Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2B•10 CVH and PTE engine in-car repair procedures12.21 Cylinder head location dowels (A)and gasket identification teeth (B)be fitted on reassembly. Tie the downpipe upto support it.18 Before it is released and removed, thecylinder head must first have cooled down toroom temperature (about 20ºC).19 Unscrew the cylinder head retaining boltsprogressively in the reverse order to thatshown for tightening (see illustration 12.28).The cylinder head bolts must be discardedand new bolts obtained for refitting thecylinder head.20 Remove the cylinder head complete withits manifolds. If necessary, grip the manifoldsand rock it free from the location dowels onthe top face of the cylinder block. Do notattempt to tap it sideways or lever betweenthe head and the block top face.21 Remove the cylinder head gasket. This mustalways be renewed; it is essential that thecorrect type is obtained. Save the old gasket, sothat the identification marks (teeth) can be usedwhen ordering the new one (see illustration).Preparation for refitting22 The mating faces of the cylinder head andcylinder block must be perfectly clean beforerefitting the head. Use a hard plastic or woodscraper to remove all traces of gasket andcarbon; also clean the piston crowns. Takeparticular care during the cleaning operations,as aluminium alloy is easily damaged. Also,make sure that the carbon is not allowed toenter the oil and water passages - this isparticularly important for the lubricationsystem, as carbon could block the oil supplyto the engine’s components. Using adhesivetape and paper, seal the water, oil and boltholes in the cylinder block.To prevent carbon enteringthe gap between the pistonsand bores, smear a littlegrease in the gap. Aftercleaning each piston, use a small brushto remove all traces of grease andcarbon from the gap, then wipe awaythe remainder with a clean rag.23 Check the mating surfaces of the cylinderblock and the cylinder head for nicks, deepscratches and other damage. If slight, they12.27 Fit the cylinder head gasket with the“OBEN/TOP” marking upwards . . .may be removed carefully with a file, but ifexcessive, machining may be the onlyalternative to renewal.24 If warpage of the cylinder head gasketsurface is suspected, use a straight-edge tocheck it for distortion. Refer to Part D of thisChapter if necessary.25 Ensure that new cylinder head bolts areused when refitting and clean out the boltholes in the block. Screwing a bolt into an oilfilledhole can (in extreme cases) cause theblock to fracture, due to the hydraulicpressure.Refitting26 To prevent the possibility of the valvesand pistons coming into contact as the headis fitted, turn the crankshaft over to positionNo 1 piston approximately 20 mm below itsTDC position in the bore.27 Locate the cylinder head gasket on thetop face of the cylinder block, locating it overthe dowels. Ensure that the gasket is fitted thecorrect way up, as indicated by its “OBEN-TOP” marking (see illustration).28 Lower the cylinder head into position,ensuring that it fits over the locating dowels,then insert the new retaining bolts. Handtightenthe bolts initially, then tighten them inthe order shown in the four stages to thespecified torque setting (see illustration).Where possible, use an angular torque settinggauge attachment tool for accurate tighteningof stages three and four. Alternatively, afterthe first two stages, mark the bolt heads witha dab of quick drying paint, so that the paintspots all face the same direction. Now tightenall the bolts in the sequence to the Stage 3setting, by tightening them through thespecified angle. Finally, angle-tighten all thebolts through the Stage 4 angle.29 The camshaft sprocket should bepositioned so that its TDC index mark pointeris in alignment with the TDC index spot markon the front end face of the cylinder head (seeillustration 3.6b).30 Now turn the crankshaft pulley to bring itsTDC notch in alignment with the TDC (0)indicator on the front face of the timing beltcover, taking the shortest route (not viceversa)(see illustration 3.6a).12.28 Cylinder head bolt tighteningsequence31 Refit the timing belt over the camshaftsprocket, and then tension the belt asdescribed in Section 8.32 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, and toChapter 5B for details on reconnecting theignition system components. Ensure that allcoolant, fuel, vacuum and electricalconnections are securely made.33 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.13 Sump -removal and refitting2Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Drain the engine oil as described in Chapter1.3 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe auxiliary drivebelt lower cover from insidethe right-hand wheel arch.4 Where fitted, pull free the oxygen sensorlead multi-plug, and disconnect it. If theengine has been recently run, take particularcare against burning when working in the areaof the catalytic converter.5 Undo the retaining nuts, and detach theexhaust downpipe from the manifold. Theflange gasket must be renewed whenreconnecting. Where applicable, also detachthe downpipe at the rear of the catalyticconverter, and release it from the frontmounting.6 On XR2i models, remove the frontsuspension crossmember as described inChapter 10. On all models, undo the nut and