Ford Festiva. Manual — part 26

levels to proper level.

Removal (1.6L & 1.6L Turbo)

1. Relieve fuel pressure and discharge air conditioning system (if equipped). See

FUEL PRESSURE RELEASE

under REMOVAL &

INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket.

2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and

hood. Mark hinge locations and remove hood.

3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove

air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped).

4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to

one side.

5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from

manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body.

6. For manual transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non-

turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines.

7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring

from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2
sensor wire, main wiring harness connector, TPS connector (turbocharged only), knock sensor connector, distributor wiring and
transaxle wiring. Disconnect ground wire and strap at front of engine, and reinstall lifting eye.

8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump

mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped).

9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning

compressor mounting bolts, and position compressor out of way.

10. Remove front wheels and tires. Remove front ball joints-to-steering knuckles retaining bolts. Remove splash guards. Drain transmission

oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front
exhaust pipe from exhaust manifold, or turbocharger (if equipped).

11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber

exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with
mechanic's wire. Unbolt shift linkage and stabilizer bar at transaxle. Remove nuts from front and rear engine mounts, and lower vehicle.

12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise

engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring
harness from engine. Carefully lift engine/transaxle assembly, turn assembly while raising to clear brake master cylinder, shift linkage
universal joint, radiator support and air conditioning lines (if equipped).

13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining

bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On manual transaxle, remove pressure plate, clutch
disc and flywheel. On automatic transaxle, remove flexplate.

Installation (1.6L & 1.6L Turbo)

1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle.

Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine
until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT tighten bolt.

2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front

and rear engine mounts. Tighten nuts to specification. See

TORQUE SPECIFICATIONS

table at end of article.

3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and

oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe
to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger)
to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.

4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten

lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.

5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mount

through bolt to specification. Connect alternator wiring.

6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining

bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.

7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped).

Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors.
Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.

8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter

attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install
vacuum hoses as noted in disassembly.

9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill

transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable.
Connect speedometer cable connector. Fill engine oil to capacity.

10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill

coolant to specification.

11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery

terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.

INTAKE MANIFOLD

Removal (1.3L)

CAUTION:

DO NOT allow compressor to hang by hoses. Tie up compressor with mechanic's wire.

Disconnect negative battery cable. Drain cooling system. Remove air cleaner. Remove intake manifold bracket. Disconnect throttle cable.
Mark and disconnect vacuum hoses, fuel hoses and wiring. Remove intake manifold bolts. Remove intake manifold and gasket.

Installation (1.3L)

Clean all gasket mating surfaces. Ensure surface is free of burrs, scratches and cracks. Replace all gaskets. Position gasket and manifold to
cylinder head. Install bolts and tighten to specification. To complete installation, reverse removal procedure.

Removal (1.6L)

1. Disconnect negative battery terminal. Relieve fuel pressure. See

FUEL PRESSURE RELEASE

under REMOVAL &

INSTALLATION. Drain cooling system. Disconnect intercooler tube and/or air intake tube. Disconnect air by-pass hoses. Disconnect
main engine harness electrical connection and TPS connector. Disconnect vacuum hoses from throttle body.

2. Disconnect fuel lines from fuel filter and pressure regulator. Disconnect throttle cable. Disconnect hoses from By-pass Air Control valve

(BAC). Remove BAC valve retaining nut and bolt. Remove intake manifold retaining nuts and bolts from support bracket and cylinder
head. Remove intake manifold and throttle body assembly.

Installation (1.6L)

1. Install new intake manifold gasket, ensuring coolant passage openings align with openings in cylinder head and manifold. Install intake

manifold. Tighten retaining nut and bolts and support bracket bolts to specification. See

TORQUE SPECIFICATIONS

table at end of

article.

2. Install BAC valve and connect air hoses. Connect throttle cable. Connect fuel lines to fuel filters and pressure regulator. Connect main

engine harness connector and TPS connector. Connect vacuum lines to throttle body. Install intake air tube. Connect intercooler tube
and/or intake air tube. Connect air by-pass hoses. Fill cooling system. Connect negative battery terminal. Start engine and check for
fluid leaks and correct operation.

EXHAUST MANIFOLD

Removal (1.3L)

1. Raise vehicle. Remove catalytic converter inlet pipe at exhaust manifold. Remove pulse air tube nuts at inlet pipe. Remove inlet pipe

support bracket bolts. Lower vehicle. Remove air intake duct. Remove exhaust manifold heat shroud bolts and remove shroud.

2. Disconnect oxygen sensor connector. Remove exhaust manifold nuts and remove exhaust manifold. Remove gasket from inlet pipe and

cylinder head.

Installation

Position new gasket on cylinder head and inlet pipe. Install exhaust manifold and nuts. Tighten nuts to specification. See, at end of article,

TORQUE SPECIFICATIONS

table. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification.

Removal (1.6L Non-Turbo)

Remove intake air tube. Remove front exhaust pipe to exhaust manifold retaining nuts. Remove exhaust support bracket (if equipped). Remove
heat shield. Disconnect O2 sensor electrical connector. Remove exhaust manifold.

Installation (1.6L Non-Turbo)

Install exhaust manifold gaskets. Install heavier gasket first. Install exhaust manifold and tighten retaining nuts to specification. See

TORQUE

SPECIFICATIONS

table at end of article. Connect O2 sensor electrical connector. Install manifold heat shield. Install intake air tube.

Connect front exhaust pipe to intake manifold and tighten retaining nuts to specification. Install exhaust support bracket, if removed, and
tighten engine mount bolt to specification. Start engine and check for leaks.

Removal (1.6L Turbo)

1. Disconnect negative battery cable. Drain cooling system. Remove throttle body air intake tube. Disconnect intercooler hose from

turbocharger assembly and position both intercooler hoses out of the way. Remove O2 sensor connector from its retaining clip, and
disconnect O2 sensor. Remove lower heat shield and then upper heat shield. Remove turbocharger side heat shield.

2. Remove power steering pump (leave hoses attached) and lay aside. Disconnect lower radiator hose from water pump. Position power

steering pump to access mounting bracket retaining bolts and nut. Remove both bolts and one nut, and remove bracket from engine.
Remove 2 screws retaining air cleaner duct tube, loosen clamp at turbocharger and position duct tube out of the way. Disconnect
coolant return hose at turbocharger. Remove bolt and brass sealing washers from oil supply line at engine block.

3. Raise vehicle. Remove retaining nuts and washers from exhaust pipe flange. Remove 2 bolts retaining exhaust hangers to engine block.

Slide off two rubber exhaust hangers at catalytic converter. Pull exhaust pipe downward and to LH side of vehicle. Disconnect oil return
hose at turbocharger. Disconnect coolant return hose at turbocharger. Remove 2 retaining bolts from turbocharger support bracket.
Remove 2 bolts retaining coolant by-pass tube outlet to water pump. Lower vehicle.

4. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Pull

coolant by-pass tube bracket from exhaust stud, and position tube out of way. Grasp manifold, pull off studs and move assembly slightly
to RH side of engine compartment to clear cooling fan, and remove assembly from vehicle.

5. Working on bench, remove 4 nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.

Installation (1.6L Turbo)

NOTE:

Feed O2 sensor wire and guide through upper heat shield.

NOTE:

When reinstalling turbocharger, thoroughly remove all gaskets and sealant. Use new gaskets. Add .85
oz. (25 cc) of engine oil in the oil passage of the turbocharger.

1. Position new gasket on exhaust manifold, and install turbocharger onto studs. Install 4 retaining nuts and tighten to specification. See

TORQUE SPECIFICATIONS

table at end of article.

2. Remove oil supply line from turbocharger. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first.

Carefully position turbocharger assembly in engine compartment and slide exhaust manifold on studs. Position heater tube bracket onto
exhaust stud. Install 11 retaining nuts onto exhaust manifold and tighten to specification. See

TORQUE SPECIFICATIONS

table at

end of article. Tighten heater tube clamp bolt securely.

3. Raise vehicle. Position new gasket and install 2 retaining bolts on heater tube outlet. Install 2 retaining bolts into turbocharger support

bracket and tighten bolts to specification.

4. Connect coolant return hose. Connect oil return hose and secure with clamp. Position exhaust pipe onto turbocharger, and start nuts

and washers. Install 2 retaining bolts on exhaust hanger at engine. Slide on 2 rubber exhaust hangers at catalytic converter. Tighten
exhaust pipe retaining nuts to specification. Lower vehicle.

5. Install retaining bolt and brass washers on oil supply line, carefully position oil line into vehicle and hand-start bolt into engine block.

Connect and finger tighten oil line to turbocharger. Tighten oil line bolt and oil supply line on turbocharger to specification.

6. Connect coolant supply hose. Position air cleaner duct tube on turbocharger and tighten clamp. Install 2 screws retaining air cleaner

duct tube. Position power steering pump bracket on engine, and install 2 retaining bolts and one retaining nut. Tighten to specification.
Position power steering pump on mounting bracket, and install though bolt and adjuster. Connect lower radiator hose. Install power
steering belt. Position upper heat shield and install 2 retaining bolts finger tight.

7. Position lower heat shield and install three retaining bolts finger tight. Tighten all heat shield bolts to specification. Connect O2 sensor

and install connector into its retaining clip. See

TORQUE SPECIFICATIONS

table at end of article. Position intercooler hose on

turbocharger and secure with clamp. Install throttle body air intake tube. Connect negative battery cable. Refill cooling system.

CYLINDER HEAD

Removal (1.3L)

1. Disconnect battery ground cable. Mark and disconnect fuel lines at fuel pump. Remove accessory belts, water pump pulley, crankshaft

pulley, timing belt covers, timing belt tensioner, timing belt, valve cover and exhaust and intake manifolds. Drain cooling system.

2. Mark and remove electrical connectors and vacuum hoses. Remove spark plug wires from spark plugs, and remove spark plugs. Remove

distributor cap. Disconnect vacuum hoses and distributor wiring.

3. Index distributor-to-mount position and remove hold-down bolt. Remove distributor assembly. Remove engine ground strap. Remove

front and rear engine lifting hooks. Remove upper radiator hose, by-pass hose and bracket.

4. Remove bolts retaining rocker arm shaft. Remove rocker arm assemblies. Remove cylinder head bolts. Remove head and gasket.

Inspection (1.3L)

1. Thoroughly clean and check gasket mating surface of cylinder head and block. Check cylinder for cracks, nicks, burrs or damage. Using

a straightedge and feeler gauge, check warpage over entire gasket area. Ensure cylinder head and/or block warpage does not
exceed .006" (.15 mm).

2. If warpage exceeds .006" (.15 mm), machine cylinder head and/or block gasket surface. Maximum machining allowed is .008" (.20 mm).

If more machining is required, replace block and/or cylinder head.

Installation (1.3L)

1. Place new head gasket properly on block. Carefully place cylinder head in position on block. Install head bolts. Tighten bolts in

sequence and in 2 steps. See

Fig. 1

.

2. While tightening rocker arm shaft, slide shaft springs away from retaining bolt to prevent pinching springs. Tighten rocker arm shaft bolts

in sequence and to specification. See

Fig. 5

. To complete installation, reverse removal procedure. Tighten all bolts/nuts to

specification. Fill all fluids to proper levels.

NOTE:

Turbocharger-to-exhaust manifold mounting nuts are of special quality. Ensure correct nuts are
used.

NOTE:

Ensure one brass washer is positioned on each side of oil line fitting.

NOTE:

Feed O2 sensor wire through upper heat shield. Install wire retainer under LH bolt.

NOTE:

If turbocharger was replaced: Disconnect ignition coil, crank engine for 20 seconds, connect ignition
coil, start engine and run at idle for 30 seconds and check for leaks.

NOTE:

If original timing belt is being reused, mark direction of rotation for installation reference.

Fig. 1: Installing Cylinder Head Bolts (1.3L)

Courtesy of FORD MOTOR CO.

Removal (1.6L)

1. Release fuel pressure. Drain cooling system. Disconnect negative battery terminal. Remove intake air tube from throttle body.

Disconnect air by-pass hoses. Remove spark plug wires and retainers. Remove intake air tube from air cleaner assembly. Disconnect
coolant hose from thermostat cover. Disconnect vacuum hoses and coolant hoses from throttle body and intake manifold.

2. Disconnect throttle cable and remove retaining brackets and cable. Disconnect fuel lines at fuel filter and pressure regulator. Disconnect

main harness connector. Disconnect O2 sensor connector and remove ground connection retaining screw at bracket. Disconnect
intercooler tubes from turbocharger (if equipped). Remove ground wire and strap retaining bolts at front sides of cylinder head.

3. Remove timing belt covers and timing belt. On turbocharged vehicles, remove exhaust manifold and turbocharger as an assembly. On

non-turbocharged vehicles, disconnect front exhaust pipe from exhaust manifold. Remove intake manifold support upper retaining bolts.

4. Remove cam cover. Remove cylinder head and intake manifold as an assembly. Separate intake manifold from cylinder head (if

required).

Installation (1.6L)

1. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first. Install exhaust manifold to head. Install intake

manifold to head using new gasket. Tighten all manifold nuts to specification. See

TORQUE SPECIFICATIONS

table at end of

article.

2. Ensure gasket surfaces of head and block are clean of old gasket and sealant. Place new head gasket on cylinder block. Carefully, place

cylinder head on block. Tighten cylinder head in sequence and in two stages to correct specification. See

Fig. 2

.

Fig. 2: Installing Cylinder Head Bolts (1.6L)

Courtesy of FORD MOTOR CO.

3. Install intake manifold support upper retaining bolts and tighten to specification. See

TORQUE SPECIFICATIONS

table at end of

NOTE:

Ensure coolant passage openings in gasket align with manifold and cylinder head.