Chapter 1 Routine maintenance and servicing

Zetec engine in-car repair procedures 2C•5home by hand, then tighten them securely, tothe specified torque wrench settings, wheregiven.11 Refit the auxiliary drivebelt as described inChapter 1 on completion.7 Timing belt covers -removal and refitting 4Upper cover1 Unscrew the cover’s two mounting boltsand withdraw it (see illustration).2 Refitting is the reverse of the removalprocedure; ensure that the cover edgesengage correctly with each other, and note thetorque wrench setting specified for the bolts.Middle cover3 Slacken the water pump pulley bolts.4 Remove the timing belt upper cover.5 Remove the auxiliary drivebelt (see Chapter1).6 Unbolt and remove the water pump pulley.7 Unscrew the middle cover fasteners (onebolt at the front, one at the lower rear, onestud at the top rear) and withdraw the cover.8 Refitting is the reverse of the removalprocedure. Ensure that the cover edgesengage correctly with each other, and notethe torque wrench settings specified for thevarious fasteners.Lower cover9 Slacken the water pump pulley bolts.10 Remove the crankshaft pulley (seeSection 6) then unbolt and remove the waterpump pulley.11 Unscrew the three cover securing bolts,and withdraw it (see illustration).12 Refitting is the reverse of the removalprocedure; ensure the cover edges engagecorrectly with each other, and note the torquewrench settings specified for the variousfasteners.Inner shield13 Remove the timing belt, its tensionercomponents and the camshaft sprockets (seeSections 8 and 9).7.11 Removing timing belt lower cover -bolt locations arrowed14 The shield is secured to the cylinder headby two bolts at the top, and by two studslower down; unscrew these and withdraw theshield (see illustration).15 Refitting is the reverse of the removalprocedure; note the torque wrench settingsspecified for the various fasteners.8 Timing belt - removal, refittingand adjustment 4Note: To carry out this operation, a new timingbelt (where applicable), a new cylinder headcover gasket, and some special tools (see text)7.14 Timing belt inner shield fasteners(arrowed)1 Timing belt uppercover2 Inlet camshafttoothed pulley3 Exhaust camshafttoothed pulley4 Timing belt5 Timing belttensioner6 Crankshaft toothedpulley7 Timing belt middlecover8 Timing belt lowercover9 Crankshaft pulley10 Water pump pulley7.1 Timing belt and cover details2Cwill be required. If the timing belt is beingremoved for the first time since the vehicleleft the factory, a tensioner spring andretaining pin must be obtained for fitting onreassembly.Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Slacken the water pump pulley bolts.3 Remove the cylinder head cover (seeSection 4).4 Remove the spark plugs, covering theirholes with clean rag, to prevent dirt or otherforeign bodies from dropping in (see Chapter1).5 Remove the auxiliary drivebelt (see Chapter1).6 Position the engine with No 1 piston at TDCon compression as described in Section 3.7 Unbolt and remove the water pump pulleyand, where fitted, the auxiliary drivebelt idlerpulley.8 Obtain Ford service tool 21-162, orfabricate a substitute alternative from a stripof metal 5 mm thick (while the strip’sthickness is critical, its length and width arenot, but should be approximately 180 to230 mm by 20 to 30 mm). Check that Nos 1and 4 cylinders are at TDC - No 1 on thecompression stroke - by resting this tool onthe cylinder head mating surface, and sliding1595Ford Fiesta Remake