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Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.8L Endura-DI (Lynx) Diesel - Engine Fiesta 1996 (08/1995-02/2002)
Disassembly

Special Tool(s)

Slide Hammer

205-047 (15-011)

Universal Flange Holding Wrench

205-072 (15-030A)

Locking Tool, Flywheel

303-393 (21-168)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435 (21-187)

303-435-06 (21-031B)

Adapter for 205-047

303-633 (21-227)

Remover, Camshaft Sprocket

303-651 (21-229)

Remover, Fuel Injection Pump Pulley

310-095 (23-067)
General Equipment
Scraper
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
All vehicles
  1. Using the special tool, attach the engine to the mounting stand.
    • Attach the mounting bracket.
    • Mount the engine on the mounting stand.
  1. Drain the engine.
    • Allow the oil to drain into a suitable container.

  1. Detach the positive crankcase ventilation (PCV) housing.
    • Detach the ventilation hoses.

  1. Remove the high pressure fuel supply lines.
    • Discard the high pressure fuel supply lines.

  1. Remove the power steering pump lower retaining bolts.

  1. Remove the power steering pump.

  1. Remove the generator with driveshaft.

  1. Detach the turbocharger oil supply and oil return lines.
    • Discard the sealing washers.

  1. Remove the oil filter.
    • Discard the filter.

  1. Remove the oil cooler.
    • Discard the gasket.

  1. Remove the generator bracket.

  1. Remove the valve cover.
    1. Remove the PCV hoses.
    1. Remove the valve cover bolts.
Vehicles without charge air cooler

  1. Remove the timing belt lower cover.

  1. Remove the engine front mount bracket.
Vehicles with charge air cooler

  1. Remove the timing belt cover.

  1. Remove the engine front mount bracket.
All vehicles
  1. Detension the timing belt.
    • Loosen the timing belt tensioner bolt.
  1. Remove the timing belt.
    • Discard the timing belt.

  1. Remove the timing belt tensioner.
Engines with mechanical timing belt tensioner
  1. Discard the timing belt tensioner.
All vehicles
  1. Using the special tool, remove the camshaft pulley retaining bolt.

  1. Using the special tool, remove the camshaft pulley.

  1. Remove the fuel injection pump pulley bolts.

  1. Using the special tool, remove the fuel injection pump pulley.

  1. Remove the fuel injection pump oil seal retainer.
    • Discard the seal.

  1. Remove the timing belt rear cover.

  1. Remove the oil baffle.

  1. Remove the fuel injectors.
    • Discard the bolts.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket.

  1. Using the special tool, remove the water pump pulley.

  1. Remove the water pump.
    • Discard the gasket.

  1. Using the special tool, remove the crankshaft pulley.
    • Discard the bolt.

  1. Remove the accessory drive belt idler.

  1. Remove the timing chain housing cover.
    • Discard the gasket.

  1. Remove the timing chain tensioner.

  1. Detach the fuel injection pump sprocket.

  1. Remove the timing chain, sprockets and guides.

  1. Remove the fuel injection pump bracket.

  1. Remove the fuel injection pump.
    • Discard the gasket.

  1. Using the special tool, detach the upper coolant hose from the coolant distribution pipe.

  1. Remove the coolant distribution pipe.

  1. CAUTION:
    CAUTION:Loosen the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.
    Remove the clutch disc and pressure plate.

  1. Using the special tool, remove the flywheel.
    • Discard the bolts.

  1. Remove the crankshaft position (CKP) sensor.

  1. Remove the CKP sensor retaining bracket.

  1. Remove the crankshaft rear oil seal retainer.
    • Discard the retainer.

  1. Remove the oil pan retaining nuts and bolts (16 bolts, two nuts).

  1. Using the special tools, remove the oil pan.

  1. Remove the oil pump connecting pipe.
    • Discard the O-ring seals.

  1. Remove the oil pump pick-up tube.
    • Discard the O-ring seal.
Vehicles with air conditioning

  1. Remove the air conditioning (A/C) compressor retaining bracket.
All vehicles
  1. Remove the ladder frame (14 bolts).
    • Discard the gasket.

  1. Remove the timing chain rear housing.
    • Discard the gasket.

  1. CAUTION:
    CAUTION:Keep the connecting rod bearing caps in order for installation.
    CAUTION:
    CAUTION:Keep the connecting rod bearing shells and connecting rod bearing cap shells in order for installation.
    Remove the pistons.

  1. CAUTION:
    CAUTION:Keep the main bearing lower and upper shells in order for installation.
    Remove the crankshaft.

Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine