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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Fiesta 1996 (08.1995-02.2002)

Engine - 1.4L PTE (CVH) - Cylinder Head Fiesta 1996 (08/1995-02/2002)
In-vehicle Repair

Special Tool(s)

Angle gauge

21-540

Remover/installer, cooling hose clamp

24-003
General Equipment
Steel straightedge
Feeler gauge
Materials
Name
Specification
Coolant
ESD-M97B49-A 
Silicon grease
A960-M1C171-AA 

Removal

  1. WARNING:
    WARNING:There is a risk of scalding when the engine is warm.
    Release the fuel system pressure. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. CAUTION:
    CAUTION:Disconnect the battery negative lead.
    Standard preparatory measures.
    • For removal of coolant hoses and ventilation hoses, use tool 24-003.
    • Make a note of the radio keycode.
    • Make a note of the programmed radio stations.
    • Unscrew and remove the coolant expansion tank cap.
  1. Raise the vehicle.

  1. Drain the coolant.
    • After draining, screw in the drain plug.

  1. Detach the front exhaust pipe from the exhaust manifold.
    • Remove the gasket.
    • Fit the exhaust pipe.

  1. Remove bracket - oil dipstick tube.
    • Remove timing belt, as described in Operation 21 304 0.

  1. CAUTION:
    CAUTION:Turn the spark plug connectors before disconnecting. Pull only the connector not the cable.
    Lower the vehicle.
    • Remove the clip.
    • Disconnect the throttle cable.
    • Disconnect the spark plug connectors for cylinders 1 and 2.

  1. Remove the intake pipe.
    1. Unscrew the bolts.
    1. Disconnect the hose.
    1. Detach the clamp.

  1. Separate/disconnect the multiplugs.
    1. Engine wiring harness.
    1. EI ignition coil.

  1. Disconnect the pipes.

  1. CAUTION:
    CAUTION:Plug the fuel pipes.
    Disconnect the fuel pipes.

  1. Detach the coolant hoses and the cable coolant temperature gauge sender.

  1. Remove the oil separator.
    • Pull out the oil dipstick.

  1. Disconnect the heater hose.

  1. Remove the pulley from the power steering pump.
    • For back-stop use Allen key.

  1. Remove the power steering pump and tie it up at the lock panel.

  1. Remove bracket from power steering pump.

  1. Detach the bracket for the accelerator cable.

  1. Remove the cylinder head cover.
    • Disconnect the hose from the oil separator.
    • Unscrew the bolts.
    • Remove the reinforcing panels.
    • Remove the gaskets.

  1. NOTE:
    NOTE:Slacken the cylinder head bolts in the indicated order and remove them.
    Remove the cylinder head.
    • Remove the cylinder head gasket.

Installation
  1. NOTE:
    NOTE:If the maximum permitted unevenness is exceeded, rework the cylinder head (see General Specifications).
    Check the cylinder head distortion using a steel straightedge.

  1. NOTE:
    NOTE:Choose the new cylinder head gasket by comparing it with the old gasket (identification teeth).
    NOTE:
    NOTE:Before putting the cylinder head in place, turn the crankshaft so that the first cylinder is about 20 mm before TDC.
    Install the cylinder head.
    1. Check the guide sleeves are correctly located.
    1. Cylinder head gasket identification marks.
    1. Fit the new cylinder head gasket.

  1. NOTE:
    NOTE:Use new cylinder head bolts.
    Install the cylinder head (cont.).
    • Fit the cylinder head.
    • Tighten the new cylinder head bolts in the indicated order in four stages.
    • Use a torque wrench for stages one and two.

  1. Install the cylinder head (cont.).
      CAUTION:
      CAUTION:The cylinder head bolts must not be re-torqued.
    • Use an angle gauge for stages 3 and 4.

  1. Install the cylinder head (cont.).
    • Fit the cylinder head cover with a new gasket.
    • Fit the reinforcing panels with the rippled side upwards.
    • Tighten the bolts uniformly.
    • Connect the oil separator hose.
  1. Install the timing belt as described in Operation No. 21 304 0.

  1. Fit the bracket - power steering pump.

  1. Fit the power steering pump.

  1. Fit pulley at power steering pump.
    • For back-stop use Allen key.

  1. Connect the heater hose.

  1. Attach the bracket for the accelerator cable.

  1. Fit the oil separator.
    • Insert the oil dipstick.

  1. Attach the coolant hoses and the cable coolant temperature gauge sender.

  1. Connect the fuel pipes.

  1. Connect the pipes.

  1. Join/connect the multiplugs of engine wiring harness and EI ignition coil.
  1. Install the intake pipe.
  1. NOTE:
    NOTE:Coat the spark plug sealing with silicone grease (A960-M1C171-AA).
    Connect spark plug connectors for cylinders 1 and 2.

  1. Install the throttle cable.
    1. Connect the throttle cable.
    1. Install the clip.
  1. Raise the vehicle.

  1. Install the front exhaust pipe on the exhaust manifold using a new gasket.

  1. Install the bracket - oil dipstick tube.

  1. Fit the drive belt.
  1. Lower the vehicle.
  1. Standard finishing operations.
    • Fill up with coolant.
    • Change the engine oil.
    • Check the routing of the wiring and hoses and secure them with cable ties where necessary.
    • Connect the battery negative lead.
    • Check the engine and cooling system for leaks (visual inspection).
    • Enter the radio keycode.
    • Reprogramme the pre-set radio stations.
    • Reset the clock.
    • Carry out a road test to allow the PCM to re-learn values.
    • Check the fluid levels and rectify as necessary.

In-vehicle Repair|Oil Pan > < Exhaust Manifold