Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2A•8 HCS engine in-car repair procedures11.8a Sump gasket fitting details at thetiming chain cover end (A) and the flywheelend (B)6 Undo the eighteen bolts securing the sumpto the base of the engine crankcase, thenprise free and lower the sump. If the sump isstuck tight to the engine, cut around theflange gasket with a sharp knife, then lightlytap and prise it free. Keep the sump upright asit is lowered, to prevent spillage of anyremaining oil in it. Also be prepared for oildrips from the crankcase when the sump isremoved.7 Remove any dirt and old gasket from thecontact faces of the sump and crankcase, andwash the sump out thoroughly before refitting.Check that the mating faces of the sump arenot distorted. Check that the oil pick-upstrainer is clear, cleaning it if necessary.Refitting8 Clean the gasket location faces. Apply adab of sealing compound to the mating faceswhere the ends of each cork half-gasket areto be fitted (see illustration). Stick the newcork gaskets into position on the block face,using clean thick grease to retain them, thenlocate the new rubber gaskets into their slotsin the timing chain cover and rear oil sealcarrier. The lugs of the cork gasket halves fitunder the cut-outs in the rubber gaskets (seeillustration).9 Before offering up the sump, check that thegap between the sump and the oil baffle isbetween 2.0 and 3.8 mm (see illustration).11.8b Lugs of cork gasket halves to fitunder the cut-outs in the rubber gasketsDo not use a dented or damaged sump, asthe indicated dimension is important forcorrect engine lubrication.10 Fit the sump into position, and fit theretaining bolts. Initially tighten them all fingertight,then further tighten them in the sequenceshown through Stages 1 and 2, to the torquewrench settings specified (see illustration).Note that different tightening sequences arespecified for the tightening stages. Final(Stage 3) tightening is carried out after theengine has been started and warmed up.11 Refit the lower plate to the front face ofthe clutch housing and refit the auxiliarydrivebelt lower cover.12 Refit the starter motor.13 Check that the downpipe and manifoldmating faces are clean, then locate a newgasket and reconnect the exhaust downpipeto the manifold. Where applicable, use newself-locking nuts, and tighten securely.14 Check that the sump drain plug is fittedand tightened to the specified torque, thenlower the vehicle to the ground.15 Refill the engine with oil as described inChapter 1.16 Reconnect the battery, then start theengine and run it up to its normal operatingtemperature. Check that no oil leaks areevident around the sump joint.17 After the engine has warmed up forapproximately 15 minutes, switch it off.Tighten the sump bolts to the Stage 3 torquewrench setting given in the Specifications, inthe sequence shown in illustration 11.10.11.9 Sump (A) and oil baffle (B) clearancedetails12 Oil pump -removal and refitting2Removal1 The oil pump is externally-mounted, on therear-facing side of the crankcase.2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”).3 Unscrew and remove the oil filter cartridge.It should unscrew by hand, but will probablybe tight. Use a strap wrench to loosen it off, ifrequired. Catch any oil spillage in a suitablecontainer.4 Undo the three retaining bolts and withdrawthe oil pump from the engine (seeillustration).5 Clean all traces of the old gasket from themating surfaces of the pump and engine.Refitting6 If the original oil pump has been dismantledand reassembled and is to be re-used, or if anew pump is to be fitted, it must first beprimed with engine oil prior to fitting. To dothis, turn its driveshaft and simultaneouslyinject clean engine oil into it.7 Locate a new gasket into position on thepump mounting flange, then insert the pump,engaging the drivegear as it is fitted (seeillustration). Fit the retaining bolts, andtighten to the specified torque wrench setting.11.10 Sump bolt tightening sequence -arrow indicates crankshaft pulley end ofengineSee Specifications for torque wrench settingsStage 1 - Tighten in alphabetical orderStage 2 - Tighten in numerical orderStage 3 - Tighten in alphabetical order12.4 Unscrewing the oil pump retainingbolts12.7 Refitting the oil pump. Note the newgasket