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Cylinder Head > < Camshaft Seal

Fiesta 1996 (08.1995-02.2002)

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

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Alignment Plate, Camshaft

303-376 (21-162B)

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
Lubricant for Special Tool 303-511
WSD-M1C227-A 
Silicone grease
ESE-M1C171-AA 
Lubricant (spark plug threads - Never Seez)
ESE-M1244-A 
Cable ties
 

Removal

All vehicles
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Detach the cylinder head cover plate.
    1. Open the flap and pull the breather hose off the cylinder head cover.
    1. Detach the cylinder head cover plate (six bolts).
    • Unscrew the oil filler cap.

  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 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 from the timing belt upper cover.
    1. Remove the nuts.
Vehicles built from 12/2000
  1. Remove the cylinder head cover.
All vehicles
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the drive belt cover.

  1. Slacken the drive belt and remove (vehicle from 08/1998 shown).

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

  1. Detach 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 cover.
    1. Timing belt upper cover.
    1. Timing belt lower cover.
  1. Remove the lower cover.
  1. Lower the vehicle.
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. Disconnect the plug.
    1. Disconnect the positive cable.
    1. Detach the studs.
  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. 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 03/1997
  1. Slacken and remove the timing belt.
    • Compress the timing belt tensioner using the special tool.
Timing belt tensioner from build month 04/1997
  1. Slacken and remove the timing belt (shown with engine removed).
    • Loosen the bolt.
Timing belt tensioner from build month 03/1998
  1. Slacken and remove the timing belt (shown with engine removed).
    • Detach the bolts.

  1. NOTE:
    NOTE:When re-using the timing belt, mark the running direction.
    Detach the timing belt retainer (if present).
    • Remove the timing belt from the crankshaft timing pulley.

  1. CAUTION:
    CAUTION:Counterhold using the special tool.
    Loosen the bolts until the camshaft timing pulleys can be turned on the camshafts.
    • Discard the timing pulley bolts.

  1. Remove the spark plugs with the special tool.

Installation

All vehicles
  1. Turn the camshaft to TDC cylinder number 1 and insert the special tool.
    • Turn the camshaft at the hexagonal section using a 21 mm open-ended spanner until the special tool can be inserted.
  1. NOTE:
    NOTE:Observe running direction marking 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. NOTE:
    NOTE:Use an installation trolley.
    Install the timing belt retainer (if removed).
Timing belt tensioner up to build month 03/1997
  1. Tension the timing belt.
    • Slacken the special tool and detach it.

  1. NOTE:
    NOTE:The raised surface faces outwards.
    Push the timing belt thrust washer onto the crankshaft (if removed).
Timing belt tensioner from build month 04/1997
  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 03/1998
  1. Tension the timing belt (shown with the engine removed)
    • Tension with an 8mm Allen key until the pointer is positioned exactly in the center of the square recess.
    • Tighten the bolts.

  1. Attach the lower timing belt cover.

  1. NOTE:
    NOTE:Press on the crankshaft pulley/vibration damper up to the stop.
    NOTE:
    NOTE:Use old bolts from the crankshaft pulley/vibration damper.
    Press on the crankshaft pulley/vibration damper.

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

  1. Turn the camshafts to TDC of cylinder number 1.
    • Turn the camshafts at the hexagon with an open-ended spanner until the special tool can be inserted.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulleys against special tool 303-376.
    NOTE:
    NOTE:The timing pulley bolts can be re-used once.
    NOTE:
    NOTE:Do not turn the crankshaft and the camshaft.
    NOTE:
    NOTE:Use new camshaft pulley bolts.
    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 inserted, turn the crankshaft back counter to the direction of rotation by about 20 degrees.
    Check the valve timing.
    • Turn the crankshaft two revolutions in engine running direction and set it to TDC.
    • Install special tool 303-507.
    • Carefully turn the crankshaft clockwise 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.
    Correct the valve timing.
    • Attach the special tool.

  1. NOTE:
    NOTE:Counterhold using the special tool.
    NOTE:
    NOTE:The crankshaft must remain at TDC of cylinder no. 1.
    NOTE:
    NOTE:Only if Special Tool 303-376 cannot be inserted.
    Set the valve timing.
    • Loosen the camshaft timing pulley of the camshaft concerned.
    • Turn the camshaft at the hexagonal section until special tool 303-376 can be inserted.
    • Tighten the camshaft timing pulley.
    • Check the valve timing again in accordance with the previous steps.

  1. Install the spark plugs using the special tool.
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. Remove the trolley jack.
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. Unscrew special tool 303-507 and screw in the blanking plug.

  1. Install the timing belt upper cover bolts.

  1. Tighten the power steering pump bolts.

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

  1. Fit and tension the drive belt.

  1. Install the drive belt cover.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease in order 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. 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.
Vehicles built from 12/2000
  1. NOTE:
    NOTE:First turn bolt (item 1) finger tight in order to locate.
    Attach the cylinder head cover and tighten the bolts in two stages.
    • 1st stage: 3 Nm.
    • 2nd stage: 10 Nm.
All vehicles
  1. Install the cylinder head cover plate.
    1. Install the bolts.
    1. Attach the crankcase breather hose and close the wiring harness cover.
    • Screw on the oil filler cap.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Standard finishing operations.
    • Check fluid levels and correct if necessary.

Cylinder Head > < Camshaft Seal