Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2D•16 Engine removal and overhaul procedures9.8 Locate the seal, and tap it into positionover the guideor press the seal squarely into place, using asuitable tube or socket (see illustration).9 To protect the seal lips from beingdamaged by the collet grooves in the valvestem as it is passed through the seal, wipeany oil from the stem at the top, and mask thesplit collet groove on the stem with insulatingtape. Lubricate the lips of the valve stem seal,and insert the valve (see illustration).10 Remove the tape from the groovedsection of the valve stem, then locate thespring and the upper retainer over the valve.11 Locate the valve spring compressor intoposition, and compress the spring and cupdown the valve stem so that the collet’sgroove is exposed above the upper retainer.Lightly grease the collet’s groove in the stem,(to retain the collets in position) then locatethe split collets into the groove in the stem.Slowly release and remove the valve springcompressor. As the compressor is released,ensure that the collets remain fully seated inthe groove, and the upper retainer rides upover them to secure them in position (seeillustration).12 Repeat the above operations on theremaining valves, ensuring that each valveassembly is returned to its original position, orwhere new valves have been fitted, onto theseat to which it was ground.13 When all of the valves have been fitted,support the cylinder head on a wooden block,and using a plastic or copper-faced hammer,lightly tap the end of each valve stem in turnto seat the respective valve assemblies.9.9 Insert the valve into its guide14 Refit the camshaft, tappets and rockerarms to the cylinder head as described inPart B of this Chapter.Zetec engines15 Beginning at one end of the head,lubricate and install the first valve. Applymolybdenum disulphide-based grease orclean engine oil to the valve stem, and refit thevalve. Where the original valves are being reused,ensure that each is refitted in its originalguide. If new valves are being fitted, insertthem into the locations to which they havebeen ground.16 Fit the plastic protector supplied with newvalve spring lower seat/stem oil seals to theend of the valve stem, then put the new sealsquarely on top of the guide, and leave itthere; the action of refitting the valve springpresses the lower seat/stem oil seal into place(see illustration).17 Refit the valve spring and upper seat.18 Compress the spring with a valve springcompressor, and carefully install the collets inthe stem groove. Apply a small dab of greaseto each collet to hold it in place if necessary.Slowly release the compressor, and makesure the collets seat properly.19 When the valve is installed, place thecylinder head flat on the bench and, using ahammer and interposed block of wood, tapthe end of the valve stem gently, to settle thecomponents.20 Repeat the procedure for the remainingvalves. Be sure to return the components to9.11 Insert the split collets into the groovein the valve stemtheir original locations - don’t mix them up!21 Refit the hydraulic tappets as described inPart C of this Chapter.10 Camshaft and tappets -removal, inspection and3refitting (HCS engines)Removal1 Refer to the applicable Sections in Part A ofthis Chapter and remove the cylinder head,timing chain and camshaft sprocket, and thesump.2 Invert the engine so that it is supported onits cylinder head face (on a clean work area).This is necessary to make all of the tappetsslide to the top of their stroke, thus allowingthe camshaft to be withdrawn. Rotate thecamshaft through a full turn, to ensure that allof the tappets slide up their bores, clear of thecamshaft.3 Before removing the camshaft, check itsendfloat using a dial gauge mounted on thefront face of the engine or feeler gauges. Pullthe camshaft fully towards the front (timingchain) end of the engine, then insert feelergauges between the camshaft sprocket flangeand the camshaft thrust plate to assess theendfloat clearance (see illustration). Thecamshaft endfloat must be as specified.4 Undo the two retaining bolts, and removethe camshaft thrust plate.5 Carefully withdraw the camshaft from thefront end of the engine (see illustration).9.16 Valve spring pressure is sufficient toseat lower seat/stem oil seals onreassembly10.3 Checking the camshaft endfloat10.5 Withdrawing the camshaft from thefront of the engine