Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2A•6 HCS engine in-car repair procedures7.25 Cylinder head gasket top-facemarking (“OBEN”)7.27c Cylinder head bolt tightening(Stages 2 and 3) using an angle gaugegasket onto the top face of the cylinder blockand over the dowels. Ensure that it is correctlyaligned with the coolant passages andoilways (see illustration).26 Lower the cylinder head carefully intoposition, then insert the retaining bolts andhand-tighten them.27 Tightening of the cylinder head bolts mustdone in three stages, and in the correctsequence (see illustration). First tighten all ofthe bolts in the sequence shown to theStage 1 torque setting (see illustration).When all of the bolts are tightened to theStage 1 setting, further tighten each bolt (insequence) through the Stage 2 specifiedangle of rotation. When the second stagetightening is completed on all of the bolts,further tighten them to the Stage 3 anglesetting (in sequence) to complete. Wherepossible, use an angular torque setting gaugeattachment tool for accurate tightening ofstages two and three (see illustration).28 Lubricate the pushrods with clean engineoil, and then insert them into their originallocations in the engine.29 Refit the rocker shaft assembly. As it isfitted, ensure that the rocker adjuster screwsengage with their corresponding pushrods.30 Refit the rocker shaft retaining bolts,hand-tighten them and then tighten themto the specified torque wrench setting. Asthey are tightened, some of the rocker armswill apply pressure to the ends of the valvestems, and some of the rocker pedestals willnot initially be in contact with the cylinder7.27a Cylinder head bolt tighteningsequencehead - these should pull down as the bolts aretightened. If for any reason they do not, avoidthe temptation to overtighten in order to pullthem into position; loosen off the bolts, andcheck the cause of the problem. It may bethat the rocker adjuster screws requireloosening off in order to allow the assembly tobe tightened down as required.31 Adjust the valve clearances as describedin Section 5.32 Refit the rocker cover as described inSection 4.33 The remainder of the refitting procedure isa reversal of the removal process. Tighten allfastenings to their specified torque setting(where given). Refer to the appropriate Partsof Chapter 4 for details on reconnecting thefuel and exhaust system components. Ensurethat all coolant, fuel, vacuum and electricalconnections are securely made.34 On completion, refill the cooling systemand top-up the engine oil (see Chapter 1 and“Weekly Checks”). When the engine isrestarted, check for any sign of fuel, oil and/orcoolant leakages from the various cylinderhead joints.8 Crankshaft pulley -removal and refitting2Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe right-hand front roadwheel.3 Remove the auxiliary drivebelt as describedin Chapter 1.4 Loosen off the crankshaft pulley retainingbolt. To prevent the crankshaft from turning,unbolt and remove the clutch housing coverplate. Lock the starter ring gear on theflywheel using a large screwdriver or similartool inserted through the cover plate aperture.Alternatively, remove the starter motor(Chapter 5A) and lock the ring gear throughthe starter motor aperture.7.27b Tightening the cylinder head bolts(Stage 1)5 Fully unscrew the crankshaft pulley bolt,and withdraw the pulley from the front end ofthe crankshaft. If it does not pull off by hand,lever it free using a pair of suitable leverspositioned diagonally opposite each otherbehind the pulley.6 If required, the crankshaft front oil seal canbe renewed at this stage, as described inSection 14.Refitting7 Refitting is a reversal of the removalprocedure ensuring that the pulley retainingbolt is tightened to the specified torquesetting.8 Refit the auxiliary drivebelt as described inChapter 1, and lower the vehicle to complete.9 Timing chain cover -removal and refitting2Removal1 Remove the sump as described in Section11.2 Remove the crankshaft pulley as describedin the previous Section.3 A combined timing cover and water pumpgasket is fitted during production; if this is stillin position, it will be necessary to drain thecooling system and remove the water pumpas described in Chapter 3. If the water pumpand/or the timing cover have been removed atany time, the single gasket used originally willhave been replaced by an individual gasketfor each component, in which case the waterpump can remain in position.4 Unscrew the retaining bolts, and carefullyprise free the timing chain cover.5 Clean the mating faces of the timing chaincover, and the engine.6 If necessary, renew the crankshaft front oilseal in the timing cover prior to refitting thecover (see Section 14).Refitting7 Lightly lubricate the front end of thecrankshaft and the radial lip of the timingchain cover oil seal (already installed in the