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303-05 Accessory Drive > < Turbocharger

Fiesta 1996 (08.1995-02.2002)

Fuel Charging and Controls - Turbocharger - Turbocharger Fiesta 1996 (08/1995-02/2002)
Removal and Installation

Removal

  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the catalytic convertor to exhaust manifold nuts.

  1. Disconnect the vacuum lines.
  1. Remove the exhaust gas recirculation (EGR) valve. For additional information, refer to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control.

  1. Remove the exhaust manifold nuts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:Remove and discard the catalytic convertor to exhaust center pipe gasket.
    Remove the catalytic convertor to exhaust center pipe bolts.

  1. NOTE:
    NOTE:There is a washer on the gear selector upper mechanism. Note its correct position.
    Detach the gear selector mechanism.

  1. NOTE:
    NOTE:The engine roll restrictor is under tension.
    Detach the engine roll restrictor.

  1. Secure the gear selector mechanism.
    • Install a tie strap.

  1. NOTE:
    NOTE:Remove and discard the catalytic convertor to exhaust manifold gasket.
    Remove the catalytic convertor.

  1. Detach the air cleaner outlet pipe.

  1. NOTE:
    NOTE:Remove and discard the oil feed and return pipe gasket.
    Detach the oil feed and return pipe.

  1. NOTE:
    NOTE:Remove and discard the exhaust manifold gasket.
    Remove the exhaust manifold and turbocharger.

Installation
  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    NOTE:
    NOTE:When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. It may need to be driven 16 km (10 miles) or more to relearn its adaptive strategy.
    Install the exhaust manifold and turbocharger.

  1. Install a new oil feed and return pipe gasket.

  1. Attach the oil feed and return pipe.

  1. Attach the air cleaner outlet pipe.

  1. NOTE:
    NOTE:Install a new catalytic convertor to exhaust manifold gasket.
    Install the catalytic convertor.

  1. Release the gear selector mechanism.
    • Cut the tie strap.

  1. Attach the engine roll restrictor.

  1. NOTE:
    NOTE:Make sure the washer on the gear selector upper mechanism is correctly installed.
    Attach the gear selector mechanism.

  1. NOTE:
    NOTE:Install a new catalytic convertor to exhaust center pipe gasket.
    Install the catalytic convertor to exhaust center pipe bolts.
  1. Adjust the gear selector mechanism. For additional information, refer to Section  308-06 Manual Transmission/Transaxle External Controls.
  1. Lower the vehicle.

  1. Install the exhaust manifold nuts.
  1. Install the EGR valve. For additional information, refer to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control.

  1. Connect the vacuum lines.

  1. Install the catalytic convertor to exhaust manifold nuts.
  1. Connect the battery ground cable.

303-05 Accessory Drive > < Turbocharger