Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2C•4 Zetec engine in-car repair procedures4.6 Disconnecting crankcase breatherhose from cylinder head cover unionclamp brackets and disconnect the pipe jointunion over the top of the cylinder head cover.Place absorbent rags beneath the union as itis disconnected to soak up escaping fluid andplug the open unions to prevent dirt entry andfurther fluid loss. Move the pipe(s) clear justsufficiently to allow removal of the cylinderhead cover.5 Remove the timing belt upper cover (seeSection 7).6 Disconnect the crankcase breather hosefrom the cylinder head cover union (seeillustration).7 Unplug the HT leads from the spark plugsand withdraw them, unclipping the leads fromthe cover.8 Working progressively, unscrew thecylinder head cover retaining bolts, noting thespacer sleeve and rubber seal at each, thenwithdraw the cover (see illustration).9 Discard the cover gasket; this must berenewed whenever it is disturbed. Check thatthe sealing faces are undamaged, and that therubber seal at each retaining bolt isserviceable; renew any worn or damagedseals.Refitting10 On refitting, clean the cover and cylinderhead gasket faces carefully, then fit a newgasket to the cover, ensuring that it locatescorrectly in the cover grooves (see illustration).11 Refit the cover to the cylinder head, theninsert the rubber seal and spacer sleeve ateach bolt location (see illustration). Start all4.11 Ensure rubber seal is fitted to eachcover bolt spacer, as shown4.8 Removing cylinder head coverbolts finger-tight, ensuring that the gasketremains seated in its groove.12 Working in a diagonal sequence from thecentre outwards, and in two stages (seeSpecifications), tighten the cover bolts to thespecified torque wrench setting.13 Refit the HT leads, clipping them intoplace so that they are correctly routed; each isnumbered, and can also be identified by thenumbering on its respective coil terminal.14 Reconnect the crankcase breather hose,and refit the timing belt upper cover.Reconnect and adjust the accelerator cable,then refit the air inlet components (seeChapter 4B).15 On models with power steering,reconnect the high pressure fluid pipe thenbleed the system as described in Chapter 10.5 Valve clearances -general informationRefer to Section 5 in Part B of this Chapter.6 Crankshaft pulley -removal and refitting 1Removal1 Remove the auxiliary drivebelt - eitherremove the drivebelt completely, or just6.9 Unscrew pulley bolt to releasecrankshaft pulley4.10 Ensure gasket is located correctly incover groovesecure it clear of the crankshaft pulley,depending on the work to be carried out (seeChapter 1).2 If necessary, rotate the crankshaft until thetiming marks align (see Section 3).3 The crankshaft must now be locked toprevent its rotation while the pulley bolt isunscrewed. To do this, remove the startermotor (Chapter 5A) and lock the starter ringgear teeth using a suitable screwdriver.4 It should now just be possible to reachbetween the crankshaft pulley and the bodyside member to undo and remove the pulleybolt and withdraw the pulley. However, ifadditional working clearance is needed,proceed as follows.5 If not already done, chock the rear wheelsthen jack up the front of the car and support iton axle stands (see “Jacking and VehicleSupport”). Remove the front right-handroadwheel.6 Support the weight of theengine/transmission using a trolley jack, witha wooden spacer to prevent damage to thesump.7 From above, unscrew the three boltssecuring the engine’s front right-hand (Yshaped)mounting bracket to the alternatormounting bracket. Unfasten the engine’s rearright-hand mounting from the body byunscrewing first the single nut (and washer)immediately to the rear of the timing beltcover, then the bolt in the wheel arch8 With the engine’s right-hand mountingsunfastened from the body, lower theengine/transmission on the jack until a socketspanner can be fitted to the crankshaft pulleybolt.9 With the starter ring gear teeth locked,unscrew the crankshaft pulley bolt andwithdraw the pulley (see illustration).Refitting10 Refitting is the reverse of the removalprocedure; ensure that the pulley’s keyway isaligned with the crankshaft’s locating key, andtighten the pulley bolt to the specified torquewrench setting. If the engine mountings weredisturbed, use the jack to adjust the height ofthe engine/transmission until the bolts (andnut, with washer) can be refitted and screwed