303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma 2014 Fiesta
Removal and Installation Procedure revision date: 05/2/2013

Cylinder Head

Removal

  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. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
  1. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove 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: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
    3. Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. General Equipment : Oil Drain Equipment
    Torque : 28 Nm
  1. General Equipment : Oil Drain Equipment
    General Equipment : Strap Wrench

  1. NOTE:

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

  1. Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
  1. If equipped.
  1. Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
  1. Refer to: Camshafts (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).

  1. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

    NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 0.1437  in ( 3.65  mm).

  1. Install new components as necessary.
  1. If equipped.
  1. General Equipment : Hose Clamp Remover/Installer
  1. General Equipment : Hose Clamp Remover/Installer
  1. Remove the following items:
    General Equipment : Trolley Jack
    General Equipment : Wooden Block
  1. Remove Special Service Tool : 303-F072 Support Bar, Engine
  1. Remove Special Service Tool : 303-050 (T70P-6000) Lifting Bracket, Engine

  1. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.

    NOTE: Discard the cylinder head bolts.

  1. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
    Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
    Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).

Installation

  1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

    NOTE:

    Material : Motorcraft® Metal Surface Prep / ZC-31-A

  1. NOTE: Lubricate the bolts with clean engine oil prior to installation.

    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

    Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
    Torque :
      Stage 1:  5 Nm
      Stage 2:  15 Nm
      Stage 3:  35 Nm
      Stage 4:  75°
  1. Install Special Service Tool : 303-050 (T70P-6000) Lifting Bracket, Engine
  1. Install Special Service Tool : 303-F072 Support Bar, Engine
  1. Remove the following items:
    General Equipment : Trolley Jack
    General Equipment : Wooden Block
  1. General Equipment : Hose Clamp Remover/Installer
  1. General Equipment : Hose Clamp Remover/Installer
  1. Torque : 6 Nm
  1. If equipped.
  1. Torque : 6 Nm
  1. Torque :
      Stage 1:  6 Nm
      Stage 2:  10 Nm
  1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  1. Refer to: Camshafts (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
  1. Torque : 9 Nm

  1. NOTE: Lubricate the O-ring seal with clean engine oil.

    Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
    Torque : 4 Nm
  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. NOTE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until reaching final torque of 55 Nm will cause the catalytic 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. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
    Torque : 15 Nm
  1. Install the following items:
    1. Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
    2. Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
    3. 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).
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  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: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).


Copyright © Ford Motor Company