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

Puma 1998 (06.1997-12.2001)

Engine - 1.4L Zetec-SE (Sigma)/1.6L - Engine Puma 1998 (06/1997-12/2001)
Disassembly

Special Tool(s)

Slide hammer

205-047 (15-011)

Universal flange holding wrench

205-072 (15-030A)

Pliers, valve adjusting shims

303-196 (21-107)

Socket wrench, cylinder head bolt

303-392 (21-167)

Locking tool, flywheel

303-393 (21-168)

Assembly stands

303-435 (21187)

Mounting bracket for 303-435

303-435-06 (21-031B)

Mounting plate for 303-435-06

303-435-14 (21-212)

Socket, spark plug

303-499 (21-202)

Remover, crankshaft vibration damper

303-511 (21-215)

Spark plug connector pliers

303-622 (21-226)

Adapter for 205-047

303-633
General Equipment
Workshop hoist
Materials
Name
Specification
Lubricant for Special Tool
WSD-M1C227-A 

Disassembly

All Vehicles
  1. Secure the engine to the assembly stand.
    • Attach the special tools to the engine.
  1. Drain the engine oil and detach the oil filter.
Vehicles built up to 08/1998
  1. Remove the generator.
    1. Disconnect the connector.
    1. Disconnect the lead.
    1. Unscrew the three screws.
Vehicles built from 08/1998
  1. Detach the generator.
    • Remove the nuts and bolts.
All vehicles
  1. Remove the upper timing belt cover.
    • Coolant pump belt pulley
    • Idler pulley
    • Timing belt cover
Vehicles built up to 07/1998
  1. Remove the front engine mounting bracket.
Vehicles built from 08/1998
  1. Detach the engine mounting bracket.
All vehicles
  1. Detach the engine wiring harness.

  1. Remove the cover plate from the cylinder head cover.

  1. CAUTION:
    CAUTION:The gasket of the cylinder head cover cannot be renewed separately. Always lift the cylinder head cover straight up to prevent damaging the gasket during removal.
    CAUTION:
    CAUTION:Do not pull the cable when removing the spark plug connector. Pull off the connector from the ignition coil if necessary, to avoid bending the cable. Turn the spark plug connector slightly before removing to loosen the seal.
    CAUTION:
    CAUTION:When pulling off the spark plug connector keep it in line with the spark plug.
    Detach the cylinder head cover.
    1. Pull off the spark plug connectors.
    1. Take off the ignition cable clip.
    1. Unscrew the nuts.
  1. Remove the spark plugs with Special Tool 303-499.
Vehicles built up to 07/1998
  1. NOTE:
    NOTE:Important instructions concerning the vibration damper in the chapter""Description and Operation".
    Remove the crankshaft pulley/vibration damper.
    • Grease Special Tool 303-511 and the bolt of the crankshaft pulley/vibration damper with special tool lubricant .
    • Mount the special tool.
    • Extract the crankshaft pulley/vibration damper by screwing the bolt out.
    • Remove the Special Tools.
Vehicles built from 08/1998
  1. Detach the crankshaft pulley/vibration damper.
All vehicles
  1. Detach the lower timing belt cover.
Timing belt tensioner with cam
  1. Slacken and remove the timing belt.
    • Undo the bolt.

  1. Detach the timing belt tensioner.
Timing belt tensioner with slot
  1. Slacken and remove the timing belt.
    • Undo the bolts.
  1. Detach the timing belt tensioner.
    • Remove the screws.
All vehicles
  1. CAUTION:
    CAUTION:The timing pulley bolts can only be re-used once.
    Detach the camshaft timing pulleys.
    • Prevent from turning using the special tool.
    • If necessary mark the timing pulley bolts with coloured paint. Renew any bolts that already have paint markings.

  1. Remove the crankshaft timing pulley.

  1. Detach the inner timing belt cover.

  1. NOTE:
    NOTE:Loosening sequence
    NOTE:
    NOTE:Lay the bearing caps in order to one side, ready for installation. Identification numbers are provided on the outer face of the camshaft bearing caps.
    Remove the camshafts.
    • Loosen the bolts on the camshaft bearing caps a turn at a time until the camshaft comes free.
    • Remove the camshaft bearing caps.
    • Remove the camshaft oil seal.

  1. NOTE:
    NOTE:Lay the valve tappets in order to one side, ready for installation.
    Remove the valve tappets and valve adjusting shims using the special tool.

  1. Pull off the crankcase ventilation hose.

  1. Remove the three lower intake manifold bolts from the cylinder block and detach the engine oil dipstick tube.

  1. CAUTION:
    CAUTION:The cylinder head must be allowed to cool to below 30 degrees C before it is detached.
    CAUTION:
    CAUTION:Place the cylinder head onto a soft surface.
    NOTE:
    NOTE:Loosening sequence
    Remove the cylinder head.
    • Unscrew the cylinder head bolts using the special tool.

  1. CAUTION:
    CAUTION:Do not damage the impeller of the coolant pump.
    Remove the coolant pump.

  1. Detach the thermostat housing and the oil pressure switch.

  1. Disconnect the positive crankcase ventilation.
Vehicles built up to 11/1999
  1. CAUTION:
    CAUTION:Detach the oil pan from below to prevent any oil sludge or abraded particles entering the engine.
    Detach the oil pan.
Vehicles built from 12/1999
  1. Drain the engine oil and remove the oil pan bolts (shown with engine installed in the vehicle).
    1. Unscrew the drain plug.
    1. Remove the oil pan bolts.

  1. CAUTION:
    CAUTION:To avoid damaging the sealing surfaces, only use the special tool specified to remove the oil pan. Do not use a chisel or screwdriver to detach the oil pan.
    Detach the oil pan.
    1. Attach the special tools and lock against the oil pan.
    1. Release the oil pan from the cylinder block by several blows.
All vehicles
  1. Detach the oil pick-up pipe and the oil pump with the gasket.
    • Drive out the oil seal from the oil pump onto a level surface.

  1. CAUTION:
    CAUTION:Undo the bolts two turns at a time until the clutch pressure plate is no longer under tension.
    Immobilise the flywheel with the special tool and detach the clutch.

  1. Detach the flywheel still immobilised with the special tool.

  1. Remove the crankshaft position sensor (CKP).

  1. Detach the crankshaft rear oil seal carrier and the mounting for the CKP sensor.
  1. Detach the cylinder block with crank gear (shortblock) from the assembly stand.
    • Detach the special tools from the cylinder block.

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