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In-vehicle Repair|Disassembly > < Cylinder Head

Fiesta 1996 (08.1995-02.2002)

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

Special Tool(s)

Remover, driveshaft

16-087

21-068 A Engine lifting bracket

21-068 A Engine lifting bracket

Remover/installer, radiator hose clamps

24-003
General Equipment
Puller

Removal

All Vehicles
  1. General note.
  1. When removing coolant and ventilation hoses, if necessary For additional information, refer to Section  303-03 Engine Cooling.
  1. WARNING:
    WARNING:Risk of scalding if the engine is hot.
    Preparatory operations
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
    • Open the coolant recovery tank.
  1. Disconnect the battery ground cable.

  1. NOTE:
    NOTE:When slackening the nuts, hold with an Allen key to prevent from turning.
    Slacken the nuts on the two suspension struts five turns each.

  1. WARNING:
    WARNING:Danger of scalding if the engine is warm.
    NOTE:
    NOTE:After draining, tighten the drain plug to 22 Nm.
    Drain off the coolant.

  1. Remove the air intake pipe.
    1. From the intake manifold (clamp).
    1. Unclip
    1. Pull it out of the air cleaner housing (push fit).
    1. Detach the resonator hose (clamp).

  1. Detach the upper coolant hose.

  1. Detach the hoses.
    1. Vent hose.
    1. Heater coolant hoses.

  1. Detach the radiator vent hose.

  1. Disconnect the plugs and wiring:
    1. Plug of injection pump wiring loom
    1. Glow plug wiring
    1. Plug of the temperature gauge sender unit.
    1. Plug of the engine coolant temperature sensor (ECT sensor)
    1. Plug of oil pressure switch
    1. Plug of diesel fuel heater
  1. Detach the brake servo vacuum line.

  1. Disconnect the plug of the exhaust gas recirculation valve (EGR valve).

  1. Detach the accelerator cable.
    1. Detach the accelerator cable with the rubber bush and retainer from the bracket.
    1. Unhook the accelerator cable.

  1. Disconnect the fuel lines.
    1. Fuel return line
    1. Fuel feed line

  1. Detach the transmission ground lead.
    • Lift the clip and pull off the hydraulic pipe.
    • Plug the openings.
  1. Detach the hydraulic pipe of the clutch operating system.

  1. Detach the bracket of the power steering pressure pipe.

  1. NOTE:
    NOTE:Collect the power steering fluid.
    Detach the power steering hose and pressure pipe.

  1. Remove the belt tensioner.

  1. Remove the front engine mounting auxiliary bracket.

  1. Remove the battery.
    • Detach the retaining strap.
    • Lift out the battery.

  1. Remove the battery box.

  1. Raise the vehicle.
  1. Detach the lower coolant hose.

  1. Disconnect the air conditioning plug.
    • Cut the two cable ties.

  1. Detach the lower right-hand coolant hose.

  1. Disconnect the three plugs at the bottom of the radiator on the left-hand side.

  1. NOTE:
    NOTE:Do not remove the air conditioning condenser.
    Detach the air conditioning condenser at the bottom and tie up.

  1. Remove the radiator (two bolts on each side; right-hand side shown).
    • Carefully withdraw the radiator, radiator crossmember and fan plate with the fan from below.

  1. Detach the air conditioning compressor.
    • Let the compressor hang down and tie it securely.

  1. Disconnect the starter motor.

  1. Disconnect the plug of the multi-function switch (where fitted).

  1. Disconnect the plug of the reversing lamp switch (where fitted).

  1. Detach the shift rod and gearshift stabilizer and tie up.
    1. Shift rod
    1. Shift rod stabilizer

  1. Detach the rear exhaust pipe from the flexible intermediate pipe.
    • Remove the seal.

  1. Disconnect the generator.

  1. Detach the left and right-hand lower suspension arms (left-hand side shown).

  1. Disconnect the speedometer drive cable.

  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:Escaping oil. Close off the opening with an auxiliary plug.
    Press the left-hand front driveshaft out of the transmission.
    • Swing the driveshaft forward and tie it up.

  1. Remove the front driveshaft center bearing.
Vehicles from build month 12/1996 and vehicles for non-European markets
  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.
    Remove the right-hand front driveshaft from the transmission.
      CAUTION:
      CAUTION:After freeing the driveshaft, immediately secure the differential, using suitable plugs, to stop it from turning.
    • Free the right-hand driveshaft from the transmission by giving it a light tap.
Vehicles from build month 01/1997 for European markets
  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 loosening the driveshaft, immediately secure the differential, using suitable plugs, to prevent it from turning.
    Extract the right-hand front driveshaft from the transmission.
All vehicles
  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 boots of the drive shaft.
    Tie up the right-hand front driveshaft at the front.

  1. Remove the engine roll restrictor.
  1. Preparatory measures for removing the engine and transmission assembly.
    • Position an assembly table with wooden blocks under the engine and transmission assembly.
    • Lower the vehicle until the engine and transmission assembly rests on the wooden blocks.
      NOTE:
      NOTE:Make sure that the assemblies are secure.
    • Secure the engine on the assembly table with the tensioning straps.

  1. Remove the rear engine mounting.
    1. Screws
    1. Nuts
    1. Remove the transmission breather.

  1. Remove the front engine mounting.
  1. Raise the vehicle slowly until the engine and transmission are clear.

  1. Attach the engine lifting bracket.
  1. Lift the engine, together with the transmission, using the workshop hoist.

  1. Remove the resonator.

  1. Remove the starter motor.

  1. Unscrew the front flange bolts.

  1. Unscrew the rear flange bolts.
  1. Press the transmission off the engine and remove it.
    • Remove the adapter plate.

In-vehicle Repair|Disassembly > < Cylinder Head