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

Fiesta 2002.25 (11.2001-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Engine Fiesta 2002.25 (11/2001-)
Disassembly

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Adapter for 205-072

205-072-02 (15-030A-02)

Lifting Bracket, Engine

303-122 (21-068A)

Remover, Crankshaft Timing Pulley

303-249 (21-132)

Remover, Crankshaft Seal

303-293 (21-143)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435 (21-187)

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-13A (21-170B)

Locking Tool, Crankshaft

303-734 (21-262)
General Equipment
Engine hoist
Engine vacuum cleaner
Spatula
All vehicles
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.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material entering the components.
NOTE:
NOTE:Cylinder Number 1 is located at the transmission end.
  1. Drain the engine oil.
    • Discard the seal.
    • Allow the oil to drain into a suitable container.

  1. Detach the engine wiring harness from the timing belt upper cover.

  1. Disconnect the fuel injector wiring harness electrical connector.

  1. Disconnect the fuel heater electrical connector.

  1. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

  1. Disconnect the generator electrical connector and the oil pressure switch electrical connector.

  1. Remove the generator power supply cover.

  1. Remove the generator power supply.
Vehicles with exhaust gas recirculation (EGR) cooler
  1. Disconnect the intake air temperature (IAT) and the intake throttle electrical connector.
All vehicles
  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.

  1. Disconnect the fuel pump electrical connectors.

  1. Disconnect the fuel temperature sensor electrical connector and remove the engine wiring harness.

  1. NOTE:
    NOTE:The accessory drive belt idler pulley is retained by the generator lower retaining bolt.
    Remove the generator lower retaining bolts and the accessory drive belt idler pulley.

  1. Remove the generator.

  1. Remove the air conditioning (A/C) compressor bracket.

  1. CAUTION:
    CAUTION:Do not remove the two screws either side of the circular cutouts.
    Remove the catalytic converter heat shield.

  1. Detach the catalytic converter from the catalytic converter retaining brackets.

  1. Remove the catalytic converter.

  1. Remove the catalytic converter retaining brackets.

  1. Remove the oil level indicator tube.
    • Discard the O-ring seal.

  1. Remove the oil pressure switch.

  1. Using the special tools, secure the engine to the mounting stand.

  1. Detach the special tool from the engine.

  1. Remove the power steering pump rear retaining bolt.

  1. Remove the power steering pump.

  1. Remove the power steering pump bracket.

  1. Detach the intake air resonator outlet pipe from the intake manifold assembly.

  1. Remove the intake air resonator outlet pipe retaining bolt from the intake manifold assembly.

  1. Remove the intake air resonator.

  1. Remove the turbocharger heat shield.

  1. Disconnect the fuel injector wiring harness from the fuel injectors.

  1. Detach the fuel injector wiring harness from the fuel filter housing.

  1. Detach the positive crankcase ventilation (PCV) hose from the intake manifold assembly.

  1. Disconnect the fuel return line from the fuel injector.

  1. Detach the fuel temperature sensor manifold from the intake manifold assembly.

  1. Disconnect the fuel supply line quick release coupling from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the fuel supply line quick release coupling from the fuel pump.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Detach the glow plug wiring harness from the fuel filter housing.

  1. Detach the fuel filter housing from the intake manifold assembly.

  1. Remove the fuel filter housing.
Vehicles without EGR cooler
  1. Detach the EGR tube from the cylinder head and from the EGR valve.
Vehicles with EGR cooler
  1. Detach the EGR tube from the EGR cooler.
All vehicles
  1. Remove the EGR tube.

  1. Detach the intake manifold assembly from the cylinder head.

  1. Remove the intake manifold assembly.
    • Discard the four O-ring seals.

  1. CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Using the special tool, lock the flywheel.
    • Rotate the crankshaft until the special tool fits into one of the slots in the flywheel.

  1. Remove the crankshaft pulley.

  1. Remove the special tool.

  1. Remove the engine front mount bracket.

  1. Remove the timing belt upper cover.

  1. Remove the timing belt lower cover.

  1. Remove the CKP sensor.

  1. Remove the timing belt guide.

  1. Remove the timing belt tensioner.
    • Discard the timing belt.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the crankshaft timing pulley.

  1. Remove the crankshaft timing pulley Woodruff key.

  1. Remove the timing belt idler pulley.

  1. Remove the CMP sensor.

  1. Remove the camshaft housing assembly.

  1. Detach the coolant pipe assembly from the thermostat housing.

  1. Remove the coolant pipe assembly.
Vehicles built up to 12/2002
  1. Remove the noise vibration and harshness (NVH) shield of the fuel supply manifold.
All vehicles
  1. Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply lines, the high-pressure fuel pump, the fuel injectors and the fuel injection supply manifold.
  1. Clean the high-pressure fuel supply lines, the fuel pump, the fuel injectors, the fuel injection supply manifold and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned.
    Remove the high-pressure fuel supply line.
    • Discard the high-pressure fuel supply lines.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned.
    Detach the high-pressure fuel supply line unions from the fuel injector and the fuel injection supply manifold.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned.
    Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel injection supply manifold.
  1. Remove the high-pressure fuel supply lines.
    • Discard the high-pressure fuel supply lines.
  1. Install blanking plugs to the open threaded ports on the fuel pump, the fuel injection supply manifold and the fuel injectors.

  1. Disconnect the fuel return line from the fuel injectors.
    1. Remove the locking clip.
    1. Pull the fuel return line out of the injector.
  1. Clean the area around the fuel injector.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).

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

  1. Using the special tool, remove the high-pressure fuel pump pulley retaining nut.

  1. Using the special tool, remove the high-pressure fuel pump pulley.

  1. Detach the high-pressure fuel pump from the cylinder head.

  1. Remove the fuel pump.

  1. Remove the fuel pump support bracket.

  1. Remove the thermostat housing.

  1. CAUTION:
    CAUTION:Keep the camshaft roller followers in order for installation.
    Remove the camshaft roller followers.

  1. Disconnect the oil supply line from the turbocharger.
    • Discard the sealing washers.

  1. Remove the turbocharger oil supply line.
    • Discard the sealing washers.

  1. Remove the turbocharger oil return tube.

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

  1. CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Using the special tool, lock the flywheel.
    • Rotate the crankshaft until the special tool fits into the slot in the flywheel.

  1. CAUTION:
    CAUTION:Remove the clutch disc and pressure plate bolts in the sequence shown.
    Remove the clutch disc and pressure plate.
    • Discard the bolts.
Vehicles with dual mass flywheel
  1. Remove the flywheel.
    • Discard the bolts.
Vehicles without dual mass flywheel
  1. Remove the flywheel.
    • Discard the bolts.
All vehicles
  1. Remove the special tool.

  1. Remove the turbocharger oil return tube.

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

  1. Remove the fuel supply manifold.

  1. Remove the intermediate shaft center bearing retaining bracket.

  1. Remove the clutch housing cover.

  1. Remove the oil pan retaining bolts and nuts.
  1. CAUTION:
    CAUTION:Do not distort the oil pan.
    NOTE:
    NOTE:Do not damage the mating faces.
    Using a suitable spatula, remove the oil pan.
    • Slide the spatula around the profile of the oil pan.

  1. Remove the oil pick up pipe.
    • Discard the gasket.

  1. Remove the oil level indicator tube.

  1. Remove the water pump.

  1. Using the special tool, remove the crankshaft front seal.
    • Discard the seal.

  1. Remove the oil pump.

  1. Remove the main bearing bolt caps.
    • Discard the caps.

  1. Remove the engine bed plate rear retaining bolts.

  1. CAUTION:
    CAUTION:Remove the engine bed plate outer retaining bolts in the sequence shown.
    Remove the engine bed plate outer retaining bolts.

  1. CAUTION:
    CAUTION:Remove the main bearing retaining bolts in the sequence shown.
    Remove the engine bed plate.
    • Discard the bolts.
    • Discard the oil seal.

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

  1. Remove the crankshaft thrust half washers.

  1. CAUTION:
    CAUTION:Keep the connecting rod bearing caps in order for installation.
    Remove the connecting rod bearing caps.
    • Discard the bolts.

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

  1. CAUTION:
    CAUTION:Keep the main bearing upper shells in order for installation.
    Remove the main bearing upper shells.
  1. CAUTION:
    CAUTION:Keep the pistons in order for installation.
    Remove the pistons and connecting rods.

  1. Remove the piston cooling jets.

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