303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma 2014 Fiesta
Installation Procedure revision date: 08/30/2013

Engine - Vehicles With: Automatic Transmission

  1. WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).

  1. NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

    If using a new clutch assembly, make sure the clutch-toflexplate alignment marks are aligned.

  1. NOTE: Use caution not to damage the engine to transaxle separator plate or damage can occur.

  1. General Equipment: Spreader Bar
    Install Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

  1. NOTICE: Make sure that the locating dowels remain installed.

    NOTE: Make sure that the component is installed to the position noted before removal.

  1. Torque : 48 Nm
  1. General Equipment: Adjustable Grip Arm
    Install Special Service Tool : 300-OTC1585AE Powertrain Lift
    General Equipment : Wooden Block
  1. General Equipment: Spreader Bar
    Remove Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

  1. NOTICE: Make sure that new nuts are installed.

    NOTICE: Rotate the engine in a clockwise direction only or engine damage may occur.

    NOTE: Using a magnetic socket will help ease the installation of new flexplate-toclutch nuts. If the flexplate-toclutch nuts fall into the clutch housing, the transaxle will have to be removed to retrieve them.

    1. Tighten nuts 1, 5 and 3.
      General Equipment : Magnetic Socket
      Torque : 12 Nm
    1. Tighten all nuts in sequence 6, 5, 4, 3, 2, 1.
      Torque : 25 Nm
  1. Torque : 48 Nm

  1. NOTE: Tighten the top bolts first.

    Torque : 48 Nm
  1. Torque : 10 Nm

  1. NOTICE: The engine vehicle studs must be torqued or damage to the powertrain mount may occur.

    Torque : 8 Nm
  1. Torque :
    Transmission support insulator nuts   125 Nm
    Transmission support insulator bolts   90 Nm
  1. Torque : 48 Nm
  1. Torque : 80 Nm
  1. General Equipment: Adjustable Grip Arm
    Remove Special Service Tool : 300-OTC1585AE Powertrain Lift
  1. Torque : 70 Nm
  1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
    Torque : 15 Nm
  1. If equipped.

  1. NOTE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.

    Torque :
      Stage 1:  20 Nm
      Stage 2:  40 Nm
      Stage 3:  55 Nm
  1. Torque : 10 Nm
    1. Torque : 50 Nm
    1. Torque : 25 Nm

  1. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

  1. Torque : 48 Nm
  1. Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Torque : 25 Nm
    1. Torque : 48 Nm
    1. Torque : 24 Nm
  1. Install the following items:
    1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
    2. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Torque : 10 Nm
  1. General Equipment : Hose Clamp Remover/Installer
  1. General Equipment : Hose Clamp Remover/Installer
  1. Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Torque : 25 Nm
  1. General Equipment : Hose Clamp Remover/Installer
  1. Install the following items:
    1. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
    2. Refer to: Generator - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
  1. Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. Torque : 10 Nm
  1. Torque : 10 Nm
  1. Torque : 5.4 Nm
  1. Torque : 10 Nm
  1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the following items:
    1. Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
    2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Fill the engine with clean engine oil.
    Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  1. Refer to: Degas Bottle (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Fill the bleed the cooling system.
    Refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250, General Procedures).
  1. Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission External Controls - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250, General Procedures).


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