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Assembly|Installation > < Cylinder Head

Fiesta 2002.25 (11.2001-)

Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Engine Fiesta 2002.25 (11/2001-)
Assembly

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Lifting Bracket, Engine

303-122 (21-068A)

Gauge, Bolt Angle

303-174 (21-540)

Alignment Plate, Camshaft

303-376B (21-162B)

Socket, Cylinder Head Bolt

303-392 (21-167)

Locking Tool, Flywheel

303-393 (21-168)

Installer, Crankshaft Seal

303-395 (21-171)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-14A (21-212A)

Socket, Spark Plug

303-499 (21-202)

Locking Tool, Crankshaft

303-748 (21-259)

Locking Tool, Timing Belt Tensioner

303-1054
General Equipment
Five M8 x 20 mm studs
Engine hoist
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C913-B 
Silicone Sealant
WSE-M4G323-A4 
Adhesive - Loctite 243
WSK-M2G349-A7 
Gasket Eliminator Sealant
WSK-M2G348-A5 
High-Temperature Grease
ESD-M1C220-A 
All vehicles
  1. Attach the cylinder block (short block) to the mounting stand.
    • Install the special tools.

  1. NOTE:
    NOTE:Install a new crankshaft rear seal carrier.
    NOTE:
    NOTE:A new crankshaft rear seal carrier is supplied with an alignment sleeve which must be removed following installation.
    NOTE:
    NOTE:Do not lubricate the seal lip.
    Install the crankshaft rear seal carrier.

  1. Install the crankshaft position (CKP) sensor bracket.

  1. Install the CKP sensor.
Vehicles with manual transaxle
  1. NOTE:
    NOTE:Install new flywheel retaining bolts.
    Using the special tool, install the flywheel.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 30 Nm.
    • Stage 2: 80 degrees.
  1. Install the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
  1. Remove the special tool from the flywheel.
Vehicles with automatic transaxle
  1. NOTE:
    NOTE:Install new flexplate retaining bolts.
    Using the special tool, install the flexplate.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 30 Nm.
    • Stage 2: 80 degrees.
  1. Remove the special tool from the flexplate.
All vehicles
  1. NOTE:
    NOTE:Install a new oil pump gasket.
    Install the oil pump.

  1. NOTE:
    NOTE:Install a new pickup pipe gasket.
    Install the oil pump pickup pipe.
  1. Coat the crankshaft front seal lip with clean engine oil.

  1. NOTE:
    NOTE:Install a new crankshaft front seal.
    Using the special tool, install the crankshaft front seal.

  1. CAUTION:
    CAUTION:The crankcase may be damaged if sealant enters the blind holes.
    Install five M8 x 20 mm studs into the blind holes as shown.

  1. NOTE:
    NOTE:Attach the oil pan within ten minutes of applying sealant and tighten the bolts within a further five minutes.
    Apply a 3 to 4 mm diameter thick bead of sealant to the oil pan flange.

  1. NOTE:
    NOTE:Align the oil pan so that the cylinder block is flush with the oil pan on the flywheel side.
    Install the oil pan, loosely install the retaining bolts.
    • Remove the studs and install retaining bolts.
    • Tighten the oil pan retaining bolts in the sequence shown in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 20 Nm.

  1. NOTE:
    NOTE:Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if required.
    Install the drain plug.

  1. Install the positive crankcase ventilation (PCV) cover.

  1. CAUTION:
    CAUTION:The knock sensor (KS) cable must not touch the cylinder head or the PCV cover. Position the KS cable at approximately the 10 o'clock position.
    Install the KS.

  1. NOTE:
    NOTE:Install a new thermostat housing gasket.
    Install the thermostat housing.

  1. Install the oil pressure switch.
    • Apply adhesive to the oil pressure switch threads.

  1. CAUTION:
    CAUTION:Do not damage the coolant pump impeller.
    NOTE:
    NOTE:Install a new coolant pump gasket.
    Install the coolant pump.
  1. Turn the crankshaft to approximately 25 mm before top dead center (BTDC) on cylinder number 1.

  1. CAUTION:
    CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole marked).
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Position the cylinder head onto the two guide sleeves.
    Using the special tool, install the cylinder head.
    • Tighten the cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 15 Nm.
    • Stage 2: 30 Nm.
    • Stage 3: 90 degrees.

  1. Install the intake manifold lower retaining bolt.

  1. Attach the oil level indicator tube to the intake manifold.
    • Attach the KS electrical connector to the oil level indicator tube.

  1. Connect the PCV hose to the PCV cover.

  1. NOTE:
    NOTE:Identification numbers are provided on the outer face of the camshaft bearing caps.
    Apply sealant to the points indicated on the camshaft bearing cap no. 1 and to the mating surface of the cylinder head.
  1. Coat the camshafts and the camshaft bearing caps with clean engine oil.

  1. CAUTION:
    CAUTION:Position the camshafts in place so that none of the cams are at full lift.
    NOTE:
    NOTE:The camshaft bearing cap numbering starts at the timing belt end with E1 on the exhaust side and with I1 on the intake side.
    NOTE:
    NOTE:The exhaust camshaft has an additional cam for the camshaft position (CMP) sensor.
    Install the camshafts and camshaft bearing caps.
    • Tighten the camshaft bearing cap retaining bolts in the sequence shown in three stages.
    • Stage 1: One half turn on each bolt until all of the camshaft bearing caps are in contact with the cylinder head.
    • Stage 2: 7 Nm.
    • Stage 3: 45 degrees.
  1. Coat the camshaft journals and seal lips with clean engine oil.

  1. NOTE:
    NOTE:Install new camshaft seals.
    Using the special tool, install the camshaft seals.

  1. Install the timing belt rear cover.
  1. Set the crankshaft to approximately 20 degrees before TDC.

  1. Turn the camshafts to top dead center (TDC) on cylinder number 1 and install the special tool.
  1. NOTE:
    NOTE:Do not fully tighten the camshaft timing pulley retaining bolts at this stage. Make sure the camshaft pulleys turn on the camshafts.
    NOTE:
    NOTE:Install new camshaft pulley retaining bolts.
    Install the camshaft timing pulleys.

  1. Install the crankshaft timing belt pulley.
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Install the timing belt, beginning with the crankshaft timing pulley working counterclockwise.
    Install the timing belt.

  1. Remove the blanking plug and install the special tool.
    • Carefully turn the crankshaft against the special tool.

  1. Measuring the depth of the threaded hole in the crankshaft.
    • Depth of the threaded = 42 mm: Use an M12x29 mm crankshaft pulley center bolt.
    • Depth of the threaded = 52 mm: Use an M12x44,5 mm crankshaft pulley center bolt.

  1. Install the timing belt lower cover.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Install the crankshaft pulley.
    • Tighten the crankshaft pulley retaining bolt in two stages.
    • Stage 1: 45 Nm.
    • Stage 2: 90 degrees.
Engines with eccentric cam timing belt tensioner
  1. Install the timing belt tensioner.

  1. Tension the timing belt.
    • Tension the timing belt by turning the tensioner counterclockwise until the arrow points at the mark and tighten the bolt.
Engines with slotted bracket timing belt tensioner
  1. Install the timing belt tensioner and tension the timing belt.
    • Install the bolts finger tight.
    • Tension the timing belt by turning the tensioner clockwise until the arrow points in line with the center of the rectangular hole and tighten the bolts.
Vehicles built 09/2003 onwards
  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the timing belt tensioner.
    Install the timing belt tensioner.

  1. Tension the timing belt.
    • Remove the special tool.
Vehicles built 04/2005 onwards
  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the timing belt tensioner.
    Install the timing belt tensioner.

  1. Tension the timing belt.
    • Remove the special tool.
All vehicles
  1. CAUTION:
    CAUTION:Install a hose (order no. E890438S) to the special tool studs, to prevent damage to the camshaft pulleys.
    CAUTION:
    CAUTION:Do not tighten the camshaft pulley bolts against the timing plate.
    Using the special tool, tighten the camshaft pulleys.

  1. Remove the special tool.

  1. Remove the special tool.
  1. NOTE:
    NOTE:Only turn the crankshaft in its normal direction of rotation.
    Turn the crankshaft two revolutions.

  1. Install the special tool.
    • Carefully turn the crankshaft against the special tool.

  1. Check the valve timing.
    • If necessary loosen the camshaft pulleys and correct the camshaft alignment.
  1. Remove the special tools.

  1. Install the blanking plug.
  1. Check the valve clearances, adjust if necessary.
    For additional information, refer to: Valve Clearance Adjustment (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures).

  1. Using the special tool, install the spark plugs.
    • Apply grease to the spark plug threads.

  1. NOTE:
    NOTE:Install the stud bolts to positions 5 and 6.
    Install the valve cover.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten bolt 1 by 3 to 4 turns.
    • Stage 2: Tighten bolts 1 through 13 to 3 Nm.
    • Stage 3: Tighten bolts 1 through 13 to 9 Nm.

  1. CAUTION:
    CAUTION: Use a suitable blunt object to avoid damage to the spark plug connector gasket. Coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.
    Connect the spark plug electrical connectors and attach the wires to the valve cover.

  1. Install the engine front mount bracket.
    • Tighten the bolts in the indicated order in three stages.
    • Stage 1: Hand tighten bolt 1.
    • Stage 2: Tighten bolts 2 to 55 Nm.
    • Stage 3: Tighten bolt 3 to 55 Nm.

  1. Install the timing belt upper cover.

  1. Install the coolant pump pulley.

  1. Install the generator.

  1. NOTE:
    NOTE:Install a new oil filter.
    Install the oil filter.
  1. Install the engine wiring harness.

  1. Using the special tool attach the engine to an engine hoist.

  1. Remove the special tools.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the nuts and bolt at this stage.
    Install the exhaust manifold.

  1. Tighten the exhaust manifold upper retaining nuts and bolt in the sequence shown in two stages.
    • Stage 1: 20 Nm.
    • Stage 2: 55 Nm.

  1. Tighten the exhaust manifold lower retaining bolts.

  1. Install the exhaust manifold upper heat shield.

  1. Install the exhaust manifold lower heat shield right-hand retaining bolts.

  1. Install the exhaust manifold lower heat shield left-hand retaining bolts.

Assembly|Installation > < Cylinder Head