Ford Festiva. Manual — part 27

article. Install timing belt and covers. Install cam cover. On non-turbo engines, connect front exhaust pipe to exhaust manifold. Tighten
nuts to specification.

4. On turbocharged engines, install exhaust manifold and turbocharger assembly. Install ground wire and strap to cylinder head with

retaining bolts. Connect intercooler tubes (if equipped). Connect O2 sensor connector, and install ground wires to bracket on cylinder
head with retaining screw. Connect main engine harness connector. Connect fuel lines to fuel filter and pressure regulator. Install
throttle cable and retaining brackets.

5. Install coolant hoses and vacuum lines to intake manifold and throttle body. Install coolant hose to thermostat cover. Install intake air

tube to air cleaner. Install spark plug wires and retainers. Install intake air tube to throttle body, and connect by-pass hoses. Fill cooling
system. Connect negative battery terminal. Start engine, check for leaks and system operation.

TIMING BELT COVER

Removal & Installation (1.3L)

Remove accessory belts. Remove water pump pulley. Remove crankshaft damper. Remove bolts retaining upper and lower cover halves to
engine front. Remove both covers. To install, reverse removal procedure.

Removal & Installation (1.6L)

Raise vehicle on hoist. Remove RF tire and wheel assembly. Remove RF splash guard. Lower vehicle. Remove spark plugs and set camshaft
timing to TDC No. 1 cylinder. Remove oil dipstick. Remove water pump pulley. Remove crankshaft pulley, damper and baffle plate. Remove
upper timing belt cover. Remove center and lower timing belt covers. To install, reverse removal procedure.

TIMING BELT

Removal (1.3L)

Remove accessory belts, water pump pulley, crankshaft damper and upper and lower timing belt covers. Mark timing belt direction of rotation
for installation reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley, spring and spring cover. Remove timing belt.

Installation (1.3L)

1. Ensure timing belt and sprockets are clean and not worn or damaged. Align crankshaft and camshaft timing marks. See

Fig. 3

. No. 1

cylinder must be at TDC of compression stroke.

2. Position belt on camshaft sprocket. Install timing belt tensioner spring, spring cover and pulley. Tighten tensioner pulley bolt to

specification. See

TORQUE SPECIFICATIONS

table at end of article. To complete installation, reverse removal procedure. Tighten

all bolts and nuts to specification.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (1.3L)

Courtesy of FORD MOTOR CO.

Removal (1.6L)

NOTE:

Always rotate engine in direction of normal operation. Rotating crankshaft backwards may cause belt to
jump timing.

Remove timing belt covers, See TIMING BELT COVER procedure to remove timing belt from this engine.

Installation (1.6L)

1. Ensure timing belt and sprockets are clean and not worn or damaged. Ensure timing marks are properly positioned on camshafts and

crankshaft. Intake cam should have letter "I" aligned with arrow on belt cover. Exhaust cam should have letter "E" aligned with arrow on
belt cover. Crankshaft key should align with arrow. See

Fig. 4

.

2. Tighten tension pulley with tension spring fully extended. Install timing belt. Keep tension on opposite side of tensioner as tight as

possible. Ensure rotation mark on belt is correct.

3. Turn crankshaft 2 full turns. Check alignment of timing marks. If any mark is not aligned, remove timing belt and reset timing. Loosen

tension pulley retaining bolt allowing tension spring to tighten belt. Tighten tension pulley to specification and rotate engine 2 full
turns. Verify timing mark alignment.

4. Measure timing belt tension between camshaft pulleys. Belt deflection should be 0.33-0.45" (8.5-11.5 mm). If incorrect, loosen tension

pulley and repeat procedure. If correct tension cannot be achieved, replace tension spring.

5. Install lower, center and upper timing belt covers, and tighten bolts to specification. See

TORQUE SPECIFICATIONS

table at end of

article. Install RH engine mount. Lower engine. Tighten retaining nuts to specification. Install crankshaft pulley, damper and baffle.
Tighten baffle and damper screws and pulley retaining bolts to specification. Install water pump pulley and tighten retaining bolts to
specification.

6. Install alternator and power steering belts. Install oil dipstick. Raise vehicle and install splash guard and RF wheel and tire assembly.

Lower vehicle, install spark plugs and start engine. Inspect for leaks and check operation.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks (1.6L)

Courtesy of FORD MOTOR CO.

FRONT COVER & OIL SEAL

Removal & Installation

Front cover is the housing for the oil pump. See OIL PUMP under ENGINE OILING.

CAMSHAFT

Removal (1.3L)

Remove cylinder head. Remove rocker arm assemblies if not previously removed. Carefully remove camshaft thrust plate. Remove camshaft

front oil seal. Carefully slide camshaft out front of cylinder head. DO NOT damage bearing bores.

Inspection (1.3L)

1. Check cylinder head for warpage. See INSPECTION under

CYLINDER HEAD

under REMOVAL & INSTALLATION. Measure

camshaft lobes across their maximum dimensions. Inspect for scoring and wear. Replace camshaft if not within specification. See, in this
article,

CAMSHAFT LOBE SPECIFICATIONS

table.

2. Measure camshaft bearing journals and cylinder head bores. See

Fig. 6

and

Fig. 7

. Subtract camshaft bearing journal O.D. from

cylinder head bore I.D. to obtain oil clearance. If clearance is not within specification, replace head and/or camshaft. See, in this article,

CAMSHAFT SPECIFICATIONS

table under ENGINE SPECIFICATIONS tables.

Installation (1.3L)

1. Oil camshaft and insert carefully. Install thrust plate. Install camshaft front oil seal. Install rocker arm shaft assemblies to original

location. Ensure oil holes in rocker arm shaft face downward.

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

in sequence and to specification. See

Fig. 5

. See

TORQUE SPECIFICATIONS

table at end of article. To complete installation,

reverse removal procedure. Tighten all bolts and nuts to specification.

CAMSHAFT LOBE SPECIFICATIONS

Fig. 5: Rocker Arm Shaft Tightening Sequence (1.3L)

Courtesy of FORD MOTOR CO.

Removal (1.6L)

1. Disconnect battery ground terminal. Disconnect air by-pass hoses, and remove intake air tube. Disconnect throttle cable, and remove

retaining brackets. Remove cam cover. Remove timing belt.

2. Hold camshaft with wrench while removing pulley retaining bolt. Remove camshaft pulley(s). Remove seal plate. Remove camshaft seal

using Seal Remover (T78P-3504-N). If removing intake cam, remove distributor.

3. Note numerical and directional markings on camshaft bearing caps for installation. Remove bearing cap retaining bolts alternately and

gradually to prevent overstressing camshaft. Remove camshaft.

Inspection (1.6L)

1. Check cylinder head for warpage (if removed). See INSPECTION in

CYLINDER HEAD

. Measure camshaft lobes across their

maximum dimensions. Inspect for scoring and wear. Replace camshaft if not within specification. See

CAMSHAFT LOBE

SPECIFICATIONS

table.

NOTE:

For additional camshaft specifications, see, in this article,

CAMSHAFT SPECIFICATIONS

table

under ENGINE SPECIFICATIONS at end of this article.

NOTE:

Camshaft bearings are NOT replaceable. If not within specification, replace cylinder head and/or
camshaft.

Application

Standard Height: In. (mm)

Wear Limit: In. (mm)

1.3L

1.4332-1.4371 (36.403-36.503)

1.4273 (36.253)

1.6L

1.6098 (40.888)

1.5944 (40.498)

NOTE:

For additional camshaft specifications, see

CAMSHAFT SPECIFICATIONS

table under ENGINE

SPECIFICATIONS at end of this article.

NOTE:

Camshaft bearings are NOT replaceable. If not within specification, replace cylinder head and/or

2. Measure camshaft bearing journals and cylinder head bores (with bearing caps in place and torqued to specification). See

Fig. 7

.

Subtract camshaft bearing journal O.D. from cylinder head bore I.D. to obtain oil clearance. If clearance is not within specification,
replace head and/or camshaft. See

CAMSHAFT SPECIFICATIONS

table under ENGINE SPECIFICATIONS at end of article.

Installation (1.6L)

1. Lubricate camshaft bearings with engine oil. Position camshaft(s) in cylinder head. Ensure all tappets are in place. Install intake cam

with the "I" mark straight up and exhaust cam with the "E" mark straight up. Install bearing caps according to numbers and arrows.
Arrows point to front of engine. Tighten retaining bolts gradually and in sequence to specification See

Fig. 6

. See, at end of this article,

TORQUE SPECIFICATIONS

table.

2. Install distributor (if removed). Install camshaft seal using Seal Protector (T90P-6256-AH) and Seal Installer (T90P-6256-BH). Install

seal plate and tighten retaining screws to specification. Install camshaft pulley to specification and tighten retaining bolt to specification.

3. Install timing belt. Install cam cover. Install throttle cable and retaining brackets. Install intake air tube and connect air by-pass hoses.

Connect battery ground terminal. Start engine and check for leaks and proper operation.

Fig. 6: Cam Bearing Cap Tightening Sequence (1.6L)

Courtesy of FORD MOTOR CO.

camshaft.