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Camshaft Seal > < Crankshaft Front Seal

Fiesta 2002.25 (11.2001-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Camshaft Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Guide Studs, Cylinder Head

303-034 (21-003)

Remover/Installer, Hose Clamp

303-397 (24-003)

Installer, Crankshaft Front Seal

303-684 (21-243/1)
General Equipment
Two feeler gauges
Materials
Name
Specification
Engine oil
WSS-M2C913-B 
Loctite 7070
 
Sealer
WSE-M4G323-A4 

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
NOTE:
NOTE:Cylinder 1 is located at the transmission end.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. Remove the intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Remove the brake vacuum pump.
    For additional information, refer to: Brake Vacuum Pump - 1.4L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation).

  1. CAUTION:
    CAUTION:Protect the generator with lint-free material to prevent contamination.
    Using the special tool, remove the coolant expansion tank.

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

  1. NOTE:
    NOTE:If the engine is equipped with a thrust plate the four bolts securing the thrust plate are longer than the other retaining bolts.
    Remove the camshaft upper housing.

  1. Remove the camshaft.
    • Discard the seal.

Installation

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. CAUTION:
    CAUTION:Make sure that the sealer does not enter the camshaft lower housing blind holes. Failure to follow these instruction may result in damage to the camshaft lower housing.
    NOTE:
    NOTE:Do not damage the mating faces.
    Clean the mating faces of the camshaft upper and lower housing with Loctite 7070.

  1. CAUTION:
    CAUTION:Install the camshaft upper housing within four minutes of applying the sealer.
    Apply a 4 mm diameter bead of sealer to the camshaft lower housing mating face.
  1. Coat the camshaft and the camshaft bearings with clean engine oil.

  1. CAUTION:
    CAUTION:Make sure that no piston is at top dead centre (TDC).
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Install the camshaft.

  1. NOTE:
    NOTE:If the engine is equipped with a camshaft thrust plate, install the thrust plate and longer retaining bolts to position 3, 4, 7 and 8.
    Using the special tools, install the camshaft upper housing.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 5 Nm.
    • Stage 2: 10 Nm.

  1. NOTE:
    NOTE:A new camshaft seal is supplied with an alignment and protection sleeve that must be removed following installation.
    Using the special tool, install the camshaft seal.
    • Remove and discard the alignment and protection sleeve.

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

  1. Loosen the camshaft position (CMP) sensor.

  1. NOTE:
    NOTE:Turn the camshaft to align the camshaft pulley position indicator with the CMP sensor if necessary.
    Using a feeler gauge, install and adjust the CMP sensor.
    • XX = 1.2 mm between the CMP sensor and the camshaft pulley postion indicator.
    • XX = 0.0 mm between the CMP sensor and the camshaft pulley postion indicator, when a new CMP sensor is installed.

  1. NOTE:
    NOTE:Carry out this step if the engine is equipped with a thrust plate.
    Rotate the camshaft clockwise until the number four camshaft lobe is positioned vertically upwards. Thrust plate removed for clarity.

  1. NOTE:
    NOTE:Carry out this step if the engine is equipped with a thrust plate.
    Loosen the four bolts of securing the thrust plate.

  1. WARNING:
    WARNING:Do not push directly against the camshaft pulley.
    NOTE:
    NOTE:Carry out this step if the engine is equipped with a thrust plate.
    Using a pair of flat levers, position the camshaft as far toward the transmission end of the engine as possible. Thrust plate removed for clarity.

  1. NOTE:
    NOTE:Carry out this step if the engine is equipped with a thrust plate.
    Using a pair of feeler gauges, adjust the clearance between the thrust plate abutement face and the side of the number four cam lobe to achieve 0.3 mm on both sides as shown.
    • Tighten the bolts in the sequence shown.
  1. NOTE:
    NOTE:Carry out this step if the engine is equipped with a thrust plate.
    Coat the side of the number four cam lobe with clean engine oil

  1. Using the special tool, install the coolant expansion tank.
  1. Install the brake vacuum pump.
    For additional information, refer to: Brake Vacuum Pump - 1.4L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation).
  1. Install the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Install the intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Camshaft Seal > < Crankshaft Front Seal