Engine Mechanical - 1.6L: Removal & Installation Ford Fiesta Mk6

Removal

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. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

1. see scheme 6 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.

Scheme 1

1. Install the valve cover and tighten in sequence shown in illustration. Tighten to 10 Nm (89 lb-in).

Scheme 2

ITEM DESCRIPTION

Removal and Installation

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.

1. (Scheme 2) 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.

1. (Scheme 2) 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.

Scheme 3

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.

1. see scheme 9 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.

Scheme 4

1. Align the flexplate and crankshaft using the dowel pin location hole. Install the bolts and tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 80 degrees.

1. see scheme 9 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.

Scheme 5

1. Align the flywheel and crankshaft using the dowel pin location hole. Install the bolts and tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 80 degrees.

1. see scheme 11 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.

Scheme 6

ITEM DESCRIPTION

1. see scheme 12 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.

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.

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the valve cover. For additional information, REFER to «Valve Cover»(ref-382364-S24045576522011012300000) .
3. Remove the crankshaft pulley. For additional information, REFER to «Crankshaft Pulley»(ref-382364-S31577993342011012300000) .
4. Remove the 3 bolts and the lower timing belt cover.
5. Install the VCT Alignment Tool.
6. Remove the timing belt. Rotate the timing belt tensioner clockwise. Align the 2 holes on the tensioner and install a small screwdriver or holding pin. Remove the timing belt.
7. Remove the crankshaft sprocket gear.
8. Remove the bolt and the timing belt tensioner.
9. Remove the VCT Alignment Tool.
10. Remove the 2 camshaft phaser and sprocket plugs.
11. Remove the 2 bolts and the camshaft phaser and sprockets.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

1. Loosen the 2 bolts for the LH engine lift eye.
2. Install the Camshaft Alignment Plate into the end of the camshafts.
3. Install the 2 camshaft phaser and sprockets, bolts and the VCT Alignment Tool. Tighten the 2 bolts to 25 Nm (18 lb-ft).
4. Remove the VCT Alignment Tool.
5. Remove the Camshaft Alignment Plate.
6. Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.
7. Install the Camshaft Alignment Plate into the end of the camshafts.
8. Install the VCT Alignment Tool. If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
9. Remove the VCT Alignment Tool.
10. Remove the Camshaft Alignment Plate.
11. Install the 2 camshaft phaser and sprocket plugs. Tighten to 16 Nm (142 lb-in).
12. Install the timing belt tensioner and the bolt. Tighten to 25 Nm (18 lb-ft). Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a small screwdriver or holding pin.
13. Install the crankshaft sprocket gear.
14. Install the VCT Alignment Tool.
15. Install the timing belt in the sequence shown in illustration.
16. Remove the timing belt tensioner holding tool.
17. Install the lower timing belt cover and the 3 bolts. Tighten to 9 Nm (80 lb-in).
18. Install the crankshaft pulley. For additional information, REFER to «Crankshaft Pulley»(ref-382364-S31577993342011012300000) .
19. Tighten the 2 bolts for the LH engine lift eye. 19 Nm (168 lb-in).
20. Install the valve cover. For additional information, REFER to «Valve Cover»(ref-382364-S24045576522011012300000) .

Scheme 15

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.

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. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

1. see scheme 40 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.

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.

1. see scheme 40 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.

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.

1. see scheme 40 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.

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. If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

Note. The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.

1. see scheme 40 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.

1. see scheme 41 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.

Scheme 16

1. NOTE: Lubricate the bolts with clean engine oil prior to installation. Install the cylinder head gasket, cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 4 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 35 Nm (26 lb-ft). Stage 4: Turn 75 degrees.

Scheme 17

ITEM DESCRIPTION

1. see scheme 44 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.

1. see scheme 44 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.

1. see scheme 44 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.

1. see scheme 44 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.

1. see scheme 44 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.

1. see scheme 45 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.

Note. Use the holding feature to prevent the engine mount studs from turning while removing the engine mount nuts or damage to the powertrain may occur.

1. see scheme 46 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.

Scheme 18

1. 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).