install the battery tray.
  1. Standard finishing operations
    • Change the oil (incl. oil filter).
    • Install and connect the battery.
      For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
    • Fill up with coolant.
    • Bleed the air from the cooling system.
    • Bleed the fuel system.
    • Check the engine and the cooling system for leaks (visual check).

In-vehicle Repair|Removal > < Timing Belt