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

Special Tool(s) / General Equipment

Materials

Removal

Valve Cover Only

1. Remove the fuel rail.
   Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. 1. Disconnect the electrical connector.
      
   2. Loosen the clamp and remove the hose.
      Use the General Equipment: Hose Clamp Remover/Installer

1. • Disconnect the hose couplings, detach the retainer and remove the hoses.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Remove the oil level indicator.
     
   • Disconnect the electrical connector, remove the bolt and the CMP sensor.
     

1. NOTE: Note the position of the components before removal.

   • Disconnect the electrical connectors.
     
   • Remove the bolts and the VCT oil control solenoid.
     

1. NOTE: The O-ring seals are to be reused unless damaged.

   Inspect the VCT oil control solenoid O-ring seal.
   

1. NOTE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.

   Remove the bolts and the valve cover.
   

1. Remove and discard the valve cover gasket.
   

Fuel Pump and Brake Vacuum Pump Mounting Brackets

1. Remove the following items:
   1. Remove the fuel pump.
      Refer to: Fuel Pump (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
      
   2. Remove the brake vacuum pump.
      Refer to: Brake Vacuum Pump - 1.6L EcoBoost (132kW/180PS) – Sigma (206-07 Power Brake Actuation, Removal and Installation).
      

1. • Slide the protective cover outward and disconnect the electrical connector.
     
   • Remove the bolt and the CMP sensor.
     

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

   • Remove the fuel pump bracket bolts in sequence shown. Heat and break the adhesive bond.
     Use the General Equipment: Hot Air Gun
   • Remove the fuel pump bracket.
     
   • Remove and discard the O-ring seal.
     

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the brake vacuum pump mounting bracket. Failure to follow these directions may result in damage to the brake vacuum pump mounting bracket.

   • Remove the engine cover mounting stud.
     
   • Remove the bolts and the stud.
     
   • Heat and break the adhesive bond and remove the brake vacuum pump cap.
     Use the General Equipment: Hot Air Gun

Installation

Fuel Pump and Brake Vacuum Pump Mounting Brackets

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 which make leak paths.

   Make sure that the mating faces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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 which make leak paths.

   Make sure that the mating faces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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 which make leak paths.

   Make sure that the mating faces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. NOTE: The components must be installed within 5 minutes of applying the sealant.

   Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. • Install the brake vacuum pump cap, bolts and the stud.
     Torque: 89 lb.in (10 Nm)
   • Install the engine cover mounting stud.
     Torque: 89 lb.in (10 Nm)

1. NOTE: Use a new O-ring seal.

   • Tighten the fuel pump bracket bolts in sequence shown in 4 stages.
     Torque:
       Stage 1:  27 lb.in (3 Nm)
       Stage 2:  80 lb.in (9 Nm)
       Stage 3:  97 lb.in (11 Nm)
       Stage 4:  Tighten bolts 1, 2, 5, 6, 7, 8, 9 and 10 to::   124 lb.in (14 Nm)

1. • Install the CMP sensor and the bolt.
     Torque: 80 lb.in (9 Nm)
   • Connect the electrical connector and slide the protective cover onto connector.
     

1. Install the following items:
   1. Install the brake vacuum pump.
      Refer to: Brake Vacuum Pump - 1.6L EcoBoost (132kW/180PS) – Sigma (206-07 Power Brake Actuation, Removal and Installation).
      
   2. Install the fuel pump.
      Refer to: Fuel Pump (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
      

Valve Cover Only

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 which make leak paths.

   NOTE: Clean if replacing the valve cover gasket only.

   Make sure that the mating faces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. Install the new valve cover gasket.
   

1. NOTE: The components must be installed within 5 minutes of applying the sealant.

   Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Install the valve cover and the bolts in sequence shown in 3 stages.
   Torque:
     Stage 1:  44 lb.in (5 Nm)
     Stage 2:  80 lb.in (9 Nm)
     Stage 3:  89 lb.in (10 Nm)

1. NOTE: The O-ring seals are to be reused unless damaged.

   Lubricate the VCT oil control solenoid O-ring seal.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

1. Install the VCT oil control solenoids, bolts and connect the electrical connectors.
   Torque: 71 lb.in (8 Nm)

1. • Install the PCV hose, connect the couplings and attach the retainer.
     
   • Install the oil level indicator. Connect the breather hose.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Install the CMP sensor and the bolt. Connect the electrical connector.
     Torque: 80 lb.in (9 Nm)

1. 1. Install the PCV hose and the clamp.
      Use the General Equipment: Hose Clamp Remover/Installer
   2. If equipped.
      Connect the electrical connector.
      

1. Install the fuel rail.
   Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).