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Ford Fiesta Workshop Service and Auto Repair Manuals

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Assembly|Installation > < Cylinder Head

Fiesta 1996 Engine Disassembly and Assembly Procedures

Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L - Engine Fiesta 1996 (08/1995-02/2002)
Assembly

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)

Locking Tool, Flywheel

303-393 (21-168)

Installer, Crankshaft Seal

303-395 (21-171)

Compressor, Belt Tensioner

303-429 (21-180)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-14A (21-212)

Socket, Spark Plug

303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Installer, Crankshaft Vibration Damper

303-510 (21-214)

Locking Tool, Crankshaft

303-748 (21-259)

Aligner, Clutch Plate

308-204 (16-067)
General Equipment
Torx socket T55
Torx socket E10
21 mm open-ended spanner
24 mm open-ended spanner
27 mm open-ended spanner
Micrometers
Internal micrometer
Piston ring compressor
Materials
Name
Specification
Sealer, camshaft bearing cap
WSK-M2G348-A2 
Sealer, cylinder block mating face joints, rear crankshaft oil seal, oil pan
WSE-M4G323-A4 
Sealer, oil pressure switch thread
WSK-M2G349-A7 
Engine oil
WSS-M2C912-A1 
Silicone grease, spark plugs
ESE-M1C171–AA 
Lubricant (spark plug threads - Never Seez)
ESE-M1244–A 

Assembly

All vehicles
  1. CAUTION:
    CAUTION:Crank drive components, as well as pistons and cylinder liners cannot be renewed separately. Please also observe the important notes on this subject in the section "Description and Operation".
    NOTE:
    NOTE:The threads and contact faces of all bolts and washers must be lubricated with engine oil before installation.
    Preparatory operations.
    • The threads and contact faces of all bolts and washers must be lubricated with engine oil before installation.
    • Thoroughly clean all mating faces and reusable parts, and check them for damage. Observe the important notes in "Description and Operation" regarding the cleaning of the cylinder block.
  1. Attach the cylinder block with crank gear (short block) to the mounting stand (303-435) using special tools 303-435-14 and 303-435-06.

  1. NOTE:
    NOTE:Correct seating of oil seal housing.
    Attach the new rear crankshaft oil seal housing with oil seal and attach the crankshaft position (CKP) sensor mounting.

  1. Install the CKP sensor.

  1. NOTE:
    NOTE:Tightening sequence and position of locating stud for the flywheel.
    Attach the flywheel.
    • Attach the flywheel, immobilize with the special tool and tighten in two stages according to the tightening sequence.
    • 1st stage: 30 Nm.
    • 2nd stage: 80 degrees.

  1. NOTE:
    NOTE:Align the oil pump driveshaft to the crankshaft.
    Attach the oil pump and the oil intake pipe with a new gasket.
    • The oil pump is located by two guide sleeves and does not need to be aligned with the cylinder block.

  1. NOTE:
    NOTE:Lubricate the sealing lip of the oil seal and the crankshaft journals with engine oil.
    Install the front crankshaft oil seal using the special tool.
Vehicles built up to 11/1999
  1. Apply sealer to the cylinder block mating face and to the rear crankshaft oil seal housing mating face.
    • The applied sealer must extend 10 mm beyond the mating face joints.

  1. Align the oil pan.
    • Locate the oil pan with a new gasket and tighten the bolts finger tight.
    • Using a steel rule, align the oil pan so that the cylinder block is flush with the oil pan on the flywheel side.
Vehicles built from 12/1999
  1. CAUTION:
    CAUTION:Use studs. The cylinder block may be damaged if sealer enters the blind holes.
    Install five studs (M8x20) into the blind holes shown.

  1. NOTE:
    NOTE:Attach the oil pan within 10 minutes of applying the sealer.
    Apply a 3 mm bead of sealer to the oil pan flange.

  1. NOTE:
    NOTE:Tightening sequence.
    Tighten the oil pan bolts in two stages.
    • 1st stage: 10 Nm.
    • 2nd stage: 20 Nm.
Vehicles built up to 11/1999
  1. NOTE:
    NOTE:Tightening sequence.
    Tighten the oil pan bolts.
All vehicles
  1. Attach the clutch.
    • Centralize the clutch plate on the clutch pressure plate using the special tool.
    • Tighten the bolts evenly, working diagonally.
    • Detach the special tool.

  1. Attach the crankcase ventilation.

  1. CAUTION:
    CAUTION:Check the thermostat and renew as necessary.
    NOTE:
    NOTE:Only renew the thermostat oil seal if it is necessary.
    NOTE:
    NOTE:Apply sealer to the thread of the oil pressure switch.
    Attach the thermostat housing with a new gasket and the oil pressure switch.
    1. Thermostat housing with new gasket.
    1. Oil pressure switch.

  1. CAUTION:
    CAUTION:Do not damage the coolant pump impeller.
    Fit the coolant pump with a new gasket.

  1. NOTE:
    NOTE:Tightening sequence.
    NOTE:
    NOTE:The cylinder head is located by two guide sleeves.
    NOTE:
    NOTE:The removed cylinder head bolts can be reused.
    Attach the cylinder head.
    • Ensure that all 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 valve adjustment shims.
    • If necessary, use a suitable 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. Set the piston to approx. 25 mm before TDC of cylinder no. 1.
    • The flywheel must be in the position shown.

  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 is fitted with an additional cam for the camshaft position sensor (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. Check the valve clearances and adjust them as necessary.
    For additional information, refer to: Valve Clearance (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
  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: 7 Nm.
    • 3rd stage: 16 Nm.

  1. NOTE:
    NOTE:Lubricate the sealing lip of the oil seal and the camshaft journals with engine oil.
    Press in a new camshaft oil seal using the special tool.

  1. Attach the timing belt inner cover.
  1. NOTE:
    NOTE:Use new camshaft pulley bolts.
    Install the camshaft timing pulleys so that it is still just possible to turn them.

  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. NOTE:
    NOTE:If the special tool cannot be installed, turn the crankshaft back counter to the direction of rotation about 20 degrees.
    Turn the crankshaft to TDC of cylinder no. 1.
    • Remove the blanking plug from the timing peg bore and attach the special tool.
    • Carefully turn the crankshaft clockwise until the crank web contacts the special tool.

  1. Attach the crankshaft timing pulley.
Timing belt tensioner up to build month 03/97
  1. Install the ancillary components on the timing belt side.
    1. Timing belt tensioner.
    1. Timing belt tensioner
Timing belt tensioner from build month 04/97
  1. Install the timing belt tensioner.
Timing belt tensioner from build month 03/98
  1. Install the timing belt tensioner.
  1. Fit the timing belt.
    • Fit the timing belt starting at the crankshaft timing pulley and working counter-clockwise.
Timing belt tensioner up to build month 03/97
  1. Tension the timing belt.
    • Slacken the special tool and detach it.
Timing belt tensioner from build month 04/97
  1. NOTE:
    NOTE:Do not turn the eccentric when tightening it. Counterhold using an Allen key.
    Tension the timing belt.
    • Using a 6 mm Allen key, turn the eccentric counter-clockwise until the arrow is in line with the center of the window.
    • Tighten the bolt.
Timing belt tensioner from build month 03/98
  1. Tension the timing belt.
    • Using an 8mm Allen key, tension until the pointer is positioned exactly in the center of the square recess.
    • Tighten the bolts.

  1. Attach the components on the timing belt side (if detached).
    1. Timing belt retainer
    1. Timing pulley thrust washer

  1. Attach the timing belt lower cover.

  1. Remove the special tool.

  1. Attach the special tool.
    • Carefully turn the crankshaft clockwise until the crank web contacts the special tool.

  1. Press the pulley/vibration damper onto the crankshaft using the special tool.

  1. NOTE:
    NOTE:Renew the bolts.
    Install the crankshaft pulley/vibration damper bolt.
    • Tighten the bolt in two stages.
    • 1st stage: 40 Nm.
    • 2nd stage with special tool 303-174: 90 degrees.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulleys against special tool 303-376.
    NOTE:
    NOTE:The crankshaft and camshaft must not be turned.
    Tighten the camshaft timing pulleys.

  1. Remove the special tool.

  1. Detach 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 Special Tool 303-507.

  1. 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.
    • If necessary mark the timing pulley bolts with paint. Renew any bolts with paint markings.
    • 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. Adjust the valve clearances.
    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 7/1998
  1. Install the front engine mounting bracket.
Vehicles built from 8/1998
  1. Install the front engine mounting bracket.

  1. Coat the spark plug thread with lubricant and install using the special tool.

  1. CAUTION:
    CAUTION:Check the cylinder head cover gasket for damage and install a new one if necessary.
    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 in line with the spark plug axis.
    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. Screw on the cylinder head cover nuts and tighten in two stages.

        2. 1. Stage 1: 3 Nm

        2. Stage 2: 10 Nm

    1. Push on the spark plug connectors until they engage.
    1. Insert the ignition cable clip.
Vehicles built from 12/2000
  1. CAUTION:
    CAUTION:Check the cylinder head cover gasket for damage and install a new one if necessary.
    Install 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.
All vehicles
  1. Attach the timing belt upper cover.
    • Timing belt cover
    • Idler pulley.
    • Coolant pump pulley
Vehicles with 1.25l engine
  1. Attach the intake manifold to the cylinder block.

  1. Attach the engine wiring harness.
    1. Temperature/manifold absolute pressure (T-MAP) sensor connector.
    1. Idle air control valve (IAV) connector.
    1. Oil pressure switch connector.
    1. Crankshaft position sensor connector.

  1. Attach the engine wiring harness.
    1. Engine coolant temperature sensor (ECT sensor) connector.
    1. Connector rail for injectors.
    1. Camshaft position (CMP) sensor connector.
    • Clip the wiring harness in place.

  1. Attach the oil dipstick tube.
Vehicles with 1.4l or 1.6l engine
  1. NOTE:
    NOTE:Apply sealer to the thread of the oil pressure switch.
    Attach the ancillary components.
    1. Install the intake manifold and connect the crankcase breather hose.
    1. Engine wiring harness.
    1. Cylinder head cover plate.
    1. Attach the EGR pipe to the inlet manifold and install the EGR valve (21 mm) (if detached).
    1. Oil dipstick tube.

Vehicles built up to 7/1998
  1. Install the generator.
    1. Install the three bolts.
    1. Attach the cable.
    1. Attach the connector.
Vehicles built from 8/1998
  1. Install the generator.
    • Attach the generator connector.
  1. Attach the oil filter.
  1. Fill up with engine oil.

  1. Hook the engine into the workshop hoist using the special tool.

  1. Remove the engine from the mounting stand.
    • Remove the special tools.

  1. Install the intermediate bearing bracket and the exhaust manifold with a new gasket.

  1. Attach rear and center exhaust manifold heat shield.

Assembly|Installation > < Cylinder Head