Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2C•10 Zetec engine in-car repair procedures11.17 Oil liberally when refitting hydraulictappetscaps. Tighten the bearing cap bolts to thespecified torque wrench setting, thenmeasure the endfloat using a DTI (Dial TestIndicator, or dial gauge) mounted on thecylinder head so that its tip bears on thecamshaft right-hand end.16 Tap the camshaft fully towards the gauge,zero the gauge, then tap the camshaft fullyaway from the gauge, and note the gaugereading. If the endfloat measured is found tobe at or beyond the specified service limit, fita new camshaft and repeat the check; if theclearance is still excessive, the cylinder headmust be renewed.Refitting17 On reassembly, liberally oil the cylinderhead hydraulic tappet bores and the tappets(see illustration). Note that if new tappets arebeing fitted, they must be charged with cleanengine oil before installation. Carefully refit thetappets to the cylinder head, ensuring thateach tappet is refitted to its original bore, andis the correct way up. Some care will berequired to enter the tappets squarely intotheir bores.18 Liberally oil the camshaft bearings andlobes. Ensuring that each camshaft is in itsoriginal location, refit the camshafts, locatingeach so that the slot in its left-hand end isapproximately parallel to, and just above, thecylinder head mating surface.19 Ensure that the locating dowels are11.21a Camshaft bearing cap tighteningsequenceNote: View from front of vehicle - locatebearing caps according to etched numbers,aligned as described in text11.19 Apply sealant to mating surface ofcamshaft right-hand bearing capspressed firmly into their recesses, and checkthat all mating surfaces are completely clean,unmarked and free from oil. Apply a thin filmof suitable sealant (Ford recommendLoctite 518) to the mating surfaces of eachcamshaft’s right-hand bearing cap (seeillustration). Referring to paragraph 6 ofSection 10, some owners may wish to fit thenew camshaft oil seals at this stage.20 All camshaft bearing caps have a singledigitidentifying number etched on them (seeillustration). The exhaust camshaft’s bearingcaps are numbered in sequence 0 to 4, theinlet’s 5 to 9; see illustration 11.21a for details.Each cap is to be fitted so that its numberedside faces outwards, to the front (exhaust) orto the rear (inlet).21 Ensuring that each cap is kept square tothe cylinder head as it is tightened down, andworking in the sequence shown, tighten thecamshaft bearing cap bolts slowly and by oneturn at a time, until each cap touches thecylinder head (see illustration). Next, goround again in the same sequence, tighteningthe bolts to the first stage torque wrenchsetting specified, then once more, tighteningthem to the second stage setting. Work onlyas described, to impose gradually and evenlythe pressure of the valve springs on the caps.Fit the camshaft-aligning tool; it should slipinto place as described in paragraph 8 ofSection 8 (see illustration).22 Wipe off all surplus sealant, so that noneis left to find its way into any oilways. Follow11.21b Fit camshaft-aligning tool to setTDC position while camshaft toothedpulleys are refitted11.20 Etched marks on camshaft bearingcaps must be arranged as shown, and faceoutwardsthe sealant manufacturer’s instructions as tothe time needed for curing; usually, at least anhour must be allowed between application ofthe sealant and starting the engine.23 If using Ford’s recommended procedure,fit new oil seals to the camshafts as describedin paragraph 5 of Section 10.24 Using the marks and notes made ondismantling to ensure that each is refitted toits original camshaft, refit the sprockets to thecamshafts, tightening the retaining boltsloosely. Slip the timing belt back onto thesprockets (refer to paragraph 19 of Section 8)and tighten the bolts securely - use the forkedholding tool described in paragraph 16 ofSection 8.25 The remainder of the reassemblyprocedure, including checking the camshaftalignment (valve timing) and setting the timingbelt tension, is as described in paragraphs 15to 25 of Section 8.12 Cylinder head -removal and refitting4RemovalNote: The following text assumes that thecylinder head will be removed with both inletand exhaust manifolds attached. Thissimplifies the procedure, but makes it a bulkyand heavy assembly to handle - an enginehoist will be required, to prevent the risk ofinjury, and to prevent damage to any delicatecomponents as the assembly is removed andrefitted. If it is wished first to remove themanifolds, refer to Chapter 4D, then amendthe following procedure accordingly.1 Depressurise the fuel system (see Chapter4D).2 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).3 Refer to Chapter 4D and remove the airinlet components.4 Equalise the pressure in the fuel tank byremoving the filler cap, then undo the fuelfeed and return lines connecting the engine tothe chassis (see Chapter 4D). Plug or cap allopen fittings.