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Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle

Fiesta 1996 (08.1995-02.2002)

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

Special Tool(s)

Slide Hammer

205-047 (15–011)

Universal Flange Holding Wrench

205-072 (15-030A)

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)

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)

Pliers, Spark Plug Connector

303–622 (21-226)

Adapter for 205-047

303–633 (21–227)

Disassembly

All vehicles
  1. Detach rear and center exhaust manifold heat shield.

  1. Detach the exhaust manifold with catalytic converter bracket and intermediate bearing bracket.
    • Remove the exhaust manifold gasket.

  1. Mount the engine on the mounting stand.
    • Attach the special tools to the engine.
  1. Drain the engine oil and detach the oil filter.
Vehicles built up to 08/1998
  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.
    • Detach the generator connector.
Vehicles with 1.25l engine
  1. Detach the oil dipstick tube.

  1. Detach the engine wiring harness.
    1. Engine coolant temperature sensor (ECT sensor) connector
    1. Connector rail for injectors
    1. Camshaft position (CMP) sensor connector
    • Unclip the wiring harness.

  1. Detach 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 (CKP) sensor connector.

  1. Detach the intake manifold from the cylinder block.
Vehicles built up to 07/1998
  1. Remove the front engine mounting bracket.
Vehicles built from 08/1998
  1. Detach the engine mounting bracket.
Vehicles with 1.4l or 1.6l engine

  1. Detach the ancillary components.
    1. Detach the intake manifold and disconnect the hose from the crankcase breather.
    1. Engine wiring harness.
    1. Cylinder head cover plate.
    1. Detach the EGR pipe from the intake manifold and from the exhaust gas recirculation valve (EGR valve) (21 mm) (if present).
    1. Oil dipstick tube.
All vehicles
  1. Remove the timing belt upper cover.
    • Coolant pump pulley
    • Idler pulley
    • Timing belt cover
Vehicles built up to 01/2001
  1. CAUTION:
    CAUTION:The gasket of the cylinder head cover cannot be renewed separately. To avoid damaging the gasket when removing, lift off the cylinder head cover vertically upwards.
    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.
    Remove the cylinder head cover.
    1. Detach the spark plug connectors.
    1. Remove the ignition cable clip.
    • Use special tool 303-622 for angled spark plug connectors.
    1. Remove the nuts.
Vehicles built from 12/2000
  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. Remove the spark plugs with Special Tool 303-499.

  1. Detach the crankshaft pulley/vibration damper.

  1. Remove the timing belt lower cover.

  1. Detach the timing belt-side ancillary components (if present).
    • Detach the timing belt retainer.
    • Remove the timing pulley thrust washer.
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 piston using the special tool until the holes in the housing and those in the piston align.
Timing belt tensioner up to build month 03/97
  1. NOTE:
    NOTE:When re-using the timing belt, mark the running direction.
    Detach the timing belt tensioner.
    1. Timing belt tensioner
    1. Timing belt tensioning pulley
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.

  1. Detach the timing belt tensioner.
Timing belt tensioner from build month 03/98
  1. Slacken and remove the timing belt.
    • Loosen the bolts.
  1. Detach the timing belt tensioner.
    • Remove the bolts.
All vehicles
  1. Remove the camshaft timing pulleys.
    • Counterhold using the special tool.
    • Discard the timing pulley bolts.

  1. Detach the crankshaft timing pulley.

  1. Detach the timing belt inner cover.

  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 camshaft.
    • Loosen the camshaft bearing cap bolts one turn at a time until the camshaft is released.
    • Detach the camshaft bearing caps.
    • Remove 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. CAUTION:
    CAUTION:The cylinder head must have cooled to below 30°C before removal.
    CAUTION:
    CAUTION:Lay the cylinder head down on a soft surface.
    NOTE:
    NOTE:Loosening sequence.
    Remove the cylinder head.
    • Remove the cylinder head bolts using the special tool.

  1. CAUTION:
    CAUTION:Do not damage the coolant pump impeller.
    Remove the coolant pump.

  1. Detach the thermostat housing and the oil pressure switch.

  1. Detach the positive crankcase ventilation.
Vehicles built up to 11/1999
  1. CAUTION:
    CAUTION:Remove oil pan downwards to prevent oil sludge and swarf from entering the engine.
    Detach the oil pan.
Vehicles built from 12/1999
  1. Remove the oil pan bolts.
    1. Remove the drain plug.
    1. Remove the oil pan bolts.

  1. CAUTION:
    CAUTION:Avoid damaging the mating faces by using only the special tool listed to detach the oil pan. Do not use a chisel or screwdriver to detach the oil pan.
    Detach the oil pan using the special tool
    • Attach the special tools and lock against the oil pan.
    • Release the oil pan from the cylinder block by several blows.
    • Detach the special tool and install the drain plug.
All vehicles
  1. Detach the oil intake pipe and the oil pump with gasket.
    • Drive the oil seal out of the oil pump on a flat surface.

  1. CAUTION:
    CAUTION:Loosen the bolts by two turns until the clutch pressure plate is released.
    Using the special tool, immobilize the flywheel and remove the clutch.

  1. Detach the flywheel (immobilized by the special tool).

  1. Remove the crankshaft position (CKP) sensor.

  1. Detach the rear crankshaft oil seal housing and the crankshaft position (CKP) sensor mounting.
  1. Detach the cylinder block with crank drive (short block) from the mounting stand.
    • Detach the special tools from the cylinder block.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle