Engine - 1.

3L Endura-E (HCS) -
Fiesta 1996 (08/1995-02/2002)
Specifications
 Print 

Engine Data

Description Endura-E (50 PS) Endura-E (60 PS)

Engine management EEC V EEC V
Emission standard 96 EEC 96 EEC
Fuel 95 RON 95 RON
Engine code JJE J4L
Firing order 1-2-4-3 1-2-4-3
Bore 73.96 mm 73.96 mm
Stroke 75.48 mm 75.48 mm
Capacity 1299 cm 3 1299 cm 3
Compression ratio 9.5:1 9.5:1
Compression pressure at starter motor
13 - 16 bar 13 - 16 bar
speed
4500 rev/min - 37 kW/50 5000 rev/min - 44 kW/60
Power output (EC)
PS PS
Torque, at 2500 rev/min 93 Nm 103 Nm
Maximum engine speed, intermittent 5175 rev/min 5675 rev/min
Maximum engine speed, continuous 4950 rev/min 5450 rev/min
Idle speed 850 ± 50 rev/min 850 ± 50 rev/min
Maximum oil consumption 0.5L/1000 km
Engine Oil

Viscosity Specification
Engine oil
SAE 5W-20 WSS-M2C948-B
SAE 5W-30 WSS-M2C913-C
Alternative engine oils (for top-up only)
SAE 5W-30 ACEA A5/B5
Valve Timing

Description Degrees
Intake valve opens before TDC 18
Intake valve closes after BDC 38
Exhaust valve opens before BDC 45
Exhaust valve closes after TDC 7
Camshaft

Description mm
Chain length (46 links) 438.15
Cam lift, intake 5.25
Cam lift, exhaust (with valve clearance of 0.3 mm) 5.14
Cam lift, exhaust (with valve clearance of 0.5 mm) 5.266
Bearing Ø - camshaft 39.615 - 39.635
Inner Ø - bearing bush, standard 39.662 - 39.682
Inner Ø - bearing bush, oversize, service 39.662 - 39.713
Camshaft thrust plate thickness 4.457 - 4.508
Camshaft clearance (axial) 0.02 - 0.19
Valves
 Description mm
Valve clearance (engine cold), intake 0.20
Valve clearance (engine cold), exhaust 0.50
Valve tappet Ø 13.081 - 13.094
Tappet clearance in cylinder block 0.016 - 0.062
Free valve spring length 41
Valve springs - inner Ø 20.25 - 20.75
Valve spring wire - Ø 3.77 - 3.83
Valve length, intake 103.70 - 104.40
Valve length, exhaust 104.02 - 104.72
Valve head Ø, inlet 34.4 - 34.6
Valve head Ø, exhaust 28.90 - 29.10
Valve stem Ø (inlet), standard 7.025 - 7.043
Valve stem Ø (inlet), oversize 0.2 mm 7.225 - 7.243
Valve stem Ø (inlet), oversize 0.4 mm 7.425 - 7.443
Valve stem Ø (exhaust), standard 6.999 - 7.017
Valve stem Ø (exhaust), oversize 0.2 mm 7.199 - 7.217
Valve stem Ø (exhaust), oversize 0.4 mm 7.399 - 7.417
Valve stem guide clearance, intake 0.020 - 0.069
Valve stem guide clearance, exhaust 0.046 - 0.095
Valve lift (without clearance), intake 8.35 ± 0.35
Valve lift, exhaust (with valve clearance of 0.3 mm) 8.17
Valve lift, exhaust (with valve clearance of 0.5 mm) 8.37
Cylinder Head

Descrition mm
Maximum distortion 0.02
Cylinder Block

Description mm
Cylinder block - cylinder liner bore 77.086 - 77.127
Cylinder bore Ø, standard class 1 73.940 - 73.950
Cylinder bore Ø, standard class 2 73.950 - 73.960
Cylinder bore Ø, standard class 3 73.960 - 73.970
Cylinder bore Ø, oversize 0.5 mm 75.000 - 75.010
Center main bearing width (without thrust half-rings) 22.040 - 22.100
Installed main bearing shells, standard, vertical inner Ø 57.009 - 57.056
Installed main bearing shells, undersize 0.254 mm, vertical inner Ø 56.755 - 56.802
Installed main bearing shells, undersize 0.508 mm, vertical inner Ø 56.501 - 56.548
Installed main bearing shells, undersize 0.762 mm, vertical inner Ø 56.247 - 56.294
Main bearing parent bore Ø, standard 60.623 - 60.636
Main bearing parent bore Ø, oversize 61.003 - 61.016
Camshaft bearing parent bore Ø, standard 42.888 - 42.918
Camshaft bearing parent bore Ø, oversize 43.396 - 43.420
Camshaft bearing bushes, standard Ø 39.662 - 39.682
Camshaft bearing bushes Ø, oversize cylinder block 39.662 - 39.682
Camshaft bearing bushes Ø, standard and oversize service 39.662 - 39.713
Main bearing clearance (radial) 0.009 - 0.056
Crankshaft

Description mm
Main bearing journal Ø, standard 56.980 - 57.000
Main bearing journal Ø, undersize (green) 0.254 mm 56.726 - 56.746
Width of main bearing shells 18.29 - 18.69
 Description mm
Big-end bearing journal Ø, standard 40.99 - 41.01
Big-end bearing journal Ø, undersize (green) 40.74 - 40.76
Big-end bearing journal Ø, undersize service 0.508 mm 40.49 - 40.51
Big-end bearing journal Ø, undersize service 0.762 mm 40.24 - 40.26
Crankshaft clearance (axial) 0.05 - 0.26
Thickness of thrust half-ring, standard 2.80 - 2.85
Thickness of thrust half-ring, oversize 2.99 - 3.04
Connecting Rod

Description mm
Bore Ø, big-end 43.99 - 44.01
Bore Ø, small end 17.99 - 18.01
Installed big-end bearing shells, vertical inner Ø, standard 41.016 - 41.050
Installed big-end bearing shells, vertical inner Ø, undersize 0.254 mm 40.966 - 41.000
Installed big-end bearing shells, vertical inner Ø, undersize 0.508 mm 40.516 - 40.550
Installed big-end bearing shells, vertical inner Ø, undersize 0.762 mm 40.266 - 40.300
Installed big-end bearing shells, vertical inner Ø, undersize 1.016 mm 40.016 - 40.050
Big-end bearing radial clearance 0.006 - 0.060
Big-end bearing clearance (axial) 0.100 - 0.250
The crankshaft must not be reworked.

Pistons

Description mm
Piston diameter, class 1 73.91 - 73.92
Piston diameter, class 2 73.92 - 73.93
Piston diameter, class 3 73.93 - 73.94
Piston Ø, standard service 73.93 - 73.955
Piston Ø, oversize 0.5 mm 74.46 - 74.485
Piston Ø, 1.0 mm 74.96 - 74.985
Piston installation clearance, production 0.020 - 0.040
Piston installation clearance, service engine 0.015 - 0.050
Piston ring gap (installed), top 0.25 - 0.45
Piston ring gap (installed), middle 0.45 - 0.75
Piston ring gap (installed), bottom 0.2 - 0.5
Piston ring axial clearance, top (maximum) 0.2
Piston ring axial clearance, bottom (maximum) 0.1
180 degrees offset to the oil scraper ring
Ring gap position, top
gap
90 degrees offset to the oil scraper ring
Ring gap position, middle
gap
Ring gap position, bottom aligned with piston pin
Piston pin length 63.6 - 64.4
Piston pin Ø, white 18.026 - 18.029
Piston pin Ø, red 18.029 - 19.032
Piston pin Ø, blue 18.032 - 18.035
Piston pin Ø, yellow 18.035 - 18.038
Piston pin interference fit (in connecting rod) at
0.016 - 0.048
21°C
Piston pin clearance (in piston) at 21°C 0.008 - 0.014
Lubricants, Fluids, Sealers and Adhesives

Item Specification
Sealer for oil pressure switch WSK-M2G349-A7
 Item Specification
Spark plug thread lubricant ESE-M1244-A
Sealer, oil pan to cylinder block WSE-M4G323-A4
Power steering hydraulic fluid ESPM-2C-166-H
Coolant (Motorcraft Super Plus 4 Anti-Freeze) ESDM-97B49-A
Brake fluid (DOT 4) SAM-6C9103-A
Silicone grease ESE - M1C171 - AA
Engine Oil Pressure

Description bar
Oil pressure (minimum, oil temperature 80°C) at 800 rev/min 0.6
Oil pressure (minimum, oil temperature 80°C) at 2000 rev/min 1.5
Pressure relief valve opening pressure 2.41 - 2.96
Engine Oil Pump

Description mm
Oil pump, max. inner/outer rotor clearance 0.051 - 0.127
Oil pump (clearance between outer rotor and housing) 0.14 - 0.26
Axial clearance of outer/inner rotor in oil pump cover 0.025 - 0.06
Capacities

Litres
Engine oil, initial fill with filter 3.40
Engine oil, with filter change 3.25
Engine oil, without filter change 2.75
Coolant 7.1
If engine oils of other brands are used, it is imperative to make sure that these
conform to API SG/CD or better in the particular viscosity class.

Torque Specifications

lb-
Description Nm lb-ft
in
Rear engine mounting to transmission 69 51 -
Front engine mounting, bracket to body 61 45 -
Front engine mounting bracket to engine mounting and cylinder
69 51 -
head bracket
Engine roll restrictor to transmission 50 37 -
Engine roll restrictor to front crossmember 70 52 -
Right-hand front driveshaft center bearing to center bearing
24 18 -
bracket
Air conditioning compressor to oil pan 25 18 -
Power steering pump to bracket 23 17 -
Flange bolts, transmission to engine 44 32 -
Shift rod stabilizer 55 41 -
Ground lead to transmission 44 32 -
Cable to starter motor 11 8 -
Shift rod to transmission 23 17 -
Generator to bracket 24 18 -
Suspension arm to spindle carrier 52 38 -
Track rod to spindle carrier 36 27 -
Catalytic converter to exhaust manifold
Stage 1 25 18 -
Stage 2 40 30 -
Exhaust manifold to cylinder head 23 17 -
 lb-
Description Nm lb-ft
in
Catalytic converter to engine 47 35 -
Flange (exhaust) 47 35 -
Main bearing caps 95 70 -
Big-end bearing caps
Stage 1 4 - 35
90 90
Stage 2 -
degrees degrees
Rear oil seal carrier 18 13 -
Flywheel 67 49 -
Clutch pressure plate 30 22 -
Timing chain tensioner 8 - 71
Camshaft thrust plate 11 8 -
Camshaft sprocket 28 21 -
Timing cover 9 - 80
Crankshaft pulley 115 85 -
Starter motor 44 32 -
Timing chain tensioner 8 - 71
Generator bracket 47 35 -
Coolant pump 10 - 89
Coolant pump pulley 12 9 -
Thermostat housing 27 20 -
Oil pump 18 13 -
Oil pump cover 10 - 89
Oil pan
Stage 1 7 - 62
Stage 2 10 - 89
Oil drain plug 25 18 -
Oil pressure switch 14 10 -
Oil filter 15 11 -
Oil dipstick tube to intake manifold 2 - 18
Rocker shaft 43 32 -
Cylinder head
Stage 1 30 22 -
90 90
Stage 2 -
degrees degrees
90 90
Stage 3 -
degrees degrees
Cylinder head cover 6 - 62
Intake manifold to cylinder head 18 13 -
Spark plugs 17 13 -
Camshaft position (CMP) sensor 10 - 89
Front engine mounting bracket to cylinder head 69 51 -
Intake manifold protective shield 17 13 -
Engine coolant temperature (ECT) sensor 18 13 -
Fuel distribution pipe 17 13 -
Injector cable guide 2 - 18
Throttle body 10 - 89
Fuel pipe bracket 6 - 53
Idle air control (IAC) valve 10 - 89
Accelerator cable abutment bracket 10 - 89
Crankshaft position (CKP) sensor 4 - 35

Engine - 1.3L Endura-E (HCS) - Engine Fiesta 1996 (08/1995-02/2002)

  Print 

Description and Operation

General

The basic engine for the Fiesta is the Endura-E engine. This familiar 1,3 liter engine has
been revised and is now available in two versions with 37 kW (50 PS) and 44 kW (60
PS). The 37 kW variant will only be available in Germany and Austria.

The main changes to the previous model include sequential, electronically controlled
multiport fuel injection, a new aluminium oil pan and a thermoplastic intake manifold.

From '99 1/2 MY the mass air flow (MAF) and the intake air temperature (IAT) sensor
are no longer installed.

The new temperature/manifold absolute pressure (T-MAP) sensor will be integral with
the intake manifold.

Cylinder Block

Thread repairs to the cylinder block are permitted provided that Helicoil thread inserts
are used. The remaining material thickness must be at least 3,2 mm for diameters up to
9,5 mm and at least 4,8 mm for larger diameters. Water plugs must not be removed.

Crankshaft
 NOTICE: The bolts of the main and big-end bearings must not be reused.
The crankshaft runs on five bearings. The bearing caps are numbered at the factory and
should be refitted accordingly during installation. The first main bearing has a seat for
the tensioning arm of the chain tensioner.

NOTE: When measuring the crankshaft, note the colored marks.

The crankshaft and the main bearing caps have colored marks which indicate their size.
With the bearing caps these marks are on the bearing caps themselves, and on the
crankshaft the colored marks are on the crank webs.

Cylinder Head

The cast iron cylinder head is positioned on the cylinder block with two sleeves, and
fastened with ten bolts.
 NOTICE: The cylinder head bolts may be re-used once, they must however be
clearly marked for re-use by a punch mark.
NOTE: The cylinder head bolts must be tightened in three stages according to the
tightening sequence.
The cylinder head mating face is allowed to show distortion of 0,25 mm over the whole
length.

Thread repairs are permitted provided that Helicoil thread inserts are used.

Cylinder Head Gasket

NOTE: Reworking of the cylinder head mating face is not permitted.

The cylinder head gasket is made of aramide fiber with filler and must be renewed every
time it is removed. The gasket is steel-coated for protection around the oil pressure
bore and the cylinder bore.

Pistons

The pistons are made of an aluminium-silicone alloy, and have three piston rings:

Barrel faced plane ring (top)

Napier ring (middle)

Oil scraper ring (bottom)

Piston rings can be renewed separately, without reworking the cylinder liners.

On installation, the piston ring gaps must be distributed around the circumference and
spaced at least 90 degrees apart.

The arrows on the piston crown point forwards.

Oil Pan
 NOTICE: When installing the aluminium oil pan, make sure that the aluminium oil
pan and the rear side of the cylinder block form a flat surface.
NOTE: The timing cover and the crankshaft oil seal carrier must be flush with the
cylinder block.
NOTE: The oil pan fitted in vehicles with air conditioning is made of aluminium,
otherwise it is made of sheet steel.
On installation, the tightening sequence for the bolts must be observed.

Renew the gasket of the aluminium oil pan if there is any visible damage to it.

Sealer should be applied to the cylinder block when installing the oil pan.

Thread repairs on the oil pan are permitted provided Helicoil thread inserts are used.

Intake Manifold

NOTICE: Do not use the intake manifold as a levering/resting point when

removing or installing the engine.
The intake manifold is made of thermoplastic. This design has two advantages: it
reduces weight and conducts less heat than the die-cast version.

The use of plastic also improves the flow characteristics, reduces the tendency to
condensation at cold start and improves the response of the engine during a warm start.

Valve Train

NOTE: When removing and installing the rocker shaft, do not adjust the rocker arm
bolts.
The valve timing is controlled by the crankshaft via a single roller chain to the low lying
camshaft. The camshaft transmits the timing actions to the valves via tappets, push
rods and a rocker shaft.

Thermostat
 NOTICE: To ensure that the thermostat functions correctly, always ensure that it
is installed correctly.
The gasket of the thermostat housing must be renewed every time the thermostat
housing is fitted.

Engine - 1.3L Endura-E (HCS) - Cylinder

Fiesta 1996 (08/1995-02/2002)
Head
 Print 

In-vehicle Repair
Special Tool(s) / General Equipment
Angle gauge

303-174 (21-540)

Engine lifting eye order no.: 6630411

Assembly stand
Workshop jack
Materials
Name
Specification
Lubricant for spark plugs ('Never Seeze')
ESE-M1244-A 
Coolant
ESDM-97B49-A 
Engine oil
WSS-M2C912-A1 
Cable ties
 
Silicone grease
ESE - M1C171 - AA 

Removal
All Vehicles
1. Release the fuel system pressure. For additional information, refer to Section 
310-00 Fuel System - General Information.
2. Disconnect the battery ground cable. For additional information, refer to
Section  414-01 Battery, Mounting and Cables.
3. Drain off the coolant. For additional information, refer to Section  303-03
Engine Cooling.
4. Pull off the EI coil connector.
 Unclip the wiring.
5. Disconnect the intake pipe from the air cleaner.

6. Disconnect the intake pipe from the throttle body.

7. NOTICE: Twist the spark plug connectors slightly before disconnecting
them. Pull on the connector and not on the cable.
Pull off the spark plug connectors.
 Unclip the HT leads and lay them to one side.

8. Detach the accelerator cable.

1. Unclip the accelerator cable.
2. Pull off the clip.
3. Unhook the accelerator cable from the throttle plate lever.
9. Disconnect the upper coolant hose from the thermostat housing.
 Unclip the wiring loom and remove the clip.

10. Remove the oil filler cap.

 Pull the crankcase breather hose off the T-piece.

11. Disconnect the plug of the heated oxygen sensor (HO2S).

Vehicles with mass air flow (MAF) sensor
12. Disconnect the plugs and remove the vacuum lines.
1. Two plugs (engine wiring loom)
2. Brake servo vacuum line
3. Evaporative emission control valve (EVAP) vacuum line
 Unclip the wiring bracket.

Vehicles with temperature/manifold absolute pressure (T-MAP) sensor

13. Separate the connectors and pull off the vacuum hoses.
1. Engine wiring loom plug
2. Vacuum line - fuel pressure control
3. Vacuum hose - crankcase ventilation
4. Brake servo vacuum line
5. T-MAP sensor connector
All vehicles
14. Disconnect the plugs from the camshaft position sensor (CMP sensor) and
oil pressure switch.

15. Pull out the plug of the engine coolant temperature sensor (ECT sensor).
16. Disconnect the coolant hose to the heat exchanger (quick-release fitting).

17. Remove the oil dipstick tube.

18.Disconnect the fuel lines. For additional information, refer to Section  310-00
Fuel System - General Information.
19. Remove the cylinder head cover with gasket (four bolts with extended
washers).
20. NOTE: Do not turn the bolts on the rocker arms.
NOTE: Put the push rods aside in order.
Remove the rocker shaft.
 Remove the push rods.
 Remove the spark plugs.

21. Remove the heat shield.

22. Remove the exhaust manifold from the catalytic converter.

23. Remove the crankshaft position sensor (CKP sensor) cover.

 Disconnect the plug from the CKP sensor.
 24. Remove the cable guide.

25. NOTE: Use wooden blocks as intermediate supports. The engine must not tilt.
Support the engine with a trolley jack.

26. Detach the front engine mounting bracket.

27. NOTE: Mark the bolts for re-use with a centre punch. Re-use the bolts times
only. Unscrew the bolts in the sequence shown.
Remove the cylinder head.
 Lift the cylinder head off the cylinder block.
 Put the cylinder head down onto a suitable surface.
 Remove the cylinder head gasket.
 Remove the guide sleeves (from the cylinder head or cylinder block).
 Installation
All Vehicles
1. General Remarks.
 Renew the self-locking nuts.
 Thoroughly clean all mating faces and reusable parts and check them for
damage. Do not use a scraping tool to clean the cylinder head mating face.
 Oil passages, for example in the cylinder block, cylinder head etc., must be
free of dirt and swarf.
2. NOTE: First insert the guide sleeves.
Install a new cylinder head gasket.
3. Install the cylinder head.
 Install the cylinder head and tighten the cylinder head bolts finger-tight.
 Tighten the cylinder head bolts in three stages in the tightening sequence
shown.
 First stage: 30 Nm
 Second stage using 303-174 special tool: 90 degrees
 Third stage using 303-174 special tool: 90 degrees
4. NOTE: Use new nuts.
Attach the front engine mounting bracket.

5. Remove the trolley jack.

6. NOTE: Wait 10 seconds between the two tightening stages.
Install the exhaust manifold on the catalytic converter and tighten in two
stages, working diagonally.
 First stage: 25 Nm
 Second stage: 40 Nm
 7. Install the heat shield.

8. NOTE: Do not mix up the push rods when re-installing them.

Install the valve gear.
1. Insert the push rods.
2. Install the rocker shaft.
 9. Install the rocker bolts and spark plugs.
 Coat the spark plug thread with lubricant .

10.Adjust the valve clearances.

For additional information, refer to Valve Clearances in this section.
11. NOTE: Use a new gasket.
Install the cylinder head cover (four bolts with extended washers).
12. Connect the plug to the EI ignition coil.
 Clip the leads in place.

13. Attach the cable guide.

14. Install the CKP sensor cover.
 Connect the CKP sensor plug.

15.Connect the fuel lines. For additional information, refer to Section  310-00
Fuel System - General Information.
16. Connect the coolant hose to the heat exchanger.

17. Install the oil dipstick tube.

 18. Connect the ECT sensor plug.

19. Connect the CMP sensor and oil pressure switch plugs.

Vehicles with mass air flow (MAF) sensor

20. Connect the plugs and install the vacuum lines.
1. Two plugs (engine wiring loom)
2. Vacuum line - brake servo
3. Vacuum line - EVAP
 Clip the wiring bracket in place.
Vehicles with temperature/manifold absolute pressure (T-MAP) sensor
21. Join the connectors and push on the vacuum hoses.
1. Engine wiring loom plug
2. Vacuum line - fuel pressure control
3. Vacuum hose - crankcase ventilation
4. Vacuum line - brake servo
5. T-MAP sensor connector

All vehicles
22. Connect the HO2S plug.
23. Push on the oil filler cap.
 Push the crankcase breather hose onto the T-piece.

24. Connect the upper coolant hose to the thermostat housing.

 Attach the clips and clip the wiring loom in place.
25. Install the accelerator cable.
1. Hook the accelerator cable into the throttle plate lever.
2. Install the clip.
3. Clip the accelerator cable in place.

26. Push on the spark plug connectors until they click in place.
 Lightly coat the spark plug connector seal with silicone grease .
 Clip the ignition cables in place.
27. Connect the intake pipe to the air cleaner.

28. Connect the intake pipe to the throttle body.

 29. Finishing operations.
 Change the engine oil and the oil filter.
 Fill up with coolant. For additional information, refer to Section  303-03
Engine Cooling.
 Check the fluid levels and correct as necessary.
 Check the cooling system for leaks.
 Check the routing of cables and hoses and fix them in place with cable ties.
 Connect the battery ground cable. For additional information, refer to Section 
414-01 Battery, Mounting and Cables.
 Start the engine, bring it up to operating temperature and check for leaks.

Engine - 1.3L Endura-E (HCS) - Engine Fiesta 1996 (08/1995-02/2002)

 Print 

Disassembly
Special Tool(s) / General Equipment
Immobilizing tool, flywheel

303-393 (21-168)

Assembly stand

303-435 (21-187)

Mounting frame for 303-435

303-435-02 (21-050 A)

Oil filter strap wrench

Micrometers
Two-legged puller
Three-legged puller
Torque wrench
Internal micrometer
Materials
Name
Specification
Plastigage
obtainable from: Replacement Services Limited, 30 Euston Street, Freemans Industrial
Estate, Leicester, LE2 7ST. 
Engine oil
WSS-M2C912-A1 
Sealer, oil pan to cylinder block
WSE-M4G323-A4 
Lubricant for spark plugs ('Never Seeze')
ESE-M1244-A 
Silicone grease
ESE - M1C171 - AA 

Disassembly
All Vehicles
1. Remove the exhaust manifold heat shield.

2. Detach the catalytic converter from the cylinder block.

1. Detach the upper mounting (if equipped).
2. Detach the lower mounting.
3. Detach the exhaust manifold and the catalytic converter.

4. Mount the engine with the mounting bracket on the assembly stand.

5. Remove the alternator (four bolts).

6. Detach the generator bracket with belt tensioner and idler pulley (if
equipped).

7. Disconnect the ignition cables.

 Pull off the spark plug connectors.
8. NOTE: Only loosen the bolts, do not remove them.
Remove the clutch and loosen the flywheel bolts.
1. Mount the special tool.
2. Remove the clutch.
3. Loosen the flywheel bolts.

9. Detach the ancillary components.

1. Drain off the engine oil.
2. Remove the oil filter.
3. Detach the DIS ignition coil (two bolts).
4. Detach the oil dipstick tube and pull it out of the cylinder block.
10. Detach the ancillary components.
1. Pull out the plugs of the camshaft position sensor (CMP sensor) and the oil
pressure switch.
2. Remove the oil pressure switch.
3. Remove the oil pump (two bolts, one nut). Remove the gasket.
4. Remove the intake manifold complete (six bolts). Remove the gasket.
11. Remove the coolant pump pulley.
12. NOTE: Do not remove the gasket.
Remove the coolant pump.

13. NOTE: If necessary use a three-legged puller to pull off the pulley. If a puller is
being used, check that the pulley bolt is properly seated to avoid damaging the
crankshaft.
Remove the crankshaft pulley.
1. Remove the single screw.
2. Remove the pulley.
14. Remove the cylinder head cover.
1. Remove the oil filler cap. Detach the crankcase ventilation hose.
2. Remove the cylinder head cover (four bolts and four washers). Remove the
gasket.
3. Remove the rocker shaft (four bolts).
4. Remove the valve push rods and put them aside in order.
Vehicles 12/1997 onwards
15. Remove the thermostat housing.
1. Remove the thermostat housing.
 Remove the thermostat and gasket.
2. Remove the spark plugs.

All vehicles

16. NOTICE: Mark the bolts for re-use with a center punch. The bolts can be
re-used once. Unscrew the bolts in the sequence shown.
Remove the cylinder head (ten bolts).
17. Remove the flywheel.
 Remove the screws.
 Remove the special tool.
18. NOTE: A steel oil pan shown, the aluminium oil pan is similar.
NOTE: Only remove the oil pan downwards, so that no abraded particles or oil
sludge enter the engine.
Remove the oil pan (18 bolts).

19. Remove the crankshaft rear oil seal carrier.

  Remove the gasket.
 Drive out the oil seal onto a flat surface.

20. Remove the timing cover.

 Remove the gasket.
 Drive out the oil seal onto a flat surface.

21. Remove the timing chain.

1. Detach the oil slinger ring from the crankshaft.
2. Remove the timing chain tensioning arm from the pin of the front main
bearing.
3. Detach the timing chain tensioner from the cylinder block (two bolts).
4. Undo the camshaft sprocket bolts and remove the camshaft position sensor
(CMP sensor) sender. Remove the camshaft sprocket with the timing chain.
22. NOTICE: Position the engine upright.
Remove the camshaft.
 Rotate the camshaft through 360 degrees, to bring the valve tappets into TDC
position.
 Carefully remove the camshaft from the cylinder block.

23. NOTE: Make sure that the valve tappets are set in order to one side.
Remove the eight valve tappets.
 24. Pull off the crankshaft sprocket with a two-legged puller.

25. NOTE: Carefully remove carbon deposits with a plastic scraper. Do not damage
the piston ring running surfaces.
NOTE: Set the connecting rods, big-end bearing caps and bearing shells aside
in order.
Remove the pistons with the connecting rods.
1. Detach the big-end bearing caps.
2. Press the connecting rod and piston out of the cylinder block.
26. NOTE: Lay the main bearing caps and bearing shells in order to one side. Align
the main bearing and thrust half washers. Mark the position of the thrust half
washers.
Remove the main bearing caps.
 Take out the bearing shells and thrust half washers.

27. Remove the crankshaft.

28. Remove the crankshaft position sensor (CKP).
Engine - 1.3L Endura-E (HCS) - Engine Fiesta 1996 (08/1995-02/2002)

 Print 

Assembly
Special Tool(s) / General Equipment
Installer, timing cover oil seal

303-091 (21-046)

Adapter for 303-172

303-171-01 (21-102-01)

Adapter for 303-172

303-171-02 (21-102-02A)

Adapters for 303-171-02

303-171-04 (21-102-04)

Installer/aligner, crankshaft rear oil seal

303-172 (21-102)

Angle gauge

303-174 (21-540)

Immobilizing tool, flywheel

303-393 (21-168)

Assembly stand

303-435 (21-187)

Mounting frame for 303-435

303-435-02 (21-050A)

Aligner, clutch disc

308-204 (16-067)
Dial gauge
Piston ring compressor
Piston ring expander
Steel straight-edge

Assembly
All Vehicles
1. Preparatory operations
 Clean all mating faces and reusable parts thoroughly and check them for
damage.
 Oil passages, for example in the cylinder block, cylinder head etc., must be
free of dirt and swarf. Do not use a scraping tool on the cylinder head.
2. Install the CKP sensor.

3. NOTE: The thrust half-washer oil grooves must be visible.

Install the crankshaft.
 Place the bearing shells and thrust half rings in position in the cylinder block.
 Coat the main bearing journals, all bearing shells, all bolt threads and bolt
contact surfaces with engine oil .
4. NOTE: The arrows on the bearing caps must face forwards.
Position the main bearing cap.

5. Measure the end float of the crankshaft.

 Attach the dial indicator gauge .
 Measure the end float by lifting the crankshaft.
 Correct the end float by installing new thrust half rings if necessary.

6. NOTE: Install the piston rings with the manufacturer's marking facing
upwards. If there is no manufacturer's marking, ensure that the tapered face
 ring and oil scraper ring are installed as shown in the illustration opposite.
NOTE: Arrange the piston ring gaps as specified in General Specifications.
Install the piston rings on the piston using proprietary piston ring pliers .
 Lubricate the pistons and cylinder liners with engine oil .

7. NOTE: The arrow mark on the piston points forwards. The associated cylinder
numbers are stamped on the connecting rod big-end.
NOTE: Guide each connecting rod by hand to avoid damaging the bearings.
Install the pistons and connecting rods.
 Compress the piston rings using a proprietary piston ring compressor .
 Press the piston into the cylinder bore using a hammer handle, ensuring that
the connecting rod journal concerned is in BDC position.
 Measure the big-end bearing clearances as described in steps to
 Renew the bearing shells if necessary.

8. Measure the big-end bearing clearances.

9. NOTICE: Use new bolts.

NOTE: Ensure that the connecting rod and bearing cap numbers match and
that the connecting rods have sufficient axial play.
Attach the big-end bearing caps.
 1. Coat the bearing shells, bearing journals and the threads and contact surfaces
of the bolts with engine oil .
2. Install the big-end bearing cap with bearing shells and tighten in two stages.
 First stage: 4 Nm
 Second stage using 303-174 special tool: 90 degrees

10. NOTE: The marking on the sprocket must be visible.

Install the crankshaft sprocket.
 Install the sprocket with the aid of the pulley, bolt and washer.

11. Insert the eight valve tappets.

 Lubricate the bolt contact faces with engine oil .
12. Install the camshaft.
 Lubricate the camshaft bearing, camshaft and retaining plate with engine oil .
 Insert the camshaft from the front bearing and install the retaining plate.
 Secure the thrust plate with two bolts.

13. Install the timing chain tensioner.

 Install the timing chain tensioner to the cylinder block (two bolts).
 Check for parallel at two points across "A".
 If the tolerance is exceeded, undo, turn and re-install the timing chain
tensioner and then re-measure.
14. NOTE: The markings on the sprockets must be opposite each other.
Install the timing chain.
1. Place the camshaft timing chain and sprocket in position.
2. Position the sender for the CMP sensor and tighten the bolts.
3. Slide the timing chain tensioner arm onto the stud.

15. Rotate the crankshaft and check the adjustment markings.

16. NOTICE: Apply a drop of engine oil to the outer rubber of the oil seal to
prevent it from being skewed when it is pressed in. It is essential to avoid
getting engine oil on the sealing lip.
Install a new oil seal to the timing cover.
1. Slide the special tool onto the hub of the crankshaft pulley.
2. Slide the oil seal onto the hub of the crankshaft pulley.
 Apply a drop of engine oil to the outer rubber of the oil seal to prevent it from
being skewed.
 Put the crankshaft pulley in position and press the seal home by tightening
the bolt.

17. Remove the crankshaft pulley, take off the special tool and reinstall the
crankshaft pulley.
18. NOTE: The mating face at the oil pan must not be offset from the cylinder
block.
Install the timing cover.
 Centre the timing cover with the pulley and then tighten the bolts (four bolts).
 Remove the pulley.
 Tighten the fifth bolt.
 19. Install the crankshaft rear oil seal carrier.
 Install the oil seal carrier with the new gasket and tighten the bolts finger-
tight.

20. NOTICE: Only remove the support ring after installation. Apply a drop of
engine oil to the outer rubber of the oil seal to prevent it from being skewed.
It is essential to avoid getting engine oil on the sealing lip.
NOTE: The special tool must lie centrally on the oil seal, to prevent it tilting
when it is pressed in.
NOTE: The crankshaft guide pin must line up with the hole in the special tool.
Install crankshaft rear oil seal
1. Slide the crankshaft rear oil seal onto the crankshaft.
 Apply a drop of engine oil to the outer rubber of the oil seal to prevent it from
being skewed.
2. Install the special tools.
  Draw in the oil seal as far as it will go by tightening the nut.

21. Remove the special tools and support ring.

22. Secure the crankshaft rear oil seal carrier.

Vehicles with an aluminium oil pan

23. NOTE: Apply sealant to the surfaces indicated.
Apply sealant to the cylinder block.
 Apply sealant to the surfaces indicated.
24. WARNING: The oil pan and the transmission side of the cylinder block
must not be offset.
Line up the oil pan with the cylinder block using a steel straight-edge .

25. NOTE: The arrow must point towards the front of the vehicle.
Install the oil pan.
 Install the oil pan and tighten the bolts in three stages.
 First stage: To 7 Nm in alphabetical order.
 Second stage: To 10 Nm in numerical order.
 Third stage: Allow to warm up for 15 minutes and then retighten to 10 Nm in
alphabetical order.
Vehicles with a steel oil pan
26. NOTE: Apply sealant to the surfaces indicated.
Apply sealer to the cylinder block.
 Apply sealant to the surfaces indicated.
27. NOTE: Push the lugs of the cork gasket under the recess in the rubber
gaskets.
Install a new oil pan gasket.
 Insert the rubber gaskets in the grooves of the oil seal carrier.
 Install the cork gaskets.

28. NOTE: The arrow must point towards the front of the vehicle.
Install the oil pan.
 Install the oil pan and tighten the bolts in three stages.
 First stage: To 7 Nm in alphabetical order.
 Second stage: To 10 Nm in numerical order.
 Third stage: Allow to warm up for 15 minutes and then retighten to 10 Nm in
alphabetical order.
All vehicles
29. Install the flywheel (six bolts).
 Immobilize the crankshaft.
 Lubricate the bolts with engine oil and tighten them, working diagonally.
30. Install the crankshaft pulley.

31. Install a new cylinder head gasket.

 32. NOTE: Check the marks on the bolts to see whether they can be re-used.
Otherwise use new bolts.
Install the cylinder head.
 Install the cylinder head and tighten the cylinder head bolts finger-tight.
 Tighten the cylinder head bolts in three stages in the tightening sequence
shown.
 First stage: 30 Nm
 Second stage using 303-174 special tool: 90 degrees
 Third stage using 303-174 special tool: 90 degrees

Vehicles 12/1997 onwards

33. Install the thermostat housing. (Vehicles 12/1997 onwards shown)
1. Install the thermostat housing.
2. Install the spark plugs.
1. Coat the spark plug threads with lubricant .
All vehicles
34. Install the rocker shaft.
1. Insert the valve push rods.
2. Install the rocker shaft (four bolts).

35.Adjust the valve clearances.

For additional information, refer to Valve Clearances in this section.
36. NOTE: Use a new gasket.
Install the cylinder head cover.
1. Attach the cylinder head cover (four bolts and four washers).
2. Install the oil filler cap and crankcase breather hose.
37. Attach the coolant pump.

38. Attach the coolant pump pulley.

39.Fill the oil pump with 0,15 litres of engine oil before installation.
 Turn the drive shaft of the oil pump one turn anti-clockwise by hand.
40. NOTE: Apply sealant to the threads of the oil pressure switch.
Install the components.
1. Install the intake manifold complete with a new gasket (six bolts).
2. Attach the oil pump with a new gasket (three bolts).
3. Install the oil pressure switch.
 Apply sealant to the threads of the oil pressure switch.
 Connect the plugs of the CMP sensor and oil pressure switch.

41. Install the components.

1. Guide the oil dipstick tube into the cylinder block and attach it.
2. Install the oil filter.
3. Attach the DIS ignition coil (two bolts).
4. Install the oil drain plug.
42. Center the clutch disc.
 Center the clutch disc on the clutch pressure plate and hold it in place with
the special tool.

43. Install the clutch disc and pressure plate.

1. Position the clutch pressure plate with the special tool and the centered clutch
disc on the flywheel guide pins.
2. Tighten the bolts of the clutch pressure plate uniformly, working diagonally.
3. Remove the special tool.
 44. Attach the generator bracket with belt tensioner and idler pulley (if
equipped).

45. NOTE: Install the front bolts first.

Install the generator (four bolts).
46. Connect the HT leads.
 Lightly coat the spark plug connector seals with silicone grease .
 Push on the spark plug connectors until they click into place.

47. Remove the engine from the mounting bracket and assembly stand.

48. Attach the exhaust manifold and the catalytic converter.

49. Attach the catalytic converter to the cylinder block.

50. Install the exhaust manifold heat shield.

 51. Standard finishing operations.
 Top up the engine oil .
 Start the engine, bring it up to operating temperature and check for leaks.
 Check the oil pan bolts.

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Specifications
 Print 

Engine Data

1.25l Zetec 1.4l Zetec 1.6l Zetec

Description
SE SE SE
Engine management EEC V EEC V EEC
Emission standard 96 EEC 96 EEC 96 EEC
Fuel 95 RON 95 RON 95 RON
Engine code from '96 MY (emission level
DHA
D3/Germany)
Engine code '96,5 MY to '99,5 MY (emission level
FHA
D3/Germany)
Engine code from '99 MY (emission level
DHB
D4/Germany)
Engine code from '99,5 MY (emission level Stage
DHC/DHD*
II /Europe)
Engine code from '99,5 MY (emission level
FHA
D4/Germany)
Engine code from '99,5 MY (emission level Stage
FHE
II /Europe)
Engine code 2001 MY (emission level Stage IV) DHF
Engine code 2000.5 MY (emission level D4/E4) L1T
Engine code 2001 MY (emission level Stage IV) L1V
1-3-4- 1-3-4-
Firing order 1-3-4-2
2 2
Bore diameter mm 71.9 76.0 79.0
Stroke mm 76.5 76.5 81.4
cm
Displacement 3 1242 1388 1595
Compression ratio 10:1 10.3:1 11:1
Power output (EC) kW 55 66 76
Power output (EC) PS 75 90 103
Power output (EC), at rpm 5200 5600 6000
Torque Nm 110 125 145
Torque at rpm 4000 4500 4000
Max. engine speed, continuous rpm 5950 6350 6450
Max. engine speed, intermittent rpm 6175 6575 6800
* DHA and DHD engines - MAF-calibration, CTX automatic transmission from
'99 MY.

* DHB and DHC engines - speed density calibration, iB5 manual transmission

Camshaft

Description 1.25l Zetec SE 1.4l Zetec SE 1.6l Zetec SE

Drive Timing belt Timing belt Timing belt
Inlet opens before TDC Degrees 2 4 6
Inlet closes after BDC Degrees 42 44 46
Exhaust opens before BDC Degrees 34 34 38
Exhaust closes after TDC Degrees 10 10 6
Valves

Description 1.25l Zetec SE 1.4l Zetec SE 1.6l Zetec SE

Valve control Bucket tappets Bucket tappets Bucket tappets
Valve clearance (engine cold), inlet mm 0.17 - 0.23 0.17 - 0.23 0.17 - 0.23
Valve clearance (engine cold), exhaust mm 0.27 - 0.33 0.27 - 0.33 0.31 - 0.37
Free valve spring length mm 53.2 53.2 53.2
Valve spring inside diameter mm 16.85 - 17.15 16.85 - 17.15 16.85 - 17.15
Valve spring wire diameter mm 2.77 - 2.83 2.77 - 2.83 2.77 - 2.83
Number of turns (active) 7.2 7.2 7.2
Valve length, inlet mm 97.65 97.35 96.95
Valve length, exhaust mm 99.70 99.40 99.40
Valve head diameter, inlet mm 25.95 - 26.25 27.95 - 28.25 29.95 - 30.25
Valve head diameter, exhaust mm 21.95 - 22.25 23.95 - 24.25 23.95 - 24.25
Cylinder Block Dimensions

Description 1.25l Zetec SE 1.4l Zetec SE 1.6l Zetec SE

Cylinder bore dia., class 1 mm 71.900 - 71.910 76.000 - 76.010 79.000 - 79.010
Cylinder bore dia., class 2 mm 71.910 - 71.920 76.010 - 76.020 79.010 - 79.020
Cylinder bore dia., class 3 mm 71.920 - 71.930 76.020 - 76.030 79.020 - 79.030
Crankshaft Dimensions

Description 1.25l Zetec SE 1.4l Zetec SE 1.6l Zetec SE

Crankshaft end float mm 0.220 - 0.430 0.220 - 0.430 0.220 - 0.430
Piston Dimensions

1.25l Zetec
Description 1.4l Zetec SE 1.6l Zetec SE
SE
Piston diameter, class 1 (1.25l up to m 71.875 - 75.975 - 78.955 -
13.10.96 and 1.4l) m 71.885 75.985 78.965
Piston diameter, class 2 (1.25l up to m 71.885 - 75.985 - 78.965 -
13.10.96 and 1.4l) m 71.895 75.995 78.975
Piston diameter, class 3 (1.25l up to m 71.895 - 75.995 - 78.975 -
13.10.96 and 1.4l) m 71.905 80.005 78.985
m 71.885 -
Piston diameter, class 1 (from 14.10.96) - -
m 71.915
m 71.895 -
Piston diameter, class 2 (from 14.10.96) - -
m 71.925
m 71.905 -
Piston diameter, class 3 (from 14.10.96) - -
m 71.935
m 71.875 -
Piston diameter, class 1 (from 05.03.97) - -
m 71.905
m 71.885 -
Piston diameter, class 2 (from 05.03.97) - -
m 71.915
 1.25l Zetec
Description 1.4l Zetec SE 1.6l Zetec SE
SE
m 71.895 -
Piston diameter, class 3 (from 05.03.97) - -
m 71.925
m
Piston ring gap, upper 0.2 - 0.3 0.2 - 0.3 0.18 - 0.28
m
m
Piston ring gap, middle 0.3 - 0.5 0.3 - 0.5 0.7 - 0.9
m
m
Piston ring gap, lower 0.3 - 0.7 0.15 - 0.65 0.15 - 0.65
m
m
Piston ring end float, upper 0.04 - 0.08 0.04 - 0.08 0.04 - 0.08
m
m
Piston ring end float, middle 0.03 - 0.06 0.03 - 0.06 0.025 - 0.07
m
The piston ring gaps must be distributed evenly around the circumference of
the piston. This also applies to the elements of the oil scraper ring. Offset the
ring gaps by 120° to one another.

Cylinder Head

Description 1.25l Zetec SE 1.4l Zetec SE 1.6l Zetec SE

Maximum distortion (mating face) mm 0.05 0.05 0.05
Engine Oil

Viscosity/ambient
Type Specification
temperature
Recommended engine oils:
ACEA A1/B1 and WSS-
SAE 5W30 / below -20 to over Ford Formula E Economy
M2C912-A1 or WSS-M2C913-
40 degrees Celsius Motor Oil
A
Engine oils for topping up:
SAE 10W30 / -20 to over 40 Ford Super Multigrade Engine ACEA A1/B1 or A2/B2 and/or
degrees Celsius Oil API/SH/CD EC
SAE 10W40 / -20 to over 40 Ford XR+ High Performance ACEA A3/B3 and/or
degrees Celsius High Lubricity Engine Oil API/SH/CD EC
SAE 5W40 / below -20 to over Ford Formula S Synthetic ACEA A3/B3 and/or
40 degrees Celsius Motor Oil API/SH/CD EC
If these specified engine oils are not available, other engine oils may be used,
provided they at least fulfil the API/SH/EC specification.

Lubricants, Sealers and Adhesives

Item Specification
Sealer, oil pan contact surface to oil seal carrier, oil pan to cylinder block,
WSK-M4G323-A4
oil pan to oil pump
Oil pressure switch sealer (Loctite 243) WSK-M2G349-A7
Sealer, camshaft bearing cap to cylinder head WSK-M2G348-A2
Lubricant, spark plug threads (Never Seez) ESE-M1244-A
Lubricant for Special Tool 21-215 WSD-M1C227-A
Coolant (Motorcraft Super Plus 4 AntiFreeze) ESDM-97B49-A
Power steering fluid ESPM-2C-166-A
Transmission fluid (AFT) ESP-M2C166-H
A92CT-7000-
Transmission fluid (Tutela)
EM/FC
Silicone grease ESE-M1C171-AA
Engine Lubrication
 Description
Oil pressure (minimum, oil temperature 80 degrees C) at 800 rpm bar 1.0
Oil pressure (minimum, oil temperature 80 degrees C) at 2000 rpm bar 2.5
Pressure relief valve opening pressure bar 5
If other engine oil brands are used, it must be ensured that they conform to
the relevant API SH/EC or higher viscosity class.

Capacities - 1.25l/1.4L

Description Litres
Engine oil, for initial fill 4.25
Engine oil, for oil change incl. filter (EFL500) 3.75
Engine oil, for oil change incl. filter (EFL10) 3.80
Engine oil, for oil change excl. filter 3.50
Capacities - 1.6l

Description Litres
Engine oil, for initial fill incl. filter (EFL600) 4.50
Engine oil, for initial fill incl. filter (EFL10) 4.30
Engine oil, for oil change incl. filter (EFL600) 4.25
Engine oil, for oil change incl. filter (EFL10) 4.10
Engine oil, for oil change excl. filter 3.75
Tightening Torques

Description Nm lb-ft lb-in

Exhaust pipe to flexible exhaust pipe 47 35 —
Exhaust manifold to catalytic converter 47 35 —
Stabilizer link rod 47 35 —
Lower suspension arm to wheel knuckle 52 38 —
Track rod to wheel knuckle 36 27 —
Nut - halfshaft hub 270 199 —
Center bearing to bracket 24 18 —
Battery cable to starter motor 6 — 53
Solenoid switch cable to starter 11 8 —
Radiator crossmember 25 18 —
Fluid pipes to transmission 21 15 —
Ground lead to transmission 30 22 —
Ground lead to generator 11 8 —
Suspension strut nut 45 33 —
Wheel nuts 85 63 —
Battery box 25 18 —
Tightening Torques

Description Nm lb-ft lb-in

Front engine mounting bracket bolts 55 41 —
Rear engine mounting bracket nuts 69 51 —
Rear engine mounting bracket bolts 49 36 —
Engine roll restrictor to engine 50 37 —
Engine roll restrictor to front crossmember 70 52 —
Tightening Torques

Description Nm lb-ft lb-in

EGR pipe to intake manifold 20 15 —
EGR pipe bracket to cylinder head 9 — 80
 Description Nm lb-ft lb-in
EGR pipe to EGR valve 55 41 —
EGR valve to cylinder head 31 23 —
EGR pipe to exhaust manifold 72 53 —
Tightening Torques

Description Nm lb-ft lb-in

Drive belt idler pulley 24 18 —
Power steering pump to cylinder block 23 17 —
Tightening Torques

Description Nm lb-ft lb-in

Coolant pump to cylinder block 9 — 80
Coolant pump belt pulley 24 18 —
Thermostat housing to cylinder block 9 — 80
Coolant outlet housing to cylinder head 20 15
Engine coolant temperature sensor (ECT sensor) to coolant outlet 12 9
Blower thermoswitch to coolant outlet housing 9 — 80
Radiator drain plug 20 15 —
Tightening Torques

Description Nm lb-ft lb-in

Oil pump to cylinder block 9 — 80
Oil baffle to cylinder block 9 — 80
Oil intake pipe to main bearing bridge and to oil pump 9 — 80
Oil pan to cylinder block 20 15 —
Oil pressure switch to cylinder block 15 11 —
Oil dipstick tube to cylinder head 9 — 80
Oil drain plug 37 27 —
Oil filter 17 13 —
Oil filter connector to cylinder block connector 45 33 —
Tightening Torques

Description Nm lb-ft lb-in

Cylinder head to cylinder block stage 1 15 11 —
Cylinder head to cylinder block stage 2 30 22 —
Cylinder head to cylinder block stage 3 (degrees) 90 90 —
Front engine mounting bracket 55 41 —
Cylinder head cover to cylinder head, stage 1 3 — 27
Cylinder head cover to cylinder head, stage 2 10 — 89
Cylinder head cover plate 6 — 53
Intake manifold 18 13 —
Fuel rail 23 17 —
Exhaust manifold studs 10 — 89
Exhaust manifold 54 40 —
Camshaft position sensor (CMP sensor) 8 — 71
Spark plugs 15 11 —
Front engine lifting eye (up to 6/98) 50 37 —
Rear engine lifting eye 20 15 —
Coolant outlet studs 10 — 89
DIS ignition coil to coolant outlet housing 6 — 53
Tightening Torques

Description Nm lb-ft lb-in

Camshaft bearing caps, stage 1 6 — 53
 Description Nm lb-ft lb-in
Camshaft bearing caps, stage 2 15 11 —
Upper timing belt cover to cylinder block 9 — 80
Lower timing belt cover to crankcase 9 — 80
Anti-skip device to cylinder block 9 — 80
Timing belt tensioning pulley 20 15 —
Camshaft pulley bolt 60 44 —
Tightening Torques

Description Nm lb-ft lb-in

Crankshaft position (CKP) sensor mounting to cylinder block 9 — 80
Crankshaft position (CKP) sensor to mounting 9 — 80
Rear crankshaft oil seal carrier 9 — 80
Crankcase breather to cylinder block 9 — 80
Bore blanking plug for TDC peg 20 15 —
Tightening Torques

Description Nm lb-ft lb-in

Vibration damper to crankshaft, stage 1 40 30 —
Vibration damper to crankshaft, stage 2 (degrees) 90 90 —
Big-end bearing cap to connecting rod, stage 1 8 — 71
Big-end bearing cap to connecting rod, stage 2 (degrees) 90 90 —
Flywheel to crankshaft, stage 1 30 22 —
Flywheel to crankshaft, stage 2 (degrees) 80 80 —
Clutch to flywheel 30 22 —

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Engine
 Print 

Description and Operation

General

The Zetec-SE engine is of all aluminium construction and meets the strict emission
levels of emission standard EEC-96 as well as the German D3 emission standard. From
08 /1998 it meets the strict D4 emission standard.

Cylinder Head Cover

NOTE: The cylinder head cover is made of magnesium, and the gasket is vulcanized
onto it and therefore cannot be renewed separately. A new cylinder head cover does
not need to be installed every time it is removed. Therefore inspect the gasket and
only install a new cylinder head cover if the gasket is damaged.
The cylinder head cover is attached to four camshaft bearing caps. These studs are
sealed with four rubber bungs with torque limiters. If any leaks are detected, the four
bungs can be renewed separately.

It is permissible to lightly coat the rubber bungs with engine oil for installation.

Wipe off any excess oil with a clean cloth.

Four new plugs must be used when a new cylinder head cover is installed. These are
delivered along with the cylinder head cover.

Cylinder head cover - vehicles built 12/2000 onwards

From this time the cylinder head cover is made of plastic.

It is no longer secured on four of the camshaft bearing caps. Instead the cylinder head
cover is secured around the flange with 12 bolts and the cylinder head has been
modified accordingly. The cylinder head cover gasket can be changed separately.

Camshafts, Camshaft Bearing Caps and Camshaft Timing Pulleys

NOTICE: The camshaft bearing caps are tightened in three stages to a maximum
of 16 Nm following the tightening sequence.
NOTE: The camshaft timing belt pulleys are not positively keyed onto the camshafts.
The camshafts must be lubricated with engine oil prior to installation.

Check the camshaft bearings whenever the camshafts are renewed. If damaged, the
cylinder head and camshaft bearing caps must be changed.

The exhaust camshaft has an additional cam for the camshaft position (CMP) sensor.

Both camshafts have a forged-on hexagon (21 mm) so that they can be turned.

Both camshafts have a slot on the end, into which the tool for setting TDC fits.
The numbering of the bearing caps starts at the timing belt end with:

I1 on the inlet side

E1 on the exhaust side

The front bearing caps are accurately positioned on the cylinder head by means of guide
sleeves and must be installed using sealant.

Cylinder Head

NOTICE:

The cylinder head mating face must not be re-machined.

The valve seats and valve stem guides must not be re-machined.

Thread repairs are not permitted on the cylinder head.

NOTE: If new valves are installed, they are to be ground in without re- cutting the
seats.
The cylinder head is made of aluminium and is accurately positioned on the cylinder
block with two guide sleeves.

Replacement cylinder heads are supplied complete with the valves and camshaft bearing
caps already installed.

The studs must be renewed.

To ensure that the cylinder head is properly sealed, the maximum permitted
unevenness on the cylinder block mating face is 0,05 mm.

Cylinder head gasket

NOTE: The cylinder head gasket can only be installed properly in one position.
The cylinder head gasket is a multi-layer steel gasket which must be renewed every
time it is disassembled.

Cylinder Block

NOTICE:

To avoid damaging the cylinder block mating face, only place the cylinder block
on a soft support.

Thread repairs on the cylinder block are not permitted.

Machining the cylinder block mating faces is not permitted.

Do not damage the impeller of the coolant pump during removal and installation.
An exchange cylinder block is delivered complete with crankshaft, pistons and all oil
passage blanking plugs and water drain plugs.

The cylinder block is of die-cast aluminium with cylinder liners made of cast iron.

An exchange cylinder block is delivered complete with crankshaft, pistons and all oil
passage blanking plugs and water drain plugs.

The core plug (formerly frost plug) can be replaced with a heating coil for north
European territories.

Do not re-use the water drain plugs.

To ensure that the cylinder head is properly sealed, the maximum permitted
unevenness on the cylinder block mating face is 0,05 mm.

Crankshaft

NOTICE: The crankshaft and conrod assembly must not be dismantled.

NOTE: Because of the very fine bearing clearance and bearing shell tolerances,
components of the crankshaft and conrod assembly cannot be renewed separately.
Measurement of the bearing clearances (main bearings and big-end bearings) cannot
be performed using traditional methods.
The crankshaft is attached to the cylinder block by means of a lower crankcase made of
aluminium.

The main bearing cap assembly is shaped to fit the cylinder block and is not located by
means of guide sleeves.

Pistons
 NOTICE: The pistons must not be removed.
The pistons are made of an aluminium alloy and have three piston rings:

Plain compression ring (top)

Napier ring (middle)

Oil scraper ring (bottom)

The arrows on the piston crown point towards the timing belt end.

There are no oversize pistons available.

Oil pan - vehicles built up to 11/1999

The oil pan is made of aluminium.

During installation align the oil pan so that it forms a flush surface with the flywheel end
of the cylinder block.

When installing the oil pan, tighten the oil pan bolts to the specified torque in the
specified order.

A new oil pan gasket must be used every time the oil pan is installed.

Before the oil pan is installed, apply the specified sealer to the cylinder block faces, the
oil pump flange and the mounting face of the crankshaft rear oil seal carrier (only when
this is not renewed).

The bead of specified sealant should be continued 10 mm beyond the joints in the
mating faces.

Oil pan - vehicles built 12/1999 onwards

The oil pan is made of aluminium.

A liquid gasket is used to form the seal between the oil pan and the cylinder block.

Valve Train

NOTICE: The timing belt pulley bolts must only be re-used once.
The two overhead camshafts are driven from the crankshaft by a toothed belt and they
control the valves through tappets with adjusting shims above.

Three different timing belt tensioners are used, depending on the build month, as
described below.

Hydraulic timing belt tensioner

Installed up to and including build month 03/1997.

Mechanical timing belt tensioner (with eccentric)

From build month 04/1997.

Mechanical timing belt tensioner (with slot)

Installed from build month 03/1998.

Timing belt skip-prevention device

No longer installed from build month 06/1997.

Crankshaft Pulley/Vibration Damper Vehicles up to 07/1998

NOTICE:

The bolt of the pulley/vibration damper must only be used once.

The relative position of the camshaft and the crankshaft, i.e. the valve timing,
must be checked every time the vibration damper is released and secured.
NOTE: The crankshaft pulley/vibration damper must only be pressed on using the
special tool because if the bolt is used the torque of the bolt is reached before the
vibration damper is home.
Crankshaft Pulley/Vibration Damper

Vehicles built from 08/1998

NOTE: The crankshaft pulley/vibration damper and the crankshaft timing pulley
located behind it can be turned freely on the crankshaft if the bolt is not tightened to
specification. The crankshaft pulley/vibration damper must be installed properly
before the valve timing can be adjusted and checked.
Crankshaft pulley/vibration damper

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Crankshaft Front Seal
 Print 

In-vehicle Repair
Special Tool(s)
 Remover, crankshaft oil seal

303-293 (21143)

Installer, crankshaft oil seal

303-395 (21171)

Materials
Name
Specification
Engine Oil
WSS-M2C912-A1 

Removal
1. Remove the timing belt.
For additional information, refer to Timing belt in this section.
2. Raise the vehicle. For additional information, refer to Section  100-02 Jacking
and Lifting.
3. Remove the crankshaft timing pulley.

4. Remove the crankshaft front oil seal using the special tool.
 Installation
1. Install the crankshaft front oil seal using the special tool.
 Before assembly, lubricate the crankshaft spigot and oil seal lip with engine
oil .

2. Push on the crankshaft timing pulley.

3. Lower the vehicle.

4. Install the timing belt.
 For additional information, refer to Timing belt in this section.

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Valve Seals
 Print 

In-vehicle Repair
Special Tool(s)
Installer, valve stem oil seals

303-037 (21007A)

Compressor, valve spring

303-361 (21155)

Adapter for 303 - 361

303-361-04 (2115504)

Adapter for 303 - 361

303-361-05 (2115505)

Installer, valve collets

303-362 (21156)

Connector, air supply (cylinder head)

303-363 (21157)

Pliers, valve stem seals

303-508 (21211)

Materials
Name
Specification
Engine oil
WSS - M2C912 - A1 

Removal
1. Remove the camshafts.
For additional information, refer to Camshafts in this section.
2. Remove the ignition coil (four bolts).
3. Fit the special tools.
 Apply compressed air (7-10 bar) to the cylinder being worked on.

4. Remove the valve spring using the special tool.

 Compress the valve spring.
 Take out the valve collets, valve spring retainer and valve spring.

5. Remove the valve stem seal using the special tool.

 6. Repeat the previous steps on all the other valves.

Installation
1. Push the valve stem seal fitting sleeve onto the valve stem.

2. NOTICE: The valve stem seals for the inlet valves are green, those for the
exhaust valves are brown.
Install the valve stem seal.
 Lubricate the valve stem and valve stem seal lip with engine oil .
 Slide the valve stem seal onto the valve stem with the special tool.
3. Install the valve spring using the special tool.
 Compress the valve spring using the special tool and pull the valve stem seal
fitting sleeve from the valve stem.
 Fit the valve collets with the special tool.

4. Repeat the previous steps on all the other valves.

5. Remove the special tools.
 6. Install the ignition coil.

7. Install the camshafts.

For additional information, refer to Camshafts in this section.

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Camshaft
 Print 

In-vehicle Repair
Special Tool(s)
Universal Flange Holding Wrench

205-072 (15030A)

Pliers, Valve Shim

303-196 (21107)

Installer, Crankshaft Seal

303-395 (21171)

Materials
Name
Specification
Sealer, camshaft bearing cap to cylinder head
WSK-M2G348-A2 
Engine oil
WSS-M2C912-A1 

Removal
All vehicles
1. Remove the timing belt.
For additional information, refer to: Timing Belt (303-01B Engine - 1.25L/1.4L
Zetec-SE (Sigma)/1.6L, In-vehicle Repair).

2. NOTICE: Counterhold using the special tool.

Remove the camshaft timing pulleys.
 Discard the timing pulley bolts.

3. NOTE: Loosening sequence.

NOTE: Keep the bearing caps in order for reassembly. Identification numbers
are on the outer face of the camshaft bearing caps.
Remove the camshafts.
 Loosen the camshaft bearing cap bolts one turn at a time until the camshaft is
released.
 Remove the camshaft bearing caps.
 Remove the camshaft oil seal.
Vehicles built up to 01/2001
4. NOTE: Keep the valve tappets and adjusting shims in order for reassembly.
Remove the valve tappets and adjusting shims using the special tool.

Vehicles built from 01/2001

5. NOTE: Keep the valve tappets in order for reassembly.
Remove the valve tappets using the special tool.
 Installation
Vehicles built from 01/2001
1. NOTE: Install each valve tappet in the location from which it came.
Install the valve tappets using the special tool.
 If necessary, change the tappet to adjust the valve clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).

Vehicles built up to 01/2001

2. NOTE: Install the valve tappets and adjustment shims in the places from which
they came.
Install the valve tappets and adjusting shims.
 If necessary, change the adjusting shim to adjust the valve clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
All vehicles
3. NOTE: The identification numbers are located on the outside of the camshaft
bearing caps.
Apply sealer to the areas shown on camshaft bearing cap no. 1 and the
opposite surface on the cylinder head.

4. NOTICE: Install the camshaft with none of the cams at full lift.
NOTE: The camshaft bearing cap numbering starts at the timing belt end with
E1 on the exhaust side and with I1 on the intake side.
NOTE: The exhaust camshaft is fitted with an additional cam for the CMP
sensor.
Install the camshafts and camshaft bearing caps.
 Before installation, lubricate the camshafts and camshaft bearings with engine
oil.
5. NOTE: Tightening sequence.
Fit the camshaft bearing caps and tighten the bolts in three stages.
 1st stage: Tighten the bolts evenly half a turn at a time until the camshaft
bearing caps contact the cylinder head.
 2nd stage: 7 Nm
 3rd stage: 16 Nm

6. Check the valve clearances.

For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
7. Press in a new camshaft oil seal using the special tool.
 Coat the camshaft and the sealing lip of the camshaft oil seal with engine oil.
 8. NOTE: Use new camshaft pulley bolts.
Install the camshaft timing pulleys so that it is still just possible to turn them.
9. Install the timing belt.
For additional information, refer to: Timing Belt (303-01B Engine - 1.25L/1.4L
Zetec-SE (Sigma)/1.6L, In-vehicle Repair).

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Cylinder Head
 Print 

In-vehicle Repair
Special Tool(s)
Universal Flange Holding Wrench

205–072 (15-030A)

Lifting Bracket, Engine

303–122 (21-068A)

Gauge, Bolt Angle

303–174 (21-540)
Pliers, Valve Shim

303–196 (21-107)

Alignment Plate, Camshaft

303–376 (21-162B)

Socket, Cylinder Head Bolt

303–392 (21-167)

Installer, Crankshaft Seal

303–395 (21-171)

Compressor, Belt Tensioner

303–429 (21-180)

Socket, Spark Plug

303–499 (21-202)

Timing Peg, Crankshaft TDC

303–507 (21-210)

Installer, Crankshaft Vibration Damper

303-510 (21-214)
 Pliers, Spark Plug Connector

303-622 (21-226)

Locking Tool, Crankshaft

303-748 (21-259)

Materials
Name
Specification
Sealer, camshaft bearing cap
WSK-M2G348-A2 
Never Seez
ESE-M1244-A 
Engine oil
WSS-M2C912-A1 
Coolant
ESDM-97B49-A 
Silicone grease, spark plugs
ESE-M1C171–AA 
Lubricant (spark plug threads - Never Seez)
ESE-M1244–A 

Removal
All vehicles
1. General note:
 If necessary, use remover 303-397 when removing coolant hoses and vent
hoses.
2. Release pressure in fuel system.
For additional information, refer to: Fuel System Pressure Release (310-00
Fuel System - General Information, General Procedures).
3. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01
Battery, Mounting and Cables, General Procedures).
4. Raise the vehicle.
For additional information, refer to: Lifting (100-02 Jacking and Lifting,
Description and Operation).

5. NOTICE: When the engine is hot there is a risk of scalding.

Open the coolant expansion tank.
6. Slacken and remove the drive belt.
7. Detach the heat shield from the catalytic converter.
8. Remove the coolant pump pulley and the drive belt idler pulley.

9. Remove the crankshaft pulley/vibration damper.

Vehicles with air conditioning
10. Loosen the bolts and pull the power steering pump back by 10 mm.

All vehicles
11. Remove the bolts from the timing belt covers.
1. Timing belt upper cover.
2. Timing belt lower cover.

12. Remove the lower cover.

13. Drain the coolant.
  Reinstall the drain plug after draining.

14. Lower the vehicle.

15.Remove the battery
For additional information, refer to: Battery (414-01 Battery, Mounting and
Cables, Removal and Installation).
16. Remove the battery tray.
1. Detach the wiring bracket.
2. Remove the bolts.

17. Remove the intake hose.

 18.Disconnect the fuel lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General Procedures).
Vehicles with 1.25l engine
19. Detach the accelerator cable.
 Detach the clips and unhook the accelerator cable.

Vehicles with 1.4l or 1.6l engine

20. Detach the accelerator cable.
1. Detach the clip.
2. Twist out of the bracket.
All vehicles
21. Detach / separate the connectors.
1. Throttle position (TP) sensor.
2. EI ignition coil.
3. Engine coolant temperature (ECT) sensor
4. Detach the engine wiring harness connector.

22. Detach / separate the connectors.

1. Camshaft position (CMP) sensor.
2. Heated oxygen (HO2S) sensor.
23. Detach the coolant hose from the coolant outlet housing.

24. Detach the coolant hoses.

1. From the coolant outlet housing.
2. To the coolant expansion tank.
25. Detach the vacuum hoses from the throttle body.
 Brake servo.
 Fuel pressure regulator.
 EGR valve (if present).

26. Detach the vacuum hoses from the exhaust gas recirculation valve (EGR
valve) (if present).
27. Remove the exhaust manifold heat shield.

28. Detach the exhaust manifold from the catalytic converter.

Vehicles built up to 07/1998
29. Remove the generator.
1. Detach the connector.
2. Disconnect the lead.
3. Remove the three bolts.

Vehicles built from 08/1998

30. Remove the generator and lay it to one side.
1. Detach the connector.
2. Disconnect the positive cable.
3. Detach the studs.
All vehicles
31. Remove the three lower intake manifold bolts from the cylinder block and
detach the oil dipstick tube.

Vehicles built up to 01/2001

32. Remove the cover plate from the cylinder head cover.
1. Unclip the fuel pipes.
2. Detach the positive crankcase ventilation hose (PCV hose).
3. Unclip the carbon canister vacuum pipe bracket.
4. Remove the bolts.
 33. NOTICE:

Do not pull on the cable when detaching the spark plug connector. If
necessary, detach the connector from the ignition coil to avoid bending the
cable. Turn the spark plug connector slightly before detaching it in order to
loosen the seal.

Detach the spark plug connector in line with the spark plug axis.

Do not damage the cylinder head cover gasket as this cannot be renewed
separately.
Remove the cylinder head cover vertically upwards.
1. Detach the spark plug connectors. Use special tool 303-622 for angled spark
plug connectors.
2. Remove three bolts of the timing belt upper cover.
3. Remove the nuts.

Vehicles built from 01/2001

34. Detach the PCV hose and the fuel supply and return lines from the
cylinder head cover.
35. NOTICE:

Do not pull on the cable when detaching the spark plug connector. If
necessary, remove the ignition coil plug to avoid bending the cable. Turn the
spark plug connector slightly before removing it, to loosen the seal.

Detach the spark plug connector in line with the spark plug axis.
Disconnect the spark plug electrical connectors and unclip the wires from the
cylinder head cover.

36. Remove the cylinder head cover.

All vehicles
37. Position a trolley jack with a wooden support underneath the oil pan and
jack it up slightly to take the load off the front engine mounting.
38. NOTE: Support the engine with a trolley jack and wooden block.
Detach the front engine mounting bracket.

39. Remove the timing belt upper cover.

Vehicles built up to 07/1998
40. Remove the front engine mounting bracket.
Vehicles built from 08/1998
41. Remove the front engine mounting bracket (shown with engine removed).

Timing belt tensioner up to build month 03/97

42. NOTE: When re-using the timing belt, mark the running direction.
Slacken and remove the timing belt.
 Compress the timing belt tensioner using the special tool.

Timing belt tensioner from build month 04/97

43. NOTE: When re-using the timing belt, mark the running direction.
 Slacken and remove the timing belt (shown with engine removed).
 Loosen the bolt.

Timing belt tensioner from build month 03/98

44. NOTE: When re-using the timing belt, mark the running direction.
Slacken and remove the timing belt (shown with engine removed).
 Detach the bolts.

All vehicles

45. NOTICE: Counterhold using the special tool.

Remove the camshaft timing pulleys.
 Discard the timing pulley bolts.
 46. Remove the spark plugs with the special tool.

47. NOTE: Loosening sequence.

NOTE: Keep the bearing caps in order for reassembly. The identification
numbers are located on the outside of the camshaft bearing caps.
Remove the camshafts.
 Loosen the camshaft bearing cap bolts one turn at a time until the camshaft is
released.
 Detach the camshaft bearing caps.
 Detach the camshaft oil seal.
Vehicles built up to 01/2001
48. NOTE: Keep the valve tappets and adjusting shims in order for reassembly.
Remove the valve tappets and adjusting shims using the special tool.

Vehicles built from 01/2001

49. NOTE: Keep the valve tappets in order for reassembly.
Remove the valve tappets using the special tool.
All vehicles
50. Detach the timing belt cover bracket from the cylinder head (two bolts).

51. Remove the three lower intake manifold bolts and detach the oil dipstick
tube.
 52.Disconnect the fuel lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General Procedures).
53. NOTICE:

The cylinder head must cool to below 30 degrees C prior to removal.

Place the cylinder head on a soft surface.

NOTE: Loosening sequence.
Detach the cylinder head using the special tool.

54. Lift the cylinder head from the cylinder block and put it down on a soft
surface.
 Remove the cylinder head gasket.
 Installation
All vehicles
1. NOTE: Ensure that all mating faces are clean.
Set the crankshaft to approx. 25 mm before TDC.
Place the cylinder head on the cylinder block.
 Fit a new gasket.

2. NOTE: Tightening sequence.

NOTE: The cylinder head is located by two guide sleeves.
NOTE: Used cylinder head bolts can be reused.
Install the cylinder head using the special tool.
 Ensure that the mating faces are clean.
 Fit a new cylinder head gasket.
 Install the cylinder head, tightening in three stages in the sequence indicated.
 1st stage: 15 Nm.
 2nd stage: 30 Nm.
 3rd stage with special tool 303-174: 90 degrees.
Vehicles built from 01/2001
3. NOTE: Install each valve tappet in the location from which it came.
Install the valve tappets.
 If necessary, change the tappet to adjust the valve clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).

Vehicles built up to 01/2001

4. NOTE: Install the valve tappets with adjusting shims in the locations from
which they came.
Install the valve tappets and adjusting shims.
 If necessary, change the particular adjusting shim to adjust the valve
clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
All vehicles
5. Install the three lower intake manifold bolts and attach the oil dipstick tube.

Vehicles built up to 07/1998

6. Install the front engine mounting bracket.
Vehicles built from 08/1998
7. Install the front engine mounting bracket.

8. Move the timing belt upper cover into the installation position.
9. Install the front engine mounting.

10. Attach the catalytic converter to the exhaust manifold.

 11. Install the exhaust manifold heat shield.
12. Install the timing belt cover bracket.

13. Remove the trolley jack.

14. NOTE: The identification numbers are located on the outside of the camshaft
bearing caps.
Apply sealer to the areas shown on camshaft bearing cap no. 1 and to the
opposite surface on the cylinder head.
15. NOTICE: Install the camshaft with none of the cams at full lift.
NOTE: The exhaust camshaft has an additional cam for the camshaft position
(CMP) sensor.
Install the camshafts.
 Before installation, lubricate the camshafts and camshaft bearings with engine
oil.

16. Identification numbers on the camshaft bearing caps.

1. Begins with I1 at the timing belt end for intake-side camshaft bearing caps.
2. Begins with E1 at the timing belt end for exhaust-side camshaft bearing caps.
17. NOTE: Tightening sequence.
Fit the camshaft bearing caps and tighten the bolts in three stages.
 1st stage: Tighten the bolts evenly half a turn at a time until the camshaft
bearing caps contact the cylinder head.
 2nd stage: 6 Nm.
 3rd stage: 15 Nm.
18. Check the valve clearance and correct if necessary.
19. Press in a new camshaft oil seal using the special tool.

20. Turn the camshafts to TDC of cylinder no. 1.

 Turn the camshafts at the hexagon with an open-ended spanner until the
special tool can be inserted.
21. NOTICE: Counterhold using the special tool.
NOTE: Use new camshaft pulley bolts.
Install the camshaft timing pulleys so that it is still just possible to turn them
on the camshafts.

22. NOTE: Marked running direction on re-used timing belt.

Fit the timing belt.
 Fit the timing belt working counter-clockwise from the crankshaft timing
pulley.
 23.Raise the vehicle.
For additional information, refer to: Lifting (100-02 Jacking and Lifting,
Description and Operation).
24. Install the timing belt lower cover.

25. NOTE: Use the bolt removed from the crankshaft pulley/vibration damper.
Install the crankshaft pulley/vibration damper using the special tool.
 26. Remove the blanking plug and install the special tool.
 Carefully turn the crankshaft until the crank web contacts the special tool.

27. NOTE: Use a new bolt.

Install the crankshaft pulley/vibration damper bolt.
 Tighten the bolts in two stages.
 1st stage: 40 Nm
 2nd stage: 90 degrees

28. Remove the special tool.

 29. Attach the special tool.
 Carefully turn the crankshaft until the crank web contacts the special tool.

Timing belt tensioner up to build month 03/97

30. Tension the timing belt.
 Slacken the special tool.
Timing belt tensioner from build month 04/97
31. Tension the timing belt (shown with engine removed).
 Using a 6 mm Allen key, turn the eccentric counter-clockwise until the arrow
is in line with the center of the window.
NOTE: Do not turn the eccentric when tightening it. Counterhold using
an Allen key.
 Tighten the bolt.

Timing belt tensioner from build month 03/98

32. Tension the timing belt (shown with the engine removed)
 Using an 8mm Allen key, tension until the pointer is positioned exactly in the
center of the square recess.
 Tighten the bolts.
33. NOTICE: Do not tighten the camshaft timing pulleys against special tool
303-376.
NOTE: Do not turn the crankshaft and the camshaft.
Tighten the bolts of the camshaft timing pulleys.

34. Remove special tool 303-376.

35. Remove the special tool.

36. NOTE: If special tool 303-507 cannot be screwed in, turn the crankshaft back
 counter to the direction of engine rotation by about 20 degrees.
Check the valve timing.
 Turn the crankshaft two revolutions in the direction of engine rotation and set
it to TDC.
 Screw in special tool 303-507.
 Carefully turn the crankshaft in the direction of engine rotation until the crank
web contacts the special tool.
 Use special tool 303-376 to check TDC position.
 Remove special tools 303-376 and 303-507.

37. NOTE: Only if special tool 303-376 cannot be inserted.

Set the valve timing.
 Screw in the special tool.

38. NOTICE: Do not tighten the camshaft timing pulley against special tool
303-376.
NOTE: Only if special tool 303-376 cannot be inserted.
Set the valve timing.
 Loosen the camshaft timing pulley of the affected camshaft, counterholding
using the special tool.
  Turn the camshaft at the hexagonal section using an open-ended spanner
until special tool 303-376 can be inserted.
 Tighten the camshaft timing pulley; the crankshaft must remain at TDC.
 Remove special tool 303-376 and unscrew special tool 303-507.
 Check the valve timing again in accordance with the previous step.

39. Install the blanking plug in the timing peg bore.

40. NOTE: Apply lubricant to the spark plug threads.

Install the spark plugs using the special tool.
 41. Install the bolts of the timing belt cover.
 Timing belt upper cover.

Vehicles with air conditioning

42. Tighten the power steering pump bolts.

All vehicles
43. Install the coolant pump pulley and the drive belt idler pulley.
 44. Fit and tension the drive belt.

Vehicles built up to 07/1998

45. Install the generator.
1. Three bolts.
2. Attach the cable.
3. Attach the connector.
Vehicles built from 08/1998
46. Install the generator.
1. Attach the connector.
2. Attach the cable.
3. Tighten the studs.

All vehicles
47. Install the vacuum hoses on the EGR valve (if present).
48. Connect the vacuum hoses to the throttle body.
 Brake servo
 Fuel regulator
 EGR valve (if present)

49. Attach the coolant hoses.

1. Heater hose to coolant outlet housing.
2. Hose to coolant expansion tank.
 50. Attach the coolant hose to the coolant outlet housing.

51. NOTICE:

Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease, to
avoid damaging the spark plug connector seal.

Push on the spark plug connector keeping it in line with the spark plug.
NOTE: Coat the inside of the spark plug connectors with silicone grease to a
depth of 5 - 10 mm.
Install the cylinder head cover.
1. Attach the nuts and tighten in two stages.
 1st stage: 3 Nm.
 2nd stage: 10 Nm.
2. Push on the spark plug connectors until they engage.
3. Install three bolts of the timing belt upper cover.
 52. Install the cover plate of the cylinder head cover.
1. Install the bolts.
2. Install the PCV hose.
3. Clip in the carbon canister vacuum pipe bracket.
4. Clip on the fuel pipes.

Vehicles built from 12/2000

53. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
Attach the cylinder head cover.
 Screw in bolt no. 1 finger tight.
 Tighten bolt nos. 2 to 13 in the sequence shown.
54. NOTICE: Use suitable blunt object to avoid damaging the spark plug
connector seal. Coat the inside of the spark plug connector with silicone grease
to a depth of 5 - 10 mm.
Connect the spark plug electrical connectors and clip the wires to the cylinder
head cover.

55. Install the PCV hose and the fuel supply and return lines on the cylinder
head cover.
All vehicles
56. Attach the connector.
1. CMP sensor.
2. HO2S.

57. Attach the connectors.

1. TP sensor.
2. EI ignition coil.
3. ECT sensor.
4. Attach the engine wiring harness connector.

58. Install the cylinder head cover plate.

1. Tighten the bolts.
2. Attach the crankcase breather hose and close the wiring harness cover.
 Screw on the oil filler cap.
Vehicles with 1.25l engine
59. Attach the accelerator cable.
 Hook in the accelerator cable and secure it to the bracket with the clip.

Vehicles with 1.4l or 1.6l engine

60. Attach the accelerator cable.
1. Attach the clip.
2. Screw the cable into the bracket.
All vehicles
61.Connect the fuel lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General Procedures).
62. Install the intake hose.

63.Raise the vehicle.

For additional information, refer to: Lifting (100-02 Jacking and Lifting,
Description and Operation).
64.Drain the engine oil.
 Install the oil drain plug with a new seal.
65. Install the battery tray.
1. Attach the cable bracket.
2. Install the battery tray.
 66. Standard finishing operations
 Change the oil (incl. oil filter).
 Install and connect the battery.
For additional information, refer to: Battery (414-01 Battery, Mounting and
Cables, Removal and Installation).
 Fill up with coolant.
 Bleed the air from the cooling system.
 Bleed the fuel system.
 Check the engine and the cooling system for leaks (visual check).

Engine - 1.25L/1.4L Zetec-SE

Fiesta 1996 (08/1995-02/2002)
(Sigma)/1.6L - Engine
 Print 

Disassembly
Special Tool(s)
Slide Hammer

205-047 (15–011)

Universal Flange Holding Wrench

205-072 (15-030A)

Pliers, Valve Shim

303-196 (21-107)

Alignment Plate, Camshaft

303–376 (21-162B)
Socket, Cylinder Head Bolt

303-392 (21-167)

Locking Tool, Flywheel

303–393 (21-168)

Compressor, Belt Tensioner

303–429 (21-180)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-14A (21-212)

Socket, Spark Plug

303–499 (21-202)
 Pliers, Spark Plug Connector

303–622 (21-226)

Adapter for 205-047

303–633 (21–227)

Disassembly
All vehicles
1. Detach rear and center exhaust manifold heat shield.

2. Detach the exhaust manifold with catalytic converter bracket and intermediate
bearing bracket.
 Remove the exhaust manifold gasket.
 3. Mount the engine on the mounting stand.
 Attach the special tools to the engine.

4. Drain the engine oil and detach the oil filter.

Vehicles built up to 08/1998
5. Remove the generator.
1. Detach the connector.
2. Disconnect the lead.
3. Remove the three bolts.
Vehicles built from 08/1998
6. Remove the generator.
 Detach the generator connector.

Vehicles with 1.25l engine

7. Detach the oil dipstick tube.

8. Detach the engine wiring harness.

1. Engine coolant temperature sensor (ECT sensor) connector
2. Connector rail for injectors
 3. Camshaft position (CMP) sensor connector
 Unclip the wiring harness.

9. Detach the engine wiring harness.

1. Temperature/manifold absolute pressure (T-MAP) sensor connector.
2. Idle air control valve (IAV) connector
3. Oil pressure switch connector.
4. Crankshaft position (CKP) sensor connector.

10. Detach the intake manifold from the cylinder block.

Vehicles built up to 07/1998
11. Remove the front engine mounting bracket.

Vehicles built from 08/1998

12. Detach the engine mounting bracket.

Vehicles with 1.4l or 1.6l engine

13. Detach the ancillary components.
1. Detach the intake manifold and disconnect the hose from the crankcase
breather.
 2. Engine wiring harness.
3. Cylinder head cover plate.
4. Detach the EGR pipe from the intake manifold and from the exhaust gas
recirculation valve (EGR valve) (21 mm) (if present).
5. Oil dipstick tube.
All vehicles
14. Remove the timing belt upper cover.
 Coolant pump pulley
 Idler pulley
 Timing belt cover

Vehicles built up to 01/2001

15. NOTICE:

The gasket of the cylinder head cover cannot be renewed separately. To

avoid damaging the gasket when removing, lift off the cylinder head cover
vertically upwards.

Do not pull on the cable when detaching the spark plug connector. If
necessary, detach the connector from the ignition coil to avoid bending the
cable. Turn the spark plug connector slightly before detaching it in order to
loosen the seal.

Detach the spark plug connector in line with the spark plug axis.
Remove the cylinder head cover.
1. Detach the spark plug connectors.
2. Remove the ignition cable clip.
 Use special tool 303-622 for angled spark plug connectors.
 Remove the nuts.
Vehicles built from 12/2000
16. NOTICE:

Do not pull on the cable when detaching the spark plug connector. If
necessary, remove the ignition coil plug to avoid bending the cable. Turn the
spark plug connector slightly before removing it, to loosen the seal.

Detach the spark plug connector in line with the spark plug axis.
Disconnect the spark plug electrical connectors and unclip the wires from the
cylinder head cover.

17. Remove the cylinder head cover.

All vehicles
18. Remove the spark plugs with Special Tool 303-499.
19. Detach the crankshaft pulley/vibration damper.

20. Remove the timing belt lower cover.

 
21. Detach the timing belt-side ancillary components (if present).
 Detach the timing belt retainer.
 Remove the timing pulley thrust washer.

Timing belt tensioner up to build month 03/97

22. NOTE: When re-using the timing belt, mark the running direction.
Slacken and remove the timing belt.
 Compress the timing belt tensioner piston using the special tool until the
holes in the housing and those in the piston align.
Timing belt tensioner up to build month 03/97
23. NOTE: When re-using the timing belt, mark the running direction.
Detach the timing belt tensioner.
1. Timing belt tensioner
2. Timing belt tensioning pulley

Timing belt tensioner from build month 04/97

24. NOTE: When re-using the timing belt, mark the running direction.
Slacken and remove the timing belt (shown with engine removed).
 Loosen the bolt.
 25. Detach the timing belt tensioner.

Timing belt tensioner from build month 03/98

26. Slacken and remove the timing belt.
 Loosen the bolts.

27. Detach the timing belt tensioner.

 Remove the bolts.
All vehicles
28. Remove the camshaft timing pulleys.
  Counterhold using the special tool.
 Discard the timing pulley bolts.

29. Detach the crankshaft timing pulley.

30. Detach the timing belt inner cover.

 31. NOTE: Loosening sequence.
NOTE: Keep the bearing caps in order for reassembly. The identification
numbers are located on the outside of the camshaft bearing caps.
Remove the camshaft.
 Loosen the camshaft bearing cap bolts one turn at a time until the camshaft is
released.
 Detach the camshaft bearing caps.
 Remove the camshaft oil seal.

Vehicles built up to 01/2001

32. NOTE: Keep the valve tappets and adjusting shims in order for reassembly.
Remove the valve tappets and adjusting shims using the special tool.
Vehicles built from 01/2001
33. NOTE: Keep the valve tappets in order for reassembly.
Remove the valve tappets using the special tool.

All vehicles
34. NOTICE:

The cylinder head must have cooled to below 30°C before removal.

Lay the cylinder head down on a soft surface.

NOTE: Loosening sequence.
Remove the cylinder head.
 Remove the cylinder head bolts using the special tool.
35. NOTICE: Do not damage the coolant pump impeller.
Remove the coolant pump.

36. Detach the thermostat housing and the oil pressure switch.
 37. Detach the positive crankcase ventilation.

Vehicles built up to 11/1999

38. NOTICE: Remove oil pan downwards to prevent oil sludge and swarf from
entering the engine.
Detach the oil pan.

Vehicles built from 12/1999

39. Remove the oil pan bolts.
 1. Remove the drain plug.
2. Remove the oil pan bolts.

40. NOTICE: Avoid damaging the mating faces by using only the special tool
listed to detach the oil pan. Do not use a chisel or screwdriver to detach the oil
pan.
Detach the oil pan using the special tool
 Attach the special tools and lock against the oil pan.
 Release the oil pan from the cylinder block by several blows.
 Detach the special tool and install the drain plug.

All vehicles
41. Detach the oil intake pipe and the oil pump with gasket.
 Drive the oil seal out of the oil pump on a flat surface.
42. NOTICE: Loosen the bolts by two turns until the clutch pressure plate is
released.
Using the special tool, immobilize the flywheel and remove the clutch.

43. Detach the flywheel (immobilized by the special tool).

 44. Remove the crankshaft position (CKP) sensor.

45. Detach the rear crankshaft oil seal housing and the crankshaft position
(CKP) sensor mounting.

46. Detach the cylinder block with crank drive (short block) from the
mounting stand.
 Detach the special tools from the cylinder block.

Engine - 1.25L/1.4L Zetec-SE Fiesta 1996 (08/1995-02/2002)

(Sigma)/1.6L - Engine
 Print 

Assembly
Special Tool(s) / General Equipment
Universal Flange Holding Wrench

205-072 (15-030A)

Lifting Bracket, Engine

303-122 (21-068A)

Gauge, Bolt Angle

303-174 (21-540)

Pliers, Valve Shim

303-196 (21-107)

Alignment Plate, Camshaft

303-376 (21-162B)

Socket, Cylinder Head Bolt

303-392 (21-167)

Locking Tool, Flywheel

303-393 (21-168)
Installer, Crankshaft Seal

303-395 (21-171)

Compressor, Belt Tensioner

303-429 (21-180)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-14A (21-212)

Socket, Spark Plug

303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)
 Installer, Crankshaft Vibration Damper

303-510 (21-214)

Locking Tool, Crankshaft

303-748 (21-259)

Aligner, Clutch Plate

308-204 (16-067)

Torx socket T55

Torx socket E10
21 mm open-ended spanner
24 mm open-ended spanner
27 mm open-ended spanner
Micrometers
Internal micrometer
Piston ring compressor
Materials
Name
Specification
Sealer, camshaft bearing cap
WSK-M2G348-A2 
Sealer, cylinder block mating face joints, rear crankshaft oil seal, oil pan
WSE-M4G323-A4 
Sealer, oil pressure switch thread
WSK-M2G349-A7 
Engine oil
WSS-M2C912-A1 
Silicone grease, spark plugs
ESE-M1C171–AA 
Lubricant (spark plug threads - Never Seez)
ESE-M1244–A 

Assembly
All vehicles

1. NOTICE: Crank drive components, as well as pistons and cylinder liners

cannot be renewed separately. Please also observe the important notes on this
 subject in the section "Description and Operation".
NOTE: The threads and contact faces of all bolts and washers must be
lubricated with engine oil before installation.
Preparatory operations.
 The threads and contact faces of all bolts and washers must be lubricated
with engine oil before installation.
 Thoroughly clean all mating faces and reusable parts, and check them for
damage. Observe the important notes in "Description and Operation"
regarding the cleaning of the cylinder block.
2. Attach the cylinder block with crank gear (short block) to the mounting stand
(303-435) using special tools 303-435-14 and 303-435-06.
3. NOTE: Correct seating of oil seal housing.
Attach the new rear crankshaft oil seal housing with oil seal and attach the
crankshaft position (CKP) sensor mounting.

4. Install the CKP sensor.

5. NOTE: Tightening sequence and position of locating stud for the flywheel.
Attach the flywheel.
 Attach the flywheel, immobilize with the special tool and tighten in two stages
 according to the tightening sequence.
 1st stage: 30 Nm.
 2nd stage: 80 degrees.

6. NOTE: Align the oil pump driveshaft to the crankshaft.

Attach the oil pump and the oil intake pipe with a new gasket.
 The oil pump is located by two guide sleeves and does not need to be aligned
with the cylinder block.

7. NOTE: Lubricate the sealing lip of the oil seal and the crankshaft journals with
engine oil.
Install the front crankshaft oil seal using the special tool.
Vehicles built up to 11/1999
8. Apply sealer to the cylinder block mating face and to the rear crankshaft oil
seal housing mating face.
 The applied sealer must extend 10 mm beyond the mating face joints.

9. Align the oil pan.

 Locate the oil pan with a new gasket and tighten the bolts finger tight.
 Using a steel rule, align the oil pan so that the cylinder block is flush with the
oil pan on the flywheel side.
Vehicles built from 12/1999

10. NOTICE: Use studs. The cylinder block may be damaged if sealer enters
the blind holes.
Install five studs (M8x20) into the blind holes shown.

11. NOTE: Attach the oil pan within 10 minutes of applying the sealer.
Apply a 3 mm bead of sealer to the oil pan flange.

12. NOTE: Tightening sequence.

 Tighten the oil pan bolts in two stages.
 1st stage: 10 Nm.
 2nd stage: 20 Nm.

Vehicles built up to 11/1999

13. NOTE: Tightening sequence.
Tighten the oil pan bolts.

All vehicles
14. Attach the clutch.
 Centralize the clutch plate on the clutch pressure plate using the special tool.
 Tighten the bolts evenly, working diagonally.
 Detach the special tool.
 15. Attach the crankcase ventilation.

16. NOTICE: Check the thermostat and renew as necessary.

NOTE: Only renew the thermostat oil seal if it is necessary.
NOTE: Apply sealer to the thread of the oil pressure switch.
Attach the thermostat housing with a new gasket and the oil pressure switch.
1. Thermostat housing with new gasket.
2. Oil pressure switch.
17. NOTICE: Do not damage the coolant pump impeller.
Fit the coolant pump with a new gasket.

18. NOTE: Tightening sequence.

NOTE: The cylinder head is located by two guide sleeves.
NOTE: The removed cylinder head bolts can be reused.
Attach the cylinder head.
 Ensure that all mating faces are clean.
 Fit a new cylinder head gasket.
 Install the cylinder head, tightening in three stages in the sequence indicated.
 1st stage: 15 Nm.
 2nd stage: 30 Nm.
 3rd stage with special tool 303-174: 90 degrees.
Vehicles built from 01/2001
19. NOTE: Install each valve tappet in the location from which it came.
Install the valve tappets.
 If necessary, change the tappet to adjust the valve clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).

Vehicles built up to 01/2001

20. NOTE: Install the valve tappets with adjusting shims in the locations from
which they came.
Install the valve tappets and valve adjustment shims.
 If necessary, use a suitable adjusting shim to adjust the valve clearance.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
All vehicles
21. Set the piston to approx. 25 mm before TDC of cylinder no. 1.
 The flywheel must be in the position shown.

22. NOTE: The identification numbers are located on the outside of the camshaft
bearing caps.
Apply sealer to the areas shown on camshaft bearing cap no. 1 and to the
opposite surface on the cylinder head.
23. NOTICE: Install the camshaft with none of the cams at full lift.
NOTE: The exhaust camshaft is fitted with an additional cam for the camshaft
position sensor (CMP sensor).
Install the camshafts.
 Before installation, lubricate the camshafts and camshaft bearings with engine
oil.

24. Identification numbers on the camshaft bearing caps.

1. Begins with I1 at the timing belt end for intake-side camshaft bearing caps.
2. Begins with E1 at the timing belt end for exhaust-side camshaft bearing caps.
 25.Check the valve clearances and adjust them as necessary.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
26. NOTE: Tightening sequence.
Fit the camshaft bearing caps and tighten the bolts in three stages.
 1st stage: Tighten the bolts evenly half a turn at a time until the camshaft
bearing caps contact the cylinder head.
 2nd stage: 7 Nm.
 3rd stage: 16 Nm.
27. NOTE: Lubricate the sealing lip of the oil seal and the camshaft journals with
engine oil.
Press in a new camshaft oil seal using the special tool.

28. Attach the timing belt inner cover.

29. NOTE: Use new camshaft pulley bolts.
Install the camshaft timing pulleys so that it is still just possible to turn them.
30. Turn the camshafts to TDC of cylinder no. 1.
 Turn the camshafts at the hexagon with an open-ended spanner until the
special tool can be inserted.

31. NOTE: If the special tool cannot be installed, turn the crankshaft back counter
to the direction of rotation about 20 degrees.
Turn the crankshaft to TDC of cylinder no. 1.
 Remove the blanking plug from the timing peg bore and attach the special
tool.
 Carefully turn the crankshaft clockwise until the crank web contacts the
special tool.
 32. Attach the crankshaft timing pulley.

Timing belt tensioner up to build month 03/97

33. Install the ancillary components on the timing belt side.
1. Timing belt tensioner.
2. Timing belt tensioner

Timing belt tensioner from build month 04/97

34. Install the timing belt tensioner.
Timing belt tensioner from build month 03/98
35. Install the timing belt tensioner.

36. Fit the timing belt.

 Fit the timing belt starting at the crankshaft timing pulley and working
counter-clockwise.
Timing belt tensioner up to build month 03/97
37. Tension the timing belt.
 Slacken the special tool and detach it.
Timing belt tensioner from build month 04/97
38. NOTE: Do not turn the eccentric when tightening it. Counterhold using an Allen
key.
Tension the timing belt.
 Using a 6 mm Allen key, turn the eccentric counter-clockwise until the arrow
is in line with the center of the window.
 Tighten the bolt.

Timing belt tensioner from build month 03/98

39. Tension the timing belt.
 Using an 8mm Allen key, tension until the pointer is positioned exactly in the
center of the square recess.
 Tighten the bolts.
40. Attach the components on the timing belt side (if detached).
1. Timing belt retainer
2. Timing pulley thrust washer

41. Attach the timing belt lower cover.

42. Remove the special tool.

43. Attach the special tool.

 Carefully turn the crankshaft clockwise until the crank web contacts the
special tool.

44. Press the pulley/vibration damper onto the crankshaft using the special
tool.
45. NOTE: Renew the bolts.
Install the crankshaft pulley/vibration damper bolt.
 Tighten the bolt in two stages.
 1st stage: 40 Nm.
 2nd stage with special tool 303-174: 90 degrees.

46. NOTICE: Do not tighten the camshaft timing pulleys against special tool
303-376.
NOTE: The crankshaft and camshaft must not be turned.
Tighten the camshaft timing pulleys.
47. Remove the special tool.

48. Detach the special tool.

49. NOTE: If special tool 303-507 cannot be screwed in, turn the crankshaft back
counter to the direction of engine rotation by about 20 degrees.
Check the valve timing.
 Turn the crankshaft two revolutions in the direction of engine rotation and set
it to TDC.
 Screw in special tool 303-507.
 Carefully turn the crankshaft in the direction of engine rotation until the crank
web contacts the special tool.
 Use special tool 303-376 to check TDC position.
 Remove special tools 303-376 and 303-507.

50. NOTE: Only if special tool 303-376 cannot be inserted.

Set the valve timing.
 Screw in Special Tool 303-507.
51. NOTE: Only if special tool 303-376 cannot be inserted.
Set the valve timing.
 Loosen the camshaft timing pulley of the affected camshaft, counterholding
using the special tool.
 If necessary mark the timing pulley bolts with paint. Renew any bolts with
paint markings.
 Turn the camshaft at the hexagonal section using an open-ended spanner
until special tool 303-376 can be inserted.
 Tighten the camshaft timing pulley; the crankshaft must remain at TDC.
 Remove special tool 303-376 and unscrew special tool 303-507.
 Check the valve timing again in accordance with the previous step.

52. Install the blanking plug in the timing peg bore.

 53.Adjust the valve clearances.
For additional information, refer to: Valve Clearance (303-01B Engine -
1.25L/1.4L Zetec-SE (Sigma)/1.6L, General Procedures).
Vehicles built up to 7/1998
54. Install the front engine mounting bracket.

Vehicles built from 8/1998

55. Install the front engine mounting bracket.

56.Coat the spark plug thread with lubricant and install using the special tool.
57. NOTICE:

Check the cylinder head cover gasket for damage and install a new one if
necessary.

Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease to
avoid damaging the spark plug connector seal.

Push on the spark plug connector in line with the spark plug axis.
NOTE: Coat the inside of the spark plug connectors with silicone grease to a
depth of 5 - 10 mm.
Install the cylinder head cover.
1. Screw on the cylinder head cover nuts and tighten in two stages.
1. Stage 1: 3 Nm

2. Stage 2: 10 Nm

2. Push on the spark plug connectors until they engage.

3. Insert the ignition cable clip.
Vehicles built from 12/2000

58. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
Install the cylinder head cover.
 Screw in bolt no. 1 finger tight.
 Tighten bolt nos. 2 to 13 in the sequence shown.

59. NOTICE: Use suitable blunt object to avoid damaging the spark plug
connector seal. Coat the inside of the spark plug connector with silicone grease
to a depth of 5 - 10 mm.
Connect the spark plug electrical connectors and clip the wires to the cylinder
head cover.

All vehicles
60. Attach the timing belt upper cover.
 Timing belt cover
 Idler pulley.
 Coolant pump pulley
Vehicles with 1.25l engine
61. Attach the intake manifold to the cylinder block.

62. Attach the engine wiring harness.

1. Temperature/manifold absolute pressure (T-MAP) sensor connector.
2. Idle air control valve (IAV) connector.
3. Oil pressure switch connector.
4. Crankshaft position sensor connector.
63. Attach the engine wiring harness.
1. Engine coolant temperature sensor (ECT sensor) connector.
2. Connector rail for injectors.
3. Camshaft position (CMP) sensor connector.
 Clip the wiring harness in place.

64. Attach the oil dipstick tube.

Vehicles with 1.4l or 1.6l engine
65. NOTE: Apply sealer to the thread of the oil pressure switch.
Attach the ancillary components.
1. Install the intake manifold and connect the crankcase breather hose.
2. Engine wiring harness.
3. Cylinder head cover plate.
4. Attach the EGR pipe to the inlet manifold and install the EGR valve (21 mm)
(if detached).
5. Oil dipstick tube.

Vehicles built up to 7/1998

66. Install the generator.
1. Install the three bolts.
2. Attach the cable.
3. Attach the connector.
Vehicles built from 8/1998
67. Install the generator.
 Attach the generator connector.

68. Attach the oil filter.

69.Fill up with engine oil.
70. Hook the engine into the workshop hoist using the special tool.

71. Remove the engine from the mounting stand.

  Remove the special tools.

72. Install the intermediate bearing bracket and the exhaust manifold with a
new gasket.

73. Attach rear and center exhaust manifold heat shield.

Engine - 1.4L PTE (CVH) - Specifications Fiesta 1996 (08/1995-02/2002)

 Print 

Engine Data

1,4 PTE
Engine management Bosch M5.1.4
Fuel Premium 95 RON unleaded
Engine code F4B
Firing order 1-3-4-2
Bore mm 77,24
Stroke mm 74,30
Cubic capacity cm3 1392
Compression ratio 9,5 : 1
Compression ratio at starter motor speed bar 12-14
Power output (DIN) kW 55
Power output (DIN) PS 75
Power output (DIN) at rev/min 5500
Torque (DIN) Nm 105
Idle speed rev/min 870
Maximum engine speed, continuous rev/min 6100
Maximum engine speed, intermittent rev/min 6100
Spark plugs AGPR 32 C1
Dimensions

Cylinder block 1,4 PTE

Cast mark 88SM-6015-AA
Number of main bearings 5
Cylinder bore diameter , standard class 1 (production) mm 77,22-77,23
Cylinder bore diameter , standard class 2 (production) mm 77,23-77,24
Cylinder bore diameter , standard class 3 (production) mm 77,24-77,25
Cylinder bore diameter, standard class 4 (production) mm 77,25-77,26
Cylinder bore diameter, oversize class A (production) mm 77,51-77,52
Cylinder bore diameter, oversize class B (production) mm 77,52-77,53
Cylinder bore diameter , oversize class C (production) mm 77,53-77,54
Cylinder bore diameter , standard (Service) mm 77,245-77,255
Cylinder bore diameter, 1st oversize 0,29 (Service) mm 77,525-77,535
Cylinder bore diameter , 2nd oversize 0,50 (Service) mm 77,745-77,755
Main bearing clearance mm 0,011-0,058
Main bearing parent bore, standard mm 62,287-62,300
Main bearing parent bore, oversize mm 62,687-62,700
Dimensions
 Crankshaft 1,4 PTE
Main bearing journalØ, standard mm 57,98-58,00
Main bearing journalØ, 1st undersize 0,50 mm 57,73-57,75
Main bearing journalØ, 2nd undersize 0,50 mm 57,48-57,50
Main bearing journalØ, 3rd undersize 0,75 mm 57,23-57,25
Centre main bearing width, standard mm 28,825-28,875
Centre main bearing width, oversize mm 29,255-29,205
Thickness of thrust half rings, standard mm 2,301-2,351
Thickness of thrust half rings, oversize mm 2,491-2,541
Main bearing journal end float mm 0,09-0,30
Big-end bearing journalØ, standard mm 47,89-47,91
Big-end bearing journalØ, undersize 0,25 mm 47,64-47,66
Big-end bearing journalØ, undersize 0,50 mm 47,39-47,41
Big-end bearing journalØ, undersize 0,75 mm 47,14-47,16
Big-end bearing journalØ, undersize 1,00 mm 46,89-46,91
Dimensions

Connecting rods 1,4 PTE

BoreØ, big-end mm 50,89-50,91
BoreØ, small end mm 20,589-20,609
Inner diameter of big-end bearing shells (fitted), standard mm 47,916-47,950
Inner diameter of big-end bearing shells (fitted), 1st undersize 0,25 mm 47,666-47,700
Inner diameter of big-end bearing shells (fitted), 2nd undersize 0,50 mm 47,416-47,450
Inner diameter of big-end bearing shells (fitted), 3rd undersize 0,75 mm 47,166-47,200
Inner diameter of big-end bearing shells (fitted), 4th undersize 1,00 mm 46,916-46,950
Big-end bearing clearance (radial) mm 0,006-0,060
Dimensions

Pistons 1,4 PTE

PistonØ (production), standard class 1 mm 77,190-77,200
PistonØ (production), standard class 2 mm 77,200-77,210
PistonØ (production), standard class 3 mm 77,210-77,220
PistonØ (production), standard class 4 mm 77,220-77,230
PistonØ (production), oversize class A mm 77,480-77,490
PistonØ (production), oversize class B mm 77,490-77,500
PistonØ (production), oversize class C mm 77,500-77,510
Clearance in bore, production mm 0,020-0,040
PistonØ (Service), standard mm 77,210-77,235
PistonØ (Service), oversize 0,29 mm 77,490-77,515
PistonØ (Service), oversize 0,50 mm 77,710-77,735
Clearance in bore (Service) mm 0,01-0,045
Piston ring gap (fitted), upper compression ring mm 0,30-0,50
Piston ring gap (fitted), lower compression ring mm 0,30-0,50
Piston ring gap (fitted), oil scraper ring mm 0,40-1,40
The piston ring gaps must be evenly spaced around the piston circumference.
This also applies to each part of the oil scraper ring. Arrange the gaps at 120°
to each other.

Dimensions

Piston pins 1,4 PTE

Piston pin length mm 63,00-63,80
Piston pinØ, white mm 20,622-20,625
Piston pinØ, red mm 20,625-20,628
Piston pinØ, blue mm 20,628-20,631
 Piston pins 1,4 PTE
Piston pinØ, yellow mm 20,631-20,634
Piston pin clearance in piston mm 0,005-0,011
Interference fit in connecting rod mm 0,013-0,045
Dimensions

Cylinder head 1,4 PTE

Cast mark 945M-6090-AB
Combustion chamber volume cm3 38,88-41,88
Valve seat angle 44°30'-45°30'
Valve seat width mm 1,75-2,32
Upper correction angle (production), inlet/exhaust ° 30
Service correction cutter, inlet/exhaust ° 15
Lower correction angle (production), inlet ° 77
Lower correction angle (production), exhaust ° 70
Service correction cutter, inlet ° 75
Service correction cutter, exhaust ° 70
Stem bore, inlet and exhaust valves, standard mm 8,063-8,094
Stem bore, inlet and exhaust valves, 1st oversize 0,2 mm 8,263-8,294
Stem bore, inlet and exhaust valves, 1st oversize 0,4 mm 8,463-8,494
Cylinder head bore (standard), camshaft bearing 1 mm 44,783-44,808
Cylinder head bore (standard), camshaft bearing 2 mm 45,033-45,058
Cylinder head bore (standard), camshaft bearing 3 mm 45,283-45,308
Cylinder head bore (standard), camshaft bearing 4 mm 45,533-45,558
Cylinder head bore (standard), camshaft bearing 5 mm 45,783-45,808
Cylinder head bore (oversize), camshaft bearing 1 mm 45,188-45,163
Cylinder head bore (oversize), camshaft bearing 2 mm 45,438-45,413
Cylinder head bore (oversize), camshaft bearing 3 mm 45,688-45,663
Cylinder head bore (oversize), camshaft bearing 4 mm 45,938-45,913
Cylinder head bore (oversize), camshaft bearing 5 mm 46,188-46,163
Valve tappet bore (standard) mm 22,235-22,265
Valve tappet bore (oversize) mm 22,489-22,519
Max. permissible cylinder head unevenness mm 0,15
Cylinder head mating face skimming (maximum) mm 0,30
Min. combustion chamber depth mm 17,40
Dimensions

Camshaft 1,4 PTE

Number of camshaft bearings 5
Drive Timing belt
Camshaft retaining plate (thickness) mm 4,99-5,01
Cam lift (inlet/exhaust) mm 5,79
Cam length (between heel and tip), inlet mm 38,305
Cam length (between heel and tip), exhaust mm 37,289
Bearing journal Ø, camshaft bearing 1 mm 44,75
Bearing journal Ø, camshaft bearing 2 mm 45,00
Bearing journal Ø, camshaft bearing 3 mm 45,25
Bearing journal Ø, camshaft bearing 4 mm 45,50
Bearing journal Ø, camshaft bearing 5 mm 45,75
Valve timings, inlet valve opens after TDC ° CS 15
Valve timings, inlet valve closes after BDC ° CS 30
Valve timings, exhaust valve opens before BDC ° CS 28
Valve timings, exhaust valve closes before TDC ° CS 13
Camshaft end float mm 0,05-0,15
Dimensions

Valves 1,4 PTE

m
Valve lift, inlet 9,3-9,7
m
m
Valve lift, exhaust 9,3-9,7
m
Free valve spring length (with varying colour code depending on the m
47,20
manufacturer) m
Colour code, valve spring blue-blue
m 136,29-
Valve length, inlet
m 136,75
m 132,97-
Valve length, exhaust
m 133,43
m
Valve head Ø, inlet 39,90-40,10
m
m
Valve head Ø, exhaust 33,90-34,10
m
m
Valve stem Ø (standard), inlet 8,025-8,043
m
m
Valve stem Ø (standard), exhaust 7,999-8,017
m
m
Valve stem Ø (oversize 0,2), inlet 8,225-8,243
m
m
Valve stem Ø (oversize 0,2), exhaust 8,199-8,217
m
m
Valve stem Ø (oversize 0,4), inlet 8,425-8,443
m
m
Valve stem Ø (oversize 0,4), exhaust 8,399-8,417
m
m
Clearance in valve stem guide, inlet 0,020-0,063
m
m
Clearance in valve stem guide, exhaust 0,046-0,089
m
Dimensions

Timing belt tension Scale divisions on test gauge 21-113

New timing belt 10-11
Used timing belt 4-6
Check used timing belt 4-6
Dimensions

Drive belt tension N

New drive belt 400-500
Used drive belt 300-400
Engine oil

Viscosity/Ambient temperature Description Specification

Recommended engine oil:
SAE 5W30 / below -20 to over Ford Formula E Economy ACEA A1-96/B1-96 and WSS-
40 degrees Centigrade Motor Oil M2C912-A1
Alternative engine oils:
SAE 10W30 / -20 to over 40 Ford "Super" Multigrade ACEA A1-96/B1-96 or A2-
degrees Centigrade Motor Oil 96/B2-96 or API/SH/CD EC
SAE 10W40 / -20 to over 40 Ford XR+ High-performance ACEA A3-96/B3-96 or
degrees Centigrade High-lubricity Motor Oil API/SH/CD EC
Viscosity/Ambient temperature Description Specification
SAE 5W40 / under -20 to over Ford Formula S Synthetic ACEA A3-96/B3-96 or
40 degrees Centigrade Motor Oil API/SH/CD EC
If engine oils with these specifications are not available, only engine oils which at least meet
the API/SH/CD EC specification may be used.
Lubricants, Fluids and Sealers

Ford
Specification
Transmission fluid WSD-M1C230-A
Coolant ESD-M97B49-A
High temperature grease: transmission input shaft splines, clutch release
ESDM-1C-220-A
bearing guide sleeve
Spark plug threads: "Never Seez" ESE-M1244-A
Sealer for sump mating face intersections (Hylosil 502) WSK-M4G320-A
Sealer for sump mating face intersections (Hylosil 502) WSK-M4G320-A
A960-M1C171-
Silicon grease
AA
Fill capacities

Description Litres
Engine oil, initial fill including filter 3,86
Engine oil, oil change including filter change 3,50
Engine oil, oil change without filter change 3,25
Coolant 7,1
Transmission fluid (iB5) 2,8
Engine lubrication

Description
Oil pressure approx. 80°C at idle speed bar 1,00
Oil pressure approx. 80°C, at 2000 rev/min bar 2,80
Pressure relief valve opening pressure bar 4,70-6,00
Oil pressure warning light comes on at bar 0,3-0,5
Oil pump, rotor/housing (clearance) mm 0,060-0,190
Oil pump, inner to outer rotor gap mm 0,050-0,180
Oil pump, rotor to mating face (end float) mm 0,014-0,100
Torque Specifications

Description Nm lb-ft lb-in

Wheel nuts 85 63
Intake pipe to cylinder head cover 10 7
Intake air temperature sensor (IAT sensor) 15 11
Lower suspension arm ball joint to spindle carrier 80 59
Track rod end to spindle carrier 28 21
Torque Specifications

Description Nm lb-ft lb-in

Inlet manifold to cylinder head 18 13
Upper inlet manifold to lower inlet manifold (nut) 18 13
Coolant hose connector to lower inlet manifold 15 11
Inlet manifold studs to cylinder head 5 4
Fuel rail to lower inlet manifold 23 17
Torque Specifications
 Description Nm lb-ft lb-in
Exhaust manifold studs to cylinder head 5 4
Exhaust manifold to cylinder head 16 11
Exhaust pipe to exhaust manifold 38 28
Exhaust manifold heat shield 17 12
Rear exhaust pipe to catalytic converter 47 35
Exhaust manifold nut, Stage 1 16 11
Exhaust manifold nut, wait five mins. Stage 2 7 5
Torque Specifications

Description Nm lb-ft lb-in

Clutch housing cover plate (two bolts) 40 30
Starter motor 40 30
Transmission flange bolts to engine 40 30
Clutch pressure plate 30 22
Torque Specifications

Description Nm lb-ft lb-in

Coolant pump 9 6
Thermostat housing 11 8
Temperature gauge sender unit 6 4
Engine coolant temperature sensor (ECT sensor) 19 14
Ground lead to transmission 24 18
Torque Specifications

Description Nm lb-ft lb-in

Oil pressure switch 20 14
Oil level check plug to transmission 27 20
Oil pump to cylinder block 10 7
Oil filter adaptor to cylinder block 22 16
Oil pump cover plate 10 7
Oil intake pipe to cylinder block 20 15
Oil intake pipe to oil pump 10 7
Sump (with one-piece sump gasket), Stage 1 7 5
Sump (with one-piece sump gasket), Stage 2 7 5
Oil drain plug 25 19
Torque Specifications

Description Nm lb-ft lb-in

Front engine mounting to suspension strut top mount bracket 85 63
Front engine mounting bracket to cylinder block 90 66
Manifold absolute pressure sensor (MAP sensor) bracket 24 18
Brace to right-hand engine mounting (two nuts) 70 52
Brace to front crossmember 70 52
Torque Specifications

Description Nm lb-ft lb-in

Brace to engine/transmission mounting bracket 50 37
Front left-hand bracket to rubber mounting 70 52
Torque Specifications

Description Nm lb-ft lb-in

Vertical bracket to transmission (three nuts) 72 53
 Description Nm lb-ft lb-in
Engine mounting to vertical bracket (one nut) 83 61
Engine mounting bracket to crossmember 83 61
Engine mounting to bracket (two bolts) 47 35
Transverse brace to vertical bracket (two bolts) 68 50
Transverse brace to transmission (two bolts) 44 33
Torque Specifications

Description Nm lb-ft lb-in

Transmission mounting, rear left 70 52
Transmission mounting, rear right 50 37
Torque Specifications

Description Nm lb-ft lb-in

Timing belt tensioner 18 13
Timing belt cover 10 7
Drive belt lower cover 11 8
Lower timing belt cover 10 7
Crankshaft position sensor (CKP sensor) 5 4
Crankshaft rear oil seal carrier 10 7
Engine/transmission flange bolts 40 30
Camshaft thrust plate 11 8
Main bearing cap 95 70
Big-end bearing cap 33 24
Crankshaft multi-groove belt pulley 108 80
Flywheel 87 64
Special tool 21-168 to cylinder block 40 30
Engine bracket 67 49
Torque Specifications

Description Nm lb-ft lb-in

Bracket for power steering pump and alternator 24 18
Power steering pump to bracket 24 18
Alternator to bracket 24 18
Belt pulley to power steering pump 24 18
Torque Specifications

Description Nm lb-ft lb-in

Cylinder head cover 7 5
Cylinder head bolts, Stage 1 30 22
Cylinder head bolts, Stage 2 50 37
Cylinder head bolts, Stage 3 905 905
Cylinder head bolts, Stage 4 905 905
Camshaft timing belt pulley 57 42
Engine lifting eye to cylinder head 44 33
Rocker nuts 27 20
Torque Specifications

Description Nm lb-ft lb-in

EI coil to bracket 6 4
EI coil bracket to cylinder head 10 7
Spark plugs 25 19
Rocker stud to cylinder head 21 15

Engine - 1.4L PTE (CVH) - Engine Fiesta 1996 (08/1995-02/2002)

  Print 

Description and Operation

The PTE engine (54 kW/73 PS) is equipped with sequential multiport fuel injection (SFI).

PTE means the engine has a Pent roof-shaped combustion chamber, high Torque and
low Emissions.

P=Pent roof

T=high Torque

E=low Emission

The engine has a camshaft with an extra cam for the camshaft position sensor (CMP
sensor). This is necessary to support the sequential multiport fuel ignition (SFI).

Engine Code and Engine Serial Number on Cylinder Block

1. Engine code. - 2. Engine serial number

Description of Engine Code (F4B)

 1st letter: cubic capacity (F = 1,4 litres)

 2nd number/letter: engine type (4 = PTE SFI version)
 3rd letter: vehicle model

Engine - 1.4L PTE (CVH) - Valve Seals Fiesta 1996 (08/1995-02/2002)

 Print 

In-vehicle Repair
Special Tool(s) / General Equipment
Valve spring compressor

21-097
 Installer, valve collets

21-156

Adaptor, air supply cylinder

21-157

Remover, valve stem oil seals

21-165

Brass drift
Materials
Name
Specification
Hypoid oil
SQM-2C9002-AA 
Lubricant for spark plugs (Never Seeze)
ESE-M1244-A 
Silicon grease
A960-M1C171-AA 

Removal

1. NOTICE: Disconnect the battery negative lead.

Preparations
 Ask for the radio keycode.
 Make a note of the preset radio stations.
2. Detach the throttle cable.
3. Disconnect the plug from the EI ignition coil.

4. Detach the intake pipe.

NOTICE: Turn the spark plug connector before disconnecting. Pull

only the connector not the cable.
 Undo all the spark plug connectors.
 Unscrew the bolts.
 Detach the hose from the inlet manifold.
1. Detach the clamp.
5. Remove the spark plugs.

6. Detach the bracket for the accelerator cable.

7. Detach the upper timing belt cover.

 Pull off the timing belt cover.
 8. Detach the cylinder head cover.
1. Detach the crankcase ventilation hose.
2. Disconnect the oil separator hose.
 Unscrew the bolts.
 Remove the reinforcing panels.
 Remove the gasket.

9. NOTE: Lay the parts down in order ready for re-use.

Remove the rockers.
1. Nut
2. Rocker guide
3. Rocker
4. Spacer plate
 Remove the hydraulic tappet.
10. Screw the compressed air connection into the spark plug hole.
 Apply pressure of 7-10 bar to the cylinder.

11. Release the collets by tapping on the spring retainer lightly with a brass
drift.

NOTICE: Do not let the valve collets fall into the engine.
 Compress the valve spring.
 Remove the valve collets with Special Tool 21-156.
 Release the special tool and remove it.
 Remove the valve spring with the upper valve spring retainer.
12. Remove the valve springs of the cylinder being supplied with compressed
air.
13. Remove the lower valve spring retainer with the integrated valve stem
seals.

Installation
1. Install the lower valve spring retainers with the integrated valve stem seals.
 Mask the collet grooves on the valve stem with adhesive tape.
 Lubricate the valve stems with hypoid oil.
 Coat the valve stem oil seals with engine oil and fit them.
 Remove the adhesive tape.
2. Install the valve spring.
 Locate the valve spring and upper valve spring retainer in position.
 Compress the valve spring.
NOTE: Make sure the collets are correctly seated.
 Insert the valve collets using Special Tool 21-156.
 Release the special tool and remove it.
 Remove the air line connector.

3. Repeat the procedure for all cylinders.

4. Seat the valve collets using a brass drift.
 5. Turn the crankshaft to approx. 60°before TDC (three tooth divisions of the
camshaft timing belt pulley).

6. NOTICE: Do not turn the crankshaft for approx. 15 minutes.

NOTE: Make sure the rocker arm guide is correctly seated. Renew the self-
locking nuts.
Fit the rockers.
1. Spacer plate
2. Rocker
3. Rocker guide
4. Nut
7. Fit the cylinder head cover.
 Locate the cylinder head cover in position with a new gasket.
 Fit the reinforcing panels with the rippled side upwards.
 Tighten the bolts uniformly.
 Install the crankcase ventilation hose.
 Connect the oil separator hose.

8. Fit the timing belt pulley upper cover.

 9. Attach the bracket for the accelerator cable.

10. NOTE: Apply lubricant (Never Seeze, ESE-M1244-A) to the spark plug threads.
NOTE: Coat the spark plug sealing with silicone grease (A960-M1C171-AA).
Install the spark plugs.
11. Install the air intake pipe.
1. Fit the bolts.
2. Connect the hose to the inlet manifold.
3. Attach the clamp.

12. Attach the cable.

13. Connect the EI ignition coil plug.

 14. Standard finishing operations.
 Check the wiring and hoses are correctly routed and, where necessary, secure
them with cable ties.
 Connect the battery negative lead.
 Remove the protective covers.
 Enter the radio keycode.
 Reprogramme the preset radio stations.
 Reset the clock.
 Carry out a road test to allow the PCM to re-learn values.
 Check the fluid levels and correct as necessary.

Engine - 1.4L PTE (CVH) - Camshaft Fiesta 1996 (08/1995-02/2002)

 Print 

In-vehicle Repair
Special Tool(s)
Installer, oil seal

21-094

Remover, oil seal

21-096
 Tension gauge, timing belt

21-113

Materials
Name
Specification
Sealer (Hylosil 502)
WSK-M4G320-A 
Hypoid oil
SQM-2C9002-AA 
Silicon grease
A960-M1C171-AA 

Removal

1. NOTICE: Disconnect the battery negative lead.

Standard preparatory measures.
 Make a note of the radio keycode.
 Make a note of the preset radio stations.
2. Remove the battery.
1. Disconnect battery positive lead.
2. Disconnect positive lead from battery clamp.
3. Remove bracket.
4. Remove insulating tapes (if applicable).

3. Remove the battery box.

4. NOTICE: Turn the spark plug connectors before disconnecting. Pull only
the connector not the cable.
Remove the throttle cable.
 Remove the clip.
 Disconnect the throttle cable.
 Disconnect the spark plug connector for cylinders 1 and 2.

5. Remove the air cleaner.

1. Disconnect the rubber ring.
2. Remove the bolts.
3. Disconnect the hose.
4. Pull out the breather hose.
6. Remove the timing belt as described in Operation No. 21 304 0.
7. Detach the bracket for the accelerator cable.

8. Detach the cylinder head cover.

1. Detach the crankcase ventilation hose.
2. Disconnect the oil separator hose.
 Unscrew the bolts.
 Remove the reinforcing panels.
 Remove the gasket.
9. Detach the brake master cylinder.

10. Remove the EI ignition coil.

1. Disconnect the HT leads from the EI igntition coil.
2. Disconnect the plug from the EI ignition coil.
 Remove the four bolts.
 11. Detach the bracket for the EI coils from the cylinder head.

12. NOTE: Keep the parts in order ready for re-use.

Remove the rockers.
1. Nut
2. Rocker guide
3. Rocker
4. Spacer plate
13. NOTE: Screw two bolts and nuts into the special tool (10 x 45 and 10 x 50) to
hold the pulley instead of the original pins.
Remove the camshaft timing belt pulley.

14. Remove the camshaft blanking cover.

 Make a hole in the middle of the blanking cover and lever it out.

15. NOTE: Keep the parts in order ready for re-use.

 Remove the hydraulic valve tappets.

16. Remove the camshaft retaining plate.

1. Unscrew the bolts.
2. Lit out the retaining plate.

17. Carefully slide the camshaft out towards the rear.

18. Remove the camshaft oil seal.

Installation
1. Install the camshaft.
 Coat the camshaft bearings, the camshaft and the retaining plate with engine
oil.
 Slide the camshaft in carefully.
 Install the camshaft retaining plate.
 Tighten the bolts.
2. Install a new oil seal.
1. Radial oil seal.
 Coat the oil seal lip and the camshaft running surface with engine oil.
2. Insert the oil seal in the special tool and draw it in with the timing belt pulley
bolt as far as the stop.

3. Turn the crankshaft to approx. 60°before TDC.

4. Lubricate the hydraulic valve tappets with hypoid oil and fit them.
 5. Fit the new camshaft blanking cover using sealer (WSK-M4G320-A).

6. NOTICE: Do not turn the crankshaft for approx. 15 minutes after installing
the rockers.
NOTE: Make sure the rocker arm guides are seated correctly. Use new self-
locking nuts.
Fit the rockers.
1. Spacer plate
2. Rocker
3. Rocker guide
4. Nut
 7. Fit the bracket of the EI ignition coil.

8. NOTE: The numbering of the HT leads must correspond with the numbering on
the EI ignition coil.
Fit the EI ignition coil.
 Insert the two bolts.
 Tighten the four bolts.
 Connect the HT leads to the EI ignition coil.
1. Connect the plug to the EI ignition coil.
9. NOTE: Apply sealer (WSK-M4G320-A) to the thread of the new bolt.
Fit the camshaft timing belt pulley.

10. Fit the cylinder head cover.

 Locate the cylinder head cover in position with a new gasket.
 Fit the reinforcing panels with the rippled side upwards.
 Tighten the bolts uniformly.
 Install the crankcase ventilation hose.
 Connect the oil separator hose.
11. Install the timing belt as described in Operation Number 21 304 0.
12. Attach the bracket for the accelerator cable.

13. Attach the brake master cylinder.

14. Install the battery box.

 Secure battery cable by clips.
15. Install the battery.
1. Install the bracket.
2. Install the battery positive lead.
3. Connect the battery positive lead.
4. Fit insulator strap (if removed).

16. Install the air cleaner.

1. Hang in the rubber ring.
2. Install the bolts.
3. Connect the hose.
4. Insert the breather hose.
 17. NOTE: Coat the spark plug sealing with silicone grease (A960-M1C171-AA).
Install the trottle cable.
 Connect the throttle cable.
 Install the clip.
 Connect the spark plug connector for cylinders 1 and 2.

18. Finishing operations.

 Check that the wiring and hoses are correctly routed and, where necessary,
secure them with cable ties.
 Connect the battery negative lead.
 Enter the radio keycode.
 Reprogramme the radio stations.
 Adjust the clock.
 Carry out a road test to allow the PCM to re-learn values.
 Check the fluid levels and correct as necessary.

Engine - 1.4L PTE (CVH) - Cylinder Head Fiesta 1996 (08/1995-02/2002)

 Print 
In-vehicle Repair
Special Tool(s) / General Equipment
Angle gauge

21-540

Remover/installer, cooling hose clamp

24-003

Steel straightedge
Feeler gauge
Materials
Name
Specification
Coolant
ESD-M97B49-A 
Silicon grease
A960-M1C171-AA 

Removal

1. WARNING: There is a risk of scalding when the engine is warm.

Release the fuel system pressure. For additional information, refer to Section 
310-00 Fuel System - General Information.

2. NOTICE: Disconnect the battery negative lead.

Standard preparatory measures.
 For removal of coolant hoses and ventilation hoses, use tool 24-003.
 Make a note of the radio keycode.
 Make a note of the programmed radio stations.
 Unscrew and remove the coolant expansion tank cap.
3. Raise the vehicle.
4. Drain the coolant.
 After draining, screw in the drain plug.
 5. Detach the front exhaust pipe from the exhaust manifold.
 Remove the gasket.
 Fit the exhaust pipe.

6. Remove bracket - oil dipstick tube.

 Remove timing belt, as described in Operation 21 304 0.

7. NOTICE: Turn the spark plug connectors before disconnecting. Pull only
the connector not the cable.
Lower the vehicle.
 Remove the clip.
 Disconnect the throttle cable.
 Disconnect the spark plug connectors for cylinders 1 and 2.

8. Remove the intake pipe.

1. Unscrew the bolts.
2. Disconnect the hose.
3. Detach the clamp.

9. Separate/disconnect the multiplugs.

1. Engine wiring harness.
2. EI ignition coil.
 10. Disconnect the pipes.

11. NOTICE: Plug the fuel pipes.

Disconnect the fuel pipes.
12. Detach the coolant hoses and the cable coolant temperature gauge
sender.

13. Remove the oil separator.

 Pull out the oil dipstick.

14. Disconnect the heater hose.

15. Remove the pulley from the power steering pump.
 For back-stop use Allen key.

16. Remove the power steering pump and tie it up at the lock panel.
17. Remove bracket from power steering pump.

18. Detach the bracket for the accelerator cable.

19. Remove the cylinder head cover.

 Disconnect the hose from the oil separator.
 Unscrew the bolts.
 Remove the reinforcing panels.
 Remove the gaskets.
20. NOTE: Slacken the cylinder head bolts in the indicated order and remove
them.
Remove the cylinder head.
 Remove the cylinder head gasket.

Installation
1. NOTE: If the maximum permitted unevenness is exceeded, rework the cylinder
head (see General Specifications).
Check the cylinder head distortion using a steel straightedge.
2. NOTE: Choose the new cylinder head gasket by comparing it with the old
gasket (identification teeth).
NOTE: Before putting the cylinder head in place, turn the crankshaft so that
the first cylinder is about 20 mm before TDC.
Install the cylinder head.
1. Check the guide sleeves are correctly located.
2. Cylinder head gasket identification marks.
3. Fit the new cylinder head gasket.

3. NOTE: Use new cylinder head bolts.

Install the cylinder head (cont.).
 Fit the cylinder head.
 Tighten the new cylinder head bolts in the indicated order in four stages.
 Use a torque wrench for stages one and two.
4. Install the cylinder head (cont.).

NOTICE: The cylinder head bolts must not be re-torqued.

 Use an angle gauge for stages 3 and 4.
5. Install the cylinder head (cont.).
 Fit the cylinder head cover with a new gasket.
 Fit the reinforcing panels with the rippled side upwards.
 Tighten the bolts uniformly.
 Connect the oil separator hose.
6. Install the timing belt as described in Operation No. 21 304 0.
7. Fit the bracket - power steering pump.

8. Fit the power steering pump.

9. Fit pulley at power steering pump.
 For back-stop use Allen key.

10. Connect the heater hose.

11. Attach the bracket for the accelerator cable.

12. Fit the oil separator.
 Insert the oil dipstick.

13. Attach the coolant hoses and the cable coolant temperature gauge sender.
14. Connect the fuel pipes.

15. Connect the pipes.

16. Join/connect the multiplugs of engine wiring harness and EI ignition coil.
 17. Install the intake pipe.
18. NOTE: Coat the spark plug sealing with silicone grease (A960-M1C171-AA).
Connect spark plug connectors for cylinders 1 and 2.
19. Install the throttle cable.
1. Connect the throttle cable.
2. Install the clip.

20. Raise the vehicle.

21. Install the front exhaust pipe on the exhaust manifold using a new gasket.
22. Install the bracket - oil dipstick tube.

23. Fit the drive belt.

24. Lower the vehicle.

25. Standard finishing operations.
 Fill up with coolant.
 Change the engine oil.
 Check the routing of the wiring and hoses and secure them with cable ties
where necessary.
 Connect the battery negative lead.
  Check the engine and cooling system for leaks (visual inspection).
 Enter the radio keycode.
 Reprogramme the pre-set radio stations.
 Reset the clock.
 Carry out a road test to allow the PCM to re-learn values.
 Check the fluid levels and rectify as necessary.

Engine - 1.4L PTE (CVH) - Engine Fiesta 1996 (08/1995-02/2002)

 Print 

Disassembly
Special Tool(s) / General Equipment
Aligner, clutch plate

16-067

Mounting bracket

21-064

Retaining bolts for 21 - 064

21-064-01

Crankshaft front oil seal installer

21-093 A

Crankshaft rear oil seal installer

21-095

Remover, oil seal

21-096
 Remover, timing belt pulley

21-098

Tension gauge, timing belt

21-113

Mounting plate

Mounting plate

Locking tool, crankshaft

21-168

Separator, sump

21-179

Angle gauge

21-540

Dial gauge
Magnetic fixture
Piston ring compressor
Steel straightedge
Piston ring pliers
Micrometer
Oil filter strap wrench
Plastic scraper
Materials
Name
Specification
Plastigage
From: Replacement Services Limited, 30, Euston Street, Freemans Industrial Estate,
Leicester, LE2 7ST 
Sealer (Hylosil 502)
WSK-M4G320-A 
Twelve workshop-made studs
M6x30 

Disassembly
1. Fit the engine and mounting plate onto the assembly stand.

2. Preparations
 Drain the engine oil.
 Detach the oil dipstick and oil dipstick tube.
 Detach the oil filter using a strap wrench.
3. Remove the adaptor plate.
4. Lock the crankshaft by inserting the special tool in the flywheel.

5. Remove the crankshaft pulley.

6. Detach the crankcase ventilation hose.

  Disconnect the plug.
 Unscrew and remove the oil pressure switch.

7. Remove the oil pressure switch.

8. Detach the multiplug for the camshaft position sensor (CMP sensor).

9. Detach the timing belt cover (two parts).

10. Detach the timing belt and the timing belt tensioner.
1. Slacken the bolts of the timing belt tensioner.
 Press the timing belt tensioner all the way to the left.
2. Remove the timing belt.
3. Detach the timing belt tensioner.

11. Remove the inlet manifold.

 Remove the gasket.
12. Remove the heat shield.

13. Detach the exhaust manifold.

 Remove the gasket.
14. Remove the cylinder head cover.
 Disconnect the hose from the oil separator.
 Unscrew the bolts.
 Remove the reinforcing panels.
 Remove the gasket.

15. Remove the cylinder head.

 Slacken the cylinder head bolts in the indicated order and remove them.
 Remove the cylinder head.
 16. Remove the cylinder head gasket and the two guide sleeves.

17. NOTE: Slacken all the bolts of the clutch pressure plate evenly.
Dismantle the clutch.

18. Detach the crankshaft position sensor (CKP sensor).

19. NOTE: Mark the installation position.
Remove the flywheel.
 Remove the special tool.

20. NOTE: Remove the bolts in the specified sequence.

NOTE: Remove the sump downwards so that no oil sludge or residues enter
the engine.
Detach the sump.
21. Detach the sump (continued).
22. Remove the crankshaft rear oil seal.
1. Special tool
2. Radial oil seal

23. Detach the crankshaft oil seal carrier.

24. Detach the bracket of the CKP sensor.

25. Remove the oil baffle plate.
26. Detach the coolant pump.

27. Detach the crankshaft timing belt pulley.

 Remove the thrust washer.
28. Turn the cylinder block through 1805.

29. Remove the crankshaft front oil seal.

30. Remove the oil pump with the oil intake pipe.
1. Detach the oil intake pipe bracket.
2. Remove the oil pump.
31. NOTICE: Remove the carbon deposits using a plastic scraper. Do not
damage the piston ring contact surfaces.
Remove the ring of carbon from the top edge of the cylinder.
 Set the piston to the half stroke position.
 Carefully remove the ring of carbon using a suitable scraper.

32. NOTE: Keep the big-end bearing shells in order for reuse.
Remove the pistons and connecting rods.
 Detach the big-end bearing caps.
 Push the pistons, connecting rods and bearing shells out of the cylinder block.

33. NOTE: Keep the main bearing shells in order for reuse. Keep the centre main
bearing together with its thrust rings.
Remove the crankshaft.
 Detach the main bearing caps.
 Lift the crankshaft out of the cylinder block.
34. NOTE: Keep the main bearing shells in order for reuse.
Remove the main bearing shells and the thrust half rings.

35. Remove all the blanking plugs and covers.

 Clean all the oil passages thoroughly.
Engine - 1.4L PTE (CVH) - Engine Fiesta 1996 (08/1995-02/2002)

 Print 

Assembly
Special Tool(s) / General Equipment
Aligner, clutch plate

16-067
Mounting bracket

21-064

Retaining bolts for 21 - 064

21-064-01

Crankshaft front oil seal installer

21-093 A

Crankshaft rear oil seal installer

21-095

Remover, oil seal

21-096

Remover, timing belt pulley

21-098
 Tension gauge, timing belt

21-113

Mounting plate

Mounting plate

Locking tool, crankshaft

21-168

Separator, sump

21-179

Angle gauge

21-540

Dial gauge
Magnetic fixture
Piston ring compressor
Steel straightedge
Piston ring pliers
Micrometer
Oil filter strap wrench
Plastic scraper
Materials
Name
Specification
Plastigage
From: Replacement Services Limited, 30, Euston Street, Freemans Industrial Estate,
Leicester, LE2 7ST 
Sealer (Hylosil 502)
WSK-M4G320-A 
Twelve workshop-made studs
M6x30 
1. Preparations.
 Clean the seats of the removed blanking plugs and covers.
 Thoroughly clean all the mating faces and reusable parts and check them for
damage.
 Fit new blanking plugs and covers with sealer (WSK-M4G320-A).
2. NOTE: Compare the measurements with the values given in the General
Specifications (refer to step 38, for explanation of paint marks) and if
necessary, grind or renew the crankshaft.
Measure the diameter of the main and big-end journals using a micrometer.
 Take two measurements in each case, with the second measurement at 90°to
the first.

3. Paint marks on main and big-end bearing journals (production repair sizes).
 Standard diameter main and big-end bearing journals are not colour coded.
 Main bearing journals with 0,25 mm undersize have a green mark.
 Big-end bearing journals with 0,25 mm undersize have a green mark on the
first crank web adjoining the big-end bearing journal.
4. Paint marks on bearing shells (production repair sizes).
 Standard size main and big-end bearing shells are not colour coded.
 Standard main and big-end bearing shells (+0,01 mm) have a yellow mark.
 Standard main bearing shells for oversize cylinder blocks (+0,4 mm) and
standard main bearing journals have a black mark.
 Standard main bearing shells for standard cylinder blocks and undersize main
bearing journals have a green mark.

5. Paint marks on main bearing caps (production repair sizes).

 Standard main bearing caps do not have any paint mark.
 Oversize main bearing caps (+0,4 mm) have a black mark.
 Bearing shells for undersize crankshafts or oversize cylinder blocks are
marked accordingly on the rear face (see Spare Parts Microfiche).
 6. Service bearing shells.
7. Preparations for measuring the bearing clearance.
NOTE: Carry out the following steps with care.
 Measure each bearing individually with a length of Plastigage thread.
 The bearing shells and journals must be oil free.
 In each case only the bearing cap of the bearing being measured is fitted and
tightened to the specified torque.
 The measurement should be carried out near the respective dead centre
position.

8. NOTICE: Do not turn the crankshaft during the measuring procedure. Do

not hit the bearing caps.
Measure the crankshaft main bearing clearance.
 Put the bearing shells dry in their correct positions in the cylinder block.
 Lay a length of Plastigage thread across the bearing on the bearing journal.

9. Measure the crankshaft main bearing clearance (continued).

NOTE: Measure the bearing clearances in turn in numerical order (one
to five).
 Fit the bearing caps and matching shells, with the arrows pointing towards
the timing belt, and tighten the bolts.
 Remove the bearing cap.
10. Measure the crankshaft main bearing clearance (continued).
 Compare the Plastigage thread with the Plastigage scale.
 If necessary, renew the bearing shells and repeat the measuring procedure
from step

11. Install the crankshaft.

 Coat all main bearing journals, thrust half rings and bearing shells, and also
all bolt threads and head undersides with engine oil.
 Insert the bearing shells.
 Insert the thrust half rings in the centre main bearing.
1. Oil grooves in the thrust half rings.
 12. Install the crankshaft (continued).
 Insert the crankshaft.
NOTE: The bearing cap numbering starts at the timing belt end to
which the arrows also point.
 Install the crankshaft main bearing caps with their corresponding bearing
shells.
 Tighten the bolts.

13. NOTE: Compare the measurements with the values given in General
Specifications and correct as necessary using new thrust half rings.
Check the crankshaft end float.
 Set up the dial gauge.
 Measure the crankshaft end float by lifting the crankshaft using a screwdriver.
14. Measure the piston ring gaps.
NOTE: The values given in General Specifications relate to a gauge ring
used in production. The values obtained when measured in the cylinder
may exceed these values by 0,15 mm.
 Fit the piston ring 12 mm below the cylinder block mating face.

15. Measure the piston ring gaps (continued).

 Compare the measurement with the values given in the General Specifications
and, if necessary, renew the piston ring.
16. NOTE: Connecting rod numbering (the numbering starts at the timing belt
end). The cast pips next to the piston pin bore point must be nearer the timing
belt.
Install the pistons and connecting rods.
1. Cast pips.
2. Connecting rod numbering.
17. Install the pistons and connecting rods (cont.).
 Lubricate the pistons and cylinder bores with engine oil.
 Distribute the piston ring gaps evenly around the circumference. In the case
of the oil scraper ring, the intermediate ring gaps should each be set
120°from the expander gap.
 Compress the piston rings using a piston ring compressor.
NOTE: The big-end bearing journals must be at bottom dead centre
position.
 Press pistons nos. 1 and 4 into the cylinders using the handle of a hammer.
 Insert the corresponding bearing shells dry in the connecting rods and the
bearing caps.
 Install the bearing caps.
 Turn the crankshaft through 1805 and install pistons nos. 2 and 3.

18. Measure the big end bearing clearances.

 Measure the big-end bearing clearance as described in steps 43, to
19. NOTE: The numbers on the connecting rods and big-end bearing caps must
match.
Fit big end bearing caps.
 Coat the bearing shells, bearing journals and the threads and undersides of
the bolt heads with engine oil.
 Fit the appropriate big-end bearing caps and bearing shells and tighten the
bolts.

20. NOTE: If the oil pump is new or has been overhauled, prime it with engine oil
and rotate the pump mechanism.
Fit the oil pump with the oil intake pipe and a new gasket.

21. NOTICE: Press the oil seal into the tool as far as it will go.
NOTE: Lay the special tool on a vice and use a hammer handle to press the oil
seal into place.
Fit the oil seal in the special tool.
1. Wrong way.
 2. Right way.

22. Install the crankshaft front oil seal.

 Lubricate the oil seal lip and crankshaft running face with engine oil.
 Using the pulley bolt, draw the oil seal into the oil pump housing as far as the
stop.
 Remove the special tool.
23. NOTE: The thrust face of the timing belt pulley must face outwards.
Fit the timing belt pulley.
 Apply grease to the crankshaft spigot.
 Slide on the thrust washer with the curved side facing outwards.
 Press on the timing belt pulley with the aid of the belt pulley.
 Remove the belt pulley again.
 Remove Special Tool 21-168.

24. Fit the coolant pump with a new gasket.

25. NOTICE: The oil seal carrier must be flush with the cylinder block.
Fit the crankshaft rear oil seal carrier with a new gasket.

26. Fit the CKP sensor bracket.

27. Fit the rear oil seal.
 Lubricate the oil seal lip and crankshaft running face with oil.
 Fit the oil seal in the special tool (refer to step ).
 Draw in the oil seal using two flywheel bolts.
28. NOTE: The installation position is marked.
NOTE: Use new bolts. Apply sealer (WSK-M4G320-A) to the bolt threads.
Install the flywheel.
 Immobilise the flywheel.
 Tighten the bolts uniformly, working diagonally.

29. Centre the clutch disc on the clutch pressure plate.

 Hold it in place with the special tool.
30. Install the clutch pressure plate and centred clutch disc.
 Tighten the bolts uniformly, working diagonally.
 Remove the special tools.

31. Install the CKP sensor.

32. Install the oil baffle plate.

33. Fit the sump.

 Apply sealer (WSK-M4G320-A) to the joins between the oil seal carrier and oil
pump housing.
 Lay the one-piece sump gasket in place and fit it in the groove of the oil seal
carrier and the oil pump housing.
34. Fit the assembly studs (M6x30).

35. Fit the sump (continued).

 Put the sump in place and tighten the bolts.
 Remove the studs and insert sump bolts.
NOTE: Tightening order.
 Tighten the bolts in the indicated order (two stages).
NOTE: Renew the oil seal.
 Tighten the oil drain plug.
36. NOTE: If the maximum permitted unevenness is exceeded, rework the cylinder
head (see General Specifications).
Check the cylinder head distortion using a steel straightedge.

37. Fit the cylinder head gasket.

1. Insert the guide bushes.
2. Choose the new cylinder head gasket by comparing it with the old gasket
(identification teeth).
3. Fit the cylinder head gasket.
38. NOTE: Before putting the cylinder head in place, turn the crankshaft so that
the first cylinder is about 20 mm before TDC.
Install the cylinder head.
 Fit the cylinder head.
 Tighten the new cylinder head bolts in the indicated order in four stages.
 Use a torque wrench for stages one and two.
39. NOTICE: The cylinder head bolts must not be re-torqued.
NOTE: Use an angle gauge for stages 3 and 4.
Fit the cylinder head (continued).
40. Turn the camshaft timing belt pulley to the TDC mark.
1. TDC mark on cylinder head.
2. TDC mark on camshaft timing belt pulley.

41. Turn the crankshaft to the TDC mark.

1. TDC mark on cylinder block.
2. TDC mark on crankshaft timing belt pulley.
42. Fit the timing belt tensioner and timing belt.
 Fit the bolts.
 Press the timing belt tensioner all the way to the left.
 Fit the timing belt anti-clockwise, starting at the crankshaft.
 Adjust the timing belt tension as described in step
 Tighten the bolts.
43. NOTICE: Check the timing belt tension again after 500 km.
Adjust the timing belt tension.
 Pretension the timing belt with the timing belt tensioner.
 Turn the crankshaft at least two turns in the clockwise direction to TDC
position for cylinder no. 1.
 Turn the crankshaft back anti-clockwise through approx. 605 (three tooth
divisions on the camshaft timing belt pulley).
 Fit the special tool and check the timing belt tension.
 If the timing belt tension does not correspond to the required values (new
timing belt 10 to 11 scale divisions, used timing belt 4 to 6 scale divisions),
turn the crankshaft clockwise to TDC for cylinder no. 1.
 Release the timing belt tensioner and adjust the tension as required.
 Turn the crankshaft 90°further in the clockwise direction.
 Turn the crankshaft back anti-clockwise to 605 before the TDC position
(measuring position).
 Fit the special tool and read off the belt tension.
 Repeat the process until the timing belt tension is correct.
44. Fit the cylinder head cover.
 Fit the cylinder head cover with a new gasket.
 Fit the reinforcing panels with the rippled side upwards.
 Tighten the bolts uniformly.
 Connect the oil separator hose.
45. Fit the exhaust manifold with a new gasket.

46. Attach the heat shield.

47. Fit the inlet manifold together with a new gasket.

48. Fit the timing belt cover (two parts).

49. Connect the plug to the CMP sensor.

 50. Connect the crankcase ventilation hose.
Fit the oil pressure switch.
NOTE: Apply sealer (WSK-M4G320-A) to the thread of the oil pressure switch.
empty

51. NOTE: Dowel pins.

Fit the adaptor plate.
52. Install the crankshaft pulley.
 Immobilise the flywheel as described in step
 Remove Special Tool 21-168.

53. Fill up with engine oil.

 Fit the oil dipstick tube with a new O-ring and insert the dipstick.
NOTE: Lubricate the seal with engine oil.
 Install a new oil filter using an oil filter strap wrench.
 Fill up with engine oil.
 54. Detach the engine from the stand.

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
Specifications
 Print 

Engine Data

Engine management Endura - DE

EEC V
Emission standard
93 EEC 96 EEC
Fuel Diesel
Engine code RTK RTJ
Injection sequence 1-3-4-2
Bore mm 82,5 mm
Stroke 82,0 mm
Cubic capacity, effective 1753 cm 3
Compression ratio 21,5 : 1
Compression pressure at starter motor speed 28 - 34 bar
Power output (EEC) 44 kW
at 4800 rev/min
Torque (EEC) at 105 Nm
at 2500 rev/min
Idle speed 920 rev/min - 950 rev/min
Idle speed (with air conditioning) 950 rev/min
Max. engine speed, continuous 5350 rev/min ± 50 rev/min
Max. intermittent engine speed 5200 rev/min ± 50 rev/min
Dimensions

Endura - DE
Cylinder Block
Number of main
5
bearings
Dimensions in mm
 Endura - DE
Cylinder bore-Ø - Class
82,500 - 82,515
A
Cylinder bore-Ø - Class
82,515 - 82,530
B
Cylinder bore-Ø - Class
82,660 - 82,675
C
Cylinder bore-Ø - Class
82,675 - 82,690
D
Cylinder bore-Ø - Class
83,000 - 83,015
E
Cylinder bore-Ø - Class
83,500 - 83,515
F
Main bearing clearances
0,025 - 0,085
(radial)
Main bearing parent
54,005 - 54,042
bore
Crankshaft
Main bearing journal-Ø -
53,970 - 53,990
standard
1st undersize 0,25 53,720 - 53,740
2nd undersize 0,50 53,470 - 53,490
Big-end bearing journal-
48,970 - 48,990
Ø - standard
1st undersize 0,25 48,720 - 48,740
2nd undersize 0,50 48,470 - 48,490
Big-end bearing
0,025 - 0,085
clearances
Crankshaft end float 0,1436 - 0,3688
Connecting rod end float
0,125 - 0,325
relative to crank web
Max. turning torque
without connecting rods 10
and pistons
Connecting rods
Bore Ø - big-end 52,000 - 52,020
Bore Ø - small-end 26,012 - 26,020
Distance between
connecting rod bores - 129,872 - 129,948
Class A
Distance between
connecting rod bores - 129,932 - 130,008
Class B
Distance between
connecting rod bores - 129,992 - 130,068
Class C
Distance between
connecting rod bores - 130,052 - 130,128
Class D
Big-end bearing radial
0,016 - 0,074
clearance
Pistons
Piston Ø - Class A 82,460 - 82,475
Piston Ø - Class B 82,475 - 82,490
C 82,621 - 82,639
Piston Ø - Class D 82,636 - 82,654
Piston Ø - Class E 82,961 - 82,979
 Endura - DE
Piston Ø - Class F 83,461 - 83,479
Measured at right-angles
to piston pin bore
Piston clearance (initial
0,025 - 0,055
fit) - Class A-F
Piston protrusion at TDC 0,500 - 0,840
Piston ring gaps (fitted) Dimensions in mm
Upper compression ring 0,30 - 0,32
Lower compression ring 0,30 - 0,32
Oil scraper ring 0,250 - 0,580
Piston ring clearance in
piston groove, upper 0,090 - 0,122
ring
Lower ring 0,050 - 0,082
Oil scraper ring 0,030 - 0,062
The piston-ring gaps must be evenly distributed on the
circumference of the piston. This also applies to the elements of
Ring gap position
the oil scraper ring. In each case, offset the ring gaps by
120°_with respect to each other.
Piston pins
Dimensions in mm
Piston pins 25,96 - 26,00
Piston pin type "Floating" in piston and connecting rod
Piston pin retention Snap-ring
Cylinder head
Dimensions in mm
Camshaft bearing Ø -
30,500 - 30,525
standard
Camshaft bearing-Ø -
30,575 - 30,600
oversize
Bore Ø - valve tappet -
35,000 - 35,030
standard
Bore Ø - valve tappet -
35,500 - 35,530
oversize
Bore Ø - valve stem
8,000 - 8,025
guide - standard
Bore Ø - valve stem
8,263 - 8,288
guide - 1st oversize
Bore Ø - valve stem
8,463 - 8,488
guide - 2nd oversize
Thickness of cylinder
Number of tooth marks
head gasket
with piston protrusion of
1,36 (2)
0,500 - 0,680 mm
with piston protrusion of
1,42 (3)
0,681 - 0,740 mm
with piston protrusion of
1,52 (4)
0,741 - 0,840 mm
Max. permissible
unevenness over entire 0,08 mm
cylinder head area
Do not overhaul cylinder
head mating face.
Camshaft
Valve timings, inlet
6°
valve opens BTDC
 Endura - DE
Valve timings, inlet
32°
valve closes ABDC
Valve timings, exhaust
57°
valve opens BBDC
Valve timings, exhaust
7°
valve closes ATDC
Cam lift (camshaft) -
9,0 mm
Inlet
Cam lift - Exhaust 10,0 mm
End float 0,100 mm - 0,240 mm
Dimensions in mm
Bearing journal Ø 27,960 - 27,980
Bearing clearances 0,020 - 0,079
Valve clearances (cold) -
0.35 ± 0,05
Inlet
Valve clearances (cold) -
0.50 ± 0.05
Exhaust
Adjustment shim
3,000 - 4,750
thickness
in steps of 0,050
Engine Oil

Viscosity/Ambient temperature Description Specification

Recommended engine oil
SAE 5W30 / -20 to over 40 degrees
WSS-2C913-A ACEA A3/B3
Centigrade
Alternative engine oils
SAE 5W40 / below -20 to over 40 degrees Ford Formula S Synthetic
ACEA A3/B3
Celsius Motor Oil
If engine oils with these specifications are not available, only engine oils meeting, as a
minimum, the API/SH/CD EC (Energy Conserving) and the CCMC PD2 specifications should
be used.
Engine Lubrication

Oil Pressure bar

Oil pressure (minimum) - at idle speed 0,75
(oil temperature approx. 80 °C) - at 2000 rev/min 1,50
Pressure relief valve opening pressure 2-4
Oil pump, max. inner/outer rotor clearance 0,174 mm
Lubricants, Fluids and Sealers

Ford
Specification
WSD-M2C200-
Transmission fluid
C
SQM-2C9002-
Hypoid oil
AA
ESPM-2C-166-
Power steering hydraulic fluid
H
Ford DOT 4 brake fluid for hydraulic clutch system SAM 6C9103A
Motorcraft Super-Plus 4 coolant concentrate ESD M97B-49A
SPM-4G-9112-
Sealer for camshaft bearing cap no. 1; sump/cylinder block
F/G
High temperature grease for transmission input shaft, guide sleeve - clutch
ESD-M1C220-A
release bearing, pilot bearing - crankshaft and clutch splines
Filling Capacities

Litres
Engine oil, initial fill with filter 5,0
with filter change 5,0
without filter change 4,5
Coolant - vehicles with manual transmission 9,3
Transmission fluid 2,8
Transmission fluid 10 - 15 mm below filler/check bore
Torque Specifications

Description Nm lb-ft lb-in

Rear engine mounting bracket (nuts) 70 52
Rear engine mounting bracket (bolts) 50 37
Front engine mounting bracket (outer nut) 120 89
Front engine mounting bracket (inner nut) 70 52
Front engine mounting reinforcing bracket 50 37
Bracket, front engine mounting 33 24
Bracket, right-hand engine mounting 45 33
Engine roll restrictor to cylinder block 50 37
Engine roll restrictor to front axle 70 52
Right-hand front driveshaft centre bearing 24 18
Lower suspension arm to spindle carrier 52 38
Track rod to spindle carrier 36 27
Stabiliser link rod to suspension strut 47 35
Rear exhaust pipe to flexible intermediate pipe 47 35
Stabiliser bar to transmission 55 41
Shift linkage to transmission 23 17
Compressor - Air Conditioning 25 18
Hexagon socket head bolt - tensioning pulley 6 4
Front engine mounting reinforcing bracket 50 37
Drive belt tensioner 6 4
Driveshaft stub nut 270 199
Wheel nuts 85 63
Resonator 11 8
Starter motor 44 32
Flange bolts - transmission to engine 44 32
Ground lead to transmission 44 32
Suspension strut nut 45 33
Torque Specifications

Description Nm lb-ft lb-in

Injection pump 24 18
Injection pump cover 7 5
Injection pump bracket to cylinder block 23 17
Injection pump to bracket 20 15
Injection pump to bracket 20 15
Injection pipes 25 18
Injectors 70 52
Injection pump timing belt pulley 23 17
Timing belt tensioner for injection pump timing belt 45 33
Torque Specifications
 Description Nm lb-ft lb-in
Coolant pump 23 17
Coolant pipe bracket to cylinder block 23 17
Radiator 24 18
Coolant drain plug to radiator 22 16
Torque Specifications

Description Nm lb-ft lb-in

Power steering pump bracket 23 17
Tensioning pulley for power steering drive belt 6 4
Power steering pump 23 17
Bracket for power steering fluid feed pipe 24 18
Belt pulley of power steering pump 23 17
Cover of power steering pump 10 7
Torque Specifications

Description Nm lb-ft lb-in

Flywheel - stage 1 18 13
Flywheel - stage 2 45° 45°
Flywheel - stage 3 45° 45°
Clutch 30 22
Crankshaft main bearing caps - stage 1 27 20
Crankshaft main bearing caps - stage 2 75° 75°
Big-end bearing caps, stage 1 25 18
Big-end bearing caps, stage 2 60° 60°
Big-end bearing caps - stage 3 20° 20°
Front plate 24 18
Crankshaft rear oil seal housing 20 15
Auxiliary shaft thrust plate 9 7
Auxiliary shaft oil seal housing 23 17
Bracket of engine mounting to cylinder block 33 24
Blanking plug for TDC adjustment hole 24 18
Auxiliary shaft timing belt pulley 45 33
Bolt of rear cover 24 18
Flange of crankshaft front timing belt pulley - stage 1 150 111
Flange of crankshaft front timing belt pulley - stage 2 -90° (undo) -90° (undo)
Flange of crankshaft front timing belt pulley - stage 3 120 89
Flange of crankshaft front timing belt pulley - stage 4 60° 60°
Crankshaft pulley/vibration damper 35 26
Alternator bracket 46 34
Alternator to bracket 25 18
Clamp bolt for alternator belt tensioner 6 4
Crankshaft position sensor (CKP sensor) to cylinder block 10 7
CKP sensor bracket 14 10
Torque Specifications

lb-
Description Nm lb-ft
in
Cylinder head bolts, stage 1. 10 7
Cylinder head bolts, stage 2. 100 74
- -
Cylinder head bolts, stage 3.
180°(undo) 180°(undo)
Cylinder head bolts - stage 4. 70 52
Cylinder head bolts - stage 5. 120° 120°
 lb-
Description Nm lb-ft
in
Cylinder Head Cover 5 4
Fuel filter bracket 23 17
Vacuum pump 20 15
Thermostat housing 22 16
Exhaust Manifold 24 18
Exhaust gas recirculation valve (EGR valve) 20 15
EGR pipe clip 10 7
Upper inlet manifold 23 17
Intake manifold to cylinder head 23 17
Exhaust manifold studs 13 10
Catalytic converter to exhaust manifold 24 18
Retaining plate for oil separator, fuel filter, fuel heater 20 15
Vacuum pump 20 15
Engine lifting eye 23 17
Camshaft bearing caps 20 15
Oil pressure switch 20 15
Flange for camshaft timing belt pulley 30 22
Injectors 70 52
Glow plugs 28 21
EGR valve 20 15
EGR pipe clip 10 7
Clamp bolt of camshaft timing belt tensioner 50 37
Camshaft timing belt pulley 9 7
Camshaft timing belt pulley (with automatic timing belt
35 26
tensioner) with M8 bolt
Camshaft timing belt pulley (with automatic timing belt
48 35
tensioner) with M10 bolt
Adjusting cam 45 33
Upper and lower timing belt cover 7 5
Side timing belt cover 8 6
Torque Specifications

Description Nm lb-ft lb-in

Oil intake pipe bracket 22 16
Oil pan 11 8
Oil drain plug on sump 24 18
Oil pump 23 17
Oil baffle 20 15
Oil dipstick tube bracket 10 7
Oil Pressure Switch 20 15

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
Engine
 Print 

Description and Operation

The 44kW (60PS) indirect injection Diesel engine is based on the familiar swirl chamber
Diesel engine which has been revised in line with the latest technology.

The engine not only conforms to European Emission Regulations, but also meets all
other expectations in relation to fuel consumption, quiet running, flexibility and power
delivery.
Crankshaft

The crankshaft runs in five main bearings. Thrust half bearings are fitted at the third
bearing to control the crankshaft end float.

Timing belt pulley - crankshaft

The timing belt pulleys used to drive the valve train and fuel injection pump are a sliding
fit on the crankshaft and are retained by the crankshaft central bolt.

The fuel injection pump drive pulley is positively located by pins that locate into the
crankshaft on one surface and the camshaft timing belt pulley on the other. On the front
pulley there is an O-ring seal which must be renewed during every installation. It is
important not to assemble the O-ring seal dry; always lubricate it with clean engine oil
prior to installation.

Crankshaft central bolt

The crankshaft central bolt is a "Torque to Yield bolt" which must be renewed each time
it is undone.

Camshaft timing belt

 

Item
Part Number
Description
1
-
Timing belt tensioner
2
-
Adjusting cam
3
-
Timing belt
4
-
Camshaft timing gear
The toothed timing belt drives the camshaft and maintains the correct relationship
between camshaft and crankshaft.

NOTICE: Because a new timing belt is very stiff when first installed, the
adjustment procedure must be adhered to exactly.
The timing belt tension is maintained by the automatic tensioner. However, the first
time the belt is tensioned, the adjusting cam is used.

The camshaft timing pulley is a taper fit on the camshaft and is retained by friction
applied by a clamping bolt.

Valve tappets & adjusting shims

The camshaft operates the valves directly via the valve tappets.

NOTICE: When installing adjustment shims, the writing must face the tappet.
Adjustment shims are available for setting the valve clearances. The thickness of each
shim is marked on one face.

Cylinderhead

Item
Part Number
Description
1
-
Guide dowel holes
2
-
Gasket thickness indicator
The cylinder head gasket is available in three thicknesses. A particular piston protrusion
requires a certain thickness of gasket and this is determined by the number of notches
on the gasket thickness indicator.

Crankshaft oil seals

NOTE: The crankshaft rear oil seal is supplied complete with the oil seal carrier. I
tmust be fitted using the tool shown.
 NOTICE: Removing the support ring too early will cause the oil seal to shrink
thereby making it unusable.
Both the front and rear oil seals are made from PTFE and therefore must be fitted dry.

When supplied as a service parts, both oil seals have a support ring which should only
be removed after fitting. Some support rings may drop out of their own accord after an
oil seal has been fitted.

Crankcase ventilation

The crankcase ventilation valve is on the upper surface of the valve cover. Like all
crankcase ventilation components, the valve must always be kept clean to ensure
optimal engine operation.

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
Valve Seals
 Print 
In-vehicle Repair
Special Tool(s) / General Equipment
Universal flange holding wrench

15-030 A

Installer, valve stem seals

21-007 A

Valve spring compressor

21-024

Adapter for 21-024

21-024-05

Timing peg, crankshaft TDC position

21-104

Installer, oil seal

21-110

Installer, valve stem collets

21-156
 Pliers, valve stem oil seals

21-165

Remover/installer, cooling hose clamp

24-003

Two-legged puller
Materials
Name
Specification
Sealer
SPM-4G-9112-F/G 
Valve stem installation sleeves
 
Engine Oil
ACEA A3/B3 

Removal
1. General note.
 This operation was carried out on an engine with a mechanical timing belt
tensioner.
 When removing and installing coolant and ventilation hoses, if necessary For
additional information, refer to Section  303-03 Engine Cooling.
2. Remove the camshaft timing belt as described in Operation No. 21 304 0.
3. Raise the vehicle.
 4. Lower the vehicle.

5. NOTICE: Support the engine with a trolley jack.

Detach the engine support bar.
6. Slacken the flange bolt of the camshaft timing pulley.

7. Remove the camshaft timing pulley.

8. Detach the crankcase ventilation hose.

9. Remove the flange bolt of the camshaft timing pulley.
10. Pull off the flange of the camshaft timing pulley using a proprietary two-
legged puller.
 Remove the Woodruff key.

11. Remove the cylinder head cover.

1. Detach the crankcase ventilation hoses.
2. Remove the bolts.
 12. Remove the oil baffle.

13. NOTICE: Slacken the nuts of the camshaft bearing caps evenly, a turn at
a time.
Remove the camshaft.
 Take out the bearing caps, bearing shells and camshaft and put them down in
order.
 Remove the camshaft seal.
14. NOTE: Put down the valve tappets in order.
Remove the valve tappets and the valve shims and check them for wear.

15. Release the valve spring retainers by tapping lightly on the ends of the
valve stems.
 16. Turn the crankshaft to bring the pistons of cylinders nos. 1 and 4 to TDC.
 Mark the position.

17. NOTE: Only carry out the following operations for cylinders nos. 1 and 4.
Remove the valve springs.
1. Compress the valve springs.
2. Remove the valve collets. Remove the valve spring retainers and valve
springs and put them down in order.
 18. Remove the valve stem seals.

Installation

1. NOTICE: Cover the grooves in the valve stems with installation sleeves.
NOTE: Remove the installation sleeves after installation.
Lubricate the new valve stem seals with engine oil and fit them.
2. Fit the valve springs. Locate the valve springs and valve spring retainers in
position.
1. Compress the valve springs.
2. Fit the valve collets.

3. Turn the crankshaft to bring the pistons of cylinders nos. 2 and 3 to TDC.
 Turn the crankshaft on through 180°.
 4. Carry out steps xx to xx on cylinders nos. 2 and 3.
5. Adjust the positions of the valve collets.

6. NOTE: The lettering on the valve shims faces downwards.

NOTE: Installation order.
Lubricate the valve tappets and valve shims with engine oil and fit them.
7. Turn the crankshaft a further 1 1/3 turns until it is just before TDC.

8. Put the camshaft bearing shell lower halves in place and coat them with
engine oil.
 Fit the camshaft and turn it until the slot in the eccentric on the camshaft is
parallel with the upper edge of the cylinder head (with the larger semi-circle
at the top).
9. Align the camshaft.
10. Put the camshaft bearing shells upper halves in place and coat them with
engine oil.

11. Apply sealer (SPM-4G-9112-F/G) to bearing cap no. 1 in the areas

indicated.
12. Install the camshaft.
NOTE: The bearing caps must lie flat.
 Fit camshaft bearing caps nos. 1, 3 and 5.
NOTE: Tightening sequence.
 Screw on the nuts and tighten them.

13. Fit the oil baffle.

 14. Seal the parting line between the bearing cap and the cylinder head on
both sides with a thin bead of sealer(SPM-4G9112-F/G).

15. NOTE: Clean the cylinder head cover gasket and check it for damage. Only
renew it if it is damaged. The gasket can be reused several times if it is in
good condition.
NOTE: Before fitting the gasket, coat it lightly with engine oil.
Fit the cylinder head cover.
1. Screw in the bolts.
2. Attach the crankcase ventilation hoses.
16. NOTE: Coat the running surface and the sealing lip of the oil seal with engine
oil. The text on the oil seal faces outwards during installation.
Fit the camshaft oil seal using the special tool and an M8 bolt.

17. Fit the flange of the camshaft timing pulley.

 Insert the Woodruff key.
 Draw on the flange with the bolt.
18. Fit the camshaft timing pulley.

19. Connect the PCV hose.

20. Tighten the flange bolt of the camshaft timing pulley.
 21. Raise the vehicle.
NOTE: The timing pin must be screwed in as far as it will go.
 Fit the timing pin.
 Carefully turn the crankshaft in the normal direction of rotation of the engine
until it comes up against the timing pin.

22. Turn the crankshaft to the TDC position.

23. Lower the vehicle.
24. Attach the engine support bar.
25. Fit a new camshaft timing belt as described in Operation No. 21 304 0.

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
Cylinder Head
 Print 

In-vehicle Repair
Special Tool(s)
Timing pin, crankshaft TDC position

21-104
 Socket, cylinder head bolts

21-164

Angle gauge, bolt tightening

21-540

Timing pin, camshaft pulley

23-019

Remover/installer, cooling hose clamp

24-003

Materials
Name
Specification
Motorcraft Super-Plus 4 coolant concentrate
ESD-M97B-49A 
Sealer
SPM-4G-9112-F/G 
Valve stem installation sleeves
 

Removal
1. General Remarks.
 This operation was carried out on an engine with a mechanical timing belt
tensioner.
 If necessary, use remover 303-03 when removing coolant hoses and vent
hoses. For additional information, refer to Section  303-03 Engine Cooling.
2. Standard preparatory measures
 Make a note of the radio keycode.
 Make a note of the preset radio stations.

WARNING: Risk of scalding when the engine is at operating

temperature.
 Open the coolant recovery tank.
3. Raise the vehicle.
Drain off the coolant.
 WARNING: Risk of scalding when the engine is at operating
temperature.
 Tighten the plug again after draining.

4. NOTICE: Support the engine with a trolley jack.

Remove camshaft timing belt as described in Operation No. 21 304 0.
5. Remove the camshaft timing belt pulley.
 Take out the special tool.

6. Detach the coolant hose.

7. WARNING: The timing belt tensioner is spring-loaded.

Detach the timing belt rear cover.
1. Remove the camshaft timing belt tensioner.
 2. Detach the timing belt pulley.
 Detach the cover plate.

8. NOTE: Seal the opening with adhesive tape.

Detach the air intake hose.

9. Detach the coolant hoses from the thermostat housing.

10. Disconnect the following plugs and wiring.
1. Glow plug wiring
2. Plug - engine coolant temperature sensor (ECT sensor)
3. Plug - coolant temperature gauge sender unit.
4. Plug - oil pressure switch

11. Detach the vacuum pump oil return hose.

12. Detach bracket of the glow plug wiring.

13. Detach the brake servo vacuum line.

14. Detach the fuel feed line.

15. Detach the fuel line to the fuel heater.
 Unclip the fuel heater.
16. Disconnect vacuum hose and plug of the exhaust gas recirculation valve
(EGR valve).

17. Detach the heater coolant hose.

18. Remove the injection pipes and disconnect the leak-off hoses.
19. Detach the catalytic converter from the exhaust manifold.

20. Support the engine with a trolley jack, so that the front engine mounting
is free of load.
21. Detach the engine support bar.
22. Remove the cylinder head cover.
1. Detach the crankcase ventilation hoses.
2. Remove the bolts.
 23. Remove the oil baffle.

24. NOTE: Loosening sequence

Remove the cylinder head.
 Take off the cylinder head and put it down on wooden blocks.
 Remove the seal.
 Installation
1. Measure the piston protrusion.
NOTE: Carry out two measurements per cylinder a distance of 5 mm
from the edge of the piston.
 Measure the protrusion of the piston of each cylinder at TDC.
 Measure the difference in height between the piston crown and the cylinder
block.
 The largest measurement determines the choice of cylinder head gasket (see
General Specifications).
 2. Line up the crankshaft and camshaft.
 Turn the crankshaft until the piston of cylinder no. 1 is at TDC.
 Turn the camshaft until the groove in the eccentric on the camshaft is parallel
with the upper edge of the cylinder head (with the larger semi-circle at the
top).
 The crankshaft and camshaft must not be turned any more.

3. NOTE: The cylinder head gasket is marked "TOP/OBEN".

Fit a new cylinder head gasket.
1. Check that the locating sleeves are seated correctly.
2. Thickness marking as measured in step
4. NOTE: Do not oil the cylinder head bolts.
NOTE: Tightening sequence.
Fit the cylinder head and tighten the new cylinder head bolts in two stages.
5. Fit the cylinder head (continued).
NOTE: For stage 3, slacken one cylinder head bolt by itself, then
tighten it to the specified torque and angle. Only then move on to the
next cylinder head bolt.
 Wait three minutes and then tighten the cylinder head bolts according to
tightening sequence in stage 3.
6. Fit the oil baffle.

7. Seal the parting line between the bearing cap and the cylinder head on both
sides with a thin bead of sealer(SPM-4G9112-F/G).
8. NOTE: Clean the cylinder head cover gasket and check it for damage. Only
renew if damaged. If it is in good condition, re-use it several times.
NOTE: Before fitting the gasket, lightly coat it in engine oil.
Fit the cylinder head cover.
1. Tighten the bolts.
2. Attach the crankcase ventilation hoses.

9. Attach the catalytic converter to the exhaust manifold.

10. Fit the injection pipes and connect the leak-off hoses.

11. Connect the vacuum hose and plug to the EGR valve.

12. Attach the heater coolant hose.

13. Attach the fuel line to the fuel heater.
 Clip on the fuel heater.
14. Attach the brake servo vacuum line.

15. Attach the fuel feed line.

16. Attach the bracket of the glow plug wiring.
17. Attach the vacuum pump oil return hose.

18. Connect the following plugs and wiring.

1. Glow plug wiring
2. Plug - ECT sensor
3. Plug - temperature gauge sender unit
4. Plug - oil pressure switch
 19. Attach the coolant hoses to the thermostat housing.

20. NOTE: Remove the adhesive tape.

Fit the air intake hose.

21. Fit the camshaft timing belt tensioner.

1. Timing belt tensioner
2. Compress the spring of the timing belt tensioner and secure it with the clamp
bolt.
 22. NOTE: Do not tighten the bolts.
Fit the camshaft timing belt pulley.

23. Attach the coolant hose.

24. Connect the battery negative lead.
25. Attach the engine support bar.
 Fill up with coolant.
 Carry out an oil change.
 Check the routing of the vacuum hoses and wiring and secure them with
cable ties where necessary.
 Enter the radio keycode.
 Reprogramme the preset radio stations.
 Reset the clock.
 Carry out a road test to enable the PCM (EEC V) to collect data.
 Check the fluid levels and correct as necessary.
 Check the engine and cooling system for leaks (visual inspection).
26. Standard finishing operations.

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
  Print 

Disassembly
Special Tool(s)
Universal flange holding wrench

15-030A

Mounting bracket, engine

21-031B

Socket, cylinder head bolts

21-164

Crankshaft locking tool

21-168

Puller, crankshaft timing belt pulley

21-200

Socket, injectors

23-045

Disassembly
All Vehicles
1. General Remarks.
 As of 08/1995, the camshaft timing belt drive has been revised. It is not
possible to renew any of the gears or the belt itself with replacement parts
 from previous build years.
 If necessary, when removing coolant and ventilation hoses, For additional
information, refer to Section  303-03 Engine Cooling.
2. secure the engine to the assembly stand.
 Attach the mounting bracket.
 Secure the engine to the assembly stand.

3. NOTE: Escaping oil.

Drain off the engine oil.
Detach the oil pump with the oil filter.
4. Remove the alternator (shown with the air conditioning compressor).
1. Slacken and remove the drive belt.
2. Detach the belt tensioner.
3. Remove the alternator bolts.

5. Remove the injection pump belt pulley.

6. Remove the crankshaft pulley/vibration damper.
 Immobilise the crankshaft using the ring gear.
 Remove the bolts.

7. Remove the timing belt upper cover.

8. Remove the timing belt lower cover.

9. Remove the injection pump timing belt cover.

 10. Slacken the bolt of the auxiliary shaft timing belt pulley.
11. Remove the cylinder head cover.
1. Detach the crankcase ventilation hoses.
2. Remove the bolts.

Engines with automatic timing belt tensioner

12. Remove the camshaft timing belt.
1. Unscrew the bolt of the adjusting cam and remove the adjusting cam and the
timing belt.
2. Detach the camshaft timing belt tensioner.
3. Undo the bolt of the camshaft timing belt pulley.
Engines with automatic timing belt tensioner
13. NOTE: Position a screwdriver between the camshaft timing belt pulley and the
timing belt rear cover.
Detach the camshaft timing belt pulley (continued).
 Release the camshaft timing belt pulley from its conical seat by tapping it
lightly with a light metal drift.
Engines with mechanical timing belt tensioner
14. Remove the camshaft timing belt pulley.
 Undo the bolts of the timing belt pulley.
 Release the timing belt tensioner clamp bolt and slacken the timing belt.
 Tighten the timing belt tensioner clamp bolt.
 Remove timing belt and discard.

All vehicles
15. Remove the injection pump timing belt.
 Undo the bolts of the timing belt pulley.
 Release the timing belt tensioner clamp bolt and slacken the timing belt.
 Tighten the timing belt tensioner clamp bolt.
 Remove timing belt and discard.
 

16. WARNING: The timing belt tensioner is spring-loaded.

Remove the timing belt tensioner and the injection pump timing belt pulley.
1. Timing belt tensioner
2. Timing belt pulley

Engines with mechanical timing belt tensioner

17. WARNING: The timing belt tensioner is spring-loaded.

Remove the timing belt tensioner and the camshaft timing belt pulley.
1. Timing belt tensioner bolts
2. Camshaft timing belt pulley bolts
All vehicles
18. Remove the engine mounting bracket.

 
19. Remove the timing belt side cover.
20. Remove the oil dipstick tube.

21. Detach the hose.

22. Remove the fuel feed line.

23. Disconnect the injection pipes and leak-off hoses.

24. Remove the injection pump bracket.

25. Remove the injection pump.

26. Remove the thermostat housing, coolant hose and coolant pipe.

27. Remove the alternator bracket.

28. Remove the coolant pipe bracket.

 29. Remove the oil baffle.

30. Remove injectors and heat shields. Remove the glow plugs.
1. Injectors
2. Glow plug wiring
3. Glow plugs

31. NOTE: Loosening sequence

Remove the cylinder head.
 Take off the cylinder head and put it down on wooden blocks.
 Remove the seal.
32. Remove the flange of the crankshaft front timing belt pulley.
33. Remove the auxiliary shaft timing belt pulley and oil seal housing.
NOTE: Immobilise the timing belt pulley with the old timing belt.
1. Bolt of the auxiliary shaft timing belt pulley
2. Bolts of the auxiliary shaft oil seal housing

34. Remove the auxiliary shaft with the thrust plate.

35. Remove the coolant pump.

36. NOTICE: Only use a collet.
Remove the crankshaft rear timing belt pulley.
1. Fit the collet.
2. Pull the collet back as far as the stop.

37. Pull off the crankshaft rear timing belt pulley (continued)
 Screw in the spindle and pull off.
38. Remove the clutch.

39. Remove the flywheel.

 40. Remove the crankshaft position sensor (CKP).

41. NOTE: The oil seal is integrated in the housing.

Remove crankshaft rear oil seal housing.
 42. Remove the CKP sensor bracket.

43. NOTICE: Remove the sump downwards so that no oil sludge or abraded
particles get into the engine.
Remove the sump.

44. Remove the front plate.

 Press out the crankshaft front oil seal.

45. Remove the oil intake pipe with the bracket.

46. NOTICE: Do not damage the piston ring zone.
Remove the pistons.
NOTE: Put the big-end bearing caps and big-end bearing shells down in
order.
 Detach the big-end bearing caps.
 Remove the ring of carbon around the upper edge of the cylinders using a
proprietary scraper.
 Press out the pistons with the connecting rods and big-end bearing shells.

47. Remove the crankshaft.

 Remove the main bearing caps.
 Take out the crankshaft.
 Take out the bearing shells and thrust half washers and put them down in
order for re-use.
Engine - 1.8L Endura-DE (Kent) Diesel -
Fiesta 1996 (08/1995-02/2002)
Engine
 Print 

Assembly
Special Tool(s) / General Equipment
Universal flange holding wrench

15-030A

Aligner, clutch disk

16-067

Mounting bracket, engine

21-031B

Timing pin, crankshaft TDC position

21-104

Centring tool, remover and installer, oil seal

21-148A
Adjustment tool, camshaft TDC

21-162B

Socket, cylinder head bolts

21-164

Locking tool, crankshaft

21-168

Aligner, crankshaft rear oil seal

21-217

Angle gauge, bolt tightening

21-540

Timing pin, injection pump

23-019

Timing pin, injection pump

23-029
 Socket, injectors

23-045

Timing pin, crankshaft position sensor (CKP sensor)

23-049

Remover/installer, cooling hose clamp

24-003

Dial gauge with magnetic fixture

Piston ring compressor
Micrometer screw
Internal gauge
Feeler gauge
Steel straightedge
Materials
Name
Specification
Sealer
SPM-4G9112-F/G 
Engine Oil
ACEA A3/B3 
Hypoid oil
SQM-2C9002-AA 
Plastigage
Obtainable through: Replacement Services Limited, Euston Street, Freemans Industrial
Estate, Leicester, 7ST. 

Assembly
All Vehicles
1. Preparatory operations
 Thoroughly clean all mating faces and reusable parts and check for damage.
2. Clean the piston cooling oil splash nozzles and oilways.
 3. Measure the diameter of the main and big-end bearing journals using a
proprietary micrometer screw.
 Repeat the measuring operation at intervals of 90°.
 Different crankshaft sizes are used in production. The different crankshafts
are not marked.
 If the measurements do not tally with the values indicated in the General
Specifications, the crankshaft should be overhauled or renewed.

4. NOTE: Fit the main bearing caps without the bearing shells and tighten them
to the specified torque.
Measure the cylinder bores with a proprietary internal gauge.
 If the measured diameter of the cylinder bore is too large in relation to the
piston classification, overhaul or renew the cylinder block.
5. Preparations for measuring the bearing clearance.
NOTE: Carry out the following steps to the letter.
 Measure each bearing individually using a length of Plastigage thread.
 The bearing shells and journals must be free of oil and dirt.
 Fit the bearing cap of the bearing being measured and tighten to the specified
torque.
 The measurement should be carried out near the respective dead centre
position.
6. Measure the crankshaft main bearing clearance.
 Place the appropriate bearing shells dry in the cylinder block.
 Place the crankshaft dry in the cylinder block.
 Lay a length of Plastigage thread across the bearing on the bearing journal.
 7. Measure the crankshaft main bearing clearance (continued).
NOTE: The main bearing cap numbering starts at the timing belt end,
to which the arrows also point.
 Fit the main bearing cap with the associated main bearing shell as described
in step and tighten the bolts.
 Remove the main bearing cap.

8. NOTICE: Do not turn the crankshaft during the measuring procedure.

Compare the Plastigage thread with the Plastigage scale.
 The reading corresponds to the main bearing clearance.
 The main bearing shells should be renewed as necessary according to the
bearing clearance measurement.
9. Install the crankshaft.
NOTE: The main bearing cap numbering starts at the timing belt end,
to which the arrows also point.
 Lubricate the main bearing journals, main bearing shells and thrust half
washers with engine oil.
 Fit the thrust half washers in main bearing no. 3 with the lubricating groove
facing outwards.
 Fit the main bearing caps with the associated bearing shells.
 Tighten the bolts.

10. Measure the end float of the crankshaft.

 Set up the dial gauge.
 Measure the end float by lifting the crankshaft as shown.
 Rectify the end float as necessary by fitting new thrust half washers to main
bearing no. 3.
 11. Classifications.
1. Cylinder bore classification
2. Piston diameter classification
3. The piston weight classes are marked with '+' and '-'.

12. NOTE: Piston classification, if a piston has to be renewed.

Measure the piston diameter.
13. NOTE: Measure the piston ring clearance with the piston ring protruding.
Measure the piston ring clearances.
 The maximum clearance of the upper compression ring is 0,09 - 0,12 mm.
 The maximum clearance of the 2nd compression ring is 0,05 - 0,08 mm.

14. NOTICE: Do not mix up the piston rings. Re-fit the piston rings in the
same position and location.
Measure the piston ring gaps.
 The values given in the General Specifications refer to a reference gauge ring
used in production. When measured in the cylinder, the values can be
exceeded by 0,15 mm.
15. Fit the pistons.
 Lubricate the pistons and cylinder liners with engine oil.
 Distribute the piston ring gaps evenly on the circumference at intervals of
120°. This also applies to the elements of the oil scraper ring.
NOTE: The numbering on the connecting-rod begins from the timing
belt end. The arrow on the piston crown points towards the timing belt
end.
 Compress the piston rings using a proprietary piston ring compressor.
 Press the pistons into the cylinders with the handle of a hammer, guiding the
connecting rods onto the big-end bearing journals.
 Place the appropriate bearing shells, clean and dry, in the connecting rods.

16. Measure the big-end bearing clearances and fit the big-bearing caps.
 Measure the big-end bearing clearance as described in steps to
 Lubricate the big-end bearing shells and journals with engine oil.
NOTE: The numbering of the connecting rods and big-end bearing caps
must tally.
 Fit the appropriate big-end bearing caps and bearing shells and tighten the
bolts.
 17. Fit the oil intake pipe with the bracket.
NOTE: Make sure that the O-ring is seated correctly.
1. Locate the oil intake pipe in position with a new O-ring.
2. Fit the bracket.

18. NOTE: The front plate mating face must be flush with the lower edge of the
cylinder block (tolerance ± 0,1mm).
Fit the front plate with a new gasket and new oilway seals.
1. Centre the front plate using the aligner.
2. Fit the front plate.
19. NOTICE: The steps must be carried out immediately after each other to
prevent the oil seal from contracting. Do not remove the support ring from the
oil seal until immediately before installation.
NOTE: Install the oil seal dry.
Draw in the crankshaft front oil seal.
 Draw in the oil seal with the installer and the bolt of the crankshaft timing belt
pulley.

20. Install the crankshaft timing belt pulley.

NOTE: Make sure the O-ring in the timing belt pulley is in perfect
condition.
 Lubricate the O-ring and the end of the crankshaft with engine oil.
NOTE: The guide pin in the end of the crankshaft and the hole in the
timing belt pulley must line up.
 Carefully slide on the timing belt pulley as far as the stop.
21. NOTE: The sump bolts must be tightened within 20 minutes of applying the
sealer.
Apply sealer (SPM-4G-9112-F/G) to the cylinder block mating face
intersections.

22. Fit the sump.

 Locate the sump in position with a new gasket and screw in the bolts (x 14)
finger tight.
 Using a steel straightedge, align the sump so that it is flush with the mating
face of the oil seal housing.
 23. Tighten the oil pan bolts.

24. NOTICE: The sealing lip of the oil seal and the crankshaft sealing surface
must be free of oil.
NOTE: The support ring must sit in the oil seal.
Install the crankshaft rear oil seal housing.
1. Place the new crankshaft oil seal housing, together with the integrated oil
seal, in the installation position.
2. Screw in the bolts finger tight.
3. Fit the aligner and centre the oil seal housing on the crankshaft.
4. Crankshaft
5. Remove the support ring.
25. NOTICE: If the special tool cannot be removed, realign the sump.
Tighten the bolts of the crankshaft oil seal housing, working diagonally.
 Remove the locator.
26. NOTE: Use new bolts.
Fit the flywheel.
 Immobilise the crankshaft with the ring gear.

27. Centre the clutch disc on the pressure plate.

28. Fit the clutch.
1. Place the clutch pressure plate, together with the centred clutch disc, in the
installation position.
2. Tighten the bolts uniformly, working diagonally.
3. Remove the special tool.

29. Install the coolant pump.

 Place the coolant pump, together with a new gasket, and the bracket for the
spring of the timing belt tensioning pulley, in the installation position.
 Tighten the bolts.
 30. Install the auxiliary shaft with the thrust plate.
 Lubricate the auxiliary shaft, the bearing bush in the cylinder block and the
thrust plate with engine oil.
NOTE: The lubricating grooves on the thrust plate must face outwards.
 Fit the auxiliary shaft together with the thrust plate.
 Tighten the thrust plate bolts.

31. NOTE: Do not tighten the bolt of the auxiliary shaft timing belt pulley.
NOTE: The auxiliary shaft guide pin and the corresponding hole in the timing
belt pulley must line up.
Install the auxiliary shaft oil seal housing.
 Lubricate the end of the auxiliary shaft with engine oil.
 Slide the new oil seal housing with the integrated oil seal and the support ring
onto the end of the auxiliary shaft.
 Tighten the bolts of the oil seal housing.
 After securing the oil seal housing, detach the support ring and check that the
seal is seated correctly.
 32. Install the auxiliary shaft timing belt pulley.
33. NOTE: Use a new bolt.
NOTE: Lubricate the bolt head contact face with oil.
Fit the flange of the crankshaft front timing belt pulley.

34. Measure the piston protrusion.

NOTE: Carry out two measurements per cylinder a distance of 5 mm
from the edge of the piston.
 Measure the protrusion of the piston of each cylinder at TDC.
 Measure the difference in height between the piston crown and the cylinder
block mating face.
 The largest measurement determines the choice of cylinder head gasket (see
General Specifications).
35. NOTE: The straightedge must be at least 500 mm long.
Check the cylinder head mating face for distortion.
 Permitted distortion at the steps between the combustion chambers: 0,80
mm.
 Lay the straightedge transversely across all the steps between the
combustion chambers and check the distortion at three points in each case.
 Lay the straightedge lengthways over the cylinder head in three places in the
area of the combustion chambers and check the distortion at all the steps
between the combustion chambers.
 Lay the straightedge diagonally across the cylinder head and check the
distortion at all the steps between the combustion chambers.

36. Line up the crankshaft and camshaft.

 Turn the crankshaft until the piston of cylinder no. 1 is at TDC.
 Turn the camshaft until the slot in the eccentric on the camshaft is parallel
with the upper edge of the cylinder head (with the larger semi-circle at the
top).
 The crankshaft and camshaft must not be turned any more.
37. NOTE: The cylinder head gasket is marked "TOP/OBEN".
Fit a new cylinder head gasket.
1. Check that the locating sleeves are seated correctly.
2. Thickness marking as measured in step

38. NOTE: Do not oil the cylinder head bolts.

Fit the cylinder head and tighten the new cylinder head bolts in two stages.
39. Fit the cylinder head (continued).

NOTICE: For stage 3, slacken one cylinder head bolt by itself, then
tighten it to the specified torque and angle. Only then move on to the
next bolt.
 Wait three minutes and then tighten the cylinder head bolts according to
tightening sequence in stage 3.
40. Fit the injectors and glow plugs.
1. Glow plugs
2. Glow plug wiring
NOTE: Fit new injector heat shields.
3. Injectors
41. Fit the alternator bracket.

42. Fit the coolant pipe bracket.

43. Fit the thermostat housing, coolant hose and coolant pipe.
44. Fit the injection pump.

45. Fit the injection pump bracket.

 Connect the fast idle cable.
46. Connect the injection pipes and the leak-off hoses.

47. Connect the fuel feed line.

48. Install the oil dipstick tube.

 49. Attach the hose.
50. Fit the timing belt side cover.

51. Fit the engine mounting bracket.

52. NOTE: Do not tighten the bolts.

 NOTE: Centre the slots on the injection pump timing belt pulley.
Fit the injection pump timing belt pulley.

53. Fit the injection pump timing belt tensioner.

 Compress the spring of the timing belt tensioner and lock it with the clamp
bolt.

Engines with automatic timing belt tensioner.

54. Align the camshaft.
 Fit the timing tool into the groove in the camshaft eccentric.
Engines with mechanical timing belt tensioner
55. Fit the camshaft timing belt pulley and timing belt tensioner.
NOTE: Do not tighten the bolts of the camshaft timing belt pulley.
1. Fit the camshaft timing belt pulley.
2. Fit the timing belt tensioner (two bolts).
3. Squeeze the springs of the timing belt tensioner together and fix in place with
the clamping bolt.

Engines with mechanical timing belt tensioner.

56. Align the camshaft timing belt pulley.
 Align the camshaft timing belt pulley by inserting the timing pin through the
cutout in the pulley and the hole in the cylinder head.
All vehicles
57. Align the injection pump timing belt pulley and turn the crankshaft to the
TDC position.
1. Align the injection pump pulley by inserting the timing pin through the cutout
in the pulley and the hole in the injection pump housing.
NOTE: Screw in the timing pin as far as it will go; the crankshaft must
rest against the timing pin.
2. Remove the bolt and screw the timing pin into the cylinder block.
 Turn the crankshaft to the TDC position.
 

58. NOTICE: Renew the toothed belt.

NOTE: The direction of rotation is marked.
NOTE: Make sure the belt is seated correctly.
Fit the injection pump timing belt.
1. Fit the timing belt with the slack side nearest the timing belt tensioner.
2. Slacken the bolt of the timing belt tensioner and allow the tensioner to snap
against the timing belt. Tighten the timing belt tensioner bolt.
NOTE: The bolts must not be at the ends of their slots.
3. Tighten the bolts of the timing belt pulley.

Engines with automatic timing belt tensioner.

 59. NOTICE: Renew the toothed belt.
NOTE: Make sure the belt is seated correctly.
Install the camshaft timing belt.
1. Fit the camshaft timing belt tensioner.
2. Fit the adjusting cam.
NOTE: The direction of rotation is marked.
3. Fit the timing belt and lay it over the camshaft timing belt pulley.
 Slide the camshaft timing belt pulley onto its conical seat and screw in the
bolt until the camshaft timing belt pulley can still just be turned on the
camshaft.

Engines with mechanical timing belt tensioner

60. NOTICE: Renew the toothed belt.

NOTE: The direction of rotation is marked.
NOTE: Make sure the belt is seated correctly.
Install the camshaft timing belt. Fit the timing belt with the slack side nearest
the timing belt tensioner.
1. Release the timing belt tensioner clamp bolt and allow the tensioner to snap
against the timing belt. Tighten the timing belt tensioner clamp bolt.
NOTE: The bolts must not be at the ends of their slots.
2. Tighten the timing belt pulley bolts.
 61. Remove timing pins 21-104, 23-019 and 23-029.
Engines with automatic timing belt tensioner
62. NOTE: Hold the camshaft timing belt pulley steady.
Pretension the camshaft timing belt.
 Turn the adjusting cam clockwise to 9 o'clock and tighten the centre bolt of
the adjusting cam.
 Tighten the bolt of the camshaft timing belt pulley.

63. NOTICE: Remove the special tools.

Turn the crankshaft six turns in the normal direction of rotation of the engine.
Engines with automatic timing belt tensioner
64. Preparations for tensioning the timing belts.
 Turn the crankshaft further in the normal direction of rotation of the engine
until the slot in the injection pump timing belt pulley is at 11 o'clock.
 Screw in the timing pin.
 Carefully turn the crankshaft in the normal direction of rotation of the engine
until it comes up against the timing pin.
 Insert Special Tool 23-029.
Engines with automatic timing belt tensioner
65. NOTE: Hold the camshaft timing belt pulley steady.
Loosen the bolt of the camshaft timing belt pulley and slacken the camshaft
timing belt.

Engines with automatic timing belt tensioner

66. NOTE: Position a screwdriver between the camshaft timing belt pulley and the
timing belt rear cover.
Release the camshaft timing belt pulley.
 Release the camshaft timing belt pulley from its conical seat by tapping on it
lightly with a light metal drift.
 Slacken the bolt of the adjusting cam.
Engines with automatic timing belt tensioner
67. NOTE: If necessary, turn the camshaft using water pump pliers until the timing
tool can be inserted.
Insert the special tool in the camshaft.

 
68. Preparations for tensioning the timing belt (mechanical timing belt
tensioner shown).
 Remove Special Tool 21-162B.
 Turn the crankshaft two revolutions in the direction of rotation of the engine
until the slot in the injection pump timing belt pulley is at 12 o'clock.
 Turn the slot back counter to the normal direction of rotation of the engine to
11 o'clock.
 Screw in the timing pin.
 Carefully turn the crankshaft in the normal direction of rotation of the engine
until it comes up against the timing pin.
 The timing pin must be able to be inserted into the camshaft timing belt
pulley.
1. The timing pin must be able to be inserted into the injection pump timing belt
pulley.
69. Tension the injection pump timing belt (mechanical timing belt tensioner
shown)
NOTE: Slacken the bolts of the timing belt pulleys just half a turn each.
 Slacken the bolts of the camshaft timing belt pulley.
 Slacken the bolts of the injection pump timing belt pulley.
 Slacken the clamp bolt of the injection pump timing belt tensioner a quarter
turn so that the timing belt tensioner presses against the timing belt.
 Tighten the bolt of the injection pump timing belt tensioner.
1. Tighten the bolts of the injection pump timing belt pulley.
Engines with automatic timing belt tensioner
70. NOTE: Hold the bolt of the adjusting cam steady. Adjusting cam must be
between the 6 o'clock and the 9 o'clock position or between the 9 o'clock
position and the 12 o'clock position.
NOTE: Tighten the bolt smoothly.
NOTE: Hold the camshaft timing belt pulley steady. Tighten the bolt smoothly.
Tension the camshaft timing belt.
1. Tension the camshaft timing belt clockwise via the hexagon socket of the
adjusting cam until the arrows of the camshaft timing belt tensioner meet.
2. Tighten the bolt of the adjusting cam.
3. Tighten the bolt of the camshaft timing belt pulley.
 Torque for M8 bolt: 35 Nm.
  Torque for M10 bolt: 48 Nm.

71. NOTICE: Remove the special tools.

Turn the crankshaft four turns in the normal direction of rotation of the
engine.
Engines with automatic timing belt tensioner
72. NOTE: If the special tools cannot be inserted, then the adjustment must be
repeated from step
Check the valve timings.
 Turn the crankshaft further in the normal direction of rotation of the engine
until the slot in the injection pump timing belt pulley is at 11 o'clock.
 Screw in the timing pin.
 Carefully turn the crankshaft in the normal direction of rotation of the engine
until it comes up against the timing pin.
 Special Tool 23-029 must be able to be inserted.
 The timing tool must be able to be inserted in the camshaft.
  The arrows on the camshaft timing belt tensioner must not be offset by more
than 3 mm.
 Remove the special tools and fit the blanking plug in the place of the timing
pin.

 
73. Tension the camshaft timing belt.
NOTE: Leave timing pin 23-029 inserted.
1. Slacken the clamp bolt of the camshaft timing belt tensioner a quarter turn so
that the timing belt tensioner presses against the timing belt.
NOTE: All timing pins must be correctly inserted; the crankshaft must
be resting against the timing pin.
2. Tighten the clamp bolt of the camshaft timing belt tensioner.
3. Tighten the bolts of the camshaft timing belt pulley.
4. Take out the timing pins. Unscrew the timing pin and tighten the blanking
plug for the TDC setting bore.
74. Fit the oil baffle.

75. Seal the parting line between the bearing cap and the cylinder head on
both sides with a thin bead of sealer(SPM-4G9112-F/G).
76. NOTE: Clean the cylinder head cover gasket and check it for damage. Only
renew if damaged. If it is in good condition, re-use it several times.
NOTE: Before fitting, lightly coat the gasket with engine oil.
Fit the cylinder head cover.
1. Screw in the bolts.
2. Attach the crankcase ventilation hoses.

77. Fit the injection pump timing belt cover.

78. Tighten the bolt of the auxiliary shaft timing belt pulley.
79. Fit the lower timing belt cover.

80. Fit the upper timing belt cover.

 81. Fit the crankshaft pulley/vibration damper.
 Then remove Special Tool 21-168.

82. NOTICE: The setting value of 10° for the injection pump timing must be
strictly observed.
Position the crankshaft to 10° after the TDC position of the first cylinder.
 Locate the CKP sensor bracket in position without the sensor and attach it
loosely.
NOTE: When using the angle gauge 21-540 make sure that the disc is
not moved out of position by the movement of the special tool. The
special tool must be kept under tension. If the 10° mark is not quite
reached, unscrew the gauge disc so that it is no longer within the
measuring range and readjust it again.
 Place the angle gauge on the pulley/vibration damper and position the disc to
10°.
 Turn the pulley/vibration damper until the arrows on the angle gauge are
exactly lined up together.
83. Align the CKP sensor bracket (shown on an engine that has been
removed).
 Insert the special tool into the CKP sensor bracket and the flywheel bore hole.
 Tighten the CKP sensor bracket bolts and remove the special tool.

84. Check the alignment of the CKP sensor.

 Position the crankshaft to 10° after TDC of the first cylinder, as described in
steps.
NOTE: If it is not possible to insert the special tool into the flywheel
bore hole, repeat the adjustment procedure as described in steps and .
Check the alignment again.
 The special tool must be able to be inserted in the flywheel.
85. Install the CKP sensor.

86. Fit the injection pump belt pulley.

87. NOTICE: Position the alternator and screw in the bolts finger tight. First
tighten the bolt on the pulley side, then the rear upper long bolt and finally the
rear lower short bolt.
Install the alternator (shown with the air conditioning compressor).
1. Tighten the alternator bolts in accordance with the tightening sequence.
2. Fit the belt tensioner.
 Tension the drive belt. For additional information, refer to Section  303-05
Accessory Drive.

88. NOTE: Before installing the oil pump, add approx. 10 cc of engine oil to the
rotor chamber and lubricate the oil pump drive gear and driven gear with
engine oil.
Install the oil pump with the oil filter.
 89. Detach the engine from the assembly stand.

Engine - 1.8L Endura-DE (Kent) Diesel -

Fiesta 1996 (08/1995-02/2002)
Cylinder Head
 Print 

Disassembly and Assembly of Subassemblies

Special Tool(s) / General Equipment
Universal flange holding wrench

15-030A

21-007 A Installer, valve stem seals

21-007 A Installer, valve stem seals

Valve spring compressor

21-024

Adaptor for 21-024

21-024-05

Installer, oil seal

21-110
 Installer, valve stem collets

21-156

Pliers, valve stem oil seals

21-165

Socket, injectors

23-045

Two-legged puller
Materials
Name
Specification
Sealer
SPM-4G-9112-F/G 
Hypoid oil
SQM-2C-9002-AA 
Engine Oil
ACEA A3/B3 
Valve stem installation sleeves
 

Disassembly
1. Remove the upper inlet manifold.
2. Remove the vacuum pump.

3. Remove the retaining plate with the fuel heater and remove the fuel filter.

4. Remove the exhaust gas recirculation valve (EGR valve).

 5. Remove the exhaust manifold.
 Remove the seal.

6. NOTE: Immobilise the timing belt pulley with the old timing belt.
Remove the timing belt pulley.
7. Remove the oil pressure switch.
8. Remove the bracket of the power steering pump.

9. Remove the injectors and glow plugs.

1. Injectors Remove the heat shields.
2. Glow plug wiring
3. Glow plugs
10. NOTE: Hold steady with Special Tool 15-030A.
Remove the flange bolt of the camshaft timing belt pulley.

11. Pull off the flange of the camshaft timing belt pulley using a proprietary
two-legged puller.
 Take out the Woodruff key.
12. NOTICE: Slacken the nuts of the remaining bearing caps evenly a turn at
a time.
Remove the camshaft.
1. Remove camshaft bearing caps nos. 2 and 4.
2. Slacken the nuts of the remaining camshaft bearing caps evenly a turn at a
time. Remove the bearing caps, bearing shells and camshaft with the oil seal
and put them down in order.
3. Remove the vacuum pump plunger.

13. NOTE: Put the valve tappets down in order.

Remove the valve tappets with the adjusting shims.
14. Detach the parts on the right-hand side of the cylinder head.
1. Coolant connector
2. Engine lifting eye
3. Coolant hose
4. Lower inlet manifold

15. Remove the valve springs.

 Lay the cylinder head on wooden blocks.
 Release the valves by tapping lightly with a brass drift on the ends of the
valve stems.
 (1).Compress the valve springs.
 (2).Remove the valve collets.
 Remove the valves, valve spring retainers and valve springs and put them
down in order.
16. Remove the valve stem seals.

17. Remove the swirl chambers.

 Assembly
1. Preparatory measures.
 Check all parts for wear.
 Thoroughly clean all reusable parts.
2. Renew the studs for the inlet and exhaust manifold.
3. Grind in the valves.
1. Valve collets
2. Valve spring retainer
3. Valve spring
4. Valve stem seal
5. Cylinder Head
6. Valve
4. Sectional view of valve.
5. Press the swirl chambers home.
6. NOTICE: Cover the grooves on the valve stems with the installation
sleeves.
NOTE: Remove the installation sleeves after fitting the valve stem seals.
Lubricate the new valve stem seals with engine oil and fit them.

7. Fit the valve springs with the valve spring retainers.

1. Compress the valve springs using the installer.
2. Insert the valve collets in the grooves in the valve stem.
8. NOTE: Tightening sequence.
Fit the inlet manifold with a new gasket.

9. Fit the parts on the right-hand side of the cylinder head.

1. Coolant connector
2. Engine lifting eye
3. Coolant hose
10. NOTE: The lettering on the adjusting shims faces downwards.
NOTE: Installation order.
Install the valve tappets.
 Coat the valve tappets and adjusting shims with engine oil and fit them.

11. Lay the camshaft bearing shell lower halves in place and coat them with
engine oil.
 Fit the camshaft and turn it until the groove in the eccentric on the camshaft
is parallel with the upper edge of the cylinder head (with the larger semi-
circle at the top).
 12. Align the camshaft.
13. Put the camshaft bearing upper shell halves in place and coat them with
engine oil.

14. Apply sealer (SPM-4G-9112-F/G) to bearing cap no. 1 in the areas

indicated.
15. NOTE: The arrows on the camshaft bearing caps point towards the front.
NOTE: The camshaft bearing caps must lie flat.
Install the camshaft.
 Place camshaft bearing caps nos. 1, 3 and 5 in installation position and screw
on the nuts.
NOTE: Tightening sequence.
 Tighten the nuts.
 16. Fit the vacuum pump plunger.
17. NOTE: Tightening sequence.
Tighten the nuts of the camshaft bearing caps.

18. NOTE: Coat the camshaft taper and the sealing lip of the new oil seal with
engine oil.
Fit the camshaft oil seal.
19. NOTE: Hold steady with Special Tool 15-030A.
Fit the flange of the camshaft timing belt pulley. Insert the Woodruff key.
1. Fit the flange.
2. Draw the flange on with the bolt and tighten the bolt.

20. NOTE: Fit the new injector heat shields.

Fit the glow plugs and injectors.
1. Glow plugs
2. Glow plug wiring
3. Injectors
 21. Fit the power steering pump bracket.

22. NOTE: Immobilise the timing belt pulley using the old timing belt.
Fit the timing belt rear cover.
Fit the timing belt pulley.
 23. Fit the oil pressure switch.
24. NOTE: Tightening sequence.
NOTE: Plastic sleeve on the right-hand upper stud (no. 7).
Fit the exhaust manifold with a new gasket.

25. Fit the EGR valve.

1. Tighten the bolts.
2. Tighten the retaining clip bolt.
26. Install the retaining plate with the fuel heater and the fuel filter.

27. Fit the vacuum pump.

28. Fit the upper inlet manifold.

Engine - 1.8L Endura-DI (Lynx) Diesel -
Fiesta 1996 (08/1995-02/2002)
Specifications
 Print 

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Ford Formula E SAE 5W-30 engine oil WSS-M2C913-A1
Coolant WSS-M97B44-D
Manual transmission fluid WSD-M2C200-C
Power steering hydraulic fluid WSA-M2C195-A
Sealer — oil pan to ladder frame WSE-M4G323-A6
Sealer — ladder frame to cylinder block Hylomar SPM-4G9112-H
Sealer — camshaft bearing cap no. 1 WSK-M2G348-A5
Sealer — injection pump pulley WSK-M2G348-A5
Engine data — 75 PS

Description
Code RTQ/RTN
Firing order 1-3-4-2
Bore diameter 82.5 mm
Stroke 82 mm
Displacement 1753 cc
Compression ratio 19.4 : 1
Power output at 4000 rpm 55 kW (75 PS)
Torque at 1900 rpm 140 Nm
Idle speed 800 rpm
Engine Oil Capacity

Description Liters
Initial fill including oil filter 6.1
Service fill including oil filter 5.6
Service fill excluding oil filter 5.0
Cylinder Block Dimensions

Description mm
Cylinder bore diameter — Class 1 82.500-82.515
Cylinder bore diameter — Class 2 82.515-82.530
Main bearing parent bore diameter 57.683-57.696
Piston Dimensions

Description mm
Piston diameter — Class 1 82.410-82.425
Piston diameter — Class 2 82.425-82.440
Piston ring end gaps
— upper compression ring 0.310-0.500
— lower compression ring 0.310-0.500
— oil control ring 0.250-0.580
Piston ring gap position: The piston ring gaps must be distributed evenly
around the circumference of the piston. This also applies to the oil control ring
elements. Align the piston ring gaps at 120 degrees to each other.

Crankshaft Dimensions

Description mm
Main bearing journal end float 0.110-0.370
Main bearing journal diameter 53.970-53.990
Connecting rod bearing journal diameter 48.970-48.990
Connecting Rod Dimensions

Description mm
Large end bore diameter 52.000-52.020
Small end bore diameter 26.012-26.020
Connecting rod bearing radial clearance 0.016-0.074
Piston Pin Dimensions

Description mm
Piston pin diameter 27.996-28.000
Camshaft Dimensions

Description mm
Camshaft end float 0.100-0.240
Camshaft bearing journal diameter 27.960-27.980
Cylinder Head Dimensions

Description mm
Valve guide inner diameter 8.000-8.025
Camshaft bearing parent bore diameter 30.500-30.525
Maximum distortion — measured longitudinally and diagonally 0.600
Oil Pressure Specifications

Description bar
Minimum oil pressure at idle speed 0.75
Minimum oil pressure at 2000 rpm 1.50
Torque Specifications — 75 PS

Description Nm lb-ft lb-in

Lower arm ball joint retaining nuts 83 61 -
 Description Nm lb-ft lb-in
Tie-rod end retaining nuts 26 19 -
Stabilizer bar retaining nuts 47 35 -
Halfshaft center bearing cap retaining nut 27 20 -
Halfshaft center bearing bracket to cylinder block 48 35 -
Engine front mount retaining nuts 83 61 -
Engine front mount to body 83 61 -
Wiring loom retaining bracket to transaxle 12 9 -
Engine support insulator retaining bracket to subframe 48 35 -
Engine support insulator center retaining bolt 120 89 -
Engine support insulator retaining bracket to transaxle 84 62 -
Radiator support bracket retaining bolts 10 - 89
Water pump retaining bolts (M8) 23 17 -
Water pump retaining bolts (M6) 10 - 89
Vacuum line bracket to thermostat housing 9 - 80
Air conditioning (A/C) compressor to retaining bracket 25 18 -
Charge air cooler retaining bolts 5 - 44
Turbocharger retaining bracket to cylinder block 24 18 -
Power steering pipe retaining bracket to body 10 - 89
Power steering pump to retaining bracket 24 18 -
Accessory drive belt tensioner retaining bolt 23 17 -
Accessory drive belt tensioner to power steering pump bracket 24 18 -
Engine mount bracket to cylinder block 47 35 -
Engine lifting eye to cylinder head 23 17 -
Exhaust manifold to catalytic converter 40 30 -
Catalytic converter to exhaust flexible pipe 40 30 -
Catalytic converter support bracket retaining bolts 24 18 -
Vacuum line to brake booster vacuum pump 18 13 -
Brake booster vacuum pump to cylinder head 22 16 -
Transaxle retaining bolts 40 30 -
Starter motor retaining bolts 20 15 -
Starter motor retaining bracket 20 15 -
Power steering high pressure pipe to lifting eye 10 - 89
Fuel filter to bracket 23 17 -
Oil pressure switch to cylinder head 20 15 -
Oil drain plug 25 18 -
Oil intake pipe bracket to cylinder block 10 - 89
Oil pan retaining bolts 10 - 89
Oil level indicator tube retaining bolts 10 - 89
Crankshaft main bearing caps a - -
Connecting rod bearing cap retaining bolts a - -
Chain housing to cylinder block (M6) 10 - 89
Chain housing to cylinder block (M8) 23 17 -
Crankshaft rear oil seal carrier retaining bolts 20 15 -
Clutch disc pressure plate retaining bolts 30 22 -
Crankshaft position (CKP) sensor retaining bracket 10 - 89
Generator bracket to cylinder block 42 31 -
Generator to generator bracket (M8) 24 18 -
Generator to generator bracket (M10) 50 37 -
Tensioning pulley bracket to generator bracket 24 18 -
Bolt of generator tensioning pulley 24 18 -
Vacuum line bracket to cylinder head 22 16 -
Oil baffle retaining nuts 20 15 -
Camshaft bearing cap retaining nuts 20 15 -
 Description Nm lb-ft lb-in
Valve cover retaining bolts 5 - 44
Fuel injection pump to rear chain housing 20 15 -
Fuel injection pump retaining bracket 23 17 -
Fuel filter bracket to cylinder head 23 17 -
High pressure fuel-supply lines to fuel injectors 28 21 -
High pressure fuel-supply lines to fuel injection pump 28 21 -
Fuel injection pump pulley retaining bolts 42 31 -
Camshaft pulley retaining bolt 50 37 -
Timing belt tensioner to cylinder head 50 37 -
Blanking plug 24 18 -
Crankshaft pulley retaining bolt a - -
Turbocharger oil supply and return pipe retaining bolts 10 - 89
Catalytic converter retaining bracket 24 18 -
Timing belt cover retaining bolts 7 - 70
Coolant pipe bracket 25 18 -
Oil pump to cylinder block 23 17 -
Intake manifold to cylinder head 23 17 -
Exhaust manifold to cylinder head 24 18 -
Coolant expansion tank 10 - 89
Fender splash shield retaining bolts 11 8 -
Exhaust gas recirculation (EGR) pipe to intake manifold 20 15 -
Air cleaner bracket 23 17 -
Cylinder head long bolt a - -
Cylinder head short bolt a - -
Retainer for fuel injector 23 17 -
Cylinder head temperature (CHT) sensor 20 15 -
Glow plug 15 11 -
Glow plug power supply to glow plug 3 - 19
Timing belt rear cover 10 - 89
Injection pump oil seal carrier 10 - 89
Injection pump pulley 42 31 -
Engine mount to cylinder block 28 21 -
Studs to engine mounting bracket 13 10 -
Water pump pulley retaining bolts 23 17 -
Intake manifold retaining nuts and bolts 23 17 -
Intake manifold studs 10 - 89
Exhaust manifold studs 13 10 -
Turbocharger oil supply pipe retaining bracket to cylinder block 48 35 -
EGR cooler retaining bracket to block 23 17 -
EGR cooler flange to EGR valve 20 15 -
Thermostat housing to cylinder block 23 17 -
Water drain plug 9 - 80
Coolant hose retaining bracket to cylinder block 50 37 -
Flywheel retaining bolts a - -
Vehicle speed sensor (VSS) retaining bolt 10 - 89
Positive crankcase ventilation retaining bolt 23 17 -
Exhaust manifold retaining bracket 51 38 -
a) Refer to the procedure in this section

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Engine
 Print 
Description and Operation
The 55kW (75PS) diesel engine with direct injection is based on the familiar swirl
chamber diesel, but it has been brought up-to-date to the latest technology level.

This engine therefore complies with the stage II emissions standard and with all other
requirements made on new generation assemblies with regard to fuel consumption,
quiet running, flexibility and power output.

Crankshaft

The five main bearing crankshaft has thrust half rings on the third main bearing that
determine the crankshaft end float.

Crankshaft timing sprocket

The crankshaft timing sprocket drives the injection pump sprocket by means of a chain
drive. The crankshaft timing sprocket is held in position only by the clamping pressure
of the center bolt.

The crankshaft timing sprocket is located to ensure accurate positioning.

Timing belt drive

 

Item
Part Number
Description
1
-
Camshaft timing belt tensioner
2
-
Camshaft timing belt
3
-
Camshaft timing belt pulley
4
-
Injection pump timing belt pulley
The cambelt is driven by the injection pump timing pulley and transmits the valve
timing onto the overhead camshaft.

NOTICE: As a new timing belt has a strong settling effect when it is first installed,
the instructions for adjustment must be observed precisely.
The tension of the timing belt drive is maintained by an automatic timing belt tensioner.
The initial setting of the timing belt tension is carried out by the adjustment cam.

The camshaft timing pulley is retained on the camshaft by means of a taper. The
required frictional force is applied to the camshaft by a central bolt.

Valve tappet, adjusting shims

The camshaft timing is transmitted to the valve springs by eight bucket tappets.

NOTICE: The lettering must face the tappets when the adjusting shims are
installed.
Adjusting shims are available for adjusting the valve clearance. The thickness of these is
indicated on the underside.

Cylinder Head

Item
Part Number
Description
1
-
Guide sleeve hole
2
-
Identification of seal thickness
Cylinder head gaskets of various thicknesses are available. Dependent on the piston
projection, a certain thickness is assigned to the engine. This is indicated by
indentations on the cylinder head gasket.

NOTICE: Clean the gasket and sealing surfaces thoroughly. Do not use anything
sharp for cleaning.
The cylinder head gasket is an MLS (Multi Layered Steel) gasket. The gasket consists of
three steel layers. The steel layers are coated with rubber. Because of this design the
service life is increased, and because the gasket does not settle when installed, the
cylinder head bolts can be tightened with a lower clamping force. Because of this rubber
outer coating the gasket is easily grooved, and therefore must not be cleaned with
anything sharp.

Crankshaft oil seals

NOTE: The rear crankshaft oil seal is supplied with an oil seal carrier. It must be
aligned using the tool shown.
 NOTICE: If the support ring is removed too soon, the oil seal will be compressed
and made unusable.
The front and rear oil seals are made of PTFE and must be free from oil when installed.

Both oil seals are supplied with a support ring as a spare part. This may not be removed
until after assembly, or it may drop out of the oil seal of its own accord.

Crankcase ventilation

The crankcase ventilation valve is located on the top of the cylinder head cover. To
ensure optimal engine performance, this valve and all PCV hoses must be free of
contaminants at all times.

Oil Pan
The oil pan is made of steel. It is sealed with liquid, silicone based sealant (WSE-M4G-
323-A6).

NOTICE: Do not place a workshop jack under the oil pan to raise the engine when
removing the front engine mounting.
The oil pan will be pressed inwards if the engine is supported on a workshop jack. This
may cause the oil flow into the oil intake pipe to stop.

The oil drain plug has an O-ring seal, which can be used many times.

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Camshaft
 Print 

In-vehicle Repair
Materials
Name
Specification
Gasket Eliminator Sealant
WSK-M2G348-A5 

Removal
1. Remove the camshaft seal.
For additional information, refer to: Camshaft Seal (303-01E Engine - 1.8L
Endura-DI (Lynx) Diesel, In-vehicle Repair).
2. Check the valve clearances.
For additional information, refer to: Valve Clearance (303-01E, General
Procedures).

3. NOTICE: Loosen the nuts of camshaft bearing caps number one, three,
and five by one turn each until the camshaft is released.
NOTE: Keep the nuts and camshaft bearing caps in order.
Remove the camshaft.
4. NOTE: Keep the valve tappets and adjustment shims in order.
Remove the valve tappets and adjustment shims.

Installation
1. NOTE: Coat the valve tappets and adjustment shims with clean engine oil.
Install the valve tappets and adjustment shims.
2. NOTE: The larger semi-circle points upwards.
Install the camshaft.

3. NOTE: Coat the camshaft bearing caps with clean engine oil.
Install the camshaft bearing caps.
 Coat bearing cap number one with sealant on the marked surfaces.

4. Check the valve clearances.

For additional information, refer to: Valve Clearance (303-01E, General
Procedures).
 5. Install the camshaft seal.
For additional information, refer to: Camshaft Seal (303-01E Engine - 1.8L
Endura-DI (Lynx) Diesel, In-vehicle Repair).

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Cylinder Head
 Print 

In-vehicle Repair
Special Tool(s)
Engine Lifting Bracket

303-122 (21-068A)

Angle Gauge, Bolt Tightening

303-174 (21-540)

Removal
1. Standard preparatory measures.
 Make a note of the radio keycode.
 Make a note of the programmed radio stations.
2. Remove the camshaft.
For additional information, refer to Camshaft in this section.
3. Detach the connectors and the hoses.
1. Injection pump connector
2. Glow plug wiring
3. Coolant temperature sender connector.

4. Detach the connectors and the hoses.

1. Exhaust gas recirculation (EGR) valve vacuum hose.
2. Intake air temperature (IAT) sensor plug.
3. EGR valve electrical connector
4. Brake booster vacuum line
5. NOTICE: Escaping fuel. For additional information, refer to Section  100-
02 Jacking and Lifting.
Disconnect the fuel lines.

6. Detach the injector lines from the injection pump and injection nozzles.
7. Detach the oil separator.

8. Detach the turbocharger oil feed and return line.

9. Detach the heater coolant hoses.

10. Disconnect the coolant hoses from the thermostat housing.
11. Remove the thermostat housing.

12. Detach the catalytic converter from the exhaust manifold.

 13.Raise and support the vehicle. For additional information, refer to Section 
100-02 Jacking and Lifting.

14. NOTICE: If the flexible pipe is bent too sharply, damage may be caused
which can lead to failure of the component.
Protect the flexible pipe with a support sleeve or suitable splints.

15. Detach the rear of the exhaust pipe from the flexible pipe.
 Remove the seal.
 16. Using the special tool, detach the coolant hoses from the EGR cooler.

17. Lower the vehicle.

18. Lift the cylinder head out of the vehicle using the special tool.

Installation
1. NOTE: Install a new cylinder head gasket.
Using the special tool, position the cylinder head on the cylinder block.
2. NOTICE: Use new cylinder head bolts.
Tighten the cylinder head bolts.
 Tighten the cylinder head bolts in three stages following the tightening
sequence.
 1st stage: 20 Nm
 2nd stage: 54 Nm
 3rd stage: 90 Nm

3. NOTE: Do not retighten the cylinder head bolts.

Using the special tool, tighten the cylinder head bolts.
 4 th stage, short bolts: 70 degrees
 4 th stage, long bolts: 90 degrees
4. Raise the vehicle.
5. Using the special tool, attach the coolant hoses to the EGR cooler.

6. Attach the rear of the exhaust pipe to the flexible pipe.

7. Remove the support sleeve from the flexible exhaust pipe.
8. Lower the vehicle.
9. Install the catalytic converter on the exhaust pipe.

10. Attach the thermostat housing.

11. Connect the coolant hoses to the thermostat housing.

12. Install the heater coolant hoses.
13. Install the turbocharger oil feed and return line.

14. Attach the oil separator.

15. Install the injector lines at the injector pump and at the injectors.

16. Connect the fuel lines.

17. Connect the hoses and connectors.

1. Injection pump connector
2. Glow plug wiring
3. Coolant temperature sender connector.
 18. Install the connectors and hoses.
1. Exhaust gas recirculation EGR) valve vacuum hose.
2. Intake air temperature (IAT) sensor) plug.
3. EGR valve electrical connector
4. Brake booster vacuum line

19.Install the camshaft.

For additional information, refer to Camshaft in this section.
20. Standard finishing operations.
 Change the engine oil and the oil filter.
 Enter the radio keycode.
 Programme the pre-set radio stations.

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Engine
 Print 

Disassembly
Special Tool(s) / General Equipment
 Slide Hammer

205-047 (15-011)

Universal Flange Holding Wrench

205-072 (15-030A)

Locking Tool, Flywheel

303-393 (21-168)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435 (21-187)

303-435-06 (21-031B)

Adapter for 205-047

303-633 (21-227)

Remover, Camshaft Sprocket

303-651 (21-229)

Remover, Fuel Injection Pump Pulley

310-095 (23-067)

Scraper

NOTICE: Diesel fuel injection equipment is manufactured to very precise

tolerances and fine clearances. It is therefore essential that absolute cleanliness is
observed when working with these components. Always fit blanking plugs to any open
orifices or lines.
All vehicles
1. Using the special tool, attach the engine to the mounting stand.
 Attach the mounting bracket.
 Mount the engine on the mounting stand.
2. Drain the engine.
 Allow the oil to drain into a suitable container.
3. Detach the positive crankcase ventilation (PCV) housing.
 Detach the ventilation hoses.

4. Remove the high pressure fuel supply lines.

 Discard the high pressure fuel supply lines.
5. Remove the power steering pump lower retaining bolts.

6. Remove the power steering pump.

7. Remove the generator with driveshaft.

8. Detach the turbocharger oil supply and oil return lines.
 Discard the sealing washers.

9. Remove the oil filter.

 Discard the filter.
10. Remove the oil cooler.
 Discard the gasket.

11. Remove the generator bracket.

12. Remove the valve cover.

1. Remove the PCV hoses.
2. Remove the valve cover bolts.
Vehicles without charge air cooler
13. Remove the timing belt lower cover.

14. Remove the engine front mount bracket.

Vehicles with charge air cooler
15. Remove the timing belt cover.

16. Remove the engine front mount bracket.

All vehicles
17. Detension the timing belt.
 Loosen the timing belt tensioner bolt.
 18. Remove the timing belt.
 Discard the timing belt.
19. Remove the timing belt tensioner.

Engines with mechanical timing belt tensioner

20. Discard the timing belt tensioner.
All vehicles
21. Using the special tool, remove the camshaft pulley retaining bolt.
22. Using the special tool, remove the camshaft pulley.

23. Remove the fuel injection pump pulley bolts.

24. Using the special tool, remove the fuel injection pump pulley.
25. Remove the fuel injection pump oil seal retainer.
 Discard the seal.

26. Remove the timing belt rear cover.

 27. Remove the oil baffle.

28. Remove the fuel injectors.

 Discard the bolts.

29. NOTICE: Remove the cylinder head bolts in the sequence shown.
Remove the cylinder head.
 Discard the gasket.
30. Using the special tool, remove the water pump pulley.

31. Remove the water pump.

 Discard the gasket.
32. Using the special tool, remove the crankshaft pulley.
 Discard the bolt.

33. Remove the accessory drive belt idler.

34. Remove the timing chain housing cover.

 Discard the gasket.
35. Remove the timing chain tensioner.

36. Detach the fuel injection pump sprocket.

37. Remove the timing chain, sprockets and guides.

38. Remove the fuel injection pump bracket.

39. Remove the fuel injection pump.

 Discard the gasket.
40. Using the special tool, detach the upper coolant hose from the coolant
distribution pipe.

41. Remove the coolant distribution pipe.

42. NOTICE: Loosen the clutch pressure plate retaining bolts by two turns at a
time in the sequence shown.
Remove the clutch disc and pressure plate.

43. Using the special tool, remove the flywheel.

 Discard the bolts.

44. Remove the crankshaft position (CKP) sensor.

45. Remove the CKP sensor retaining bracket.

46. Remove the crankshaft rear oil seal retainer.

 Discard the retainer.
47. Remove the oil pan retaining nuts and bolts (16 bolts, two nuts).

48. Using the special tools, remove the oil pan.

49. Remove the oil pump connecting pipe.

 Discard the O-ring seals.
 50. Remove the oil pump pick-up tube.
 Discard the O-ring seal.

Vehicles with air conditioning

51. Remove the air conditioning (A/C) compressor retaining bracket.
All vehicles
52. Remove the ladder frame (14 bolts).
 Discard the gasket.

53. Remove the timing chain rear housing.

 Discard the gasket.

54. NOTICE:

Keep the connecting rod bearing caps in order for installation.

 Keep the connecting rod bearing shells and connecting rod bearing cap
shells in order for installation.
Remove the pistons.

55. NOTICE: Keep the main bearing lower and upper shells in order for
installation.
Remove the crankshaft.

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Cylinder Head
 Print 

Disassembly and Assembly of Subassemblies

Special Tool(s)
 Installer, Valve Stem Seal

303-037 (21-007A)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060 (21-024)

303-060-05 (21-024-05)

Installer, Camshaft Seal

303-199A (21-110 A)

Installer, Valve Stem Collets

303-362 (21-156)

Pliers, Valve Stem Seal

303-390 (21-165)

Socket, Cylinder Head Temperature Sensor

303-680 (21-239)

Materials
Name
Specification
Sealer
WSK-M2G348-A5 
Hypoid oil
SQM-2C-9022-AA 
Engine oil
WSS-M2C912-A1 

Disassembly
1. Remove the engine front lifting eye.
2. Remove the injector nozzles and detach the glow plug wiring.

3. Remove the glow plugs.

4. Remove the brake vacuum pump.

5. Using the special tool, remove the cylinder head temperature (CHT) sensor
and the oil pressure switch.
 Discard the CHT sensor.

6. Remove the oil pressure switch.

7. Detach the components on the right-hand side of the cylinder head.
1. Engine lifting eye.
2. Coolant connection.
 Coolant hose.

8. Remove the exhaust manifold upper retaining bolts.

 Remove the exhaust gas recirculation (EGR) flange bolts (2 bolts).

9. Remove the exhaust manifold lower retaining bolts.

10. NOTICE: Loosen the nuts on the camshaft bearing caps evenly a turn at a
time.
Remove the camshaft.
1. Remove camshaft bearing caps two and four.
2. Loosen the nuts on the other camshaft bearing caps evenly a turn at a time.
3. Remove the brake vacuum pump plunger.
 Remove the bearing caps, bearing shells and the camshaft with the oil seal.

11. NOTE: Position the valve tappets in order to one side for further reuse.
Remove the valve tappets and valve adjustment shims.
12. Loosen the valve collets.
 Position a socket on the valve spring seat and gently strike it with a hammer.
13. NOTE: Position the cylinder head on wooden blocks.
Using the special tools, remove the valve springs.
1. Using the special tools, compress the valve springs.
2. Using the special tool, remove the valve collets.
 Remove the valves, valve collets and the valve springs and position them in
order to one side.

14. Using the special tool, remove the valve seals.

 Assembly
1. Grind in the valves.

2. NOTICE: Protect the grooves on the valve stems with protective sleeves.
NOTE: Only remove the protective sleeves after the valve stem oil seals have
been installed.
Coat the new valve seals with engine oil and install them.

3. Coat the valves with hypoid oil and insert them.

4. Install the valve springs.
 Install the valve springs with the valve spring retainers.
 Using the special tool, compress the valve springs.
 Install the valve collets into the grooves on the valve stem.
5. NOTE: The lettering on the valve adjustment shims faces downwards.
NOTE: Coat the valve tappets and the valve adjustment shims with engine oil
before installation.
NOTE: Installation sequence.
Install the valve tappets.

6. Insert the camshaft lower half shells and coat them with engine oil.
7. Align the camshaft.
 Insert the camshaft and turn it until the groove on the eccentric cam is
parallel to the upper edge of the cylinder head (the larger semi-circle faces
upwards).
 8. Insert the camshaft upper half shells and coat them with engine oil.
9. Apply sealant to the bearing caps at the positions shown.

10. NOTE: The arrows on the camshaft bearing caps must point to the front of the
engine.
NOTE: Tighten the camshaft bearing caps evenly a turn at a time.
Install the camshaft.
1. Install the brake vacuum pump plunger.
2. Position camshaft bearing caps "1", "3" and "5" and tighten the nuts
fingertight.
3. Position the other camshaft bearing caps and tighten the nuts fingertight.
11. NOTE: Tighten the camshaft bearing caps evenly a turn at a time.
Tighten the camshaft bearing cap retaining nuts.

12. NOTE: Coat the camshaft taper and oil seal lip with engine oil.
Using the special tool, install the camshaft oil seal.
13. Install the intake manifold.

14. Tighten the exhaust manifold lower retaining bolts.

15. Tighten the exhaust manifold upper retaining bolts.

 Tighten the EGR flange bolts (2 bolts).
 16. Install the components on the right-hand side of the cylinder head.
1. Engine lifting eye.
2. Coolant connection.
 Coolant hose.

17. NOTICE: Install a new cylinder head temperature (CHT) sensor.

Install the CHT sensor.
18. Install the oil pressure switch.

19. Install the brake vacuum pump.

20. Install the glow plugs.

21. NOTE: Make sure that the fuel injectors are installed in their original position.
NOTE: Install new fuel injector to cylinder head sealing washers.
NOTE: Install new fuel injector retaining clamps.
NOTE: Install new fuel injector retaining clamps retaining bolts.
Install the fuel injectors and retaining clamps.
 Tighten the bolts in two stages.
 5 Nm
 90 degrees

22. Install the glow plug wiring harness.

 23. Install the engine front lifting eye.

Engine - 1.8L Endura-DI (Lynx) Diesel -

Fiesta 1996 (08/1995-02/2002)
Engine
 Print 

Assembly
Special Tool(s) / General Equipment
Universal Flange Holding Wrench

205-072 (15-030A)

Gauge, Bolt Angle

303-174 (21-540)

Timing Peg, Crankshaft TDC

303-193 (21-104)

Installer, Camshaft Seal

303-199A (21-110A)
 Alignment Plate, Camshaft

303-376 (21-162B)

Locking Tool, Flywheel

303-393 (21-168)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Aligner, Oil Pump

303-652 (21-230)

Aligner, Clutch Disc

308-204 (16-067)

Alignment Peg, Crankshaft Position Sensor bracket

310-057 (23-049)

Micrometer
Feeler gauges
Internal micrometer
Piston ring compressor
Dial indicator gauge holding fixture
Dial indicator gauge
Plastigage
Materials
Name
Specification
Sealant
WSE-M4G323-A4 
Sealant
WSK-M2G348-A5 
Engine oil SAE 5W 30
WSS-M2C912-A1 

Assembly
All vehicles
 NOTICE: Diesel fuel injection equipment is manufactured to very precise
tolerances and fine clearances. It is therefore essential that absolute cleanliness is
observed when working with these components. Always fit blanking plugs to any open
orifices or lines.
Coat the main bearing journals, bearing shells and thrust half washers with clean
engine oil.

NOTICE: Install the main bearing upper and lower shells in the correct order
Install the main bearing shells to the cylinder block and to the main bearing
caps.
Position the crankshaft in the cylinder block.
NOTE: The grooves in the thrust half washers must face outwards.
Install the crankshaft thrust half washers into the third main bearing with oil
grooves facing outwards.
NOTE: Install the main bearing caps with arrows pointing forward. Caps are
identified 1, 2, 3, 4, 5 from the front to the rear.
Install the crankshaft.
Tighten the bolts in three stages in the sequence shown.
Stage 1: Tighten the bolts 1 through 10 to 45 Nm.
Stage 2: Tighten the bolts 1 through 10 to 70 Nm.
Stage 3: Tighten the bolts 1 through 10 to 60 degrees.

Coat the cylinder bores with clean engine oil.

NOTE: Install the pistons with the arrows pointing to the front of the engine.
NOTE: The piston ring gaps and oil supply ring elements must be distributed
evenly around the circumference.
Using a suitable piston ring compressor, install the pistons.
Install clean and dry connecting rod bearing shells in the connecting rods.
 NOTICE: Connecting rod bearing cap bolts must only be used two times.
NOTE: Stamp the bolt heads with a center punch to indicate usage.
NOTE: The big-end bearing caps identification marks must point to the front of
the engine.
Install the connecting rod bearing caps.
Tighten the bolts in four stages.
Stage 1: Tighten the bolts finger tight.
Stage 2: 27 Nm.
Stage 3: 60 degrees.
Stage 4: 20 degrees.
After installation lubricate the journals with engine oil.

NOTE: Install a new timing chain rear housing gasket.

Install the timing chain rear housing.
 NOTE: Install a new ladder frame gasket.
Install the ladder frame (14 bolts).
Align the ladder frame flush with the cylinder block.
Tighten the bolts in the sequence shown.

Vehicles with air conditioning

Install the air conditioning (A/C) compressor retaining bracket.

All vehicles
NOTE: Install a new oil pump pickup tube O-ring seal.
Install the oil pump pick-up tube.
NOTE: Install new O-ring seals.
Install the oil pump connecting pipe.

NOTE: Do not damage the mating faces.

NOTE: The mating faces and blind holes must be free of oil and sealer residue.
Clean the mating faces of the oil pan and ladder frame.

NOTICE: Make sure that the sealer does not enter the ladder frame blind
holes. Failure to follow this instruction may result in damage to the engine
assembly.
NOTE: Install the oil pan within ten minutes of applying the sealer.
NOTE: Once the oil pan has contact with the ladder frame it must not be
removed.
Install the oil pan.
Apply a 2.5 mm diameter bead of sealant to the ladder frame (dotted line).
Tighten bolts and nuts in the sequence shown.
NOTE: Inspect the oil pan drain plug seal for damage. Install a new drain plug and
seal if required.
Install the drain plug.

NOTE: A new crankshaft rear oil seal carrier is supplied with an alignment sleeve
that must be removed following installation.
NOTE: Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at
this stage.
Install the crankshaft rear oil seal carrier.
Tighten the crankshaft rear oil seal carrier retaining bolts.
 Remove the crankshaft rear oil seal carrier alignment sleeve.

NOTE: Do not fully tighten the crankshaft position (CKP) sensor retaining bracket
bolts at this stage.
Install the CKP sensor retaining bracket.

NOTE: Install new flywheel bolts.

Using the special tool, install the flywheel.
Tighten the bolts in three stages in the sequence shown.
Stage 1: 18 Nm.
 Stage 2: 45 degrees.
Stage 3: 45 degrees.

Remove the special tool.

Using the special tool, centralize the clutch disc on the pressure plate.

NOTICE: Tighten the clutch pressure plate retaining bolts finger tight and
then by two turns at a time in the sequence shown to the specified torque.
Using the special tool, install the clutch disc and pressure plate.
Remove the special tool.
Using the special tool, install the CKP sensor retaining bracket.

Install the coolant distribution pipe.

 Using the special tool, attach the upper coolant hose to the coolant distribution
pipe.

NOTE: Install a new fuel injection pump gasket.

Install the fuel injection pump.

Install the fuel injection pump bracket.

 Install the timing chain, sprockets and guides.

NOTE: Do not tighten the fuel injection pump sprocket bolts at this stage.
Install the fuel injection pump sprocket.
Install the timing chain tensioner.

Using the special tool, install the timing chain housing cover.
Tighten the bolts in the sequence shown in three stages.
Bolts 1 to 5: 10 Nm
Bolt 6:23 Nm
Bolts 7 to 19: 10 Nm

Install the accessory drive belt idler.

Using the special tool, install the crankshaft pulley.
Tighten the bolt in two stages.
Stage 1: 100 Nm.
Stage 2: 180 degrees.

Install the special tool.

Remove the cylinder block blanking plug.
NOTE: Only turn the crankshaft in the normal direction of rotation.
Turn the crankshaft to top dead center (TDC).
Turn the crankshaft slowly until the crankshaft stops.
NOTE: Using a 6 mm drill bit, set the fuel injection pump to crankshaft TDC.
Install the fuel injection pump sprocket.

Remove the special tool.

NOTE: Only turn the crankshaft in the normal direction of rotation.

NOTE: Using a suitable marker, mark the crankshaft pulley to show TDC.
Turn the crankshaft 90 degrees.
NOTE: Install a new water pump gasket.
Install the water pump.

Using the special tool, install the water pump pulley.

 NOTICE: The thickness of the new cylinder head gasket must be the same as
that of the old one (hole/tooth marked).
NOTE: "TOP (OBEN)" mark.
Install a new cylinder head gasket.

NOTE: The turbocharger oil return hose must be attached when the cylinder head
is installed.
Install the cylinder head.
 NOTICE: Install new cylinder head bolts.
Install the cylinder head bolts.
Using the special tool, tighten the bolts in four stages in the sequence shown.
Stage 1: Tighten the bolts 1 through 10 to 20 Nm.
Stage 2: Tighten the bolts 1 through 10 to 54 Nm.
Stage 3: Tighten the bolts 1 through 10 to 90 degrees.
Stage 4: short bolts: 70 degrees, long bolts: 90 degrees.

NOTE: Make sure that new bolts are installed.

Install the fuel injectors.
Tighten the bolts in two stages.
Stage 1: 5 Nm
Stage 2: 90 degrees

Install the oil baffle.

 Install the timing belt rear cover.

NOTE: Install a new fuel injection pump oil seal retainer.

Install the fuel injection pump oil seal retainer.
Using sealant, seal the fuel injection pump pulley to the fuel injection pump
sprocket.
Apply sealant to the outer edge of the fuel injection pump pulley bolt holes.

Install the fuel injection pump pulley.

Using the special tool, install the camshaft oil seal.

NOTE: Do not fully tighten the camshaft pulley retaining bolt at this stage.
Install the camshaft pulley retaining bolt.

Install the special tool.

 Install the special tool.

NOTE: Only turn the crankshaft in the normal direction of rotation.

Turn the crankshaft to top dead center (TDC).
Turn the crankshaft slowly until the crankshaft stops.
NOTICE:

Make sure that the crankshaft does not rotate during installation of the
special tool.

Make sure the crankshaft is at the TDC position before locking the special
tool.

Make sure that the special tool engages correctly.

Using the special tool, lock the crankshaft in position.
 NOTE: Use only latest level timing belts. These are identified by a laser etched
Ford logo.
Check the timing belt.

Engines with mechanical timing belt tensioner

Install a new automatic timing belt tensioner.
All vehicles
Check the timing belt tensioner.
Make sure that the tensioner pointer rotates clockwise freely.
Arrow denotes counterclockwise rotation of tensioner.
 Rotate the timing belt tensioner adjustment arm clockwise to the 3 o'clock
position.
NOTE: Do not fully tighten the timing belt tensioner retaining bolt at this stage.
Install the timing belt tensioner.

NOTICE:

Never install a used timing belt.

Install the timing belt with the direction arrows in the direction of
crankshaft rotation.
NOTE: Install a new timing belt.
Install the timing belt.
NOTE: The camshaft pulley must be able to turn freely on the camshaft taper.
Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.
NOTE: Using an Allen key, maintain the tension on the timing belt until the timing
belt tensioner bolt is tightened.
Tension the timing belt.
Turn the timing belt tensioner adjustment arm counterclockwise to tension the
timing belt slightly.
The pointer must be positioned between the sides of the window.
Tighten the timing belt tensioner retaining bolt.

Using the special tool, tighten the camshaft pulley retaining bolt.
Remove the special tool.

Remove the special tool.

Remove the special tool.

NOTE: Only turn the crankshaft in the normal direction of rotation.
Turn the crankshaft six revolutions.

Install the special tool.

NOTE: Only turn the crankshaft in the normal direction of rotation.

Turn the crankshaft to TDC.
Turn the crankshaft slowly until the crankshaft stops.
NOTICE:
 Make sure that the crankshaft does not rotate during installation of the
special tool.

Make sure the crankshaft is in TDC position before locking the special tool.

Make sure that the special tool engages correctly.

Using the special tool, lock the crankshaft in position.

NOTICE: If the pointer is not visible in the timing belt tensioner window, the
timing belt tensioning steps must be repeated.
Check that the timing belt tensioner pointer is positioned in the window.

NOTICE: If the special tool cannot be installed, the timing belt tensioning
steps must be repeated.
Install the special tool.
If the special tool cannot be installed, repeat procedure in previous steps.
Vehicles with charge air cooler
Install the engine front mount bracket.

Install the timing belt cover.

Vehicles without charge air cooler
Install the engine front mount bracket.

Install the timing belt lower cover.

All vehicles
NOTE: Install a new valve cover gasket if necessary.
Install the valve cover.
Lubricate the valve cover gasket with engine oil before installation.
 Install the generator bracket.

NOTE: Install a new oil cooler gasket.

Install the oil cooler.
NOTE: Install a new oil filter.
Install the oil filter.

NOTE: Install new turbocharger oil supply line O-ring seals.

Install the turbocharger oil supply line.

NOTE: Install a new turbocharger oil supply line O-ring seal.

Attach the turbocharger oil supply line to the turbocharger.
 Install the generator and drive shaft.

NOTE: Install new high pressure fuel supply lines.

Install the high pressure fuel supply lines.
NOTE: Secure the oil separator to the engine lifting eye. Tighten the engine lifting
eye and then tighten the oil separator.
NOTE: Install the clip at a 45 degree angle to the horizontal.
Attach the crankcase ventilation oil separator.

Fill the engine with engine oil.

Remove the special tool.