2007 FORD FIESTA cam

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A199 Duratec-1 6V (Sigma)/Il6L Duratec-1 6V (Sigma) 303-01 A199
DISASSEMBLY
19. Using the special tool, remove the spark 23. Remove the timing belt lower cover.
plugs.
I i
Engines with eccentric cam timing belt
20. Set the crankshaft to approximately 20 tensioner
degrees before TDC. 24. Slacken the timing belt tensioner and
21. Using the special tool, lock the crankshaft. remove
the timing belt.
22. Remove the crankshaft pulley.
Discard the bolt.
Discard the timing belt.
25. Remove the timing belt tensioner.
Engines with slotted bracket timing belt
tensioner
26. Remove the timing belt tensioner and the
timing belt.
2006.0 Fiesta 1212006 G 1 54224en
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Engine - I .25L Duratec-1 6V (Sigma)ll.4L
303-01A-100 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-I 00
DISASSEMBLY
Discard the timing belt.
Vehicles built 0912003 onwards
27. Remove the timing belt.
Tension the timing belt tensioner by pulling
the timing belt and lock it with the special
tool.
Discard the timing belt. r-: 'Ii
Tension the timing belt tensioner by pulling 30. Remove the timing belt tensioner. the timing belt and lock it with the special
tool.
Discard the timing belt.
28. Remove the timing belt tensioner.
Vehicles built 0412005 onwards
29. Remove the timing belt.
All vehicles
31m &~~~l~~:lnstall a hose (order no.
E890438S) to the special tool studs, to
prevent damage to the camshaft sprockets.
Remove the camshaft pulleys.
Discard the retaining bolts.
2006.0 Fiesta 1212006 GI 54224en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)llI4L
Duratec-1 6V (Sigma)lI.GL Duratec-1 6V (Sigma) 303-01A-101
DISASSEMBLY
32. Remove the crankshaft timing belt pulley. 35. Disconnect the positive crankcase
ventilation (PCV) hose from the PCV cover.
33. Remove the timing belt rear cover.
34m ACAUTION: ~ee~ the camshaft bearing
caps and the camshafts in order for
installation.
36. Detach the oil level indicator and tube from
the intake manifold.
Detach the knock sensor (KS) electrical
connector from the oil level indicator tube.
Remove the camshafts. 37. Remove the intake manifold lower bolt.
Slacken each camshaft bearing cap retaining
bolt in the sequence shown by one turn until
the camshaft is released.
Remove the camshaft bearing caps.
Remove and discard the camshaft seals.
38.
CAUTIONS:
A~~ace the cylinder head on a suitable
soft surface.
A~emove the cylinder head bolts in the
sequence shown.
2006.0 Fiesta 1212006 G 1 54224en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-1 06 Duratec-I 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
303-01 A-I 06
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Discard the gasket. Install the CMP sensor.
91 Remove the camshaft position (CMP) sensor. 3. NOTE: Install a new coolant distribution
Discard the O-ring seal. housing gasket.
Assembly
1. N0TE:A new cylinder head is supplied
without exhaust manifold studs.
Install the exhaust manifold studs if
necessary.
2. N0TE:lnstall a new camshaft position (CMP)
O-ring seal. Install
the coolant distribution housing and
the ignition coil (El).
4. Install the engine rear lifting eye.
5. N0TE:lnstall new intake manifold gaskets.
2006.0 Fiesta 1212006 G202085en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-OIA-1 08 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 08 --
ASSEMBLY
Special Tool(s)
I Universal Flange Holding
Wrench
205-072 (1 5-030A)
Lifting Bracket, Engine
303-1 22 (2 1 -068A)
21 068A
I 1 Alignment Plate, Camshaft I
21 540
Socket, Cylinder Head Bolt
Gauge,
Bolt Angle
303- 1 74 (2 1 -540)
I I Locking Tool, Flywheel I
Special Tool(s)
Installer, Crankshaft Seal
303-395 (21 -1 71 )
Mounting Stand
303-435 (2 1 -1 87)
Mounting Bracket for 303-435
303-435-06 (21 -031
B)
c
Mounting Plate for
2006.0 Fiesta 1212006 GI 54225en
..
ES21202
Socket, Spark Plug
303-499 (21 -202)
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01A-I13 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
303-01 A-I 13
ASSEMBLY
24n ACAUTION:T~~ thickness of the new 25.
Install the intake manifold lower retaining
, cylinder head gasket must be the same as bolt.
I , that
of the old one (hole marked).
N0TE:lnstall a new cylinder head gasket.
N0TE:Position the cylinder head onto the two
guide sleeves.
Using the special tool, install the cylinder
head.
Tighten the cylinder head bolts in the
sequence shown in three stages.
Stage 1: 15 Nm.
Stage2: 30 Nm.
Stage 3: 90 degrees.
26. Attach the oil level indicator tube to the
intake manifold.
Attach the KS electrical connector to the oil
level indicator tube.
27. Connect the PCV hose to the PCV cover.
28. N0TE:ldentification numbers are provided
on the outer face of the camshaft bearing
caps.
2006.0 Fiesta 1212006 GI 54225en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)lIl4L
303-01 A-I 14 Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) 303-01 A-1 14
ASSEMBLY
Apply sealant to the points indicated on the
camshaft bearing cap no.
1 and to the mating
surface of the cylinder head.
29. Coat the camshafts and the camshaft
bearing caps with clean engine oil.
30m A~~~~10~:~osition the camshafts in
place so that none of the cams are at full
lift.
N0TE:The camshaft bearing cap numbering starts
at the timing
belt end with El on the exhaust side
and with
I1 on the intake side.
N0TE:The exhaust camshaft has an additional
cam for the camshaft position (CMP) sensor.
Install the camshafts and camshaft bearing
caps.
Tighten the camshaft bearing cap retaining
bolts in the sequence shown in three stages.
Stage 1: One half turn on each bolt until all
of the camshaft bearing caps are in contact
with the
cylinder head.
Stage
2: 7 Nm.
Stage
3: 45 degrees.
31. Coat the camshaft journals and seal lips
with clean engine oil.
32. N0TE:lnstall new camshaft seals. Using the
special tool, install the camshaft
seals.
f:
33. Install the timing belt rear cover.
34. Set the crankshaft to approximately 20
degrees before TDC.
35. Turn the camshafts to top dead center
(TDC) on cylinder number
I and install the
special tool.
36. N0TE:Do not fully tighten the camshaft
timing pulley retaining bolts at this stage.
Make sure the camshaft pulleys turn on the
camshafts.
N0TE:lnstall new camshaft pulley retaining bolts.
2006.0 Fiesta 1u2oos GI 54225en
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Engine - 1.25L Dura
303-01A-115 Duratec-1 6V (Sigma)ll.(
tec-16V (Sigma)ll.4L
iL Duratec-1 6V (Sigma) 303-01A-I15
ASSEMBLY
Install the camshaft timing pulleys.
io 37. Install the crankshaft timing belt pulley.
38. N0TE:lnstall a new timing belt.
N0TE:lnstall the timing belt, beginning with the
crankshaft timing pulley working counterclockwise.
Install the timing belt.
39. Remove the blanking plug and install the
special tool.
Carefully turn the crankshaft against the
,I special tool.
40. Measuring the depth of the threaded hole
in the crankshaft.
Depth of the threaded = 42 mm: Use an
MI 2x29 mm crankshaft pulley center bolt. Depth
of the threaded
= 52 mm: Use an
M12x44,5 mm crankshaft pulley center bolt.
41. Install the timing belt lower cover.
42. N0TE:lnstall a new crankshaft pulley
retaining bolt.
Install the crankshaft pulley.
Tighten the crankshaft pulley retaining bolt
in two stages.
Stage 1: 45 Nm.
2006.0 Fiesta 1212006 GI 54225en
procarmanuals.com