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Assembly|Installation > < Cylinder Head

Fiesta 1996 (08.1995-02.2002)

Engine - 1.8L Endura-DE (Kent) Diesel - Engine Fiesta 1996 (08/1995-02/2002)
Assembly

Special Tool(s)

Universal flange holding wrench

15-030A

Aligner, clutch disk

16-067

Mounting bracket, engine

21-031B

Timing pin, crankshaft TDC position

21-104

Centring tool, remover and installer, oil seal

21-148A

Adjustment tool, camshaft TDC

21-162B

Socket, cylinder head bolts

21-164

Locking tool, crankshaft

21-168

Aligner, crankshaft rear oil seal

21-217

Angle gauge, bolt tightening

21-540

Timing pin, injection pump

23-019

Timing pin, injection pump

23-029

Socket, injectors

23-045

Timing pin, crankshaft position sensor (CKP sensor)

23-049

Remover/installer, cooling hose clamp

24-003
General Equipment
Dial gauge with magnetic fixture
Piston ring compressor
Micrometer screw
Internal gauge
Feeler gauge
Steel straightedge
Materials
Name
Specification
Sealer
SPM-4G9112-F/G 
Engine Oil
ACEA A3/B3 
Hypoid oil
SQM-2C9002-AA 
Plastigage
Obtainable through: Replacement Services Limited, Euston Street, Freemans Industrial Estate, Leicester, 7ST. 

Assembly

All Vehicles
  1. Preparatory operations
    • Thoroughly clean all mating faces and reusable parts and check for damage.

  1. Clean the piston cooling oil splash nozzles and oilways.

  1. Measure the diameter of the main and big-end bearing journals using a proprietary micrometer screw.
    • Repeat the measuring operation at intervals of 90°.
    • Different crankshaft sizes are used in production. The different crankshafts are not marked.
    • If the measurements do not tally with the values indicated in the General Specifications, the crankshaft should be overhauled or renewed.

  1. NOTE:
    NOTE:Fit the main bearing caps without the bearing shells and tighten them to the specified torque.
    Measure the cylinder bores with a proprietary internal gauge.
    • If the measured diameter of the cylinder bore is too large in relation to the piston classification, overhaul or renew the cylinder block.
  1. Preparations for measuring the bearing clearance.
      NOTE:
      NOTE:Carry out the following steps to the letter.
    • Measure each bearing individually using a length of Plastigage thread.
    • The bearing shells and journals must be free of oil and dirt.
    • Fit the bearing cap of the bearing being measured and tighten to the specified torque.
    • The measurement should be carried out near the respective dead centre position.

  1. Measure the crankshaft main bearing clearance.
    • Place the appropriate bearing shells dry in the cylinder block.
    • Place the crankshaft dry in the cylinder block.
    • Lay a length of Plastigage thread across the bearing on the bearing journal.

  1. Measure the crankshaft main bearing clearance (continued).
      NOTE:
      NOTE:The main bearing cap numbering starts at the timing belt end, to which the arrows also point.
    • Fit the main bearing cap with the associated main bearing shell as described in step and tighten the bolts.
    • Remove the main bearing cap.

  1. CAUTION:
    CAUTION:Do not turn the crankshaft during the measuring procedure.
    Compare the Plastigage thread with the Plastigage scale.
    • The reading corresponds to the main bearing clearance.
    • The main bearing shells should be renewed as necessary according to the bearing clearance measurement.

  1. Install the crankshaft.
      NOTE:
      NOTE:The main bearing cap numbering starts at the timing belt end, to which the arrows also point.
    • Lubricate the main bearing journals, main bearing shells and thrust half washers with engine oil.
    • Fit the thrust half washers in main bearing no. 3 with the lubricating groove facing outwards.
    • Fit the main bearing caps with the associated bearing shells.
    • Tighten the bolts.

  1. Measure the end float of the crankshaft.
    • Set up the dial gauge.
    • Measure the end float by lifting the crankshaft as shown.
    • Rectify the end float as necessary by fitting new thrust half washers to main bearing no. 3.

  1. Classifications.
    1. Cylinder bore classification
    1. Piston diameter classification
    1. The piston weight classes are marked with '+' and '-'.

  1. NOTE:
    NOTE:Piston classification, if a piston has to be renewed.
    Measure the piston diameter.

  1. NOTE:
    NOTE:Measure the piston ring clearance with the piston ring protruding.
    Measure the piston ring clearances.
    • The maximum clearance of the upper compression ring is 0,09 - 0,12 mm.
    • The maximum clearance of the 2nd compression ring is 0,05 - 0,08 mm.

  1. CAUTION:
    CAUTION:Do not mix up the piston rings. Re-fit the piston rings in the same position and location.
    Measure the piston ring gaps.
    • The values given in the General Specifications refer to a reference gauge ring used in production. When measured in the cylinder, the values can be exceeded by 0,15 mm.

  1. Fit the pistons.
    • Lubricate the pistons and cylinder liners with engine oil.
    • Distribute the piston ring gaps evenly on the circumference at intervals of 120°. This also applies to the elements of the oil scraper ring.
      NOTE:
      NOTE:The numbering on the connecting-rod begins from the timing belt end. The arrow on the piston crown points towards the timing belt end.
    • Compress the piston rings using a proprietary piston ring compressor.
    • Press the pistons into the cylinders with the handle of a hammer, guiding the connecting rods onto the big-end bearing journals.
    • Place the appropriate bearing shells, clean and dry, in the connecting rods.

  1. Measure the big-end bearing clearances and fit the big-bearing caps.
    • Measure the big-end bearing clearance as described in steps to
    • Lubricate the big-end bearing shells and journals with engine oil.
      NOTE:
      NOTE:The numbering of the connecting rods and big-end bearing caps must tally.
    • Fit the appropriate big-end bearing caps and bearing shells and tighten the bolts.

  1. Fit the oil intake pipe with the bracket.
      NOTE:
      NOTE:Make sure that the O-ring is seated correctly.
    1. Locate the oil intake pipe in position with a new O-ring.
    1. Fit the bracket.

  1. NOTE:
    NOTE:The front plate mating face must be flush with the lower edge of the cylinder block (tolerance ± 0,1mm).
    Fit the front plate with a new gasket and new oilway seals.
    1. Centre the front plate using the aligner.
    1. Fit the front plate.

  1. CAUTION:
    CAUTION:The steps must be carried out immediately after each other to prevent the oil seal from contracting. Do not remove the support ring from the oil seal until immediately before installation.
    NOTE:
    NOTE:Install the oil seal dry.
    Draw in the crankshaft front oil seal.
    • Draw in the oil seal with the installer and the bolt of the crankshaft timing belt pulley.

  1. Install the crankshaft timing belt pulley.
      NOTE:
      NOTE:Make sure the O-ring in the timing belt pulley is in perfect condition.
    • Lubricate the O-ring and the end of the crankshaft with engine oil.
      NOTE:
      NOTE:The guide pin in the end of the crankshaft and the hole in the timing belt pulley must line up.
    • Carefully slide on the timing belt pulley as far as the stop.

  1. NOTE:
    NOTE:The sump bolts must be tightened within 20 minutes of applying the sealer.
    Apply sealer (SPM-4G-9112-F/G) to the cylinder block mating face intersections.

  1. Fit the sump.
    • Locate the sump in position with a new gasket and screw in the bolts (x 14) finger tight.
    • Using a steel straightedge, align the sump so that it is flush with the mating face of the oil seal housing.

  1. Tighten the oil pan bolts.

  1. CAUTION:
    CAUTION:The sealing lip of the oil seal and the crankshaft sealing surface must be free of oil.
    NOTE:
    NOTE:The support ring must sit in the oil seal.
    Install the crankshaft rear oil seal housing.
    1. Place the new crankshaft oil seal housing, together with the integrated oil seal, in the installation position.
    1. Screw in the bolts finger tight.
    1. Fit the aligner and centre the oil seal housing on the crankshaft.
    1. Crankshaft
    1. Remove the support ring.

  1. CAUTION:
    CAUTION:If the special tool cannot be removed, realign the sump.
    Tighten the bolts of the crankshaft oil seal housing, working diagonally.
    • Remove the locator.

  1. NOTE:
    NOTE:Use new bolts.
    Fit the flywheel.
    • Immobilise the crankshaft with the ring gear.

  1. Centre the clutch disc on the pressure plate.

  1. Fit the clutch.
    1. Place the clutch pressure plate, together with the centred clutch disc, in the installation position.
    1. Tighten the bolts uniformly, working diagonally.
    1. Remove the special tool.

  1. Install the coolant pump.
    • Place the coolant pump, together with a new gasket, and the bracket for the spring of the timing belt tensioning pulley, in the installation position.
    • Tighten the bolts.

  1. Install the auxiliary shaft with the thrust plate.
    • Lubricate the auxiliary shaft, the bearing bush in the cylinder block and the thrust plate with engine oil.
      NOTE:
      NOTE:The lubricating grooves on the thrust plate must face outwards.
    • Fit the auxiliary shaft together with the thrust plate.
    • Tighten the thrust plate bolts.

  1. NOTE:
    NOTE:Do not tighten the bolt of the auxiliary shaft timing belt pulley.
    NOTE:
    NOTE:The auxiliary shaft guide pin and the corresponding hole in the timing belt pulley must line up.
    Install the auxiliary shaft oil seal housing.
    • Lubricate the end of the auxiliary shaft with engine oil.
    • Slide the new oil seal housing with the integrated oil seal and the support ring onto the end of the auxiliary shaft.
    • Tighten the bolts of the oil seal housing.
    • After securing the oil seal housing, detach the support ring and check that the seal is seated correctly.
  1. Install the auxiliary shaft timing belt pulley.

  1. NOTE:
    NOTE:Use a new bolt.
    NOTE:
    NOTE:Lubricate the bolt head contact face with oil.
    Fit the flange of the crankshaft front timing belt pulley.

  1. Measure the piston protrusion.
      NOTE:
      NOTE:Carry out two measurements per cylinder a distance of 5 mm from the edge of the piston.
    • Measure the protrusion of the piston of each cylinder at TDC.
    • Measure the difference in height between the piston crown and the cylinder block mating face.
    • The largest measurement determines the choice of cylinder head gasket (see General Specifications).

  1. NOTE:
    NOTE:The straightedge must be at least 500 mm long.
    Check the cylinder head mating face for distortion.
    • Permitted distortion at the steps between the combustion chambers: 0,80 mm.
    • Lay the straightedge transversely across all the steps between the combustion chambers and check the distortion at three points in each case.
    • Lay the straightedge lengthways over the cylinder head in three places in the area of the combustion chambers and check the distortion at all the steps between the combustion chambers.
    • Lay the straightedge diagonally across the cylinder head and check the distortion at all the steps between the combustion chambers.

  1. Line up the crankshaft and camshaft.
    • Turn the crankshaft until the piston of cylinder no. 1 is at TDC.
    • Turn the camshaft until the slot in the eccentric on the camshaft is parallel with the upper edge of the cylinder head (with the larger semi-circle at the top).
    • The crankshaft and camshaft must not be turned any more.

  1. NOTE:
    NOTE:The cylinder head gasket is marked "TOP/OBEN".
    Fit a new cylinder head gasket.
    1. Check that the locating sleeves are seated correctly.
    1. Thickness marking as measured in step

  1. NOTE:
    NOTE:Do not oil the cylinder head bolts.
    Fit the cylinder head and tighten the new cylinder head bolts in two stages.

  1. Fit the cylinder head (continued).
      CAUTION:
      CAUTION:For stage 3, slacken one cylinder head bolt by itself, then tighten it to the specified torque and angle. Only then move on to the next bolt.
    • Wait three minutes and then tighten the cylinder head bolts according to tightening sequence in stage 3.

  1. Fit the injectors and glow plugs.
    1. Glow plugs
    1. Glow plug wiring
      NOTE:
      NOTE:Fit new injector heat shields.
    1. Injectors

  1. Fit the alternator bracket.
  1. Fit the coolant pipe bracket.

  1. Fit the thermostat housing, coolant hose and coolant pipe.

  1. Fit the injection pump.

  1. Fit the injection pump bracket.
    • Connect the fast idle cable.

  1. Connect the injection pipes and the leak-off hoses.

  1. Connect the fuel feed line.

  1. Install the oil dipstick tube.
  1. Attach the hose.

  1. Fit the timing belt side cover.

  1. Fit the engine mounting bracket.

  1. NOTE:
    NOTE:Do not tighten the bolts.
    NOTE:
    NOTE:Centre the slots on the injection pump timing belt pulley.
    Fit the injection pump timing belt pulley.

  1. Fit the injection pump timing belt tensioner.
    • Compress the spring of the timing belt tensioner and lock it with the clamp bolt.
Engines with automatic timing belt tensioner.
  1. Align the camshaft.
    • Fit the timing tool into the groove in the camshaft eccentric.
Engines with mechanical timing belt tensioner
  1. Fit the camshaft timing belt pulley and timing belt tensioner.
      NOTE:
      NOTE:Do not tighten the bolts of the camshaft timing belt pulley.
    1. Fit the camshaft timing belt pulley.
    1. Fit the timing belt tensioner (two bolts).
    1. Squeeze the springs of the timing belt tensioner together and fix in place with the clamping bolt.
Engines with mechanical timing belt tensioner.
  1. Align the camshaft timing belt pulley.
    • Align the camshaft timing belt pulley by inserting the timing pin through the cutout in the pulley and the hole in the cylinder head.
All vehicles
  1. Align the injection pump timing belt pulley and turn the crankshaft to the TDC position.
    1. Align the injection pump pulley by inserting the timing pin through the cutout in the pulley and the hole in the injection pump housing.
      NOTE:
      NOTE:Screw in the timing pin as far as it will go; the crankshaft must rest against the timing pin.
    1. Remove the bolt and screw the timing pin into the cylinder block.
    • Turn the crankshaft to the TDC position.

  1. CAUTION:
    CAUTION:Renew the toothed belt.
    NOTE:
    NOTE:The direction of rotation is marked.
    NOTE:
    NOTE:Make sure the belt is seated correctly.
    Fit the injection pump timing belt.
    1. Fit the timing belt with the slack side nearest the timing belt tensioner.
    1. Slacken the bolt of the timing belt tensioner and allow the tensioner to snap against the timing belt. Tighten the timing belt tensioner bolt.
      NOTE:
      NOTE:The bolts must not be at the ends of their slots.
    1. Tighten the bolts of the timing belt pulley.
Engines with automatic timing belt tensioner.
  1. CAUTION:
    CAUTION:Renew the toothed belt.
    NOTE:
    NOTE:Make sure the belt is seated correctly.
    Install the camshaft timing belt.
    1. Fit the camshaft timing belt tensioner.
    1. Fit the adjusting cam.
      NOTE:
      NOTE:The direction of rotation is marked.
    1. Fit the timing belt and lay it over the camshaft timing belt pulley.
    • Slide the camshaft timing belt pulley onto its conical seat and screw in the bolt until the camshaft timing belt pulley can still just be turned on the camshaft.
Engines with mechanical timing belt tensioner
  1. CAUTION:
    CAUTION:Renew the toothed belt.
    NOTE:
    NOTE:The direction of rotation is marked.
    NOTE:
    NOTE:Make sure the belt is seated correctly.
    Install the camshaft timing belt. Fit the timing belt with the slack side nearest the timing belt tensioner.
    1. Release the timing belt tensioner clamp bolt and allow the tensioner to snap against the timing belt. Tighten the timing belt tensioner clamp bolt.
      NOTE:
      NOTE:The bolts must not be at the ends of their slots.
    1. Tighten the timing belt pulley bolts.
  1. Remove timing pins 21-104, 23-019 and 23-029.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:Hold the camshaft timing belt pulley steady.
    Pretension the camshaft timing belt.
    • Turn the adjusting cam clockwise to 9 o'clock and tighten the centre bolt of the adjusting cam.
    • Tighten the bolt of the camshaft timing belt pulley.
  1. CAUTION:
    CAUTION:Remove the special tools.
    Turn the crankshaft six turns in the normal direction of rotation of the engine.
Engines with automatic timing belt tensioner
  1. Preparations for tensioning the timing belts.
    • Turn the crankshaft further in the normal direction of rotation of the engine until the slot in the injection pump timing belt pulley is at 11 o'clock.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.
    • Insert Special Tool 23-029.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:Hold the camshaft timing belt pulley steady.
    Loosen the bolt of the camshaft timing belt pulley and slacken the camshaft timing belt.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:Position a screwdriver between the camshaft timing belt pulley and the timing belt rear cover.
    Release the camshaft timing belt pulley.
    • Release the camshaft timing belt pulley from its conical seat by tapping on it lightly with a light metal drift.
    • Slacken the bolt of the adjusting cam.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:If necessary, turn the camshaft using water pump pliers until the timing tool can be inserted.
    Insert the special tool in the camshaft.

  1. Preparations for tensioning the timing belt (mechanical timing belt tensioner shown).
    • Remove Special Tool 21-162B.
    • Turn the crankshaft two revolutions in the direction of rotation of the engine until the slot in the injection pump timing belt pulley is at 12 o'clock.
    • Turn the slot back counter to the normal direction of rotation of the engine to 11 o'clock.
    1. Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.
    1. The timing pin must be able to be inserted into the camshaft timing belt pulley.
    1. The timing pin must be able to be inserted into the injection pump timing belt pulley.

  1. Tension the injection pump timing belt (mechanical timing belt tensioner shown)
      NOTE:
      NOTE:Slacken the bolts of the timing belt pulleys just half a turn each.
    • Slacken the bolts of the camshaft timing belt pulley.
    • Slacken the bolts of the injection pump timing belt pulley.
    1. Slacken the clamp bolt of the injection pump timing belt tensioner a quarter turn so that the timing belt tensioner presses against the timing belt.
    1. Tighten the bolt of the injection pump timing belt tensioner.
    1. Tighten the bolts of the injection pump timing belt pulley.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:Hold the bolt of the adjusting cam steady. Adjusting cam must be between the 6 o'clock and the 9 o'clock position or between the 9 o'clock position and the 12 o'clock position.
    NOTE:
    NOTE:Tighten the bolt smoothly.
    NOTE:
    NOTE:Hold the camshaft timing belt pulley steady. Tighten the bolt smoothly.
    Tension the camshaft timing belt.
    1. Tension the camshaft timing belt clockwise via the hexagon socket of the adjusting cam until the arrows of the camshaft timing belt tensioner meet.
    1. Tighten the bolt of the adjusting cam.
    1. Tighten the bolt of the camshaft timing belt pulley.
    • Torque for M8 bolt: 35 Nm.
    • Torque for M10 bolt: 48 Nm.
  1. CAUTION:
    CAUTION:Remove the special tools.
    Turn the crankshaft four turns in the normal direction of rotation of the engine.
Engines with automatic timing belt tensioner
  1. NOTE:
    NOTE:If the special tools cannot be inserted, then the adjustment must be repeated from step
    Check the valve timings.
    • Turn the crankshaft further in the normal direction of rotation of the engine until the slot in the injection pump timing belt pulley is at 11 o'clock.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.
    • Special Tool 23-029 must be able to be inserted.
    • The timing tool must be able to be inserted in the camshaft.
    • The arrows on the camshaft timing belt tensioner must not be offset by more than 3 mm.
    • Remove the special tools and fit the blanking plug in the place of the timing pin.

  1. Tension the camshaft timing belt.
      NOTE:
      NOTE:Leave timing pin 23-029 inserted.
    1. Slacken the clamp bolt of the camshaft timing belt tensioner a quarter turn so that the timing belt tensioner presses against the timing belt.
      NOTE:
      NOTE:All timing pins must be correctly inserted; the crankshaft must be resting against the timing pin.
    1. Tighten the clamp bolt of the camshaft timing belt tensioner.
    1. Tighten the bolts of the camshaft timing belt pulley.
    1. Take out the timing pins. Unscrew the timing pin and tighten the blanking plug for the TDC setting bore.

  1. Fit the oil baffle.

  1. Seal the parting line between the bearing cap and the cylinder head on both sides with a thin bead of sealer(SPM-4G9112-F/G).

  1. NOTE:
    NOTE:Clean the cylinder head cover gasket and check it for damage. Only renew if damaged. If it is in good condition, re-use it several times.
    NOTE:
    NOTE:Before fitting, lightly coat the gasket with engine oil.
    Fit the cylinder head cover.
    1. Screw in the bolts.
    1. Attach the crankcase ventilation hoses.

  1. Fit the injection pump timing belt cover.
  1. Tighten the bolt of the auxiliary shaft timing belt pulley.

  1. Fit the lower timing belt cover.

  1. Fit the upper timing belt cover.

  1. Fit the crankshaft pulley/vibration damper.
    • Then remove Special Tool 21-168.

  1. CAUTION:
    CAUTION:The setting value of 10° for the injection pump timing must be strictly observed.
    Position the crankshaft to 10° after the TDC position of the first cylinder.
    • Locate the CKP sensor bracket in position without the sensor and attach it loosely.
      NOTE:
      NOTE:When using the angle gauge 21-540 make sure that the disc is not moved out of position by the movement of the special tool. The special tool must be kept under tension. If the 10° mark is not quite reached, unscrew the gauge disc so that it is no longer within the measuring range and readjust it again.
    • Place the angle gauge on the pulley/vibration damper and position the disc to 10°.
    • Turn the pulley/vibration damper until the arrows on the angle gauge are exactly lined up together.

  1. Align the CKP sensor bracket (shown on an engine that has been removed).
    • Insert the special tool into the CKP sensor bracket and the flywheel bore hole.
    • Tighten the CKP sensor bracket bolts and remove the special tool.

  1. Check the alignment of the CKP sensor.
    • Position the crankshaft to 10° after TDC of the first cylinder, as described in steps.
      NOTE:
      NOTE:If it is not possible to insert the special tool into the flywheel bore hole, repeat the adjustment procedure as described in steps and . Check the alignment again.
    • The special tool must be able to be inserted in the flywheel.

  1. Install the CKP sensor.

  1. Fit the injection pump belt pulley.

  1. CAUTION:
    CAUTION:Position the alternator and screw in the bolts finger tight. First tighten the bolt on the pulley side, then the rear upper long bolt and finally the rear lower short bolt.
    Install the alternator (shown with the air conditioning compressor).
    1. Tighten the alternator bolts in accordance with the tightening sequence.
    1. Fit the belt tensioner.

  1. NOTE:
    NOTE:Before installing the oil pump, add approx. 10 cc of engine oil to the rotor chamber and lubricate the oil pump drive gear and driven gear with engine oil.
    Install the oil pump with the oil filter.
  1. Detach the engine from the assembly stand.

Assembly|Installation > < Cylinder Head