2013 Ford Fiesta 1.6L

5/22/2016
2013Fiesta
30301Engine1.6L
2013Fiesta
DISASSEMBLY
Procedurerevisiondate:06/04/2012
Engine
SpecialTool(s)
EngineStand
01400232orequivalent
Installer,ConnectingRod
303462(T94P6136AH)
Pin,CrankshaftTopDead
Center(TDC)
303748
Remover,InputShaftOilSeal
308375
SlideHammer
100001(T50T100A)
StrapWrench
303D055(D85L6000A)or
equivalent
Tool,VariableCamshaft
Timing(VCT)Alignment
3031097
http://www.fordtechservice.dealerconnection.com/vdirs/protech/global/default.asp?comefrom=Motocraft
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WARNING:Donotbreathedustorusecompressedairtoblowdustfromstoragecontainersor
frictioncomponents.Removedustusinggovernmentapprovedtechniques.Frictioncomponentdustmay
beacancerandlungdiseasehazard.Exposuretopotentiallyhazardouscomponentsmayoccurifdusts
arecreatedduringrepairoffrictioncomponents,suchasbrakepadsandclutchdiscs.Exposuremayalso
causeirritationtoskin,eyesandrespiratorytract,andmaycauseallergicreactionsand/ormayleadto
otherchronichealtheffects.Ifirritationpersists,seekmedicalattentionoradvice.Failuretofollowthese
instructionsmayresultinseriouspersonalinjury.
NOTICE:Donotloosenorremovethecrankshaftpulleyboltwithoutfirstinstallingthespecialtools.The
crankshaftpulleyandthecrankshafttimingsprocketarenotkeyedtothecrankshaft.Beforeanyrepair
requiringlooseningorremovalofthecrankshaftpulleybolt,thecrankshaftandcamshaftsmustbelocked
inplacebythespecialservicetools,otherwisesevereenginedamagecanoccur.
NOTICE:Duringenginerepairprocedures,cleanlinessisextremelyimportant.Anyforeignmaterial,
includinganymaterialcreatedwhilecleaninggasketsurfacesthatenterstheoilpassages,coolant
passagesortheoilpan,cancauseenginefailure.
NOTE:Earlybuildvehiclesareequippedwithathree(3)piecetimingbeltcover.Latebuildvehicleshaveatwo
(2)piecetimingcoverwhichreplacesthethree(3)piecedesign.
NOTE:Foradditionalinformation,refertotheexplodedviewundertheAssemblyprocedureinthissection.
Vehicleswithmanualtransaxle
1.
WARNING:Theclutchdiscandclutchpressureplateareheavyandmayfallifnotheldwhen
theboltsareremoved.Failuretofollowthisinstructionmayresultinseriouspersonalinjury.
NOTE:Loosentheclutchpressureplateretainingboltsevenly,bytwoturnsatatime.
Removeanddiscardthe6clutchpressureplateretainingbolts,removetheclutchdiscandpressureplate.
2.Removetheboltsandtheflywheel.
Discardthebolts.
Vehicleswithautomatictransaxle
3.Removetheboltsandtheflexplate.
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Discardthebolts.
Allvehicles
4.MounttheengineonaEngineStand.
5.DisconnecttheEvaporativeEmission(EVAP)canisterpurgevalvetubefromtheintakemanifold.
6.Disconnectthebrakeboostervacuumtubefromtheintakemanifold.
7.DetachtheEVAPtubeandcoolanttubefromthecoolantoutletbracketretainer.
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8.RemovetheboltfortheEVAPcanisterpurgevalveandremovethebrakeboostervacuumtubeandEVAP
canisterpurgevalveasanassembly.
9.Removethesparkplugwires.
10.Disconnectthecoolanthosefromthecoolantoutlet.
11.Disconnectthecoolantreturnhosefromthecylinderhead.
Detachthecoolanttubefromthefuelrailretainers.
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12.Removethenut,boltandthebracketfromthecoolantoutlet.
13.Removethe4boltsandthecoolantoutletandignitioncoilassembly.
Inspectandreplacethegasket,ifnecessary.
14.Removethe2boltsandtheenginelifteye.
15.Removethescrewandtheoillevelindicatorandtube.
InspectandreplacetheOringseal,ifnecessary.
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16.Ifequipped,removetheengineblockheater.
17.Removetheboltsandthefuelrailassembly.
18.Removethefuelinjectorclipsandthe4fuelinjectors.
19.Removeanddiscardthe8fuelinjectorOringseals.
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20.DetachtheKnockSensor(KS)fromthebottomoftheintakemanifold.
21.Removetheboltsandtheintakemanifold.
DisconnectthePCVhosefromtheintakemanifold.
22.NOTICE:Anewoilcoolermustbeinstalledorseveredamagetotheenginecanoccur.
Removetheboltandtheoilcooler.
Discardtheoilcooler.
23.Removetheboltsandthethermostathousing
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24.Removethethermostatfromtheengineblock.
Inspectthethermostatsealandreplace,ifnecessary.
25.NOTE:Markthelocationofthe2KSforinstallation.
Removethe2boltsandthe2KS.
26.Removetheboltsandthecrankcaseventoilseparator.
27.RemovetheEngineOilPressure(EOP)switch.
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28.RemovetheboltandtheCrankshaftPosition(CKP)sensor.
29.Removethe2boltsandtheVariableCamshaftTiming(VCT)oilcontrolsolenoids.
30.RemovethenutandtheHeatedOxygenSensor(HO2S)electricalconnectorbracket.
31.Loosentheretainersandremovethevalvecover.
Discardthegasket.
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32.Removetheenginemountstud.
33.Removetheboltsandcoolantpumppulley.
Earlybuildvehicles
34.NOTE:Earlybuildvehiclesareequippedwithathree(3)piecetimingbeltcover.Latebuildvehicleshavea
two(2)piecetimingcoverwhichreplacesthethree(3)piecedesign.
Removetheboltsandthetimingbeltcover.
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Latebuildvehicles
35.Openthetimingbeltsidecover.
1.Removetheenginefrontcoverstudbolt.
2.Detachthecoverfromtheretainerandopen.
36.Removetheboltsandthetimingbeltcover.
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Allvehicles
37.Removethe3boltsandtheenginemountbracket.
38.NOTICE:Onlyrotatethecrankshaftinaclockwisedirection.
Usingthecrankshaftpulleybolt,turnthecrankshaftclockwiseuntilthemarkingsonthecamshaftphaser
andsprocketsareatthe11o'clockpositionasshown.
39.Removetheengineplugbolt.
40.NOTE:TheCrankshaftTopDeadCenter(TDC)TimingPinwillcontactthecrankshaftandpreventitfrom
turningpastTDC.However,thecrankshaftcanstillberotatedinthecounterclockwisedirection.The
crankshaftmustremainattheTDCpositionduringthecrankshaftpulleyremovalandinstallation.
InstalltheCrankshaftTDCPin.
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41.NOTE:Onlyrotatethecrankshaftclockwisedirection.
RotatethecrankshaftuntilitcontactstheCrankshaftTDCPin.
42.UsingtheStrapWrench,removethecrankshaftpulleyboltandthecrankshaftpulley.
Discardthecrankshaftpulleybolt.
Earlybuildvehicles
43.Removetheboltsandthelowertimingbeltcover.
Latebuildvehicles
44.Removetheboltandthelowertimingbeltcover.
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Allvehicles
45.InstalltheVCTAlignmentTool.
46.
WARNING:Thetensionerisunderspringtension.Becarefulwhenhandlingthetensioner.
Failuretofollowthisinstructionmayresultinpersonalinjury.
Removethetimingbelt.
1.Rotatethetimingbelttensionerclockwise.
2.Alignthe2holesonthetensionerandinstallasmallscrewdriverorholdingpin.
Removethetimingbelt.
Earlybuildvehicles
47.Removetheboltsandthetimingbeltcoverbackplate.
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Allvehicles
48.Removethecrankshaftsprocketgear.
49.UsingtheInputShaftOilSealRemoverandSlideHammer,removethecrankshaftfrontoilseal.
50.Removetheboltandthetimingbelttensioner.
51.Removetheboltsandthecoolantpump.
Discardthegasket.
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52.Removethe4sparkplugs.
53.RemovetheVCTAlignmentTool.
54.NOTICE:Useanopenendedwrenchtoholdthecamshaftsbythehexagontopreventthecamshafts
fromturning.
Removethecamshaftphaserandsprocketplugs.
55.NOTICE:Useanopenendedwrenchtoholdthecamshaftsbythehexagontopreventthecamshafts
fromturning.
Removetheboltsandthecamshaftphaserandsprockets.
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56.UsingtheInputShaftOilSealRemoverandSlideHammer,removethecamshaftoilseals.
57.NOTE:Notethepositionofeachcomponentbeforeremoval.
RemovetheboltsforthecamshaftbearingcapsandVCTbridgeinthesequenceshown.
58.RemovetheVCTbridgeOringseal.
InspectandreplacetheVCTbridgeOringseal,ifnecessary.
59.NOTICE:Donotpryoncamshaftswhenremovingordamagetothecamshaftsmayoccur.
Removethecamshaftsfromthecylinderhead.
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60.Ifnecessary,removetheboltsandthecamshafttriggerwheels.
61.NOTE:Ifthecamshaftsandvalvetappetsaretobereused,markthelocationofthevalvetappetsto
makesuretheyareassembledintheiroriginalpositions.
NOTE:Thenumberonthevalvetappetsonlyreflectsthedigitsthatfollowthedecimal.Forexample,a
tappetwiththenumber0.650hasthethicknessof3.650mm.
Removeandinspectthevalvetappets.Foradditionalinformation,refertoSection30300.
62.RemovetheCrankshaftTDCPin.
63.NOTE:Makesurethatthecylinderheadisatambientairtemperaturebeforeremovingthecylinderhead
bolts.
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Removethecylinderheadboltsinthesequenceshown.
Removethecylinderhead.
Discardthecylinderheadboltsandgasket.
64.Supportthecylinderheadonabenchwiththeheadgasketsideup.Checkthecylinderheaddistortionand
thecylinderblockdistortion.Foradditionalinformation,refertoSection30300.
65.Removethecylinderheadalignmentdowels.
66.Removetheboltsfromtheoilpan.
67.Usingtheprypads,removetheoilpan.
68.Removetheboltsandthecrankshaftrearseal.
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69.Removetheboltsandtheoilpumpscreenandpickuptube.
InspectandreplacetheOringseal,ifnecessary.
70.Removetheboltsandthewindagetray.
71.NOTE:Markthelocationofthe3differentlengthbolts.
Removetheboltsandtheoilpump.
Discardthegasket.
72.Beforeremovingthepistons,inspectthetopofthecylinderbores.Ifnecessary,removetheridgeorcarbon
depositsfromeachcylinderusinganabrasivepadorequivalent,followingmanufacturer'sinstructions.
73.NOTE:Clearlymarktheconnectingrods,connectingrodcapsandconnectingrodbearingsinnumerical
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orderforcorrectorientationforreassembly.
Removetheboltsandtheconnectingrodcap.
74.NOTICE:Donotscratchthecylinderwallsorcrankshaftjournalswiththeconnectingrod.
UsingtheConnectingRodInstaller,removethepiston/rodassemblyfromtheengineblock.
75.Repeattheprevious2stepsuntilallthepiston/rodassembliesareremovedfromtheengineblock.
76.NOTE:Markthepositionoftheparts,sotheycanbeinstalledintheiroriginalpositions.
Removetheconnectingrodbearingsfromtheconnectingrodandcap.
77.NOTE:Themainbearingbeamhas2arrowspointingtowardsthefrontofengineforcorrectorientationfor
reassembly.
Removethe10boltsinthesequenceshownandthemainbearingbeam.
78.NOTE:Ifthemainbearingsarebeingreused,marktheminorderforcorrectorientationandreassembly.
Removethemainbearingsfromthemainbearingbeam.
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79.Removethecrankshaftfromtheengineblock.
80.NOTE:Ifthemainbearingsarebeingreused,marktheminorderforcorrectorientationandreassembly.
NOTE:Thecenterbulkheadhasthethrustbearing.
Removethemainbearingsfromthecylinderblock.
81.Inspectthecylinderblockandmainbearingbeam.
82.Inspectthepistonsandconnectingrods.Foradditionalinformation,refertoSection30300.
Copyright2016FordMotorCompany
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