Engine - Vehicles With: Manual Transmission

1. WARNING: Before beginning any service procedure in this section, refer to 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. Remove the following items:
   1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   2. 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 (414-01 Battery, Mounting and Cables, 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. Refer to: Generator - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-02 Generator and Regulator, 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. Refer to: Degas Bottle (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. General Equipment : Hose Clamp Remover/Installer

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. Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
   

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

1. Remove 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. Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

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

1. Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
   

1. If equipped.
   

1. General Equipment : Oil Drain Equipment
   Torque : 28 Nm

1. General Equipment : Oil Drain Equipment
   General Equipment : Strap Wrench

1. General Equipment: Adjustable Grip Arm
   Install Special Service Tool : 300-OTC1585AE Powertrain Lift
   General Equipment : Wooden Block

1. NOTICE: The engine mount studs must be held while removing the engine mount nuts or damage to the powertrain mount may occur.

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

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