Ford Fiesta: Engine Cooling - 1.6L EcoBoost (132kW/180PS) – Sigma / Coolant Pump. Removal and Installation

Special Tool(s) / General Equipment

	303-1556 Locking Tool, Timing Belt TKIT-2010B-FLM TKIT-2010B-ROW
	303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW

Removal

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 1.6L EcoBoost (132kW/180PS) – Sigma, General Procedures).
   

1. Remove the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Remove the engine appearance cover.
   

1. 1. Remove the turbocharger inlet tube retainers.
      
   • Disconnect the vent hose.
     
   • Loosen the clamp and remove the turbocharger inlet tube.
     

1. Remove the heat shield screws and the heat shield.
   

1. NOTE: It may be necessary to rotate the halfshaft to remove the front lower bolt.

   1. Remove the nuts and the axle bearing support.
      
   2. Remove the bolt.
      Loosen: 3 turn(s)
   3. Remove the bolts.
      

1. Remove the engine block bolt.
   

1. NOTE: The Crankshaft TDC (top dead center) Timing Pin will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during coolant pump removal and installation.

   
   Install Special Service Tool: 303-748  Locking Tool, Crankshaft.

1. NOTICE: Only rotate the crankshaft clockwise.

   Rotate the crankshaft slowly until the crankshaft stops.
   

1. Loosen the coolant pump pulley bolts.
   Loosen: 2 turn(s)

1. Remove the generator.
   Refer to: Generator - 1.6L EcoBoost (132kW/180PS) – Sigma (414-02 Generator and Regulator, Removal and Installation).
   

1. Remove the engine mount.
   Refer to: Engine Mount (303-01B Engine - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Remove the bolts and the accessory drive belt tensioner.
   

1. 1. Remove the timing cover stud bolt.
      
   2. Detach the cover from the retainer and open.
      

1. 1. Remove the bolts and the coolant pump pulley.
      
   2. Remove the engine mount stud.
      
   3. Detach the wiring harness retainer.
      
   4. Remove the wiring harness bracket bolt.
      
   5. Detach the wiring harness retainer.
      
   6. Remove the timing cover bolts and the timing cover.
      

1. NOTICE: Install a new timing belt if the existing belt is contaminated by coolant or oil.

   Remove the timing belt.
   Refer to: Timing Belt (303-01B Engine - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. 1. NOTICE: Only use the specified special tool.

      NOTICE: Make sure that the crankshaft is not rotated while the special tool is installed.

      Install the special service tool.
      Install Special Service Tool: 303-1556  Locking Tool, Timing Belt.

   2. NOTICE: Note the position of the components before removal.

      Mark the position of the components before removal.
      

1.   WARNING: Take extra care when handling the compressed spring.

   NOTICE: The crankshaft or camshafts must not be rotated while the timing belt is removed.

   Install a small screwdriver or holding pin.
   Rotate the timing belt tensioner and install a holding pin.
   

1.   WARNING: Take extra care when handling the compressed spring.

   Remove the bolt and timing belt tensioner.
   

1. NOTICE: Protect the timing belt and the lower timing belt cover from contamination by the coolant.

   Remove the bolts and the coolant pump.
   

Installation

1. Install the coolant pump and tighten the bolts in the sequence order.
   Torque: 89 lb.in (10 Nm)

1. NOTE: Make sure that the components are installed to the position noted before removal.

1.   WARNING: Take extra care when handling the compressed spring.

   1. Install the timing belt tensioner and tighten the bolt.
      Torque: 18 lb.ft (25 Nm)
   2. Remove the holding pin.
      

1. 1. NOTE: Make sure that the components are installed to the position noted before removal.

      
      
   2. Remove Special Service Tool: 303-1556  Locking Tool, Timing Belt.

1. 1. Install the timing cover and tighten the bolts.
      Torque: 89 lb.in (10 Nm)
   2. Finger tight.
      Install the engine mount stud.
      
   3. Finger tight.
      Install the coolant pump pulley and the bolts.
      
   4. Install and tighten the wiring harness bracket bolt.
      Torque: 71 lb.in (8 Nm)
   5. Attach the wiring harness retainer.
      
   6. Attach the wiring harness retainer.
      

1. 
   
   1. Close the cover.
      
   2. Install and tighten the timing cover stud bolt.
      Torque: 89 lb.in (10 Nm)

1. Install the accessory drive tensioner and tighten the bolts.
   Torque: 35 lb.ft (48 Nm)

1. Install the engine mount studs.
   Torque: 71 lb.in (8 Nm)

1. Install the engine mount.
   Refer to: Engine Mount (303-01B Engine - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Install the generator.
   Refer to: Generator - 1.6L EcoBoost (132kW/180PS) – Sigma (414-02 Generator and Regulator, Removal and Installation).
   

1. Remove the special service tool.
   Remove Special Service Tool: 303-748  Locking Tool, Crankshaft.

1. Install and tighten the engine block bolt.
   Torque: 177 lb.in (20 Nm)

1. NOTE: Make sure that a new component is installed.

   1. Position the support bracket and tighten the bolts.
      Torque: 35 lb.ft (48 Nm)
   2. Install the axle bearing support and tighten the nuts.
      Torque:
        Stage 1:  44 lb.in (5 Nm)
        Stage 2:  18 lb.ft (25 Nm)
        Stage 3:  18 lb.ft (25 Nm)

1. Install the heat shield and tighten the screws.
   

1. Tighten the coolant pump pulley bolts.
   Torque: 177 lb.in (20 Nm)

1. 1. Install the turbocharger inlet tube retainers.
      
   • Install the turbocharger inlet tube and tighten the clamp.
     
   • Connect the vent hose.
     

1. Install the engine appearance cover.
   

1. Install the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Fill and bleed the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 1.6L EcoBoost (132kW/180PS) – Sigma, General Procedures).