Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2D•12 Engine removal and overhaul procedures25 On automatic transmission models, cleanaround the unions, then disconnect the fluidpipes from the transmission. Plug theopenings in the transmission and the pipeunions after removal.26 Refer to Chapter 10 and remove the frontsuspension crossmember.27 Unscrew the nuts to disconnect theexhaust system front downpipe from themanifold. Undo the nuts securing the catalyticconverter to the rear part of the exhaustsystem, and remove the converter anddownpipe assembly.28 On vehicles fitted with the anti-lock brakingsystem, refer to Chapter 9 and release theright-hand modulator from its mountingbracket without disconnecting the rigid brakepipes or return hose. Tie the modulatorsecurely to the bulkhead. Additionally, undothe three bolts securing the modulator bracket.29 Disconnect both anti-roll bar links fromtheir respective suspension struts, and bothtrack rod end ball joints from their spindlecarriers (see Chapter 10).30 Unscrew the retaining nut and withdrawthe Torx-type clamp bolt securing the lowersuspension arm to the spindle carrier on eachside.31 Insert a suitable lever between the righthanddriveshaft inner joint and thetransmission housing, and prise free thedriveshaft from the transmission; be preparedfor oil spillage from the transmission casethrough the vacated driveshaft aperture. As itis being prised free, simultaneously pull theroadwheel outwards on that side to enable thedriveshaft inboard end to separate from thetransmission. Once it is free, suspend andsupport the driveshaft from the steering gear,to prevent unnecessary strain being placed onthe driveshaft joints.32 Insert a suitable plastic plug (or ifavailable, an old driveshaft joint), into thetransmission driveshaft aperture, toimmobilise the gears of the differential unit.33 Proceed as described above inparagraphs 31 and 32, and disconnect theleft-hand driveshaft from the transmission.34 Remove the oil filter, referring to Chapter 1if necessary.35 Connect a suitable lift hoist and sling tothe engine, connecting to the lift eyes. Whensecurely connected, take the weight of theengine/transmission unit so that the tension isrelieved from the mountings.36 Unbolt the engine rear right-handmounting from the body (one bolt in the wheelarch, one nut in the engine compartment),then unbolt the engine front right-handmounting from the alternator mountingbracket. Unbolt the transmission bearer fromthe underbody.37 The engine/transmission unit should nowbe hanging on the hoist only, with allcomponents which connect it to the rest ofthe vehicle disconnected or removed, andsecured well clear of the unit. Make a finalcheck that this is the case.38 Lower the engine/transmission to theground, and withdraw it from under thevehicle.39 Referring to the relevant Part of Chapter 7,separate the transmission from the engine.40 While the engine/transmission is removed,check the mountings; renew them if they areworn or damaged. Similarly, check thecondition of all coolant and vacuum hosesand pipes (see Chapter 1); components thatare normally hidden can now be checkedproperly, and should be renewed if there isany doubt at all about their condition. Wherethe vehicle is fitted with manual transmission,take the opportunity to overhaul the clutchcomponents (see Chapter 6). It is regarded bymany as good working practice to renew theclutch assembly as a matter of course,whenever major engine overhaul work iscarried out. Check also the condition of allcomponents (such as the transmission oilseals) disturbed on removal, and renew anythat are damaged or worn.Refitting41 Refitting is a reversal of removal, howevernote the following additional points:a) Refer to the applicable Chapters andSections as for removal.b) Fit new spring clips to the grooves in theinboard end of the right- and left-handdriveshaft joints. Lubricate the splineswith transmission oil prior to fitting.c) Renew the exhaust flange gaskets whenreconnecting the exhaust. Ensure that allwires are routed clear of the exhaustsystem, and that the heat shields aresecurely and correctly fitted.d) Ensure that all earth lead connections areclean and securely made.e) Tighten all nuts and bolts to the specifiedtorque.f) Fit a new oil filter, and refill the engine andtransmission with oil, with reference toChapter 1.g) Refill the cooling system with reference toChapter 1.h) Bleed the power steering system withreference to Chapter 10.42 When engine and transmission refitting iscomplete, refer to the procedures describedin Section 19 before restarting the engine.6 Engine overhaul -preliminary informationIt is much easier to dismantle and work onthe engine if it is mounted on a portableengine stand. These stands can often be hiredfrom a tool hire shop. Before the engine ismounted on a stand, the flywheel/driveplateshould be removed so that the stand boltscan be tightened into the end of the cylinderblock/crankcase.If a stand is not available, it is possible todismantle the engine with it suitablysupported on a sturdy, workbench or on thefloor. Be careful not to tip or drop the enginewhen working without a stand.If you intend to obtain a reconditionedengine, all ancillaries must be removed first, tobe transferred to the replacement engine (justas they will if you are doing a complete engineoverhaul yourself). These components includethe following:a) Alternator/power steering pump andmounting brackets.b) DIS/E-DIS ignition coil unit (and mountingbracket), distributor, HT leads and sparkplugs.c) The thermostat and housing cover.d) Carburettor/fuel injection systemcomponents.e) Inlet and exhaust manifolds.f) Oil filter.g) Fuel pump.h) Engine mountings.i) Flywheel/driveplate.j) Water pump.Note: When removing the externalcomponents from the engine, pay closeattention to details that may be helpful orimportant during refitting. Note the fittedpositions of gaskets, seals, washers, bolts andother small items.If you are obtaining a “short” engine(cylinder block/crankcase, crankshaft, pistonsand connecting rods all assembled), then thecylinder head, timing chain/belt (together withtensioner, tensioner and idler pulleys andcovers) sump and oil pump will have to beremoved also.If a complete overhaul is planned, theengine can be dismantled in the order givenbelow, referring to Part A, B or C of thisChapter unless otherwise stated.a) Inlet and exhaust manifolds.b) Timing chain/belt, tensioner andsprockets.c) Cylinder head.d) Flywheel/driveplate.e) Sump.f) Oil pump.g) Pistons (with connecting rods).h) Crankshaft.i) Camshaft and tappets (HCS engines).7 Cylinder head - dismantling4Note: New and reconditioned cylinder headsare available from the manufacturers, and fromengine overhaul specialists. Due to the factthat some specialist tools are required for thedismantling and inspection procedures, andnew components may not be readily available,it may be more practical and economical forthe home mechanic to purchase areconditioned head, rather than to dismantle,inspect and recondition the original head.1 Remove the cylinder head as described inPart A, B or C of this Chapter (as applicable).