Ford Fiesta: 1.6L EcoBoost (132 kW/180 PS) - Sigma / Engine

Special Service Tools / General Equipment

	100-001 (T50T-100-A) Slide hammer
	300-OTC1819E Floor Crane 2200 lb, Folding
	303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve TKIT-2010B-FLM TKIT-2010B-RYAD
	303-1502 Engine Lifting Device TKIT-2012A-FL TKIT-2012A-RYAD
	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FX/FMX/FLMX TKIT-1993-LMX/MX
	303-748 Crankshaft Locking Tool TKIT-2010B-FLM TKIT-2010B-RHD
	307-005 (T59L-100-B) Slide Hammer
	308-375 Remover, Input Shaft Seal TKIT-2005U-M TKIT-1999-F/FLM/LT
	310-206 Puller, Fuel Injector TKIT-2009A-FLM
Heat gun
Hose Clamp Removal/Installation Tool

Materials

Name	Specification
Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B, APM-4-C	-

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special service tools. The crankshaft pulley and the crankshaft timing sprocket are not connected to the crankshaft. Before any repair that requires loosening or removing the crankshaft pulley bolt, the crankshaft and camshafts must be locked with the special service tools, otherwise serious engine damage may occur.

NOTICE: Cleanliness is extremely important when repairing the engine. Any foreign material, including material created during the cleaning of gasket surfaces, that enters the oil passages, coolant passages or oil pan may cause engine failure.

1
NOTICE: Do not breathe dust and do not use compressed air to blow dust from storage containers or friction components. Remove dust using a method approved by the government. Friction component dust may cause cancer and lung disease. Exposure to potentially hazardous components may occur when dust is generated during repair of friction parts such as brake pads and clutch discs. Exposure may also cause skin, eye and respiratory irritation, may cause allergic reactions and/or may lead to other chronic health effects. If irritation does not go away, seek medical attention or advice. Failure to follow these instructions may result in serious injury.
Evenly loosen the 6 clutch pressure plate-to-flywheel bolts, 2 turns at a time.
2
Remove the special service tool: 300-OTC1819E 2200 lb Floor Crane, Folding.
3
Remove the special service tool: 303-1502 Engine Lifting Device.
4
If equipped with a block heater.
5
NOTE
Discard the O-rings and gaskets.
6
1. If equipped.
1. Use common service equipment: hose clamp removal/installation tool.
7
Use common service equipment: hose clamp removal/installation tool.
8
Use common service equipment: hose clamp removal/installation tool.
9
Use common service equipment: hose clamp removal/installation tool.
10
Use common service equipment: hose clamp removal/installation tool.
11
Use common service equipment: hose clamp removal/installation tool.
12
Use common service equipment: hose clamp removal/installation tool.
13
NOTE
Note the position of the component before removal.
14
NOTE
O-rings may be reused if they are not damaged.
15
NOTICE: When removing or installing the high-pressure fuel pump, insulate the openings to reduce the risk of damage.
16
NOTE
Replace all damaged coil-on-plug components.
17
NOTICE: Pull the fuel rails in the direction of the fuel injector axis, otherwise the injectors may be damaged.

NOTE
Use compressed air to remove all dirt or foreign material from the cylinder head, the engine block and the general area around the fuel rail and fuel injectors.
When removing the fuel rails, the fuel injectors may remain in the fuel rails, but usually remain in the cylinder heads and a fuel injector removal tool is required to remove them.
18
NOTE
Take special care when handling components.
Remove all fuel injectors remaining in the fuel rail.
19
NOTE
Remove the fuel injectors that remained in the cylinder head.
- Use the special service tool: 307-005 (T59L-100-B) Slide Hammer.
- Use the special service tool: 310-206 Fuel Injector Puller.
20
NOTICE: Do not place the valve cover sealing surface on a bench, as the check valve and divider leg may break.
21
NOTICE: Use a heat gun to soften the flange sealant to assist in removing the fuel pump mounting bracket. Failure to follow these instructions may damage the fuel pump mounting bracket.
Use the general equipment: heat gun.
22
NOTICE: Use a heat gun to soften the flange sealant to assist in removing the brake vacuum pump mounting bracket. Failure to follow these instructions may damage the brake vacuum pump mounting bracket.
Use the general equipment: heat gun.
23
NOTE
Note the different bolt lengths.
24
NOTE
Note the installation position.
25
Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
26
NOTE
Note the installation position.
If equipped with a block heater.
27
NOTE
Note the different bolt lengths.
28
NOTE
Rotate the crankshaft clockwise only.
11 o'clock position.
29
NOTE
The crankshaft TDC pin will contact the crankshaft and prevent it from rotating past TDC. However, the crankshaft can still rotate counterclockwise. The crankshaft must remain at TDC when removing and installing the crankshaft pulley.
Install the special service tool: 303-748 Crankshaft Locking Tool.
30
NOTE
Rotate the crankshaft clockwise only.
Slowly rotate the crankshaft clockwise until the crankshaft counterweight is against the TDC timing pin. The engine is now at TDC.
31
NOTE
The timing mark on each VCT unit must be at the 12 o'clock position.
It may be necessary to slightly rotate the camshafts to install the special tool.
Install the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.
32
Warning
The timing belt tensioner spring is under load. Always use caution when handling the tensioner. Failure to follow this instruction may result in injury.
Install the retaining pin.
33
Use the special service tools: 308-375 Input Shaft Seal Remover, 100-001 (T50T-100-A) Slide Hammer.
34
Warning
The timing belt tensioner spring is under load. Always use caution when handling the tensioner. Failure to follow this instruction may result in injury.
35
Torque: 89 lb-in (10 N·m)
36
Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.
37
NOTE
Use an open-end wrench to hold the camshafts by the hex to prevent the camshafts from rotating.
38
NOTE
Use an open-end wrench to hold the camshafts by the hex to prevent the camshafts from rotating.
39
Use the special service tool: 303-409 (T92C-6700-CH) Crankshaft Seal Remover.
40
NOTICE: Use a heat gun to soften the flange sealant to assist in removing the camshaft cap. Failure to follow these instructions may result in damage to the camshaft cap.

NOTICE: Do not pry on the camshafts during removal as this may damage the camshafts.

NOTE
Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on cylinder No. 1 for installation reference.
Use the general equipment: heat gun.
41
NOTE
If the camshafts and valve lifters are to be reused, mark the location of the valve lifters to make sure they are reinstalled in their original positions.
The number on the valve lifter reflects only the digits that follow the decimal point. For example, a lifter marked 0.650 has a thickness of 3.650 mm.
42
Install new components if necessary.
43
NOTE
Before removing the cylinder head bolts, make sure the cylinder head is at ambient air temperature.
44
Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
45
Remove the special service tool: 303-748 Crankshaft Locking Tool.
46
Shim pads.
47
NOTE
The O-ring should be reused if it is not damaged.
48
NOTE
Note the position of the 3 bolts of different lengths for installation.
1. Remove the two M6 x 55 mm bolts.
1. Remove the three M6 x 35 mm bolts.
1. Unscrew the three M6 x 25 mm bolts and remove the oil pump.
49
Remove and discard the oil pump gasket.
50
1. Clean the oil pump bolt holes with Motorcraft® Metal Brake Parts Cleaner to remove all oil residue.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C
1. Use compressed air to remove brake cleaner or oil from the oil pump bolt holes.
51
Clean the specified component with an abrasive pad.
52
NOTE
The connecting rod cap bolts are yield-type bolts. Original connecting rod cap bolts will be used when measuring the connecting rod big end bore during assembly. Connecting rod cap bolts will be discarded after measuring.
Clearly mark the connecting rods, connecting rod caps and connecting rod bearings with numbers for correct orientation during reassembly.
53
NOTE
Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
Repeat with the connecting rod installation tool until all piston/connecting rod assemblies are removed from the cylinder block.
54
NOTE
Mark the position of the components so they can be installed in their original positions.
55
Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
56
NOTE
The main bearing beam has 2 arrows pointing to the front of the engine for correct orientation during reassembly.
57
NOTE
If the main bearings are to be reused, mark them to make sure they are correctly oriented and reinstalled.
58
NOTE
If the main bearings are to be reused, mark them to make sure they are correctly oriented and reinstalled.
The center bulkhead has a thrust bearing.