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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Fiesta 2002.25 (11.2001-)

Engine - 1.3L Duratec-8V (Rocam) - Cylinder Head Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Trolley jack
Wooden block
Materials
Name
Specification
Sealant
WSK-M2G349-A4 

Removal

  1. Remove the intake manifold.
    For additional information, refer to Intake Manifold in this section.
  1. Remove the valve cover.
    For additional information, refer to Valve Cover in this section.
  1. Drain the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling / 303-03D Engine Cooling.

  1. CAUTION:
    CAUTION:Only turn the engine in the normal direction of rotation.
    NOTE:
    NOTE:The camshaft sprocket timing mark must be in the 12 o’clock position.
    NOTE:
    NOTE:Mark the position of the timing chain.
    Turn the engine until piston No. 1 is at top dead center (TDC).

  1. Remove the exhaust manifold upper heat shield.

  1. Remove the timing chain hydraulic tensioner.

  1. Detach the oil level indicator tube from the cylinder head.

  1. Remove the exhaust manifold retaining nuts in the sequence shown (engine shown removed for clarity).
    • Discard the gaskets.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the exhaust flexible pipe from the exhaust manifold.

  1. Detach the engine support insulator from the crossmember.

  1. Using a suitable wooden block , support the right-hand side of the engine.

  1. Remove the exhaust manifold lower heat shield (engine shown removed for clarity).

  1. Remove the exhaust manifold lower retaining bolts (engine shown removed for clarity).
    • Detach the exhaust manifold from the cylinder head.
  1. Lower the vehicle.

  1. Disconnect the coolant line from the coolant flow control housing.

  1. Using the special tool, disconnect the coolant hoses from the coolant control housing.

  1. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  1. Using a suitable trolley jack , support the engine and transmission assembly.

  1. Disconnect the degas hose from the coolant expansion tank.

  1. Detach the coolant expansion tank from the retaining bracket and position it to one side.

  1. Detach the power steering fluid reservoir from the radiator grille opening panel and position it to one side.

  1. Remove the engine front mount.

  1. Remove the engine front mount bracket retaining bolt.

  1. NOTE:
    NOTE:Using a suitable piece of wire, secure the timing chain to the cylinder head to prevent it from dropping into the cylinder block.
    Using the special tool, remove the camshaft sprocket.

  1. NOTE:
    NOTE:Loosen the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Guide the timing chain through the cylinder head and secure it to the cylinder block.
    • Discard the gasket.
    • Discard the cylinder head bolts.

Installation
  1. NOTE:
    NOTE:Install new cylinder head bolts.
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Guide the timing chain through the cylinder head and secure it to the cylinder head.
    Using the special tool, install the cylinder head.
    • Tighten the cylinder head bolts in the sequence shown in four stages.
    • Stage 1: Tighten bolts 1 through 10 to 40 Nm.
    • Stage 2: Tighten the front two (M8) bolts to 15 Nm.
    • Stage 3: Tighten the front two (M8) bolts to 45 degrees.
    • Stage 4: Tighten bolts 1 through 10 to 120 degrees.

  1. NOTE:
    NOTE:The camshaft sprocket timing mark must be in the 12 o´clock position.
    NOTE:
    NOTE:The camshaft sprocket timing mark and the marked links of the timing chain must line up.
    Install the camshaft sprocket and the timing chain.

  1. Using the special tool, tighten the camshaft sprocket retaining bolt.

  1. Install the engine front mount bracket retaining bolt.

  1. Install the engine front mount.
  1. Remove the trolley jack .

  1. Attach the power steering fluid reservoir to the radiator grille opening panel.

  1. Attach the coolant expansion tank to the bracket.

  1. Connect the degas hose to the coolant expansion tank.

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

  1. Using the special tool, connect the coolant hoses to the coolant flow control housing.

  1. Connect the coolant line to the coolant flow control housing.

  1. NOTE:
    NOTE:Install new exhaust manifold gaskets.
    Install the exhaust manifold (engine shown removed for clarity).
    • Tighten the bolts in the sequence shown in two stages:
    • Stage 1: 15 Nm.
    • Stage 2: 20 Nm.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the exhaust manifold lower retaining bolts (engine shown removed for clarity).

  1. Install the exhaust manifold lower heat shield (engine shown removed for clarity).

  1. Remove the wooden block .

  1. Attach the engine support insulator to the crossmember.

  1. Attach the exhaust flexible pipe to the catalytic converter.
  1. Lower the vehicle.

  1. Attach the oil level indicator tube to the cylinder head.

  1. Install the timing chain hydraulic tensioner.

  1. Install the exhaust manifold upper heat shield.
  1. Install the valve cover.
    For additional information, refer to Valve Cover in this section.
  1. Install the intake manifold.
    For additional information, refer to Intake Manifold in this section.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling / 303-03D Engine Cooling.

In-vehicle Repair|Oil Pan > < Exhaust Manifold