Engine Mechanical - 1.6L: Component Locations Ford Fiesta Mk6

Special Tool(s)

SPECIAL TOOLS CHART Alignment Plate, Camshafts 303-376B Crankshaft TDC Pin 303-748 Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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SPECIAL TOOLS CHART Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Replacer, Front Crankshaft Seal 303-420 (T92P-6701-BH) Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A)

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SPECIAL TOOLS CHART Alignment Plate, Camshaft 303-376B Timing Peg, Crankshaft TDC 303-748

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SPECIAL TOOLS CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1418

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SPECIAL TOOLS CHART Engine Support Bar 303-F072 Lifting Bracket, Engine 303-050 (T70P-6000)

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SPECIAL TOOLS CHART Heavy Duty Floor Crane 014-00071 or equivalent

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ITEM DESCRIPTION

SPECIAL TOOLS CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-382368) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
3. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-382417) .
4. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-382392) .
5. Remove the nut and cable from the positive battery cable terminal.
6. Remove the 2 bolts and the accessory drive belt splash shield.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-382413) .
8. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-382413) .
9. Remove the bolt and the PCM cover.
10. Disconnect the 3 PCM electrical connectors.
11. Remove the 3 bolts and the battery tray.
12. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.
13. Remove the selector lever cable bracket bolt, 3 battery tray nuts and the battery tray bracket.
14. Disconnect the selector lever cable from the control lever.
15. Detach the wiring harness retainer from the selector lever cable bracket.
16. Remove the 2 selector lever cable bracket bolts from the transaxle and position the selector lever cable and bracket aside.
17. Disconnect the engine harness electrical connector.
18. Disconnect the brake booster vacuum hose.
19. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
20. Detach the fuel tube from the ignition coil bracket retainer.
21. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(ref-382376) .
22. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-382413) .
23. Disconnect the lower heater hose from the heater core.
24. Detach the coolant hose retainer from the ignition coil bracket.
25. Disconnect the 2 coolant hose from the engine oil cooler.
26. Disconnect the upper radiator hose from the engine.
27. Disconnect the lower radiator hose and coolant hose from the thermostat housing.
28. Remove the bolt and position the engine ground wire aside.
29. Remove the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-382394) .
30. Remove the 3 bolts and the halfshaft bracket.
31. Disconnect the A/C compressor electrical connector.
32. Remove the nut and position the A/C line bracket aside.
33. Disconnect the A/C pressure transducer electrical connector. Detach the wiring harness retainer.
34. Detach the wiring harness retainer from the lower A/C compressor bracket.
35. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of mechanic's wire.
36. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-382375) .
37. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
38. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
39. Remove the 2 bolts and the transaxle roll restrictor.
40. NOTE: The engine mount studs must be held while removing the engine mount nuts or damage to the powertrain may occur. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned. Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount nuts.
41. Remove the 3 bolts and the engine mount.
42. Remove the 2 bolt, 2 nuts and the transaxle support insulator.
43. Lower the engine and transaxle assembly from the vehicle.
44. Detach the 2 wiring harness retainers from the ignition coil bracket.
45. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
46. Detach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer from the bracket.
47. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.
48. Detach and disconnect the LH Knock Sensor (KS) electrical connector.
49. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the 2 wiring harness retainers.
50. Disconnect the 4 fuel injector electrical connectors.
51. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
52. Disconnect the Throttle Body (TB) electrical connector. Detach the 2 wiring harness retainers from the TB .
53. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
54. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. Detach the wiring harness retainer from the engine block.
55. Disconnect the RH KS electrical connector. Detach the 2 wiring harness retainers from the intake manifold.
56. Remove the 2 nuts and disconnect the starter motor electrical terminals.
57. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts and bracket.
58. Remove the 3 bolts (2 shown in illustration) and the starter motor.
59. Remove the clutch nut access cover.
60. NOTE: Rotate the engine in a clockwise direction only or engine damage may occur. NOTE: Mark one stud and the flexplate for installation reference. Remove the 6 flexplate-to-clutch nuts and discard.
61. NOTE: Lower the engine to within a few inches of the floor. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle assembly from the lift table.
62. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.

SPECIAL TOOLS CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-382368) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
3. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-382417) .
4. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-382392) .
5. Remove the nut and cable from the positive battery cable terminal.
6. Remove the 2 bolts and the accessory drive belt splash shield.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-382413) .
8. Remove the degas bottle. For additional Information, refer to «ENGINE COOLING»(ref-382413) .
9. Remove the bolt and the PCM cover.
10. Disconnect the 3 PCM electrical connectors.
11. Remove the 3 bolts and the battery tray.
12. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.
13. Remove the 3 battery tray nuts and the battery tray bracket.
14. Release the 7 retainers (2 shown in illustration) and remove the gearshift cable cover.
15. Remove the gearshift cables. Using a suitable tool, lightly pry the gearshift cables off the transaxle shift control levers. Remove the gearshift cable by pulling the lower part of abutment down and removing from the brackets.
16. Disconnect the engine harness electrical connector.
17. Disconnect the brake booster vacuum hose.
18. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
19. Detach the fuel tube from the ignition coil bracket retainer.
20. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(ref-382376) .
21. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-382413) .
22. Disconnect the lower heater hose from the heater core.
23. Detach the coolant hose retainer from the ignition coil bracket.
24. Disconnect the 2 coolant hose from the engine oil cooler.
25. Disconnect the upper radiator hose from the engine.
26. Disconnect the lower radiator hose and coolant hose from the thermostat housing.
27. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. Remove the clip and disconnect the clutch hydraulic hose.
28. Detach the clutch hydraulic hose from the transaxle retainer.
29. Remove the bolt and position the engine ground wire aside.
30. Remove the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-382394) .
31. Remove the 3 bolts and the halfshaft bracket.
32. Disconnect the A/C compressor electrical connector.
33. Remove the nut and position the A/C line bracket aside.
34. Disconnect the A/C pressure transducer electrical connector. Detach the wiring harness retainer.
35. Detach the wiring harness retainer from the lower A/C compressor bracket.
36. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of mechanic's wire.
37. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-382375) .
38. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
39. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.
40. Remove the 2 bolts and the transaxle roll restrictor.
41. NOTE: The engine mount studs must be held while removing the engine mount nuts or damage to the powertrain may occur. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned. Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount nuts.
42. Remove the 3 bolts and the engine mount.
43. Remove the 2 bolt, 2 nuts and the transaxle support insulator.
44. Lower the engine and transaxle assembly from the vehicle.
45. Detach the 2 wiring harness retainers from the ignition coil bracket.
46. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
47. Detach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer from the bracket.
48. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.
49. Detach and disconnect the LH Knock Sensor (KS) electrical connector.
50. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the 2 wiring harness retainers.
51. Disconnect the 4 fuel injector electrical connectors.
52. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
53. Disconnect the Throttle Body (TB) electrical connector. Detach the 2 wiring harness retainers from the TB .
54. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
55. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. Detach the wiring harness retainer from the engine block.
56. Disconnect the RH KS electrical connector. Detach the 2 wiring harness retainers from the intake manifold.
57. Remove the 2 nuts and disconnect the starter motor electrical terminals.
58. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts and bracket.
59. Remove the 3 bolts (2 shown in illustration) and the starter motor.
60. NOTE: Lower the engine to within a few inches of the floor. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle assembly from the lift table.
61. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.

SPECIAL TOOLS CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

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SPECIAL TOOLS CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent

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