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Engine - Vehicles With: Manual Transaxle > < Cylinder Head

Fiesta 1996 (08.1995-02.2002)

Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L - Engine—Vehicles With: Automatic Transaxle Fiesta 1996 (08/1995-02/2002)
Removal

Special Tool(s)

Separator, ball joint

211-020 (13-006)

Remover/installer, coolant hose clip

303-397 (24-003)

Remover, halfshaft

308-237 (16-087)
Materials
Name
Specification
Cable ties
 

Removal

All Vehicles
NOTE:
NOTE:The position of the engine mountings and the engine roll restrictor is described looking from the transmission towards the engine.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. NOTE:
    NOTE:Use an Allen key to stop the piston rod from turning.
    Undo the right-hand and left-hand suspension strut nuts by five turns.
  1. Remove the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the battery box.
    1. Separate the cable ties.
    1. Remove the bolts.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. WARNING:
    WARNING:Danger of scalding if the engine is warm.
    Drain off the coolant.
    • Unscrew and remove the drain plug on the lower left of the radiator.
    • After draining, screw in the plug again.

  1. Drain off automatic transmission fluid.
    • Unscrew and remove the drain plug.
    • Once the fluid has been drained, screw in the plug again using a new seal.
  1. Lower the vehicle.

  1. Remove the intake hose.

  1. Detach the breather hose.
    1. Open the flap and disconnect the breather hose from the cylinder head.
    1. Unhook the accelerator cable.

  1. NOTE:
    NOTE:To remove the cover, unscrew the oil filler cap and screw it back on again afterwards.
    Remove the top cover from the cylinder head cover.

  1. Separate the connectors.
    1. Throttle position sensor (TP sensor).
    1. EI ignition coil.
    1. Engine coolant temperature sensor (ECT sensor).
    1. Engine wiring harness.
    1. Vehicle speed sensor (VS sensor).
  1. Separate the connectors.
    1. Camshaft position sensor (CMP sensor)
    1. HO2S sensor.
    1. Injectors
    1. Idle air control valve (IAC valve)
    1. Disconnect the wiring from the alternator. Lay the wiring loom to one side.

  1. Pull off the hoses of the exhaust gas recirculation valve (EGR valve) (if present).

  1. Disconnect the vacuum hoses from the throttle valve housing.
    • To the brake servo.
    • To the EVAP canister
    • To the fuel pressure regulator

  1. Detach the coolant hoses and the ground cable.
    1. From the coolant outlet housing
    1. To the coolant expansion tank
    1. From the coolant outlet housing
    1. Ground lead

  1. Detach the coolant hose from the radiator.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Disconnect the radiator plugs.
    • Disconnect the radiator cable.

  1. Remove the radiator shroud.

  1. Disconnect the oil pipes from the transmission.

  1. Disconnect the lower left-hand coolant hoses.
    1. From the radiator
    1. From the coolant pump
    1. From the coolant pump

  1. Detach the radiator crossmember at the bottom (left-hand side shown).
    • Remove the radiator, crossmember and fan frame together with the fan from below.

  1. Disconnect the starter motor wiring.
    1. Battery cable
    1. Solenoid switch cable

  1. Slacken and remove the drive belt.

  1. NOTE:
    NOTE:One bolt with bracket.
    Detach the power steering pump and bracket and tie it up.

  1. Unclip the gearshift cable and withdraw it from the rear.

  1. Disconnect the speedometer drive cable.
    • Withdraw it from above.

  1. NOTE:
    NOTE:Left-hand side only: detach the brake pipe bracket from the suspension strut.
    Detach the suspension arm on the right- and left-hand sides (right-hand side shown).

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:Pull off the connector from the transmission inhibit switch before removal.
    NOTE:
    NOTE:Escaping oil. Seal the transmission opening with auxiliary plugs.
    Remove the left-hand front axle halfshaft using a tyre lever.

  1. Release the front halfshaft centre bearing.
Only vehicles up to build month 12/1996 and vehicles for markets outside Europe
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After releasing the front halfshaft, immediately secure the differential with suitable auxiliary plugs to prevent it from turning.
    Detach the right-hand front axle halfshaft from the transmission.
    • Release the right-hand front halfshaft from the transmission with a light blow.
Only vehicles from build month 01/1997 for the European market
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After removing the front halfshaft, secure the differential immediately with suitable auxiliary plugs to prevent it from turning.
    Pull the right-hand halfshaft out of the transmission.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Do not damage the gaiters of the drive shaft.
    Swing the right-hand halfshaft forward and tie it up.
All vehicles
  1. Support the flexible pipe using a suitable protective gaiter. For additional information, refer to Section  309-00 Exhaust System.

  1. Disconnect the exhaust.
    • Remove the gasket.

  1. Remove the engine roll restrictor.
  1. Preparations for removing the engine
    • Position an assembly table with wooden blocks under the engine and transmission.
    • Lower the vehicle until the engine and transmission rest on the wooden blocks.
    • Secure the engine to the assembly table with a retaining strap.
  1. Disconnect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Remove the rear engine mounting bracket.

  1. Remove the front engine mounting bracket.
  1. Raise the vehicle and pull the assembly stand out from under the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

Engine - Vehicles With: Manual Transaxle > < Cylinder Head