Engine Mechanical - 1.6L: Other Ford Fiesta Mk6

Material

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Engine Code Information Label

The engine code information label, located on the front side of the timing cover, contains the following

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ITEM DESCRIPTION

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Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the ENGINE EMISSION CONTROL .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the cylinder head.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

Twin Independent Variable Camshaft Timing (VCT) System

The twin independent VCT system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Timing Drive Components

SPECIAL TOOLS Tool, Variable Camshaft Timing (VCT) Alignment 303-1097 Alignment Plate, Camshaft 303-376B

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MATERIAL SPECIFICATIONS

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ITEM DESCRIPTION

Oil Pan, Oil Pump and Oil Pump Screen and Pickup Tube

Note. Automatic transaxle shown in illustration, manual transaxle similar.

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ITEM DESCRIPTION

1. Refer to the procedures and/or exploded views in this information for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

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ITEM DESCRIPTION

MATERIAL SPECIFICATIONS

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. For additional information, refer to the exploded view under the Assembly procedure in this information.

1. Refer to appropriate graphic for further information. Items in the exploded views may not be listed in order of removal. see scheme 151or see scheme 153.

Note. In order to ensure the most accurate information, some procedural and pinpoint test steps may be under development and not immediately available at vehicle introduction.

MATERIAL SPECIFICATIONS

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

1. see scheme 153 Items in the exploded views may not be listed in order of removal.

Note. In order to ensure the most accurate information, some procedural and pinpoint test steps may be under development and not immediately available at vehicle introduction.

MATERIAL SPECIFICATIONS

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1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 engine-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
2. Using the Heavy Duty Floor Crane Spreader Bar, raise the engine and transaxle assembly onto the lift table.
3. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
4. NOTE: Rotate the engine in a clockwise direction only or engine damage will occur. NOTE: Tighten the flexplate-to-clutch nuts in a star pattern or transaxle damage can occur. NOTE: Using a magnetic socket will help ensure ease of installation. If the nuts are dropped in the clutch housing, the transaxle will have to be removed to retrieve them. Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages. Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in). Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).
5. Install the flexplate-to-clutch nut access cover.
6. Install the starter motor and the 3 bolts (2 shown in illustration). Install the 3 bolts finger-tight. Tighten the 2 upper bolts to 48 Nm (35 lb-ft). Tighten the lower bolt to 48 Nm (35 lb-ft).
7. Install the 2 upper bellhousing-to-engine bolts and bracket. Tighten to 48 Nm (35 lb-ft). Attach the wiring harness pin-type retainer to the bracket.
8. Connect the starter motor electrical terminals and install the 2 nuts. Tighten to 10 Nm (89 lb-in).
9. Connect the RH Knock Sensor (KS) electrical connector. Attach the 2 wiring harness retainers to the intake manifold.
10. Connect the Engine Oil Pressure (EOP) switch electrical connector. Attach the wiring harness retainer to the engine block.
11. Connect the Crankshaft Position (CKP) sensor electrical connector.
12. Connect the Throttle Body (TB) electrical connector. Attach the 2 wiring harness retainers to the TB .
13. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
14. Connect the 4 fuel injector electrical connectors.
15. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 2 wiring harness retainers.
16. Connect the LH KS electrical connector.
17. Connect the 2 Camshaft Position (CMP) sensor electrical connectors.
18. Attach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer to the bracket.
19. Connect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
20. Attach the 2 wiring harness retainers to the ignition coil bracket.
21. NOTE: The engine mount studs must be torqued or damage to the powertrain may occur. Torque the engine mount studs before installing the engine mount nuts. Tighten to 8 Nm (71 lb-in).
22. Using the lift table, position the engine and transaxle assembly in the vehicle.
23. Tighten the 2 nuts and 2 bolts. Tighten the 2 nuts to 125 Nm (92 lb-ft). Tighten the 2 bolts to 90 Nm (66 lb-ft).
24. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned. Install the engine mount and the 2 nuts. Tighten the 2 nuts to 80 Nm (59 lb-ft).
25. Lower the powertrain to the installed position.
26. Install the 3 engine mount bolts. Tighten to 48 Nm (35 lb-ft).
27. Install the transaxle roll restrictor and the 2 bolts and tighten in sequence shown in illustration. Tighten to 70 Nm (52 lb-ft). Tighten to 70 Nm (52 lb-ft).
28. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-382375) .
29. Position the A/C compressor and install the 2 bolts and stud bolt. Tighten to 25 Nm (18 lb-ft).
30. Attach the wiring harness retainer to the lower A/C compressor bracket.
31. Connect the A/C pressure transducer electrical connector. Attach the wiring harness retainer.
32. Position the A/C line bracket and install the nut. Tighten to 9 Nm (80 lb-in).
33. Connect the A/C compressor electrical connector.
34. Install the halfshaft bracket and the 3 bolts and tighten in sequence shown in illustration. Tighten the top bolt to 48 Nm (35 lb-ft). Tighten the 2 bottom bolts to 24 Nm (18 lb-ft).
35. Install the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-382394) .
36. Position the engine ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
37. Install the accessory drive belt splash shield and the 2 bolts. Tighten to 9 Nm (80 lb-in).
38. Connect the lower radiator hose and coolant hose to the thermostat housing.
39. Connect the upper radiator hose to the engine.
40. Connect the 2 coolant hose to the engine oil cooler.
41. Attach the coolant hose retainer to the ignition coil bracket.
42. Connect the lower heater hose to the heater core.
43. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-382413) .
44. Install the generator. For additional information, refer to «CHARGING SYSTEM»(ref-382376) .
45. Attach the fuel tube to the ignition coil bracket retainer.
46. Connect the fuel tube spring lock couplings to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
47. Connect the brake booster vacuum hose.
48. Connect the engine harness electrical connector.
49. Position the selector lever cable and bracket and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
50. Attach the wiring harness retainer to the selector lever cable bracket.
51. Connect the selector lever cable to the control lever.
52. Install the battery tray bracket, 3 battery tray nuts and the selector lever cable bracket bolt. Tighten nuts and bolt to 10 Nm (89 lb-in).
53. Attach the 2 positive battery cable wire harness retainers to battery tray bracket.
54. Install the battery tray and the 3 bolts. Tighten to 10 Nm (89 lb-in).
55. Connect the 3 PCM electrical connectors.
56. Install the PCM cover and the bolt. Tighten to 6 Nm (53 lb-in).
57. Connect the cable and nut to the positive battery cable terminal. Tighten to 10 Nm (89 lb-in).
58. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-382392) .
59. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-382417) .
60. Fill the engine with clean engine oil.
61. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-382413) .
62. Fill the and bleed cooling system. For additional information, refer to «ENGINE COOLING»(ref-382413) .
63. Check the transmission fluid level. For additional information, refer to «AUTOMATIC SHIFTING MANUAL TRANSMISSION/TRANSAXLE»(ref-382366) .

MATERIAL SPECIFICATIONS

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1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 engine-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
2. Using the Heavy Duty Floor Crane Spreader Bar, raise the engine and transaxle assembly onto the lift table.
3. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
4. Install the starter motor and the 3 bolts (2 shown in illustration). Install the 3 bolts finger-tight. Tighten the 2 upper bolts to 48 Nm (35 lb-ft). Tighten the lower bolt to 48 Nm (35 lb-ft).
5. Install the 2 upper bellhousing-to-engine bolts and bracket. Tighten to 48 Nm (35 lb-ft). Attach the wiring harness pin-type retainer to the bracket.
6. Connect the starter motor electrical terminals and install the 2 nuts. Tighten to 10 Nm (89 lb-in).
7. Connect the RH Knock Sensor (KS) electrical connector. Attach the 2 wiring harness retainers to the intake manifold.
8. Connect the Engine Oil Pressure (EOP) switch electrical connector. Attach the wiring harness retainer to the engine block.
9. Connect the Crankshaft Position (CKP) sensor electrical connector.
10. Connect the Throttle Body (TB) electrical connector. Attach the 2 wiring harness retainers to the TB .
11. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
12. Connect the 4 fuel injector electrical connectors.
13. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 2 wiring harness retainers.
14. Connect the LH KS electrical connector.
15. Connect the 2 Camshaft Position (CMP) sensor electrical connectors.
16. Attach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer to the bracket.
17. Connect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
18. Attach the 2 wiring harness retainers to the ignition coil bracket.
19. NOTE: The engine mount studs must be torqued or damage to the powertrain may occur. Torque the engine mount studs before installing the engine mount nuts. Tighten to 8 Nm (71 lb-in).
20. Using the lift table, position the engine and transaxle assembly in the vehicle.
21. Tighten the 2 nuts and 2 bolts. Tighten the 2 nuts to 125 Nm (92 lb-ft). Tighten the 2 bolts to 90 Nm (66 lb-ft).
22. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned. Install the engine mount and the 2 nuts. Tighten the 2 nuts to 80 Nm (59 lb-ft).
23. Lower the powertrain to the installed position.
24. Install the 3 engine mount bolts. Tighten to 48 Nm (35 lb-ft).
25. Install the transaxle roll restrictor and the 2 bolts and tighten in sequence shown in illustration. Tighten to 70 Nm (52 lb-ft). Tighten to 70 Nm (52 lb-ft).
26. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-382375) .
27. Position the A/C compressor and install the 2 bolts and stud bolt. Tighten to 25 Nm (18 lb-ft).
28. Attach the wiring harness retainer to the lower A/C compressor bracket.
29. Connect the A/C pressure transducer electrical connector. Attach the wiring harness retainer.
30. Position the A/C line bracket and install the nut. Tighten to 9 Nm (80 lb-in).
31. Connect the A/C compressor electrical connector.
32. Install the halfshaft bracket and the 3 bolts and tighten in sequence shown in illustration. Tighten the top bolt to 48 Nm (35 lb-ft). Tighten the 2 bottom bolts to 24 Nm (18 lb-ft).
33. Install the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-382394) .
34. Position the engine ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
35. Install the accessory drive belt splash shield and the 2 bolts. Tighten to 9 Nm (80 lb-in).
36. Attach the clutch hydraulic hose to the transaxle retainer.
37. 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. Connect the clutch hydraulic hose and install the clip.
38. Connect the lower radiator hose and coolant hose to the thermostat housing.
39. Connect the upper radiator hose to the engine.
40. Connect the 2 coolant hose to the engine oil cooler.
41. Attach the coolant hose retainer to the ignition coil bracket.
42. Connect the lower heater hose to the heater core.
43. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING»(ref-382413) .
44. Install the generator. For additional information, refer to «CHARGING SYSTEM»(ref-382376) .
45. Attach the fuel tube to the ignition coil bracket retainer.
46. Connect the fuel tube spring lock couplings to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-382416) .
47. Connect the brake booster vacuum hose.
48. Connect the engine harness electrical connector.
49. Install the gearshift cables. Attach the gearshift cables to the transaxle gearshift control levers. Install the gearshift cable by pulling the lower part of abutment down and installing them in the brackets.
50. Install the battery tray bracket and the 3 battery tray nuts. Tighten nuts and bolt to 10 Nm (89 lb-in).
51. Attach the 2 positive battery cable wire harness retainers to battery tray bracket.
52. Install the battery tray and the 3 bolts. Tighten to 10 Nm (89 lb-in).
53. Connect the 3 PCM electrical connectors.
54. Install the PCM cover and the bolt. Tighten to 6 Nm (53 lb-in).
55. Connect the cable and nut to the positive battery cable terminal. Tighten to 10 Nm (89 lb-in).
56. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-382392) .
57. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-382417) .
58. Fill the engine with clean engine oil.
59. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-382413) .
60. Fill the and bleed cooling system. For additional information, refer to «ENGINE COOLING»(ref-382413) .
61. NOTE: Before removing, clean the area around the fill plug. Remove the fill plug and using a suitable oil suction gun, fill the transaxle with manual transmission fluid until fluid level is 0.0-5.0 mm (0.0-0.2 in) below the lower edge of the fill hole. Install the fill plug and tighten to 35 Nm (26 lb-ft).
62. Adjust the gearshift cables. For additional information, refer to «MANUAL TRANSMISSION - GENERAL INFORMATION»(ref-382367) .
63. Install the gearshift cable cover and attach the 7 retainers (2 shown in illustration).
64. Bleed the clutch hydraulic system. For additional information, refer to «MANUAL TRANSMISSION - GENERAL INFORMATION»(ref-382367) .