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303-01A-1 Engine — 1.4L Duratec-16V (Sigma) 303-01A-1
.

SECTION 303-01A Engine — 1.4L Duratec-16V (Sigma)

VEHICLE APPLICATION: 2011MY Fiesta
CONTENTS PAGE
PAGE 1 OF 2
SPECIFICATIONS
Specifications...................................................................................................................... 303-01A-3
Engine Data - 1.25L........................................................................................................ 303-01A-3
Engine Data - 1.4L.......................................................................................................... 303-01A-3
Engine Data - 1.4L Liquefied Petroleum Gas (LPG)....................................................... 303-01A-3
Oil pressure..................................................................................................................... 303-01A-4
Engine Oil Capacity - 1.25L/1.4L.................................................................................... 303-01A-4
Valve Clearance - 1.25L/1.4L.......................................................................................... 303-01A-4
Cylinder block - 1.25L/1.4L............................................................................................. 303-01A-4
Cylinder head.................................................................................................................. 303-01A-4

DESCRIPTION AND OPERATION

Engine (Component Location)............................................................................................ 303-01A-5

DIAGNOSIS AND TESTING

Engine................................................................................................................................. 303-01A-6

GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01A-7

REMOVAL AND INSTALLATION

Crankshaft Front Seal..................................................................................... (21 467 0) 303-01A-9
Crankshaft Rear Seal..................................................................................... (21 468 4) 303-01A-10
Camshaft Seal................................................................................................ (21 288 0) 303-01A-11
Camshafts...................................................................................................... (21 284 0) 303-01A-12
Valve Stem Seals........................................................................................... (21 238 0) 303-01A-13
Valve Cover.................................................................................................... (21 141 0) 303-01A-15
Timing Belt...................................................................................................... (21 304 0) 303-01A-18
Cylinder Head................................................................................................. (21 163 0) 303-01A-27
Oil Pan............................................................................................................ (21 154 0) 303-01A-34
Oil Pump......................................................................................................... (21 714 0) 303-01A-37

REMOVAL
Engine — Vehicles With: 5-Speed Manual Transaxle (iB5)........................... (21 132 0;
21 132 6;
21 132 7) 303-01A-38
Engine Accessories........................................................................................ (21 139 4) 303-01A-51

DISASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01A-54

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303-01A-2 Engine — 1.4L Duratec-16V (Sigma) 303-01A-2
.
PAGE 2 OF 2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head................................................................................................. (21 165 6) 303-01A-58

ASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01A-61

INSTALLATION
Engine — Vehicles With: 5-Speed Manual Transaxle (iB5)........................... (21 132 0;
21 132 6;
21 132 7) 303-01A-72
Engine Accessories........................................................................................ (21 139 4) 303-01A-85

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303-01A-3 Engine — 1.4L Duratec-16V (Sigma) 303-01A-3
SPECIFICATIONS
Engine Data - 1.25L
Description STJA SNJA
Emission level IV
Firing order 1-3-4-2
Bore 71.9 mm
Stroke 76.5 mm
Displacement 1242 ccm
Compression ratio 11:1
Power output 44 kW (60 PS) / 60 kW (80 PS) /
6000 1/min 5800 1/min
Torque 109 Nm / 3600 1/ 114 Nm / 4200 1/
min min
Maximum permissible engine speed continuous 6450 1/min 6250 1/min
Maximum permissible engine speed intermittent 6675 1/min 6475 1/min
Idle speed 750 1/min
Maximum oil consumption 0.5L/1000km

Engine Data - 1.4L

Description SPJA
Emission level IV
Firing order 1-3-4-2
Bore 76.0 mm
Stroke 76.5 mm
Displacement 1388 cc
Compression ratio 11:1
Power output 71 kW (96 PS) / 5750 1/min
Torque 128 Nm / 4200 1/min
Maximum permissible engine speed continuous 6200 1/min
Maximum permissible engine speed intermittent 6425 1/min
Idle speed 750 1/min
Maximum oil consumption 0.5L/1000km

Engine Data - 1.4L Liquefied Petroleum Gas (LPG)

Description RTJA, RTJB
Emission level IV
Firing order 1-3-4-2
Bore 76.0 mm
Stroke 76.5 mm
Displacement 1388 cc

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303-01A-4 Engine — 1.4L Duratec-16V (Sigma) 303-01A-4
SPECIFICATIONS
Description RTJA, RTJB
Compression ratio 11:1
Power output 71 kW (96 PS) / 5750 1/min
Torque 128 Nm / 4200 1/min
Maximum permissible engine speed continuous 6200 1/min
Maximum permissible engine speed intermittent 6425 1/min
Idle speed 750 1/min
Maximum oil consumption 0.5L/1000km

Oil pressure
Description bar
Oil pressure (minimum, oil temperature 80°C) at 800 1/min 1.0
Oil pressure (minimum, oil temperature 80°C) at 2000 1/min 2.5
Pressure relief valve opening pressure 4

Engine Oil Capacity - 1.25L/1.4L

Description Liters
Initial fill including oil filter 4.05
Service fill including oil filter 3.80
Service fill excluding oil filter 3.50

Valve Clearance - 1.25L/1.4L

Description mm
Valve clearance (engine cold), intake 0.17 - 0.23
Valve clearance (engine cold), exhaust 0.27 - 0.33

Cylinder block - 1.25L/1.4L

Description mm
Crankshaft end float 0.300 - 0.800

Cylinder head
Description mm
Maximum distortion (mating face) 0.03

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Ford Formula E SAE 5W-30 Engine Oil WSS-M2C913-C
Silicone grease ESE-M1C171-AA

Torque Specifications
Description Nm lb-ft lb-in
Spark plugs 15 11 133

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303-01A-5 Engine — 1.4L Duratec-16V (Sigma) 303-01A-5
DESCRIPTION AND OPERATION

Engine – Component Location

1 2 3 4

10 9 8 7 6
E103290

Item Description Item Description

1 High-Pressure Fuel Rail 6 Downstream HO2S
2 Intake manifold 7 EI (electronic ignition) ignition coil
3 Electronic throttle plate 8 Dipstick
4 Upstream HO2S (heated oxygen sensor) 9 PCV (positive crankcase ventilation)
5 Three-way Catalytic Converter 10 Coolant thermostat

Item Description
Location - engine code and engine serial number
1 Engine serial number
2 Code
2

W2101080

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303-01A-6 Engine — 1.4L Duratec-16V (Sigma) 303-01A-6
DIAGNOSIS AND TESTING

Engine
REFER to Section 303-00 [Engine System -
General Information].

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303-01A-7 Engine — 1.4L Duratec-16V (Sigma) 303-01A-7
GENERAL PROCEDURES

Valve Clearance Adjustment

Special Tool(s)
5. Compare the measured valve clearance(s) with
303-499 the specifications.
Socket, Spark Plug
Refer to: Specifications (303-01 Engine - 1.4L
Duratec-16V (Sigma), Specifications).

ES21202

Materials
Name Specification
Engine Oil - 5W-30 WSS-M2C912-A1
Flange Sealant - Anaer- WSK-M2G348-A5 /
obic LR 2U7J-M2G348-AA
E70936
1. Refer to: Valve Cover (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and NOTE: The following steps are only necessary if
Installation). adjustments are required.
2. Special Tool(s): 303-499 6. Refer to: Camshafts (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
7. 1. Remove the valve tappet and read the
thickness from the underside.
2. The number on the valve tappet indicates
x4

the thickness of the bottom of the tappet.

However, the number only indicates the digits
after the decimal point (example: 725 =
2.725).
3. Calculate the valve tappet thickness required
E81957 (thickness of the currently installed tappet +
the measured valve clearance - the required
valve clearance).
3. CAUTION: Only rotate the crankshaft 4. Install the correct valve tappet.
clockwise.
Rotate the crankshaft until the corresponding 8. CAUTION: Make sure that the camshafts
piston is at TDC and then measure the valve and camshaft bearing caps are installed
clearance(s). in their original locations.
Apply clean engine oil to the surfaces of the
4. Note down each cylinder number and the valve bearings of the camshaft bearing caps.
clearances measured.
Material: Engine Oil - 5W-30 (WSS-M2C912-A1)
Material: Flange Sealant - Anaerobic LR
(WSK-M2G348-A5 / 2U7J-M2G348-AA)
9. Install the camshafts with the valves overlapping
on number 4 cylinder.

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303-01A-8 Engine — 1.4L Duratec-16V (Sigma) 303-01A-8
GENERAL PROCEDURES
10. 1. Tighten the bolts evenly half a turn at a time 11. 1. Turn the crankshaft back by 45° (counter to
until the camshaft bearing caps make contact the normal direction of rotation).
with the cylinder head. 2. Turn the camshafts to measure the valve
2. Torque: clearance.
• Stage 1: 7 Nm 3. Measure the valve clearances and repeat
• Stage 2: 45° this procedure as necessary until all valve
clearances are within the specified tolerance.
4. Turn the crankshaft until it stops against the
special tool.

12. Special Tool(s): 303-499

Torque: 15 Nm

x4
3 2 4 1 5

E81957

13. Refer to: Camshaft Seal (303-01 Engine - 1.4L

3 2 4 1 5 Duratec-16V (Sigma), Removal and
Installation).

E80880

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303-01A-9 Engine — 1.4L Duratec-16V (Sigma) 303-01A-9
REMOVAL AND INSTALLATION

Crankshaft Front Seal(21 467 0)

Special Tool(s) 3. Special Tool(s): 303-293
303-293
Remover, Crankshaft Seal

21143

303-395
Installer, Crankshaft Seal
303-293
E79222

21171 Installation
1. CAUTION: Only use the specified
Materials material to lubricate the seals.
Name Specification Special Tool(s): 303-395
Material: Engine Oil - 5W-30 (WSS-M2C912-A1)
Engine Oil - 5W-30 WSS-M2C912-A1

303-395
Removal
1. Refer to: Timing Belt (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
2.

E79223

2.

E79221

E79221

3. Refer to: Timing Belt (303-01 Engine - 1.4L

Duratec-16V (Sigma), Removal and
Installation).

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303-01A-10 Engine — 1.4L Duratec-16V (Sigma) 303-01A-10
REMOVAL AND INSTALLATION

Crankshaft Rear Seal(21 468 4)

Special Tool(s) 3. NOTE: New crankshaft rear seal carriers are
supplied with an alignment sleeve which must
303-393
be removed after installation.
Locking Tool, Flywheel
Torque: 9 Nm

21168

Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Remove the following items:
E79262
1. Refer to: Clutch Disc and Pressure Plate
(308-01 Clutch - Vehicles With: 5-Speed
Manual Transaxle (iB5), Removal and Installation
Installation).
2. Refer to: Oil Pan (303-01 Engine - 1.4L 1. To install, reverse the removal procedure.
Duratec-16V (Sigma), Removal and
Installation).

2. CAUTION: Make sure that new bolts are

installed.
Special Tool(s): 303-393
Torque:
• Stage 1: 30 Nm
• Stage 2: 80°

6
303-393
3
2

1
4

5
E79261

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303-01A-11 Engine — 1.4L Duratec-16V (Sigma) 303-01A-11
REMOVAL AND INSTALLATION

Camshaft Seal(21 288 0)

Special Tool(s) Installation
303-293
Remover, Crankshaft Seal 1. NOTE: Make sure that a new component is
installed.
Special Tool(s): 303-395
Material: Engine Oil - 5W-30 (WSS-M2C912-A1)
21143

303-395
303-395
Installer, Crankshaft Seal

21171

E79260
Materials
Name Specification
2. Refer to: Timing Belt (303-01 Engine - 1.4L
Engine Oil - 5W-30 WSS-M2C912-A1 Duratec-16V (Sigma), Removal and
Installation).
Removal
1. Refer to: Timing Belt (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
2. Special Tool(s): 303-293

303-293

E79259

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303-01A-12 Engine — 1.4L Duratec-16V (Sigma) 303-01A-12
REMOVAL AND INSTALLATION

Camshafts(21 284 0)
Materials 2. Install the camshafts approximately at valve
Name Specification overlap position cylinder No. 4.
Torque:
Engine Oil - 5W-30 WSS-M2C913-C • Stage 1: 7 Nm
Flange Sealant - Anaer- WSK-M2G348-A5 / • Stage 2: 45°
obic LR 2U7J-M2G348-AA

Removal
1. Refer to: Camshaft Seal (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
2. CAUTION: Note the position of each
component before removal.

3 2 4 1 5
3 2 4 1 5

3 2 4 1 5 3 2 4 1 5
E80879

Installation E80880

1. CAUTION: Make sure that the camshafts

and camshaft bearing caps are installed 3. Refer to: Valve Clearance Adjustment (303-01
in their original locations. Engine - 1.4L Duratec-16V (Sigma), General
Apply a thin coating. Procedures).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) 4. Refer to: Camshaft Seal (303-01 Engine - 1.4L
Material: Flange Sealant - Anaerobic LR Duratec-16V (Sigma), Removal and
(WSK-M2G348-A5 / 2U7J-M2G348-AA) Installation).

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303-01A-13 Engine — 1.4L Duratec-16V (Sigma) 303-01A-13
REMOVAL AND INSTALLATION

Valve Stem Seals(21 238 0)

Special Tool(s)
303-361-04 Removal
Adapter for 303-361A
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Camshafts (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
2115504
Installation).

303-361-05 2.
Adapter for 303-361A

2115505

303-361A
Compressor, Valve Spring

E80663
303361A

3. 1. Set the relevant cylinder to BDC.

303-362 Special Tool(s): 303-363
Installer, Valve Stem Collets
303-363

21156

303-363
Adapter, Air Supply (Cylinder
Head)

E80664
21157

4. Special Tool(s): 303-361A, 303-361-04,

303-361-05, 303-362
303-508
Pliers, Valve Stem Seal

21211

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303-01A-14 Engine — 1.4L Duratec-16V (Sigma) 303-01A-14
REMOVAL AND INSTALLATION

303-361A 303-361-04

303-361-05

303-362

E80665

5. Special Tool(s): 303-508

303-508
E80666

Installation
1. To install, reverse the removal procedure.

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303-01A-15 Engine — 1.4L Duratec-16V (Sigma) 303-01A-15
REMOVAL AND INSTALLATION

Valve Cover(21 141 0)

1. Torque: 9 Nm
Removal
NOTE: Removal steps in this procedure may
contain installation details.

E100129

2.

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303-01A-16 Engine — 1.4L Duratec-16V (Sigma) 303-01A-16
REMOVAL AND INSTALLATION

x12

E100130

Installation
2. CAUTION: Make sure that the mating
1. To install, reverse the removal procedure. faces are clean and free of foreign
material.
Torque:
• 1 3-4 turn(s)
• 2 - 13 9 Nm

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303-01A-17 Engine — 1.4L Duratec-16V (Sigma) 303-01A-17
REMOVAL AND INSTALLATION

4 5 13 6 7

2 3

1 10 12 9 8

11

E100134

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303-01A-18 Engine — 1.4L Duratec-16V (Sigma) 303-01A-18
REMOVAL AND INSTALLATION

Timing Belt(21 304 0)

Special Tool(s) Special Tool(s)
205-072 303-748
Universal Flange Holding Locking Tool, Crankshaft
Wrench

303748
15030A

303-1054 General Equipment

Locking Tool, Timing Belt Calliper Gauge
Tensioner
Trolley Jack
Wooden Block
3031054

Removal
303-376B
1. Remove the right-hand front wheel.
Alignment Plate, Camshaft
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).

21162B 2.

303-393
Locking Tool, Flywheel

21168

303-393-02 E98509
Adapter for 303-393

3. Loosen: 2 turn(s)

E55029

303-499
Socket, Spark Plug
x4

ES21202

E81913

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303-01A-19 Engine — 1.4L Duratec-16V (Sigma) 303-01A-19
REMOVAL AND INSTALLATION
4. Refer to: Generator - 1.4L Duratec-16V 10. CAUTION: Only rotate the crankshaft
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma) clockwise.
(414-02 Generator and Regulator, Removal Rotate the crankshaft slowly until the crankshaft
and Installation). stops.
5. Refer to: Starter Motor (303-06 Starting System,
Removal and Installation).
6. Refer to: Valve Cover (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
7. Special Tool(s): 303-499

303-499
E93515

x4
11. Install the Special Tool(s): 303-376B

E98368

8.

303-376B

E81956

12. Special Tool(s): 303-393, 303-393-02

303-393

E81958

9. Install the Special Tool(s): 303-748

E86730

303-748

E81959

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303-01A-20 Engine — 1.4L Duratec-16V (Sigma) 303-01A-20
REMOVAL AND INSTALLATION
13. 16.

2 x2 1
x3

3 x3
E98376
E81916

14. CAUTION: Use a wooden block to 17.

protect the oil pan when supporting the
engine.
General Equipment: Trolley Jack
General Equipment: Wooden Block

2 x8

x4
1
E81915

18.

E66944

15.

E98380

E98374

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303-01A-21 Engine — 1.4L Duratec-16V (Sigma) 303-01A-21
REMOVAL AND INSTALLATION
19. WARNING: Take extra care when 2.
handling the compressed spring.
Install the Special Tool(s): 303-1054 3 2

303-1054

2
4

E81926

20. Special Tool(s): 205-072

205-072

1
E101665

3. WARNING: Take extra care when

E80877 handling the compressed spring.
Remove the Special Tool(s): 303-1054
Installation
1. CAUTION: Make sure that new bolts are 303-1054
installed.
NOTE: Only tighten the bolts finger tight at this
stage.
NOTE: Make sure that the camshaft pulleys can
rotate on the camshafts.

E82114

E80878

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303-01A-22 Engine — 1.4L Duratec-16V (Sigma) 303-01A-22
REMOVAL AND INSTALLATION
4. Torque: 9 Nm 6. CAUTION: Make sure that a new bolt is
installed.
1. Torque:
• M12
• Stage 1: 40 Nm
• Stage 2: 90°
• M14
x3 • Stage 1: 100 Nm
• Stage 2: 90°
3. Torque:
• M14 15°
E95361

5. • a = 42 mm = Bolt M12 x 29
• a = 52 mm = Bolt M12 x 44,5
• a = 81 mm = Bolt M14 x 80
1
General Equipment: Calliper Gauge

a 2

E124260
3

E124291

7. Special Tool(s): 205-072

Torque: 60 Nm

205-072

E80877

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303-01A-23 Engine — 1.4L Duratec-16V (Sigma) 303-01A-23
REMOVAL AND INSTALLATION
8. Remove the Special Tool(s): 303-393, Rotate the crankshaft approx. 1¾ revolutions.
303-393-02

303-393

E93515
E86730

12. Install the Special Tool(s): 303-748

9. Remove the Special Tool(s): 303-748

303-748
303-748

E81959
E81959

13. CAUTION: Only rotate the crankshaft

10. Remove the Special Tool(s): 303-376B clockwise.
Rotate the crankshaft slowly until the crankshaft
stops.

303-376B

E81956

E93515
11. CAUTION: Only rotate the crankshaft
clockwise.
14. NOTE: The special tool can only be installed if
the valve timing is correct.

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303-01A-24 Engine — 1.4L Duratec-16V (Sigma) 303-01A-24
REMOVAL AND INSTALLATION
If the special tool cannot be installed, repeat the 17. Torque: 20 Nm
adjustment.
Install the Special Tool(s): 303-376B

E81958
303-376B

E81956 18. 1. NOTE: Only tighten the bolt finger tight at

this stage.
15. Remove the Special Tool(s): 303-376B 2. Torque: 55 Nm
3. Torque: 55 Nm

3 1
303-376B
2
E81956
E98388
16. Remove the Special Tool(s): 303-748
19. 1. Torque: 9 Nm
2. NOTE: Only tighten the bolts finger tight at
this stage.

303-748

1 x9
E81959

x4
2
E82029

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303-01A-25 Engine — 1.4L Duratec-16V (Sigma) 303-01A-25
REMOVAL AND INSTALLATION
20. 1. Torque: 80 Nm 23. Refer to: Generator - 1.4L Duratec-16V
2. Torque: 10 Nm (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)
3. NOTE: Only tighten the bolts finger tight at (414-02 Generator and Regulator, Removal
this stage. and Installation).
24. Refer to: Starter Motor (303-06 Starting System,
Removal and Installation).
25. Refer to: Valve Cover (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
2 x2 1 Installation).
26. Torque: 27 Nm

3 x3
E98376

x4
21. Remove the trolley jack.
22. Torque: 48 Nm

E81913

27.

3 x3
E98377

E98374

28.

E98509

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303-01A-26 Engine — 1.4L Duratec-16V (Sigma) 303-01A-26
REMOVAL AND INSTALLATION
29. Install the right-hand front wheel.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).

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303-01A-27 Engine — 1.4L Duratec-16V (Sigma) 303-01A-27
REMOVAL AND INSTALLATION

Cylinder Head(21 163 0)

Special Tool(s) 1. Refer to: Fuel System Pressure Release - 1.4L
303-392 Duratec-16V (Sigma)/1.6L Duratec-16V
Socket, Cylinder Head Bolt Ti-VCT (Sigma) (310-00 Fuel System -
General Information, General Procedures).
2. Refer to: Cooling System Draining, Filling and
21167
Bleeding (303-03 Engine Cooling - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), General Procedures).
Refer to: Cooling System Draining and Vacuum
Materials Filling (303-03 Engine Cooling - 1.4L
Name Specification Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), General Procedures).
Engine Oil - 5W-30 WSS-M2C913-C
3. Refer to: Battery Disconnect and Connect
General Equipment (414-01 Battery, Mounting and Cables,
Cable Ties General Procedures).
Fluid Container 4. Refer to: Camshafts (303-01 Engine - 1.4L
Hose Clamp Remover/Installer Duratec-16V (Sigma), Removal and
Installation).
Strap Wrench
5.

Removal
NOTE: Removal steps in this procedure may
contain installation details.
x4

E100490

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303-01A-28 Engine — 1.4L Duratec-16V (Sigma) 303-01A-28
REMOVAL AND INSTALLATION
6. 1. Torque: 18 Nm 2. Torque: 4 Nm

E100491

8. Torque: 9 Nm
7.
x4

E81609
E101797

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303-01A-29 Engine — 1.4L Duratec-16V (Sigma) 303-01A-29
REMOVAL AND INSTALLATION
9. General Equipment: Hose Clamp 12. 1. CAUTION: Make sure that the exhaust
Remover/Installer flexible pipe is not forcibly bent or
twisted.
Torque: 44 Nm
2. Torque: 25 Nm

1 x2
E101804
2

Vehicles built up to 08/2009

10. 1. Torque: 12 Nm E101818

13. 1. 1 - 5:
Torque:
1 x4 • Stage 1: 20 Nm
• Stage 2: 55 Nm
2. 6:
x2 Torque: 47 Nm

1
x2
E101805 4 5
2 3

11. CAUTION: Make sure that the exhaust

6 6
flexible pipe is not forcibly bent or
twisted.
General Equipment: Cable Ties
E101819

Vehicles built 08/2009 onwards

14. Torque: 10 Nm

x4

E98634

E126588

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303-01A-30 Engine — 1.4L Duratec-16V (Sigma) 303-01A-30
REMOVAL AND INSTALLATION
15. Make sure that the catalytic converter
is supported with suitable retaining
straps.

x4

E126589

E126592
16.

All vehicles
19. WARNING: Be prepared to collect
x2
escaping fluid.
General Equipment: Fluid Container

E126830

17. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or
twisted.
General Equipment: Cable Ties
E79660

E98634

18. CAUTIONS:
Make sure that the exhaust flexible pipe
is not forcibly bent or twisted.

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303-01A-31 Engine — 1.4L Duratec-16V (Sigma) 303-01A-31
REMOVAL AND INSTALLATION
20. WARNING: Be prepared to collect Make sure that no fluids are present in
escaping fluid. the cylinder head bolt threaded bores.
General Equipment: Strap Wrench Special Tool(s): 303-392
Torque:
• Stage 1: 5 Nm
• Stage 2: 15 Nm
• Stage 3: 35 Nm
• Stage 4: 75°

303-392 6 1 3 9

10 4 2 5 7
E86925
E128605

3. NOTE: The seal is to be reused unless

21. CAUTION: Make sure that the cylinder damaged.
head is at ambient air temperature
before removing the cylinder head bolts. Torque: 27 Nm

Special Tool(s): 303-392

303-392 6 9 7 1

2 8 10 5 3 E79660

E86924

Installation
1. To install, reverse the removal procedure.
2. CAUTIONS:
Make sure that new bolts are installed.

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303-01A-32 Engine — 1.4L Duratec-16V (Sigma) 303-01A-32
REMOVAL AND INSTALLATION
4. 1. Apply a thin coating. 7.
Material: Engine Oil - 5W-30
(WSS-M2C913-C)
2. Torque: 15 Nm

E128607

Vehicles built 08/2009 onwards

8. CAUTION: Jointing compound must not
be used forward of the catalytic
converter.
1
Torque: 55 Nm

E128606

4 1 5
5.

2 3

E126833

9. Torque: 10 Nm

E128607

x4
6. CAUTION: Make sure that fluid level is
to the MAX mark.
Refer to: Specifications (303-01 Engine - 1.4L
Duratec-16V (Sigma), Specifications).

E126588

E128608

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303-01A-33 Engine — 1.4L Duratec-16V (Sigma) 303-01A-33
REMOVAL AND INSTALLATION
10. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or
twisted.

E126592

11. Remove the following items:

• General Equipment: Cable Ties

E126638

12. Torque: 51 Nm

x2

E126830

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303-01A-34 Engine — 1.4L Duratec-16V (Sigma) 303-01A-34
REMOVAL AND INSTALLATION

Oil Pan(21 154 0)

Special Tool(s) WARNING: Be prepared to collect
205-047 escaping fluid.
Slide Hammer

15011

303-633
Adapter for 205-047

E79660
21227

3.
Materials
Name Specification x13
Silicone Sealant LB WSE-M4G323-A4 /
2U7J-M4G323-AA

Removal
1.

E81286

4. Special Tool(s): 205-047, 303-633

E98347
303-633
2.
205-047
E79662

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303-01A-35 Engine — 1.4L Duratec-16V (Sigma) 303-01A-35
REMOVAL AND INSTALLATION
Installation 4. NOTE: Only tighten the bolts finger tight at this
stage.
1. Install 2x M8x20 studs.

x13

E100095 E81286

5. • Bolts 1 - 4.
2. NOTE: The component must be installed within
Torque: 47 Nm
5 minutes of applying the sealant.
• Bolts 5 - 17.
Material: Silicone Sealant LB (WSE-M4G323-A4 Torque: 20 Nm
/ 2U7J-M4G323-AA)
16 12 8 5 9 13 1

2
15
3,5 mm 3

17
11 7 6 10 14 4
E79664 E79661

6. NOTE: The seal is to be reused unless

3. damaged.
Torque: 27 Nm

E100096

E79660

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303-01A-36 Engine — 1.4L Duratec-16V (Sigma) 303-01A-36
REMOVAL AND INSTALLATION
7. Torque: 4 Nm

E98347

8. Fill the engine with engine oil.

Refer to: Specifications (303-01 Engine - 1.4L
Duratec-16V (Sigma), Specifications).

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303-01A-37 Engine — 1.4L Duratec-16V (Sigma) 303-01A-37
REMOVAL AND INSTALLATION

Oil Pump(21 714 0)

Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Crankshaft Front Seal (303-01 Engine
- 1.4L Duratec-16V (Sigma), Removal and
Installation).
2. Refer to: Oil Pan (303-01 Engine - 1.4L
Duratec-16V (Sigma), Removal and
Installation).
3. Torque: 9 Nm

E91407

4. 1. M6x55
2. M6x25
3. M6x35

5. Torque: 9 Nm

2 3

2
1

E80833

Installation
1. To install, reverse the removal procedure.

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303-01A-38 Engine — 1.4L Duratec-16V (Sigma) 303-01A-38
REMOVAL

Engine — Vehicles With: 5-Speed Manual Transaxle

(iB5)(21 132 0; 21 132 6; 21 132 7)
Removal General Equipment
Special Tool(s) Wooden Block
204-605
Separator, Lower Arm Ball 1. Refer to: Fuel System Pressure Release - 1.4L
Joint Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma) (310-00 Fuel System -
General Information, General Procedures).
2. Remove the following items:
E63772
1. Refer to: Battery (414-01 Battery, Mounting
and Cables, Removal and Installation).
204-609 2. Refer to: Air Cleaner (303-12 Intake Air
Protection Cap, Ball Joint Distribution and Filtering - 1.4L
Gaiter Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), Removal and Installation).

3. Refer to: Cooling System Draining, Filling and

E75372 Bleeding (303-03 Engine Cooling - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
303-122 Ti-VCT (Sigma), General Procedures).
Lifting Bracket, Engine Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), General Procedures).
4.
21068A

308-256
Remover, Halfshaft

16089

418-537
Drill Bush, Powertrain Control E102788
Module

418537

General Equipment
Cable Ties
Hose Clamp Remover/Installer
Hydraulic Jib Crane
Mounting Table Set
Retaining Strap

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303-01A-39 Engine — 1.4L Duratec-16V (Sigma) 303-01A-39
REMOVAL
Vehicles with PCM security shield All vehicles
5. Special Tool(s): 418-537 6.

418-537

E102790

7.

E101895
x3

E102928

8.

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303-01A-40 Engine — 1.4L Duratec-16V (Sigma) 303-01A-40
REMOVAL

E106758

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303-01A-41 Engine — 1.4L Duratec-16V (Sigma) 303-01A-41
REMOVAL
9. Refer to: Quick Release Coupling (310-00 Fuel All vehicles
System - General Information, General
Procedures). 11.
General Equipment: Hose Clamp
Remover/Installer

E106849

12. General Equipment: Hose Clamp

Remover/Installer

E106851
E106848

13. Loosen: 3 turn(s)

Vehicles with 1.4L engine
10. General Equipment: Hose Clamp
Remover/Installer
x3

E103733

E107011

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303-01A-42 Engine — 1.4L Duratec-16V (Sigma) 303-01A-42
REMOVAL
14. Refer to: Wheel and Tire (204-04 Wheels and 18. Special Tool(s): 204-605
Tires, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
15. 204-605

E102189

19. Install the Special Tool(s): 204-609

E102938

16.

204-609

E81908

20. WARNING: Be prepared to collect

escaping fluids.
E102939
CAUTION: Make sure that all openings
are sealed.
17.

E102188

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303-01A-43 Engine — 1.4L Duratec-16V (Sigma) 303-01A-43
REMOVAL
Support the halfshaft. The inner joint must not 22.
be bent more than 18 degrees. The outer joint
must not be bent more than 45 degrees.
Special Tool(s): 204-605

x2

E103130

23.

204-605
x2

x2
E103447

21. Detach and secure the component to one side.

E102932

E104941

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303-01A-44 Engine — 1.4L Duratec-16V (Sigma) 303-01A-44
REMOVAL
24. Loosen: 3 turn(s) 28.

x3

E102933 E102188

25. Refer to: Wheel and Tire (204-04 Wheels and 29. Special Tool(s): 204-605
Tires, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
26. 204-605

E102189

30. Install the Special Tool(s): 204-609

E102938

27.

204-609

E81908

31. WARNING: Be prepared to collect

escaping fluids.
E102939
CAUTION: Make sure that all openings
are sealed.
• Support the halfshaft. The inner joint must
not be bent more than 18 degrees. The outer
joint must not be bent more than 45 degrees.
• Detach and secure the component to one
side.
Special Tool(s): 308-256, 204-605

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303-01A-45 Engine — 1.4L Duratec-16V (Sigma) 303-01A-45
REMOVAL

204-605

308-256
x2
E102941

32. Remove the following items: All vehicles

1. Refer to: Generator - 1.4L Duratec-16V
34.
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)
(414-02 Generator and Regulator, Removal
and Installation).

Vehicles with air conditioning

33. General Equipment: Cable Ties

x3

E104265
E106895

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303-01A-46 Engine — 1.4L Duratec-16V (Sigma) 303-01A-46
REMOVAL
35. Vehicles built up to 08/2009
38.

x2

E102937

E103437
36.
Vehicles built 08/2009 onwards
39.

E106786

37. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent. E126884

General Equipment: Cable Ties

40.

x4

E98634
E126588

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303-01A-47 Engine — 1.4L Duratec-16V (Sigma) 303-01A-47
REMOVAL
41. Make sure that the catalytic converter
is supported with suitable retaining
straps.

x4

E126589

E126592
42.

All vehicles
45.
x2

E126830

43.
E106898

46. General Equipment: Hose Clamp

Remover/Installer

E126885

44. CAUTIONS:
Make sure that the exhaust flexible pipe
is not forcibly bent or twisted. E106896

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303-01A-48 Engine — 1.4L Duratec-16V (Sigma) 303-01A-48
REMOVAL
47. Refer to: Quick Release Coupling (310-00 Fuel wooden blocks and secured with
System - General Information, General suitable retaining straps.
Procedures). General Equipment: Mounting Table Set
General Equipment: Wooden Block
General Equipment: Retaining Strap

E107831

48. WARNING: Be prepared to collect E103239

escaping fluid.
CAUTION: If the fluid is spilled on the 50.
paintwork, the affected area must be
immediately washed down with cold
water.

2 x2 1

3 x3
E98376

51.
E103121

49. WARNING: Make sure that the engine

and transmission assembly is on

x3

E102935

52. CAUTION: Make sure that no

components catch.
Raise and suppoprt the vehicle.

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303-01A-49 Engine — 1.4L Duratec-16V (Sigma) 303-01A-49
REMOVAL
53. Special Tool(s): 303-122 56.
General Equipment: Hydraulic Jib Crane

303-122

E106994

E68699

57.
54.

1 2

E79922
E88913

58.
55.

x3

E100274

E106975

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303-01A-50 Engine — 1.4L Duratec-16V (Sigma) 303-01A-50
REMOVAL
59.

E105801

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303-01A-51 Engine — 1.4L Duratec-16V (Sigma) 303-01A-51
REMOVAL

Engine Accessories(21 139 4)

Removal 2.
Special Tool(s)
303-393
Locking Tool, Flywheel

21168

303-435
Mounting Stand E102192

3.
21187

3
303-435-06
Mounting Bracket for 303-435 1 x4 4

21031B
2

303-435-14A E92508

Mounting Plate for

303-435-06 Vehicles with 1.4L engine
4.
E62805

1. Special Tool(s): 303-435, 303-435-06,

303-435-14A

E92264

E82743

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303-01A-52 Engine — 1.4L Duratec-16V (Sigma) 303-01A-52
REMOVAL
All vehicles 8.
5. Special Tool(s): 303-393
2

3
303-393
5
6
x3 1
2
1
E102228
4
E93097
9.
6.

2 3

E86496
1
E93098
10.
7.

x7
2 x8

E86926
x4
1
E81915

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303-01A-53 Engine — 1.4L Duratec-16V (Sigma) 303-01A-53
REMOVAL
11.

x7 2

E102194

12.

1 x4
x2
2
E83054

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303-01A-54 Engine — 1.4L Duratec-16V (Sigma) 303-01A-54
DISASSEMBLY

Engine(21 134 8)
Disassembly Special Tool(s)
Special Tool(s) 303-435-14A
205-047 Mounting Plate for
Slide Hammer 303-435-06

E62805
15011

303-633
205-072 Adapter for 205-047
Universal Flange Holding
Wrench

21227
15030A

1. Special Tool(s): 303-435, 303-435-06,

303-1054 303-435-14A
Locking Tool, Timing Belt
Tensioner

3031054

303-392
Socket, Cylinder Head Bolt

E82743
21167

2.
303-435
Mounting Stand

21187
x12
303-435-06
Mounting Bracket for 303-435
E102282

21031B

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303-01A-55 Engine — 1.4L Duratec-16V (Sigma) 303-01A-55
DISASSEMBLY
3. 6. Special Tool(s): 205-072

205-072

x3

E81916 E80877

4. Install the Special Tool(s): 303-1054 7.

303-1054
x4
1

2
E93512
E82632

5. 8. CAUTION: Note the position of each

component before removal.

3 2 4 1 5

x6

E82347 3 2 4 1 5
E80879

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303-01A-56 Engine — 1.4L Duratec-16V (Sigma) 303-01A-56
DISASSEMBLY
9. CAUTION: Note the position of each 12.
component before removal.

x1
3
6
x1

x4

E82350
E82348
13. Special Tool(s): 205-047, 303-633
10. Special Tool(s): 303-392

303-392 7 10 6 2

3
303-633

205-047
4 8 9 5 1 E79662
E81058
14.
11. WARNING: Be prepared to collect
escaping fluid.

x3

x4

E82351

E82337

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303-01A-57 Engine — 1.4L Duratec-16V (Sigma) 303-01A-57
DISASSEMBLY
15.

x8

E82352

16.

x6

E82353

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303-01A-58 Engine — 1.4L Duratec-16V (Sigma) 303-01A-58
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head(21 165 6)

Special Tool(s) 1. NOTE: Note the position of each component
303-361-04 before removal.
Adapter for 303-361A

2115504

303-361-05
Adapter for 303-361A

E102267
2115505

2. Torque: 8 Nm
303-361A
Compressor, Valve Spring

303361A

303-362
Installer, Valve Stem Collets
E86496

21156 3. Torque: 18 Nm

303-508
Pliers, Valve Stem Seal

x5
21211

Disassembly E102266

NOTE: Removal steps in this procedure may

contain installation details.

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303-01A-59 Engine — 1.4L Duratec-16V (Sigma) 303-01A-59
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
4. 1. Torque: 20 Nm 5. 1. Torque: 10 Nm
2. Torque: 20 Nm 2. Torque: 9 Nm

1 x4
1 x4
x2
2
E83054 E102268

6. Special Tool(s): 303-361A, 303-361-04,

303-361-05, 303-362

303-361A 303-361-04

303-361-05

303-362

E80665

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303-01A-60 Engine — 1.4L Duratec-16V (Sigma) 303-01A-60
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
7. Special Tool(s): 303-508

303-508
E80666

Assembly
8. To install, reverse the removal procedure.

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303-01A-61 Engine — 1.4L Duratec-16V (Sigma) 303-01A-61
ASSEMBLY

Engine(21 134 8)
Assembly Special Tool(s)
Special Tool(s) 303-393-02
205-072 Adapter for 303-393
Universal Flange Holding
Wrench

15030A
E55029

303-395
303-1054 Installer, Crankshaft Seal
Locking Tool, Timing Belt
Tensioner

21171
3031054

303-435
303-1097 Mounting Stand
Locking Tool, Variable
Camshaft Timing Oil Control
Unit
21187

E49165
303-435-06
303-376B Mounting Bracket for 303-435
Alignment Plate, Camshaft

21031B
21162B

303-435-14A
303-392 Mounting Plate for
Socket, Cylinder Head Bolt 303-435-06

E62805
21167

303-748
303-393 Locking Tool, Crankshaft
Locking Tool, Flywheel

303748
21168

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303-01A-62 Engine — 1.4L Duratec-16V (Sigma) 303-01A-62
ASSEMBLY
Materials 3. Torque: 9 Nm

Name Specification
Engine Oil - 5W-30 WSS-M2C913-C
Flange Sealant - Anaer- WSK-M2G348-A5 /
obic LR 2U7J-M2G348-AA
Silicone Sealant LB WSE-M4G323-A4 /
2U7J-M4G323-AA x8
General Equipment
Calliper Gauge
E82352
Round-Ended Steel Rule

1. Special Tool(s): 303-435, 303-435-06, 4. Torque: 9 Nm

303-435-14A

x3

x4

E82351
E82743

5. Install 2x M8x20 studs.

2. Torque: 9 Nm

x6

E100095

E82353

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303-01A-63 Engine — 1.4L Duratec-16V (Sigma) 303-01A-63
ASSEMBLY
6. NOTE: The component must be installed within 7. NOTE: Install all the bolts finger tight before
5 minutes of applying the sealant. final tightening.
Material: Silicone Sealant LB (WSE-M4G323-A4 General Equipment: Round-Ended Steel Rule
/ 2U7J-M4G323-AA) Torque:
• Bolts 1-13
• Stage 1: 10 Nm
• Stage 2: 20 Nm
• Bolt 14 28 Nm
3,5 mm

E79664

12 8 4 1 5 9

11

13 7 3 14 2 6 10
E93145

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303-01A-64 Engine — 1.4L Duratec-16V (Sigma) 303-01A-64
ASSEMBLY
8. Special Tool(s): 303-395 Make sure that new bolts are installed.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
Special Tool(s): 303-392
Torque:
303-395 • Stage 1: 5 Nm
• Stage 2: 15 Nm
• Stage 3: 35 Nm
• Stage 4: 75°

303-392 6 1 3 9

E79223 8

9. CAUTION: Make sure that new bolts are

installed.
Special Tool(s): 303-393 10 4 2 5 7
Torque: E86925
• Stage 1: 30 Nm
• Stage 2: 80°
12. NOTE: Make sure that these components are
installed to the noted removal position.

3
303-393
5 x1
6
6

2
1

4
E93097

E82635
10. Remove the Special Tool(s): 303-393

13. CAUTION: Make sure that the camshafts

and camshaft bearing caps are installed
in their original locations.
Apply a thin coating.
303-393
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
Material: Flange Sealant - Anaerobic LR
(WSK-M2G348-A5 / 2U7J-M2G348-AA)

E82339

11. CAUTIONS:
Make sure that no fluids are present in
the cylinder head bolt threaded bores.

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303-01A-65 Engine — 1.4L Duratec-16V (Sigma) 303-01A-65
ASSEMBLY
14. Install the camshafts approximately at valve NOTE: This step is only necessary if adjustment
overlap position cylinder No. 4. is required.
Torque: • Remove the valve tappet and read the
• Stage 1: 7 Nm thickness from the underside.
• Stage 2: 45°
• The number on the valve tappet indicates
the thickness of the bottom of the tappet.
However, the number only indicates the digits
after the decimal point (example: 725 =
2.725).
• Calculate the valve tappet thickness required
(thickness of the currently installed tappet +
the measured valve clearance - the required
valve clearance).
• Install the correct valve tappet.

3 2 4 1 5
3 2 4 1 5

3 2 4 1 5
3 2 4 1 5
E80879

18. CAUTION: Make sure that the camshafts

E80880
and camshaft bearing caps are installed
in their original locations.
NOTE: The following step are only necessary
15. Measure and note the valve clearance values. if adjustment is required.
16. Compare the measured valve clearance(s) with Apply oil to the camshaft bearing caps.
the specifications.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
Refer to: Specifications (303-01 Engine - 1.4L Material: Flange Sealant - Anaerobic LR
Duratec-16V (Sigma), Specifications). (WSK-M2G348-A5 / 2U7J-M2G348-AA)

E70936

17. CAUTION: Note the position of each

component before removal.

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303-01A-66 Engine — 1.4L Duratec-16V (Sigma) 303-01A-66
ASSEMBLY
19. Install the camshafts approximately at valve 21.
overlap position cylinder No. 4.
Torque:
• Stage 1: 7 Nm
• Stage 2: 45°

E81958

22. CAUTION: Only rotate the crankshaft

clockwise.
Rotate the crankshaft slowly until the crankshaft
3 2 4 1 5
stops.
Install the Special Tool(s): 303-748

3 2 4 1 5 303-748

E80880

E81959
20. NOTE: Make sure that new components are
installed. 23. Special Tool(s): 303-393, 303-393-02
Special Tool(s): 303-395
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
303-393

303-395

E86730

E79260

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303-01A-67 Engine — 1.4L Duratec-16V (Sigma) 303-01A-67
ASSEMBLY
24. Torque: 9 Nm NOTE: Make sure that the camshaft pulleys can
rotate on the camshafts.

x4

E93512

E80878
25. CAUTION: Make sure that new bolts are
installed. 28.
Torque: 10 Nm

3 2

x6

E82347

26. WARNING: Take extra care when

handling the compressed spring.
Torque: 20 Nm

1
E101665

E102299

27. CAUTION: Make sure that new bolts are

installed.
NOTE: Only tighten the bolts finger tight at this
stage.

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303-01A-68 Engine — 1.4L Duratec-16V (Sigma) 303-01A-68
ASSEMBLY
29. WARNING: Take extra care when 32. CAUTION: Make sure that a new bolt is
handling the compressed spring. installed.
Remove the Special Tool(s): 303-1054 1. Torque:
• M12
• Stage 1: 40 Nm
303-1054 • Stage 2: 90°
• M14
• Stage 1: 100 Nm
• Stage 2: 90°
3. Torque:
• M14 15°

E82114

30. Torque: 9 Nm
1

x3
2

E95361

3
31. • a = 42 mm = Bolt M12 x 29
• a = 52 mm = Bolt M12 x 44,5
• a = 81 mm = Bolt M14 x 80
General Equipment: Calliper Gauge
E124291

33. Special Tool(s): 205-072

Torque: 60 Nm

205-072
a

E124260

E80877

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303-01A-69 Engine — 1.4L Duratec-16V (Sigma) 303-01A-69
ASSEMBLY
34. Remove the Special Tool(s): 303-393, Rotate the crankshaft 1 and 3/4 revolutions and
303-393-02 continue until piston No. 1 is approximately 45?
before top dead center (BTDC).

303-393

E86730
E93515

35. Remove the Special Tool(s): 303-748

38. Install the Special Tool(s): 303-748

303-748
303-748

E81959
E81959

36. Remove the Special Tool(s): 303-376B

39. CAUTION: Only rotate the crankshaft
clockwise.
Rotate the crankshaft slowly until the crankshaft
stops.

303-376B

E81956

37. CAUTION: Only rotate the crankshaft

clockwise.
E93515

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303-01A-70 Engine — 1.4L Duratec-16V (Sigma) 303-01A-70
ASSEMBLY
40. NOTE: The special tool can only be installed if 42. Torque: 20 Nm
the valve timing is correct.
Install the Special Tool(s): 303-1097

E81958
303-376B

E81956 43. CAUTION: Make sure that the mating

faces are clean and free of foreign
41. Remove the Special Tool(s): 303-748 material.
Torque:
• 1 3-4 turn(s)
• 2 - 13 9 Nm

303-748

E81959

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303-01A-71 Engine — 1.4L Duratec-16V (Sigma) 303-01A-71
ASSEMBLY

4 5 13 6 7

2 3

1 11 10 12 9 8
E102335

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303-01A-72 Engine — 1.4L Duratec-16V (Sigma) 303-01A-72
INSTALLATION

Engine — Vehicles With: 5-Speed Manual Transaxle

(iB5)(21 132 0; 21 132 6; 21 132 7)
Installation
1. Special Tool(s): 303-122
Special Tool(s) General Equipment: Hydraulic Jib Crane
204-605
Separator, Lower Arm Ball 303-122
Joint

E63772

204-609
Protection Cap, Ball Joint
Gaiter
E68699

E75372
2. CAUTION: Make sure that the locating
dowels remain installed.
205-775 Torque: 48 Nm
Protector, Halfshaft Seal

E47098

303-122
Lifting Bracket, Engine

E105801

21068A 3. Torque: 48 Nm

General Equipment
Cable Ties
Hose Clamp Remover/Installer
Hydraulic Jib Crane
Mounting Table Set
Retaining Strap
Wooden Block

E106975

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303-01A-73 Engine — 1.4L Duratec-16V (Sigma) 303-01A-73
INSTALLATION
4. Torque: 48 Nm 7. 1. Torque: 6 Nm
2. Torque: 12 Nm

1 2

E79922

E88913
5. Torque: 48 Nm
8. WARNING: Make sure that the engine
and transmission assembly is on
wooden blocks and secured with
suitable retaining straps.
General Equipment: Mounting Table Set
General Equipment: Wooden Block
General Equipment: Retaining Strap

E106994

6. Torque: 35 Nm

x3

E100274

E107062

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303-01A-74 Engine — 1.4L Duratec-16V (Sigma) 303-01A-74
INSTALLATION
9. Remove the Special Tool(s): 303-122 12. 1. Torque: 80 Nm
2. Torque: 10 Nm
303-122 3. NOTE: Only tighten the bolts finger tight at
this stage.

2 x2 1

E68699

10. CAUTION: Make sure that no 3 x3

components catch. E98376
Lower the vehicle to take the load off the engine
mountings.
13. Remove the following items:
Refer to: Jacking and Lifting (100-02 Jacking • General Equipment: Mounting Table Set
and Lifting, Description and Operation). General Equipment: Wooden Block
General Equipment: Retaining Strap

14. Torque: 48 Nm

E103239

3 x3
11. Torque: 80 Nm
E98377

15. CAUTION: If the fluid is spilled on the

paintwork, the affected area must be

x3

E102935

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303-01A-75 Engine — 1.4L Duratec-16V (Sigma) 303-01A-75
INSTALLATION
immediately washed down with cold 18. Torque: 48 Nm
water.
Refer to: Clutch System Bleeding (308-00
Manual Transmission/Transaxle and Clutch -
General Information, General Procedures).

E106898

Vehicles built up to 08/2009

E103121 19. Torque: 48 Nm

16. Refer to: Quick Release Coupling (310-00 Fuel

System - General Information, General
Procedures). x2

E107831

E103437

17. General Equipment: Hose Clamp

Remover/Installer Vehicles built 08/2009 onwards
20. CAUTION: Jointing compound must not
be used forward of the catalytic
converter.
Torque: 55 Nm

4 1 5

E106896

2 3

E126833

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303-01A-76 Engine — 1.4L Duratec-16V (Sigma) 303-01A-76
INSTALLATION
21. CAUTION: Make sure that the exhaust 24. Torque: 10 Nm
flexible pipe is not forcibly bent or
twisted.

x4

E126588

E126592
25.

22. Torque: 51 Nm

x2

E126884

E126830
All vehicles
26. CAUTION: Make sure that the exhaust
23. flexible pipe is not forcibly bent.
Remove the following items:
• General Equipment: Cable Ties

E126885

E98634

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303-01A-77 Engine — 1.4L Duratec-16V (Sigma) 303-01A-77
INSTALLATION
27. Vehicles with air conditioning
30. Remove the following items:
• General Equipment: Cable Ties

31. Torque: 25 Nm

x3

E106786

28.
E106895

All vehicles
32. • Remove the special tool before completely
installing the halfshaft.
Special Tool(s): 204-605, 205-775
1. NOTE: Make sure that a new component is
installed.

1
2

E102937

29. 205-775

204-605

x2
E102942

E104265

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303-01A-78 Engine — 1.4L Duratec-16V (Sigma) 303-01A-78
INSTALLATION
33. Special Tool(s): 204-605 35. Torque: 48 Nm

E102188

36. Torque: 48 Nm

204-605

x2
E102943
E102939

34. Remove the Special Tool(s): 204-609

37. Torque: 25 Nm

204-609

E81908
E102938

38. Refer to: Wheel and Tire (204-04 Wheels and

Tires, Removal and Installation).
39. Lower the Vehicle.

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303-01A-79 Engine — 1.4L Duratec-16V (Sigma) 303-01A-79
INSTALLATION
40. Torque: 30 Nm 42. 1. Torque: 25 Nm
2. Torque: 15 Nm

x3

E102933

41. Torque: 25 Nm

x2
1 x2

2
E103724
E103783

43.

x2

E103130

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303-01A-80 Engine — 1.4L Duratec-16V (Sigma) 303-01A-80
INSTALLATION
44. NOTE: Make sure that a new component is 46. 1. WARNING: Make sure that new nuts
installed. are installed.
Torque: 6 Nm
2. Torque: 6 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm

4
2

E104969

1
45. Remove the special tool before completely
3
installing the halfshaft.
E103474
Special Tool(s): 204-605, 205-775

47. Special Tool(s): 204-605

204-605

205-775

E126685

48. Remove the Special Tool(s): 204-609

204-605

x2
204-609

E103475

E81908

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303-01A-81 Engine — 1.4L Duratec-16V (Sigma) 303-01A-81
INSTALLATION
49. Torque: 48 Nm 54. Torque: 30 Nm

x3

E126684 E103733

50. Torque: 48 Nm 55. Install the following items:

• Refer to: Generator - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)
(414-02 Generator and Regulator, Removal
and Installation).

56. General Equipment: Hose Clamp

Remover/Installer

E126683

51. Torque: 25 Nm

E106851

57.

E102938

52. Refer to: Wheel and Tire (204-04 Wheels and

Tires, Removal and Installation).
53. Lower the Vehicle.
E106849

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303-01A-82 Engine — 1.4L Duratec-16V (Sigma) 303-01A-82
INSTALLATION
Vehicles with 1.4L engine All vehicles
58. General Equipment: Hose Clamp 59. Refer to: Quick Release Coupling (310-00 Fuel
Remover/Installer System - General Information, General
Procedures).
General Equipment: Hose Clamp
Remover/Installer

E107011

E106848

60. Torque: 25 Nm

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303-01A-83 Engine — 1.4L Duratec-16V (Sigma) 303-01A-83
INSTALLATION

E107099

62.
61. Torque: 10 Nm

E102790
x3

E102928

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303-01A-84 Engine — 1.4L Duratec-16V (Sigma) 303-01A-84
INSTALLATION
Vehicles with PCM security shield
63. Tighten the shear bolt until the head is sheared
off.

E101896

All vehicles
64.

E102788

65. Refer to: Cooling System Draining, Filling and

Bleeding (303-03 Engine Cooling - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), General Procedures).
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), General Procedures).
66. Install the following items:
1. Refer to: Battery (414-01 Battery, Mounting
and Cables, Removal and Installation).
2. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma), Removal and Installation).

67. Refer to: Transmission Fluid Level Check

(308-03 Manual Transmission/Transaxle -
Vehicles With: 5-Speed Manual Transaxle
(iB5), General Procedures).

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303-01A-85 Engine — 1.4L Duratec-16V (Sigma) 303-01A-85
INSTALLATION

Engine Accessories(21 139 4)

Installation 2. 1. Torque: 20 Nm
Special Tool(s) 2. Torque: 20 Nm
303-393
Locking Tool, Flywheel

21168

303-435
1 x4
Mounting Stand
x2
2
E83054

21187 3. Torque: 18 Nm

303-435-06
Mounting Bracket for 303-435

x7
21031B

303-435-14A
Mounting Plate for E86926
303-435-06
4. Torque: 8 Nm
E62805

1. Special Tool(s): 303-435, 303-435-06,

303-435-14A

E86496

E82743

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303-01A-86 Engine — 1.4L Duratec-16V (Sigma) 303-01A-86
INSTALLATION
5. NOTE: Install all the bolts finger tight before 8. Install the Special Tool(s): 303-393
final tightening. Torque:
1. Torque: 55 Nm • Stage 1: 30 Nm
• Stage 2: 80°
2. Torque: 10 Nm

3
2 303-393
5
6

2
x3 1 1

4
E93097
E102228

9. Remove the Special Tool(s): 303-393

6. 1. Torque: 27 Nm
2. Torque: 9 Nm

303-393

2 x8

E82339
x4
1
E81915 Vehicles with 1.4L engine

7. Torque: 45 Nm 10. Torque: 55 Nm

2 3

1 E92264
E93098

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303-01A-87 Engine — 1.4L Duratec-16V (Sigma) 303-01A-87
INSTALLATION
All vehicles
11. 1. Torque: 8 Nm
2. Torque: 15 Nm
3. Torque: 4 Nm
4. Torque: 15 Nm
5. Torque: 9 Nm

1 x4 4

E92508

12. Torque: 9 Nm

E102192

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