ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Crankshaft Rear Seal > < Camshaft

Ikon 1999 (01.2000-)

Engine - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) - Cylinder Head Ikon 1999 (01/2000-)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Trolley jack

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.
  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  303-03 Engine Cooling.

  1. CAUTION:
    CAUTION:Only turn the crankshaft 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 crankshaft until piston No. 1 is at top dead center (TDC).

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

  1. Remove the timing chain hydraulic tensioner.

  1. Detach the oil level indicator tube from the cylinder head.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the exhaust manifold from the cylinder head (engine shown removed for clarity).
    • Discard the gasket and the retaining nuts.
  1. Lower the vehicle.

  1. Using the special tool, disconnect the coolant hoses from the coolant control housing.
  1. Using a trolley jack, support the engine and transaxle assembly.

  1. Remove the engine front mount.
    • Discard the nuts.

  1. Remove the engine front mount bracket retaining bolt.

  1. NOTE:
    NOTE:Use a suitable piece of wire to prevent the timing chain 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. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.
  1. Remove the trolley jack.

  1. Using the special tool, connect the coolant hoses to the coolant control housing.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    Attach the exhaust manifold to the cylinder head (engine shown removed for clarity).
    • Tighten the retaining nuts in the sequence shown in two stages.
    • Stage 1: 15 Nm
    • Stage 2: 20 Nm
  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 heat shield (engine shown removed for clarity).
  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  303-03 Engine Cooling.

Crankshaft Rear Seal > < Camshaft