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In-vehicle Repair > < Diagnosis and Testing|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L - Valve Clearance Fiesta 1996 (08/1995-02/2002)
General Procedures

Special Tool(s)

Compressor, valve clearance adjustment

303-563 (21218)

Remover/installer, valve adjusting shim

303-563-01 (21801)

Spark plug connector pliers

303-622 (21226)
General Equipment
Feeler gauges
Micrometer
Materials
Name
Specification
Silicone grease
ESE - M1C171 - AA 

Adjust

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

  1. CAUTION:
    CAUTION:Do not pull the cable when removing the spark plug connector. If necessary, Remove the ignition coil plug to avoid bending the cable. Turn the spark plug connector slightly before removing to break the seal.
    CAUTION:
    CAUTION:When pulling off the spark plug connector keep it in line with the spark plug.
    CAUTION:
    CAUTION:Do not damage the cylinder head cover gasket as it cannot be renewed separately.
    Remove the cylinder head cover, lifting it straight up.
    1. Pull off the spark plug connectors.
    • Use Special Tool 303-622 for angled spark plug connectors.
    1. Remove the three bolts of the upper timing belt cover.
    1. Unscrew 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 the cable when removing 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 break the seal. 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. Detach the cylinder head cover.
All vehicles
  1. Measure the valve clearances.
    • Turn the engine at the crankshaft in 180 degree stages in the direction of engine rotation and check the valve clearances of the remaining cylinders. The measuring sequence is the same as the firing order: 1-3-4-2.
NOTE:
NOTE:Only perform the following steps if the valve clearances need adjusting.
Vehicles built from 01/2001
  1. Remove the camshafts.
    For additional information, refer to: Camshaft (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, In-vehicle Repair).
  1. Choose a new tappet.
    • Tappet thickness required = thickness of currently installed tappet + the measured valve clearance - the required valve clearance.
      For additional information, refer to: Specifications (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, Specifications).
  1. Insert the new tappet which was determined in the previous step.
Vehicles built up to 01/2001
  1. NOTE:
    NOTE:Install the long bolt at the front.
    Mount the special tool.
    • Unscrew the outer bolts on the first and last camshaft bearing cap.
    • Attach the special tool with the compressor guide facing outwards.

  1. NOTE:
    NOTE:The cam for the affected valve must point upwards.
    Mount the special tool.
    • Insert the compressor into the lever.

  1. NOTE:
    NOTE:The groove on the valve tappets must face towards the middle of the engine.
    NOTE:
    NOTE:Do not press on the adjusting shim with the compressor.
    Remove the adjusting shim.
    1. Position the compressor on the edge of the valve tappet and press down the tappet.
    1. Tappet groove for Special Tool 303-563-01.
    1. Remove the adjusting shim.
  1. Measure the thickness of the adjusting shim with a micrometer.
  1. Select a new adjusting shim.
    • Thickness of the adjustment shim to use = the thickness of currently installed shim + the measured valve clearance - the required valve clearance.
      For additional information, refer to: Specifications (303-01B Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L, Specifications).
  1. Insert a new valve adjusting shim according to the previous step.
  1. Repeat the procedure on all cylinders, both on the intake side and the exhaust side.

  1. Remove the special tool.
All vehicles
  1. Check the valve clearance and adjust if necessary as described above.
Vehicles built from 01/2001
  1. NOTE:
    NOTE: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 a 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.
Vehicles built up to 01/2001
  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. plastic cable tie) to apply the silicone grease to avoid damaging the spark plug connector seals.
    CAUTION:
    CAUTION:Slide on the spark plug connector keeping it in line with the spark plug.
    NOTE:
    NOTE:Apply silicone grease to the inside of the spark plug connector up to a depth of 5-10 mm.
    Install the cylinder head cover.
    1. Install the spark plug connectors and ensure that they engage correctly.
    1. Install the three bolts for the upper timing belt cover.
    1. Screw on the nuts and tighten in two stages.
    • 1st stage: 3 Nm
    • 2nd stage: 10 Nm

  1. Install the cover plate of the cylinder head cover.
    1. Screw in the bolts.
    1. Install the PCV hose.
    1. Clip in the carbon canister vacuum pipe bracket.
    1. Clip on the fuel pipes.
All vehicles
  1. Standard finishing operations.
    • Connect the battery negative lead.
      For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
    • Check fluid levels and correct if necessary.

In-vehicle Repair > < Diagnosis and Testing|Engine