Engine - 1.7L - Specifications

Engine - 1.
7L - Specifications Puma 1998 (06/1997-12/2001)
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Engine Data
Description 1,7 Zetec-S VCT

Engine management EEC V
Emission standard 96 EEC
Fuel 95 RON
Engine code MHA
Firing order 1-3-4-2
Bore mm 80,0
Stroke mm 83,5
Capacity cm3 1679
Compression ratio 10,3 : 1
Engine power output in accordance with EC guidelines kW (PS) 92 (125)
Engine power output in accordance with EC guidelines at rev/min 6300
Torque Nm 157
Torque at rev/min 4500
Compression pressure at starter motor speed bar 12,4
Engine Oil
Viscosity / ambient
Description Specification
temperature
Recommended engine oil
SAE 5W30 / below -20 to over Ford Formula E Economy Motor
WSS-M2C912-A1
40 degrees Celsius Oil
Alternative engine oils
SAE 10W30 / -20 to over 40 ACEA A1/B1 or A2/B2
Ford Super Multigrade Motor Oil
degrees Celsius and/or API/SH/CD EC
SAE 5W40 / below -20 to over Ford Formula S Synthetic Motor ACEA A3/B3 and/or
40 degrees Celsius Oil API/SH/CD EC
SAE 10W40 / -20 to over 40 Ford XR+ High Performance ACEA A3/B3 and/or
degrees Celsius High Lubricity Motor Oil API/SH/CD EC
If engine oils with these specifications are not available then other engine oils
may be used provided they meet at least the API/SH/CD EC specification.
Oil Pressure
Description
Oil pressure (minimum, oil temperature 80 degrees C) at 850 rev/min bar 1,0
Oil pressure (maximum, oil temperature 80 degrees C) at 6000 rev/min bar 4,0
Pressure relief valve opening pressure bar 4,3
Capacities
Litres
Engine oil, initial fill 4,67
Engine oil, oil change with filter change 4,62
Engine oil, oil change without filter change 4,15
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Oil pan sealant WSE-M4G323-A4
Sealant, camshaft bearing caps WSK-M2G348-A5
Transmission fluid - manual transmission WSD-M2C200-C
Item Specification
Spark plug thread lubricant ESE-M12A4-A
Grease WSD-M1C227-A
Silicone grease ESE-M1C171-AA
Valves

Valve control mm Bucket tappets
Valve clearance (engine cold), intake mm 0,15-0,25
Valve clearance (engine cold), exhaust mm 0,25-0,35
Thickness of adjustment shims mm 2,50-3,39
Adjustment shims available in steps of mm 0,05
Cylinder Block

Number of main bearings 5
Cylinder bore ÀPÀ, class 1 mm 79,993-80,000
Crankshaft end float mm 0,22-0,43
Cylinder Head

Maximum unevenness (mating face) mm 0,05
Camshafts

Camshaft bearing diameter mm 25,000-25,021
Camshaft diameter (bearing journals) mm 24,959-24,975
Cam lift, intake camshaft mm 7,8
Cam lift, exhaust camshaft mm 6,65
Camshaft end float mm 0,10-0,24
Pistons

Piston ÀPÀ, class 1 mm 79,976-79,983
Piston ÀPÀ, class 2 mm Measuring shim (mm) + 79,983-79,990
Piston ring gap, upper mm 0,2-0,3
Piston ring gap, middle mm 0,3-0,5
Piston ring gap, lower mm 0,15-0,65
Piston ring end float, upper mm 0,04-0,08
Piston ring end float, middle mm 0,03-0,07
Axial play, oil scraper ring mm 0,05-0,15
Big-end bearing shells
Big-end bearing journal Big-end bore Big-end bearing radial Big-end bearing
diameter diameter clearance shell
mm mm mm mm
Big-end bearing journal Big-end bore Big-end bearing radial Big-end bearing
diameter diameter clearance shell
1,504 - 1,507
41,994-42,000 45,025-45,031 0,025-0,044
(blue)
1,507 - 1,510
45,031-45,038 0,024-0,044
(red)
1,510 - 1,513
45,380-45,045 0,023-0,044
(black)
1,507 - 1,510
41,987-41,993 45,025-45,031 0,026-0,045
(red)
1,510 - 1,513
45,031-45,038 0,025-0,045
(black)
1,513 - 1,516
45,380-45,045 0,024-0,045
(white)
1,510 - 1,513
41,980-41,986 45,025-45,031 0,027-0,045
(black)
1,513 - 1,516
45,031-45,038 0,026-0,045
(white)
1,516 - 1,519
45,380-45,045 0,025-0,045
(pink)
Torque Specifications
Description Nm lb-ft lb-in

Catalytic converter to exhaust manifold 47 35 -
Intake manifold to cylinder head 18 13 -
Intake manifold bracket to transmission 35 26 -
Catalytic converter bracket to cylinder block 47 35 -
Suspension arm to spindle carrier 52 38 -
Vibration damper to lower suspension arm 80 59 -
Battery cable to starter motor 6 - 53
Solenoid lead to starter motor 11 8 -
Radiator crossmember 25 18 -
Ground lead to transmission 33 24 -
Suspension strut nut 46 34 -
Drive belt idler pulley 25 18 -
Battery box 25 18 -
Power steering pump bracket to cylinder head. 24 18 -
High-pressure line to power steering pump 65 48 -
Exhaust pipe 47 35 -
Coolant pump to cylinder block 9 - 80
Compressor - Air Conditioning 25 18 -
Upper part of oil pan to cylinder block 20 15 -
Upper part of oil pan to clutch housing 44 32 -
Lower part of oil pan to cylinder block 9 - 80
Generator 49 36 -
Wiring to generator 11 8 -
Catalytic converter heat shield 6 - 53
Exhaust manifold heat shield 7 - 62
Gearshift stabiliser 55 41 -
Camshaft timing pulley (exhaust) 60 44 -
Camshaft timing pulley (intake) 105 77 -
Camshaft timing pulley blanking cap (intake) 38 28 -
Front engine mounting bracket 69 51 -
Front engine mounting bracket to cylinder block 55 41 -
Nut, rear engine mounting bracket 50 37 -
Rear engine mounting brace 11 8 -
Engine roll restrictor to engine 50 37 -
Engine roll restrictor to front crossmember 69 51 -
Coolant pump belt pulley 25 18 -
Drive belt idler pulley 25 18 -
Thermostat housing to cylinder block 9 - 80
Oil pump to cylinder block 9 - 80
Oil baffle plate to cylinder block 9 - 80
Oil pick-up pipe to oil baffle plate 9 - 80
Oil pressure switch to cylinder block 15 11 -
Oil dipstick tube to cylinder head 11 8 -
Oil drain plug 37 27 -
Oil filter 17 13 -
Bolt, transmission fluid check bore 35 26 -
Cylinder head bolts, stage 1. 15 11 -
Cylinder head bolts, stage 2. 30 22 -
Cylinder head bolts, stage 3. 90 ° 90 ° -
Cylinder head cover to cylinder head 10 - 89
Cover plate to cylinder head cover 6 - 53
Fuel distribution pipe to cylinder head 23 17 -
Exhaust manifold studs to cylinder head 17 13 -
Intake manifold studs to cylinder head 10 - 89
Coolant distribution pipe studs 10 - 89
Exhaust manifold to cylinder head 54 40 -
Camshaft position sensor (CMP sensor) to bracket 9 - 80
Camshaft position sensor bracket 9 - 80
Spark plugs 15 11 -
Engine lifting eye to engine (rear) 20 15 -
Engine lifting eye to engine (front) 50 37 -
EI ignition coil 6 - 53
VCT solenoid valve to cylinder head 9 - 80
Camshaft bearing caps, stage 1. 8 - 71
Camshaft bearing caps, stage 2. 17 13 -
Timing belt cover 9 - 80
Bracket, right-hand front axle halfshaft centre bearing 33 24 -
Retaining bracket, right-hand front axle halfshaft 18 13 -
Coolant distribution pipe to cylinder head 20 15 -
Coolant connection to cylinder head 9 - 80
Drive belt cover 6 - 53
Timing belt guard to cylinder block 9 - 80
Timing belt tensioner 35 26 -
Timing belt tensioner adjustment bolt 20 15 -
Crankshaft position sensor (CKP sensor) bracket to cylinder block 9 - 80
Crankshaft rear oil seal carrier 9 - 80
Crankcase breather to cylinder block 9 - 80
Blanking plug for timing peg bore, crankshaft TDC 25 18 -
Crankshaft pulley/vibration damper, stage 1 40 30 -
Crankshaft pulley/vibration damper, stage 2 90 ° 90 ° -
Big-end bearing cap to connecting rod, Stage 1 21 15 -
Big-end bearing cap to connecting rod, Stage 2 45 ° 45 ° -
Flywheel to crankshaft 85 63 -
Clutch pressure plate to flywheel 29 21 -
Engine - 1.7L - Engine Puma 1998 (06/1997-12/2001)

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Description and Operation

A new 1,7 Zetec-S VCT engine with 92 kW/125 bhp has been introduced together with
the new Puma.
It is a further development of the already familiar Zetec-SE engine series that features
1,25 and 1,4 litre versions.
The Zetec-S VCT engine is the first in a European Ford car to feature variable camshaft
timing (VCT).
An electronically controlled hydraulic adjustment unit provides variable adjustment of

the intake camshaft.
The VCT adjustment unit ensures high torque delivery throughout the entire engine
speed range.
In addition, the VCT system features internal exhaust gas recirculation, as a result of
which an external EGR system is no longer required.
The purpose of exhaust gas recirculation is to lower the combustion temperature and
the oxygen content of the mixture depending on the operating conditions of the engine.
The arrangement of the valve adjustment shims is also new. They have been made
smaller and are now located underneath the bucket tappets to minimise the weight of
the moving parts in the valve train.
Unlike the smaller Zetec-SE engines, the crankshaft is drop-forged. This achieves the
higher strength required to deliver the higher torque of the engine.
The familiar EEC V module is responsible for engine management and control of the VCT
adjustment unit.
Location of serial number, engine code and engine number

Item
Part Number
Description
1
-
Serial number
2
-
Engine code (MHA)
Item
Part Number
Description
1
-
Engine number
Cylinder block
The cylinder block is made of an aluminium-silicium alloy and does not feature
cylinder liners. The piston running surfaces have a special nickel-silicon
coating.
In service the cylinder block is supplied complete with crank gear and pistons.
NOTICE:
Always place the cylinder block down on a rubber mat to prevent

damaging the cylinder block mating faces (top and bottom).
Thread repairs on the cylinder block are not permissible.
Crank gear
NOTE: Do not dismantle the crank gear.

The bearing clearances and bearing shells have very fine tolerances, as a result
of which the crank gear components cannot be renewed individually. It is not
possible to measure the main bearing clearance using conventional methods.
The crankshaft has eight counterbalances and runs on five bearings.
The lower crankcase provides significant additional strength for the cylinder
block.

Item
Part Number
Description
1
-
Cylinder block
2
-
Bearing shells
3
-
Crankshaft
4
-
Lower crankcase
Cylinder head
The cylinder head is made of an aluminium-silicium alloy and is accurately

positioned on the cylinder block by means of two guide sleeves.
In service the cylinder head is supplied complete with fitted valves and bearing
caps. The studs must be renewed.
The cylinder head has four valves per cylinder. The valve angle is slightly
asymmetrical. The exhaust valves are inclined at 2 degrees more than the
intake valves.
The intake camshaft is equipped with variable camshaft timing.
The spark plugs are slightly offset from the middle of the combustion chamber
to permit use of the largest possible intake valves.
The valve guides and valve seats are made from sintered metal.
An additional coolant duct is located between the exhaust valve guides to

provide extra cooling for the exhaust valve seats.

Item
Part Number
Description
1
-
Exhaust camshaft
2
-
Intake camshaft
3
-
Cylinder head
4
-
Camshaft pulley
5
-
Solenoid valve of VCT adjustment unit
Cylinder head cover
NOTE: Remove the camshaft position sensor (CMP sensor) before removing
the cylinder head cover.
The cylinder head cover is made of magnesium, and the cylinder head gasket
can be renewed separately.
NOTE: The cylinder head cover gasket does not need to be renewed every
time it is taken off. Check it visually and only fit a new gasket if it is
damaged.
The cylinder head cover is attached to four studs on the camshaft bearing caps.
These studs are sealed with four rubber bungs with torque limiters. In the
event of leaks these four rubber bungs can be renewed separately.
If a new or different cylinder head cover is fitted then renew the four rubber
bungs and the seal for the VCT adjustment unit solenoid valve.
New cylinder head covers are supplied with a gasket and four new bungs.
Intake manifold
The intake manifold consists of two parts which are bolted together.
The material used is an aluminium alloy.
The gasket between the intake manifold and the cylinder head is made of
plastic. There is a steel gasket between the two halves of the intake manifold.
Exhaust manifold
The HO2S sensor is integrated directly into the exhaust manifold. The gasket
between the exhaust manifold and the cylinder head is made of steel.
Oil pan
The oil pan has been enlarged to cope with the additional oil requirements
compared to the 1,25 and 1,4 litre Zetec-SE engines.
For manufacturing reasons the oil pan consists of two parts.
NOTICE: Do not use any sharp tools to remove the oil pan.
NOTE: During removal always take off the lower part of the oil pan first, as
this makes two of the bolts on the upper part accessible.
Both parts of the oil pan are sealed using sealant WSE-M4G323-A4.
NOTE: Two bolts inside the upper part of the oil pan need additional steel
sealing rings.
NOTE: Align the oil pan to the cylinder block using a straightedge.
Timing belt tensioner

The timing belt is tensioned by a mechanical timing belt tensioner.
Timing belt tensioner adjustment. For additional information, refer to Section

303-03 Engine Cooling.
Crankshaft pulley/vibration damper
NOTICE:
After undoing and tightening the crankshaft pulley/vibration damper

bolt check the alignment of the camshaft and crankshaft.
Only use the crankshaft pulley/vibration damper bolt once.

NOTE: Only pull on the crankshaft pulley/vibration damper using the special
tool, as it will be over-torqued if pulled on with the bolt.
Pistons
The pistons are made of an aluminium-silicium alloy and are equipped with two
piston rings and a three-part oil scraper ring.
Item
Part Number
Description
1
-
Plain compression ring
2
-
Napier ring
3
-
Oil scraper ring (top)
4
-
Oil scraper ring
5
-
Oil scraper ring (bottom)
NOTE: TOP marking on plain compression ring and Napier ring.
The piston rings can be renewed separately.
Each ring gap is 90 degrees offset from the next. This also applies to the three
elements of the oil scraper ring.
The dots on the piston crown point towards the timing belt end.
There are no oversize pistons available.
The pistons cannot be renewed separately.
As a result of the variable camshaft timing it has become necessary to

introduce notches in the piston crown.
Connecting rods
The connecting rods are made of forged steel.
The big-ends are separated by fracture. This process produces a perfect fit for
the big-end bearing caps.
Valve train
Two overhead camshafts are driven by the crankshaft via a timing belt. They
control the valves via tappets and adjustment shims.
The valve clearance should be checked every 150,000 km.
The timing belt should be renewed after 150,000 km or 10 years.
The tappets are mechanical bucket tappets.
The valve adjustment shims are located underneath the bucket tappets.
This arrangement has the following advantages:
 smaller and therefore lighter adjustment shims.

 the weight of the moving parts in the valve train is reduced.
 the valve train is more stable at high engine speeds.
The valve stems are nitration-hardened and the valve seats are reinforced.
The exhaust valves are made of two different materials (two different alloys
for the valve stems and the valve heads).

Item
Part Number
Description
1
-
Bucket tappet
2
-
Valve adjustment shim
3
-
Intake duct
4
-
Exhaust valve
5
-
Valve seat
6
-
Exhaust duct
Camshafts
Check the camshaft bearings whenever the camshafts are renewed. In the
event of damage renew the cylinder head and the camshaft bearing caps.
Both camshafts have a cast hexagon (21 mm) which is used for turning them.
Both camshafts have a slot at the clutch end to take the TDC setting tool.
NOTICE:
Lubricate the camshafts with engine oil before installing them.
Tighten the camshaft bearing caps in two stages following the tightening
sequence.
The numbering of the bearing caps starts at the timing belt end, with nos. 1 to
5 on the exhaust side and 6 to 0 on the intake side.
NOTE: The camshaft timing belt pulleys are free to turn on the camshafts
once the central bolts have been undone.
The VCT adjustment unit is bolted to the intake camshaft. The hollow bolt used
for this purpose also forms part of the oil circuit of the VCT adjustment unit.
Besides the usual reference wheel for detecting the first cylinder position,
there are four more cams on its circumference, at 90 degrees to each other,
used by the camshaft timing unit to exactly determine the position of the
camshaft.
NOTE: Always renew the hollow bolt after removal.
Item
Part Number
Description
1
-
Exhaust camshaft
2
-
Reference wheel
3
-
Intake camshaft
Variable camshaft timing (VCT)
The camshaft adjustment is map-controlled, but also responds to mass air

flow, intake air temperature and coolant temperature via the PCM.
The solenoid valve is supplied with voltage pulses from the PCM that determine
the required current.
NOTE: If the PCM detects a fault in the VCT system it no longer supplies the
solenoid valve with a voltage, and the VCT adjustment unit returns to its
original position. This prevents any adjustment.
Item
Part Number
Description
1
-
Inner helical gear (connected to the camshaft)
2
-
Adjustment piston with inner and outer helical gear
3
-
Outer helical gear (connected to the camshaft timing pulley)
4
-
Adapter
5
-
VCT adjustment unit solenoid valve
The adjustment of the camshaft is performed by a piston that moves along the
axis of the camshaft.
This adjustment piston has an inner and outer helical gear.
The helical gears that engage in the adjustment piston are connected to the
camshaft timing pulley (outer gear) on the one hand and the camshaft (inner
gear) on the other.
Depending on the required setting of the camshaft, pressurised engine oil is

delivered either to the front or the back of the piston to move it backwards or
forwards along the camshaft axis.
The helical gears translate this axial movement into a rotation of the camshaft
in relation to the camshaft timing pulley.
The build height of the adjustment unit was reduced by using two pairs of
helical gears.
Adjustment angle of the intake camshaft
Item
Part Number
Description
1
-
Adjustment angle of the adjustment piston relative to the camshaft timing pulley
2
-
Adjustment angle of the camshaft relative to the adjustment piston
3
-
Camshaft timing belt pulley
4
-
Adjustment piston
5
-
Camshaft
The camshaft timing pulley is directly linked to the crankshaft via the timing
belt and is therefore not rotated in relation to the crankshaft during
adjustment.
When the applied engine oil pressure forces the adjustment piston to move
axially, the helical gears produce the following rotations:
 Rotation of the adjustment piston relative to the camshaft timing pulley via
the outer helical gear.
 Rotation of the camshaft relative to the adjustment piston via the inner
helical gear.
 These two rotations add up to give the overall adjustment angle of the
camshaft.
In this way the camshaft can be adjusted by up to 20 degrees compared to the
camshaft timing pulley.
The adjustment angle depends on the operating conditions of the engine.
Oil circuit of the VCT adjustment unit
Advancing the camshaft
Oil is supplied via the solenoid valve, through the oil supply slots on the
camshaft and the hollow bolt into chamber 1, which then becomes pressurised.
The adjustment piston is moved axially on the helical gears.
The camshaft timing is advanced.
As a result of the axial movement of the adjustment piston, the oil in chamber
2 is displaced through the gaps in the gears.
The oil can then flow back through the oil supply slots on the camshaft and the
return bore in the control piston solenoid valve to the cylinder head.
Item
Part Number
Description
1
-
Chamber 1
2
-
Adjustment piston
3
-
Chamber 2
4
-
Oil duct to chamber 1
5
-
Retarding the camshaft
Oil is supplied via the solenoid valve, through the oil supply slots on the
camshaft and the hollow bolt into chamber 2, which then becomes pressurised.
The adjustment piston is moved axially on the helical gears.
The camshaft timing is retarded.
As a result of the axial movement of the adjustment piston, the oil in chamber
1 is displaced through the gaps in the gears.
The oil can then flow back through the oil supply slots on the camshaft and the
return bore in the control piston solenoid valve to the cylinder head.
Item
Part Number
Description
1
-
Chamber 1
2
-
Adjustment piston
3
-
Chamber 2
4
-
5
-
Engine - 1.7L - Cylinder Head Puma 1998 (06/1997-12/2001)
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Disassembly and Assembly of Subassemblies

Special Tool(s)
Pliers, valve adjusting shims
303-196 (21-107)
Materials
Name
Specification
Spark plug thread lubricant
ESE-M12A4-A
Disassembly
1. NOTICE: Always place the cylinder head down onto a soft rubber surface.
NOTE: The new cylinder head is supplied with new valves but without studs.
Detach the intake manifold.
 Take off the rubber seal from the fuel distribution pipe.
2. NOTE: Two plastic centering washers for the fuel distribution pipe.
Detach the fuel distribution pipe and the front engine lifting eye.
3. Remove the components.
1. Detach the EI ignition coil.
2. Detach the engine lifting eye.
3. Detach the coolant hose spigot.
4. Detach the coolant distribution pipe.
4. Detach the exhaust manifold together with the gasket.
5. NOTE: Adjustment shims underneath the bucket tappets.

Remove the bucket tappets and keep them in order together with their
adjustment shims.
 Remove the spark plugs.
Assembly
1. Fit new studs to the new cylinder head.
2. NOTE: Lubricate the bucket tappets with engine oil prior to installation.
Insert the bucket tappets and their adjustment shims.
 Apply lubricant to the spark plug threads and install the spark plugs.
3. Attach the exhaust manifold with the gasket.

4. Fit the components.
1. Install the EI ignition coil.
2. Install the rear engine lifting eye.
3. Install the coolant hose spigot.
4. Install the coolant distribution pipe.
5. NOTE: Two plastic centering washers for the fuel distribution pipe.
Attach the fuel distribution pipe and the front engine lifting eye.
6. Fit the intake manifold.
 Place the rubber seal on the fuel distribution pipe.
Engine - 1.7L - Engine Puma 1998 (06/1997-12/2001)
Print
Assembly
Special Tool(s) / General Equipment
Remover/installer, rubber mounting
204-168 (14-043)
Universal Flange Holding Wrench
205-072 (15-030A)
Aligner, Clutch Disk
308-204 (16-067)
Mounting Bracket for 303-435
303-435-06 (21-031B)
Timing Plate, Camshaft Alignment
303-376 (21-162B)
Socket, Cylinder Head Bolt
303-392 (21-167)
Locking Tool, Flywheel
303-393 (21-168)
Installer, Crankshaft Oil Seal
303-395 (21-171)
Mounting Stand
303-435 (21-187)
Crankshaft TDC setting
303-507 (21-210)
Mounting Plate for 303-435-06
303-435-14 (21-212)
Replacer, vibration damper
303-510 (21-214)
Angle gauge
303-174 (21-540)
Pliers, Spark Plug Connector
303-622 (21-226)
Clamping strap
E18 Torx socket insert
T55 Torx socket insert
4.8 mm diameter timing pin
Materials
Name
Specification
Sealant
WSE-M4G323-A4
Sealant
WSK-M2G348-A2
Engine oil
WSS-M2C912-A1
Silicone grease
ESE-M1C171-AA
Assembly
1. NOTICE: The crank gear, pistons and cylinder running surfaces cannot be
renewed separately.
Preparatory operations.
 Thoroughly clean all mating faces and reusable parts and check them for
damage.
2. Measure the cylinder bores.
For additional information, refer to: Cylinder Bore Taper (303-00 Engine
System - General Information, General Procedures).
3. Measure the end float of the crankshaft.
For additional information, refer to: Crankshaft End Play (303-00 Engine
System - General Information, General Procedures).
4. NOTE: The dot on the piston crown faces the timing belt end.
NOTE: Lubricate the pistons and cylinder liners with engine oil.
Install the piston.
 Use a proprietary clamping strap to compress the piston rings.
5. NOTICE: The big-end bearing journal must be at BDC.

NOTE: Fit the big-end bearing shells in the correct place.
Install the piston.
 Press pistons 1 and 4 into the cylinders with the handle of a hammer.
 Coat the matching big-end bearing shells with engine oil and place them
centrally in the big-ends.
 Fit the big-end bearing caps and tighten the bolts finger tight.
 Turn the crankshaft through 180 degrees, install pistons two and three, put
on the big-end bearing caps and tighten the bolts finger-tight.
6. NOTE: Fit the big-end bearing caps in the correct positions.
Install the big-end bearing caps and tighten in two stages.
 1st stage: 21 Nm
 2nd stage: 45 degrees
7. Install the oil pan baffle.
8. Attach the oil pick-up pipe with a new gasket and a new O-ring, and the oil
pump with a new gasket.
9. Draw in the front oil seal using the bolt of the crankshaft pulley/vibration
damper.
10. Attach a new crankshaft rear oil seal carrier with the oil seal and the
assembly aid.
 Attach the CKP sensor bracket.
11.Apply a bead of sealant to the upper part of the oil pan.

12. NOTE: Bolt tightening sequence for the upper part of the oil pan.
NOTE: Tighten the bolts within five minutes.
NOTE: Align the oil pan to the cylinder block using a straightedge.
NOTE: Renew bolts 1 and 2 and fit them with new oil seals.
Install the upper part of the oil pan and secure it, following the tightening
sequence.
13.Apply a bead of sealant to the lower part of the oil pan.

14. NOTE: Bolt tightening sequence for the lower part of the oil pan.
NOTE: Tighten the bolts within five minutes.
Install the lower part of the oil pan and secure it, following the tightening
sequence.
15. NOTE: Tightening sequence and position of locating stud for the flywheel.
NOTE: Positioning aids on the oil seal carrier.
Attach the flywheel.
 Remove the special tool.
16. NOTICE: Tighten the cylinder head in three stages according to the
tightening sequence.
NOTE: The cylinder head is positioned by two guide sleeves.
Install the cylinder head, securing it in three stages following the tightening
sequence.
 Ensure that all mating faces are clean.
 Fit a new cylinder head gasket.
 2nd stage: 30 Nm
 3rd stage: 90 degrees
17. NOTE: The flywheel is in the position shown.

Set cylinder no. 1 to approx. 25 mm before TDC.
18. NOTE: Before installation, lubricate the camshafts and camshaft bearings with
engine oil.
NOTE: The inlet camshaft has additional cams for the CMP sensor and the
variable camshaft timing (VCT).
Locate the camshafts in position with the VCT solenoid valve and apply sealant
in the area of the front bearing shells.
19. NOTICE:
Install the camshafts so that none of the cams is at full lift.
Tighten the bearing caps in two stages.

NOTE: Tightening sequence and markings on bearing caps.
NOTE: The VCT solenoid valve must lie on the cylinder head.
Install the camshafts with the VCT solenoid valve and tighten in two stages
according to the tightening sequence.
 1st stage: 8 Nm
20. NOTE: Lubricate the sealing lip of the oil seal and the camshaft journals with
engine oil.
Install the camshaft oil seals.
21. Install the camshaft pulleys so that they can still just be turned on the
camshafts (inlet side shown).
 Use a E18 Torx socket attachment for the intake side.
 Use a T55 Torx socket insert on the exhaust side.
 Always renew the hollow bolts.
22. Position the crankshaft timing pulley, attach the coolant pump with a new
gasket and attach the rear timing belt cover.
23. NOTICE: Only turn the camshafts by the hexagon with a spanner.
Set the camshafts to TDC on cylinder no. 1.
 Insert the special tools.
24. NOTE: If the special tool cannot be screwed in, turn the crankshaft back anti-
clockwise by about 20 degrees.
Turn the crankshaft to TDC of cylinder no. 1.
 Unscrew the blanking plug from the alignment pin bore hole and screw in the
special tool.
 Carefully turn the crankshaft clockwise until the crankshaft web meets Special
Tool .
25. NOTE: The arrows on the timing belt run clockwise.

Attach the timing belt tensioner and lay the timing belt in place.
1. Install the timing belt.
2. Tighten the bolt finger tight.
26. Adjust the timing belt tensioner.
 Compress the spring until it is possible to press a 4.8 mm diameter timing pin
into the recess on the timing belt tensioner housing.
 Tighten the adjustment bolt.
 Slacken the timing belt tensioner and completely withdraw the 4.8 mm
diameter timing pin.
27. NOTICE: Only hold the camshafts by the hexagon with a spanner.
Tighten the camshaft timing pulleys.
28. Attach the engine mounting bracket and the timing belt guard.
 Slide on the thrust washer.
29. Install the timing belt lower cover.

30. Put the crankshaft pulley/vibration damper on the crankshaft and pull it
home.
31. NOTE: Use a new bolt.

Tighten the bolts of the crankshaft pulley/vibration damper in two stages.
 Stage 1: 40 Nm
32. Check the valve timing.

 Remove Special Tool 303-376.
 Unscrew and remove Special Tool 303-507.
 Turn the crankshaft clockwise through two revolutions to TDC.
 Turn the crankshaft to TDC of cylinder no. 1.
 Check the TDC position using the special tools.
 Detach both special tools.
33. NOTE: Only if Special Tool 303-376 cannot be inserted.

Check the valve timing.
 Undo the affected camshaft timing pulley.
 Turn the camshaft until Special Tool 303-276 can be inserted.
 Tighten the camshaft timing pulley, in doing so the crankshaft must remain at
TDC.
 Check the valve timing again.
34. Screw the blanking plug into the alignment pin bore hole.
35. Screw in the blanking cap.

 Use a new O-ring on the blanking cap.
36. Attach the EI ignition coil and the engine lifting eye.
37. NOTICE:
Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease, to
avoid damaging the spark plug connector seal.
Push on the spark plug connector in line with the spark plug axis.
NOTE: Coat the inside of the spark plug connector with silicone grease.
Attach the CMP sensor and the cylinder head cover.
 Coat the inside of the spark plug connector with silicone grease to a depth of
5-10 mm.
 Connect the spark plug electrical connectors.
38. Fit the timing belt covers.
1. Install the timing belt lower cover.
2. Install the timing belt upper cover.
3. Install the drive belt idler pulley.
4. Attach the coolant pump pulley.
39. Attach the ancillary components.

1. Crankcase breather housing.
2. CKP sensor
3. Oil pressure switch.
 Push on the positive crankcase ventilation hose.
40. NOTE: TOP marking on thermostat.
Attach the ancillary the components.
1. Attach the intake manifold using a new gasket.
2. Thermostat and thermostat housing.
3. Oil dipstick tube.
 Fit the vacuum hose.
41. Attach connectors.

1. Connect the oil pressure switch connector.
2. Connect the coolant temperature sender connector.
3. Connect the CKP sensor plug.
42. Attach the wiring harness cover with the wiring harness and connect the
injector plugs.
43. Attach connectors.

1. Connect the variable camshaft timing (VCT) solenoid valve connector.
2. Connect the camshaft position (CMP) sensor connector.
3. Connect the engine coolant temperature sensor (ECT sensor) connector.
4. Connect the throttle position sensor (TP sensor) multiplug.
5. Connect the idle air control valve (IAC valve) connector.
44. Centre the clutch disc.
 Centre the clutch disc on the clutch pressure plate using the centering tool
and secure it.
45. NOTICE: Fit the bolts finger tight, and then working at no more than two
turns at a time tighten them to the specified torque.
Install the clutch disc with the clutch pressure plate using the special tool.
1. Put the clutch pressure plate with the locator and the centred clutch disc onto
the guide pegs on the flywheel.
2. Secure the clutch pressure plate by tightening the bolts evenly, working
diagonally (six bolts).
 Detach the special tool.
46. NOTE: Only use EFL600 oil filters.
Remove the engine from the mounting stand.
 Attach the oil filter.
 Fill up with coolant .
Engine - 1.4L Zetec-SE (Sigma)/1.6L -

Puma 1998 (06/1997-12/2001)
Specifications
Print
Engine Data
1.4l 1.6l
Description
Zetec SE Zetec SE
Engine management EEC V EEC V
Emission standard 96 EEC 96 EEC
Fuel 95 RON 95 RON
Engine code up to 2000,5 MY (emission level Stage II/Europe, FHD
excluding Germany as well as D3 and D4/Germany)
Engine code from '99,5 MY Europe, excluding Germany (Stage II) FHF
Engine code from 2001,25 MY (emission level Stage IV) L1W
Injection sequence 1-3-4-2 1-3-4-2
Bore diameter mm 76.0 79.0
Stroke mm 76.0 81.4
cm
Cubic capacity (effective) 3 1388 1595
Compression ratio 10.3:1 11:1
Engine power output (EEC) kW 66 76
Engine power output (EEC) PS 90 103
rp
Engine power output (EEC) at 5600 6000
m
Torque (EEC) Nm 123 145
rp
Torque (EEC) at 4500 4000
m
rp
Maximum engine speed - continuous 6350 6450
m
rp
Maximum engine speed - intermittent (without load) 6575 6800
m
Engine Oil
Viscosity/ambient temperature Type Specification

Recommended engine oil
SAE 5W-30 / below ACEA A1/B1 and WSS-M2C912-
Ford Formula E Economy Motor Oil
-20°C to over +40°C A1 or WSS-M2C913-A
Alternative engine oils
SAE 10W-30 / -20°C to ACEA A1/B1 or A2/B2 and/or
Ford Super Multigrade Engine Oil
over +40°C API/SH/CD EC
Ford XR+ High Performance High SAE 10W-40 / -20°C to ACEA A3/B3 and/or API/SH/CD
Lubricity Engine Oil over +40°C EC
Ford Formula S Synthetic Engine SAE 5W-40 / below ACEA A3/B3 and/or API/SH/CD
Oil -20°C to over +40°C EC
Oil Pressure
Description 1.4l/1.6l Zetec SE

Oil pressure (minimum, oil temperature 80°C) at 800 rpm bar 1.0
Oil pressure (minimum, oil temperature 80°C) at 2000 rpm bar 2.5
Pressure relief valve opening pressure bar 5
If other engine oil brands are used, it must be ensured that they conform to
the relevant API SH/EC or higher viscosity class.
Capacities - 1.4l
Description Litres
Engine oil, for initial fill incl. filter 4.25
Engine oil, for oil change incl. filter (EFL500) 3.75
Engine oil, for oil change excl. filter 3.50
Capacities - 1.6l
Description Litres
Engine oil, for initial fill incl. filter (EFL600) 4.50
Engine oil, for initial fill incl. filter (EFL10) 4.30
Description Litres
Engine oil, for oil change excl. filter 3.75
Lubricants, Sealers and Adhesives
Item Specification
Sealer, oil pan contact surface to oil seal carrier, oil pan to cylinder block, WSE-M4G323-
oil pan to oil pump A4
WSK-M2G349-
Oil pressure switch sealer (Loctite 243)
A7
WSK-M2G348-
Sealer, camshaft bearing cap to cylinder head
A2
Spark plug thread lubricant ('Never Seez') ESE-M1244-A
Lubricant for Special Tool 21-215 WSD-M1C227-A
Coolant (Motorcraft Super Plus 4 AntiFreeze) ESDM-97B49-A
Power steering fluid ESPM-2C-166-A
WSD-M2C200-
Transmission fluid - manual transmission
C
Camshaft
Description 1.4l Zetec SE 1.6l Zetec SE

Drive Timing belt Timing belt
Inlet opens before TDC Degrees 2 6
Inlet closes after BDC Degrees 46 46
Exhaust opens before BDC Degrees 34 38
Exhaust closes after TDC Degrees 10 6
Valves

Valve control Bucket tappets Bucket tappets
Valve clearance (engine cold), inlet mm 0.17 - 0.23 0.17 - 0.23
Valve clearance (engine cold), exhaust mm 0.27 - 0.33 0.31 - 0.37
Free valve spring length mm 53.2 53.2
Valve springs - inner mm 16.85 - 17.15 16.85 - 17.15
Valve spring wire - mm 2.77 - 2.83 2.77 - 2.83
Number of turns (active) 7.2 7.2
Valve length, inlet mm 97.35 96.95
Valve length, exhaust mm 99.40 99.40
Valve head diameter, inlet mm 27.95 - 28.25 29.95 - 30.25
Valve head diameter, exhaust mm 23.95 - 24.25 23.95 - 24.25
Cylinder Block Dimensions

Cylinder bore dia., class 1 mm 76.000 - 76.010 79.000 - 79.010
Crankshaft end float mm 0.220 - 0.430 0.220 - 0.430
Cylinder Head
Description 1.4l/1.6l Zetec SE

Maximum distortion (mating face) mm 0.05
Piston Dimensions

Piston dia., class 1 mm 75.975 - 75.985 78.955 - 78.965
Piston ring gap, upper mm 0.2 - 0.3 0.18 - 0.28
Piston ring gap, middle mm 0.3 - 0.5 0.7 - 0.9
Piston ring gap, lower mm 0.15 - 0.65 0.15 - 0.65
Piston ring end float, upper mm 0.04 - 0.08 0.04 - 0.08
Piston ring end float, middle mm 0.03 - 0.06 0.025 - 0.07
The piston ring gaps must be distributed evenly around the circumference of
the piston. This also applies to the elements of the oil scraper ring. Offset the
ring gaps by 120° to one another.
Tightening Torques

Exhaust pipe to flexible exhaust pipe 47 35 –
Exhaust manifold to catalytic converter 47 35 –
Selector rod stabilizer 55 41 –
Lower suspension arm to wheel knuckle 52 38 –
Halfshaft centre bearing to bracket 24 18 –
Solenoid switch cable to starter 11 8 –
Radiator crossmember 25 18 –
Exhaust manifold heat shield 7 – 62
Ground lead to transmission 44 32 –
Catalytic converter bracket 47 35 –
Throttle body bracket 25 18 –
Battery box 35 26 –
Front engine mounting bracket 55 41 –
Rear engine mounting bracket nuts 69 51 –
Rear engine mounting bracket 50 37 –
Engine roll restrictor to engine 50 37 –
Engine roll restrictor to front crossmember 69 51 –
Rear engine mounting reinforcement 11 8 –
Drive belt idler pulley 24 18 –
Power steering pump to cylinder block 23 17 –
Generator to cylinder block 49 36 –
Drive belt cover 6 – 53
Coolant pump to cylinder block 9 – 80
Coolant pump pulley 24 18 –
Oil pump to cylinder block 9 – 80
Oil pan to cylinder block 20 15 –
Oil dipstick tube bracket to cylinder head 9 – 80
Oil drain plug 37 27 –
Oil pan to transmission 44 32 –
Transmission oil drain plug 35 26 –
Power steering high-pressure pipe bracket 23 17 –
Vibration damper to lower suspension arm 80 59 –
Cylinder head to cylinder block stage 1 15 11 –
Cylinder head to cylinder block stage 2 30 22 –
90 90 90
Cylinder head to cylinder block stage 3
degrees degrees degrees
Cylinder head cover, stage 1 3 – 27
Cylinder head cover, stage 2 10 – 89
Cylinder head cover plate 6 – 53
Intake manifold 18 13 –
Fuel rail 23 17 –
Exhaust manifold to cylinder head 54 40 –
Exhaust manifold studs to cylinder head 10 – 89
Camshaft position sensor (CMP sensor) 10 – 89
Spark plugs 15 11 –
Engine lifting eyes 20 15 –
Coolant outlet housing 20 15 –
Ignition coil to coolant outlet 6 – 53
Camshaft bearing caps, stage 1 7 – 62
Camshaft bearing caps, stage 2 16 12 –
Upper timing belt cover to cylinder block 9 – 80
Lower timing belt cover to crankcase 9 – 80
Timing belt tensioning pulley 23 17 –
Timing belt tensioning pulley with eccentric 23 17 –
Timing belt tensioning pulley with slot 20 15 –
Camshaft timing pulleys 60 44 –
Crankshaft position (CKP) sensor mounting to cylinder
9 – 80
block
Crankshaft position (CKP) sensor to mounting 9 – 80
Rear crankshaft oil seal carrier 9 – 80
Bore blanking plug for TDC peg 20 15 –
Pulley / vibration damper to crankshaft, stage 1 40 30 –
90 90 90
Pulley / vibration damper to crankshaft, stage 2
degrees degrees degrees
Flywheel to crankshaft 85 63 –
Clutch to flywheel 30 22 –

Puma 1998 (06/1997-12/2001)
Engine
Print
Description and Operation

General
Two engines from the Zetec-SE range are used in Puma: 1,4L cubic capacity producing
66 kW/90 PS and 1,6L cubic capacity producing 76kW/103 PS.
The Zetec-SE engine is made entirely of aluminium and conforms to the exacting
emission standard EEC-96/D3/D4.
NOTICE: Any gaskets involved in the removal of engine components must be

renewed during installation.
Location of serial number and engine code
Item
Part Number
Description
1
-
Engine code for 1,4L up to 2000,5 MY (emission level stage II/Europe except Germany and
also D3 and D4/Germany): FHD
-
Engine code for 1,4L from 99,5 MY (emission level stage II/Europe except Germany): FHF
-
Engine code for 1,6L from 2001,25 MY (emission level stage IV): L1W
2
-
Manufacturing dates
Cylinder head cover
NOTE: The cylinder head cover is made of magnesium, and the gasket is vulcanised
onto it and therefore cannot be renewed separately. The cylinder head cover and its
gasket do not need to be renewed every time they are removed. Carry out a visual
check of the gasket and renew the cylinder head cover only if the gasket is damaged.
The cylinder head cover is attached to four camshaft bearing caps. These studs are
sealed with four rubber bungs with torque limiters. If any leaks are detected, the four
bungs can be renewed separately. It is permissible to lightly coat the rubber bungs with
engine oil for installation. Wipe off any excess oil with a clean cloth. When fitting a new
cylinder head cover, use the four new rubber bungs supplied with the new cylinder head
cover.
Camshafts
NOTICE:
The camshafts must be lubricated with engine oil prior to installation.
The camshaft bearing caps are tightened in three stages to a maximum of 16 Nm

following the tightening sequence.
NOTE: The camshaft timing belt pulleys are not positively prevented from turning on
the camshafts.
Check the camshaft bearings whenever the camshafts are renewed. In the event of
damage renew the cylinder head and, if necessary, the camshaft bearing caps.
The exhaust camshaft is fitted with an additional cam for the camshaft position sensor
(CMP sensor).
Both camshafts have a forged hexagon (21 mm) for turning them.
Both camshaft ends have a slot into which the tool for setting TDC fits.
The numbering of the bearing caps starts at the timing belt end with:
I1 on the intake side
E1 on the exhaust side
The front bearing caps are accurately positioned on the cylinder head by means of guide
sleeves and must be fitted using sealant.
Cylinder head
NOTICE:
Thread repairs are not permitted on the cylinder head.
Do not skim the cylinder head mating face.
Machining the valve seats and stem guides is not permitted.

NOTE: If new valves are installed, they are to be ground in without re- cutting the
seats.
The cylinder head is made of aluminium and is accurately positioned on the cylinder
block with two guide sleeves.
In service a new cylinder head is supplied complete with installed valves and camshaft
bearing caps.
New studs must be installed.
To ensure that the cylinder head is properly sealed, the maximum permitted
unevenness on the cylinder block mating face is 0.05 mm.
Cylinder head gasket
NOTE: The cylinder head gasket can only be installed properly in one position.
The cylinder head gasket is a multi-layer steel gasket which must be renewed every
time it is disassembled.
Cylinder block
NOTICE:
In order to prevent damaging the cylinder block mating face, only ever place it
down onto a soft surface.
Thread repairs on the cylinder block are not permitted.
Machining the cylinder block mating faces is not permitted.
Do not damage the impeller of the coolant pump during removal and installation.
The cylinder block is of die-cast aluminium with cylinder liners made of cast iron.
In service a new cylinder block is supplied complete with crank gear and pistons, as well
as all oil gallery blanking plugs and coolant drain plugs.
1. In northern European countries a heating element can be fitted to the

core plug bore (previously the frost plug).
Always renew coolant drain plugs after removal.
To ensure that the cylinder head is properly sealed, the maximum permitted
unevenness on the cylinder block mating face is 0.05 mm.
Crankshaft
NOTE: Owing to the very fine tolerances for the bearing clearance and bearing shells,
the crankshaft drive components cannot be renewed separately. Bearing clearance
measurement (main bearings and big-end bearings) is not possible by traditional
methods.
Never disassemble the crank gear.
The crankshaft is attached to the cylinder block by means of a lower crankcase made of
aluminium.
Pistons
NOTICE: The pistons must not be removed.
No oversize pistons are available.
The pistons are made of an aluminium alloy and feature three piston rings:
Plain compression ring (top)
Napier ring (middle)
Oil scraper ring (bottom)
Oil pan
Vehicles built up to 12/1999

The oil pan is made of aluminium.
During installation align the oil pan so that it forms a flush surface with the flywheel end
of the cylinder block.
Spacer washers are not provided.
Note the tightening sequence and specified tightening torque during installation.
Always renew the oil pan gasket after the oil pan has been removed.
Apply the specified sealant to the cylinder block gaps, the oil pump flange and the
contact surface of the crankshaft rear oil seal carrier before attaching the oil pan.
When applied, the specified sealant must extend 10 mm past the joints in the mating
faces.
Vehicles built from 12/1999
A liquid gasket is used to form the seal between the oil pan and the cylinder block.
Valve train
NOTICE: The retaining bolts of the timing pulleys can only be re-used once.
The two overhead camshafts are driven by the crankshaft via a timing belt. They control
the valves via bucket tappets.
The valve clearances are adjusted by valve adjustment shims located on the top of the
bucket tappets. They should be checked every 100,000 km.
Two timing belt tensioners are used.
Timing belt tensioner with cam
Timing belt tensioner with slot

The timing belt should be renewed after 150,000 km or 10 years.
Crankshaft pulley/vibration damper
NOTICE:
Check the relative positions of camshafts and crankshaft (i.e. the timing) every
time the bolt of the crankshaft pulley/vibration damper is loosened and re-tightened.
Only use the crankshaft pulley/vibration damper bolt once.

Vehicles up to model year 98 1/2
NOTE: The crankshaft pulley/vibration damper bolt must only be pulled on with the
special tool. If it is tightened using the bolt, the specified torque is reached before the
pulley/vibration damper is fully home.
Vehicles from model year 98 1/2
NOTE: The crankshaft pulley/vibration damper and the crankshaft timing pulley
located behind it are free to turn on the crankshaft until the bolt is tightened to the
specified torque.
The crankshaft pulley/vibration damper must be properly installed before adjusting and
checking the valve timing.

Puma 1998 (06/1997-12/2001)
Cylinder Head
Print
Disassembly and Assembly of Subassemblies

Special Tool(s)
303-196 (21-107)
Materials
Name
Specification
Engine Oil
WSS-M2C912-A1
Disassembly
1. NOTICE: The cylinder head must be placed on a soft surface, e.g. rubber.
NOTE: The new cylinder head is supplied with new valves but without studs.
Detach the intake manifold.
 Remove the gaskets.
2. Remove the components.
1. Exhaust manifold and gasket
2. Camshaft position (CMP) sensor and heat shield
3. Detach the cylinder head ancillary components.

1. Engine lifting eyes (vehicles built up to 07/1998).
2. Fuel distribution tube and two plastic centering washers
3. Engine lifting eye.
4. Ignition coil
5. Coolant outlet housing with new gasket.
Assembly
1. NOTICE: Always place the cylinder head onto a soft surface, e.g. rubber.
NOTE: The new cylinder head is supplied with valves, but without studs for the
exhaust manifold.
Install new studs on the new cylinder head.
2. Install the cylinder head components.

1. Engine lifting eye (Vehicles built up to 07/1998 inclusive)
2. Install the fuel rail with two plastic centering washers.
3. Install the engine lifting eye.
4. Install the ignition coil.
5. Install the coolant outlet housing with new gasket.
3. NOTE: Renew the exhaust manifold gasket.
Install the components.
1. Install the exhaust manifold and gasket.
2. Install the CMP sensor and heat shield.
4. NOTE: Renew the gaskets.

Install the intake manifold.
Puma 1998 (06/1997-12/2001)
Engine
Print
Assembly
Special Tool(s) / General Equipment
Universal flange holding wrench
205-072 (15-030A)
Lifting bracket, engine
303-122 (21-068A)
Angle gauge, bolt tightening
303-174 (21-540)
303-196 (21-107)
Alignment tool, camshaft
303-376 (21-162B)
Socket wrench, cylinder head bolt
303-392 (21-167)
Locking tool, flywheel
303-393 (21-168)
Installer, crankshaft oil seal
303-395 (21-171)
Assembly stands
303-435 (21-187)
Mounting bracket for 303-435
303-435-06 (21-031B)
Mounting plate for 303-435-06
303-435-14 (21-212)
Socket, spark plugs
303-499 (21-202)
Alignment pin, crankshaft TDC setting
303-507 (21-210)
Replacer, vibration damper
303-510 (21-214)
Aligner, clutch disc
308-204 (16-067)
Steel straightedge
Workshop hoist
Materials
Name
Specification
Engine oil
WSS-M2C912-A1
Camshaft bearing cap sealant
WSK-M2G348-A2
Sealant, cylinder block mating faces, crankshaft rear oil seal, oil pan
WSE-M4G323-A4
Sealant, oil pressure switch thread
WDK-M2G349-A7
Lubricant (spark plug threads - Never Seeze)
ESE-M1244-A
Silicone grease
ESE - M1C171 - AA
Assembly
All Vehicles
1. NOTICE: The components of the crankshaft drive together with the pistons
and the cylinder liners cannot be renewed separately.
For additional information, refer to Description and Operation in this section.
Preparatory operations
 Coat all bolts and washers prior to installation with engine oil on the threads
and the underside of the heads.
 Thoroughly clean all mating faces and reusable parts and check them for
any damage.
For additional information, refer to Description and Operation in this section.
2. Attach the cylinder block with crank gear (short block) to the assembly stand
using Special Tools 303-435-14 and 303-435-06.
3. NOTE: Correct seating of the oil seal carrier.
Attach a new crankshaft rear oil seal carrier with oil seal and mounting for the
crankshaft position sensor (CKP sensor).
4. Install the CKP sensor.
5. NOTE: Tightening sequence and position of the flywheel locating guide peg.
Install the flywheel.
 Attach the flywheel, immobilise it with the special tool and tighten it in two
stages following the tightening sequence.
 Stage 1: 30 Nm
 Stage 2: 80 degrees
6. NOTE: Align the oil pump drive with the crankshaft.
Attach the oil pump and the oil pick-up pipe with a new gasket.
 The oil pump is located by two guide sleeves and does not need to be aligned
with the cylinder block.
7. NOTE: Lubricate the oil seal lip and crankshaft journal with engine oil .
Install the crankshaft front oil seal using the special tool.
8. Apply sealant to the mating face intersections of the cylinder block and the
sealing surfaces of the crankshaft rear oil seal carrier.

9. NOTE: Apply sealant to 10 mm past the joints in the mating faces.
Apply sealant to the mating face intersections of the cylinder block and the
sealing surfaces of the crankshaft rear oil seal carrier.
10. Align the oil pan.
 Install the oil pan and a new gasket and tighten the bolts finger tight.
 Using a steel rule, align the oil pan so that the cylinder block is flush with the
oil pan on the flywheel side.
11. NOTICE: Use studs. The cylinder block may be damaged if sealant enters
the blind holes.
Screw three M8x20 studs into the blind holes shown.
12. NOTE: Attach the oil pan within 10 minutes of applying sealant.
Apply a 3 mm bead of sealant to the oil pan flange.
All vehicles
13. NOTE: Tightening sequence.
Tighten the oil pan bolts.

14. Install the clutch.
 Using the special tool, centre the clutch pressure plate on the clutch disc.
 Tighten the six bolts evenly, working diagonally.
 Remove the special tool.
15. Attach the crankcase breather.
16. NOTICE: Check the thermostat and renew as necessary.

NOTE: Only renew the thermostat oil seal as necessary.
NOTE: Apply sealant to the thread of the oil pressure switch.
Attach the thermostat housing with a new gasket and the oil pressure switch.
1. Thermostat housing with a new gasket
2. Oil pressure switch
17. NOTICE: Do not damage the impeller of the coolant pump.
Attach the coolant pump with a new gasket.
18. NOTE: Tightening sequence.

NOTE: The cylinder head is inserted into two guide sleeves.
NOTE: The removed cylinder head bolts can be re-used.
Install the cylinder head.
 Make sure all mating faces are clean.
 Install a new cylinder head gasket.
 Position the cylinder head and tighten it in three stages following the given
tightening sequence.
 3rd stage: 90 degrees
19. Install the three lower intake manifold bolts and attach the engine oil
dipstick tube.
20. Push on the crankcase ventilation hose.

21. NOTE: Install the valve tappets with valve adjusting shims in order.
Install the valve tappets.
 If necessary, change the adjusting shim to adjust the valves.
22. Set the piston of cylinder no. 1 to approx. 25 mm before TDC.

 The flywheel must be in the position indicated.
23. NOTE: The identification numbers are located on the outside of the camshaft
bearing caps.
Apply sealant to camshaft bearing cap no. 1 in the areas indicated and to the
opposite area on the cylinder head.
24. NOTICE: Lay the camshafts in place so that none of the cams is at full lift.
NOTE: The exhaust camshaft is fitted with an additional cam for the camshaft
position sensor (CMP sensor).
Install the camshafts.
 Before installation, lubricate the camshafts and camshaft bearings with engine
oil .
25. NOTE: The numbering of the camshaft bearing caps starts at the timing belt
end with E1 on the exhaust side and I1 on the intake side.
NOTE: Tightening sequence.
Position the camshaft bearing caps and tighten the bolts in 3 stages.
 Stage 1: tighten the bolts evenly half a turn at a time until the camshaft
bearing caps make contact with the cylinder head.
 2nd stage: 7 Nm
 3rd stage: 16 Nm
26. Install the new camshaft oil seal.
 Coat the oil seal lip and the camshaft bearing journals with engine oil .
27. Attach the inner timing belt cover.

28. NOTICE: The timing pulley bolts can be re-used once.
Attach the camshaft timing pulleys so that they can still just be turned.
 If necessary mark the timing pulley bolts with coloured paint. Renew any
bolts that already have paint markings.
29. Set the camshaft to TDC on cylinder no. 1.
 Turn the camshafts by the hexagon with a 21 mm spanner until the special
tool can be inserted.
30. NOTE: If it is not possible to install the special tool then turn the crankshaft
back counter-clockwise through approx. 20 degrees.
Set the crankshaft to TDC on cylinder no. 1.
 Remove the blanking plug from the timing peg hole and attach the special
tool.
Tool .
31. Push on the crankshaft timing pulley.
32. Lay the timing belt in place.

 Starting at the crankshaft timing pulley and working counter- clockwise, lay
the timing belt in place.
33. Attach the lower timing belt cover.

34. Install the crankshaft pulley/vibration damper.
All vehicles
35. NOTE: For additional information, refer to Description and Operation in this
section.
Install the crankshaft pulley/vibration damper with a new bolt and tighten in
two stages.
 Stage 1: 40 Nm
Timing belt tensioner with cam

36. Install the timing belt tensioner.
37. NOTE: Do not turn the cam when tightening. Stop it from turning with an Allen
key.
Tension the timing belt.
 Using a 6 mm Allen key, turn the eccentric anti-clockwise until the arrow is in
line with the center of the rectangular hole.
 Tighten the bolt.
Timing belt tensioner with slot

38. Install the timing belt and tension it.
 Install the bolts finger tight.
 Tension with an 8 mm Allen key until the pointer is positioned in the exact
centre of the square recess.
 Tighten the bolts.

39. NOTICE: Do not tighten the camshaft timing pulley against Special Tool
303-376.
NOTE: The crankshaft and the camshaft must not turn.
Tighten the camshaft timing pulleys.
40. Unscrew the special tool and remove Special Tool 303-376.
41. NOTE: If it is not possible to screw in Special Tool 303-507, turn the
crankshaft counter-clockwise back through approx. 20 degrees.
Check the valve timing.
 Turn the crankshaft clockwise two complete revolutions, and then through to
TDC.
 Attach Special Tool 303-507.
Tool .
 Check the TDC position using the special tool.
42. NOTICE: The timing pulley bolts can be re-used once.

If necessary mark the timing pulley bolts with coloured paint. Renew any bolts
that already have paint markings.
43. NOTE: Only if Special Tool 303-507 cannot be inserted.
Adjust the valve timing.
 Undo the camshaft timing pulley for the camshaft affected, counterholding
using the Special Tool.
 Turn the camshaft by the hexagon with a 21 mm open-ended spanner until
Special Tool 303-507 can be inserted.
 Tighten the camshaft pulley; the crankshaft must remain in the TDC position.
 Check the valve timing again.
44. Install the blanking plug in the timing peg hole.
45.Adjust the valve clearances.

For additional information, refer to Valve Clearances in this section.
46. Attach the front engine mounting bracket.
47. Attach the front engine mounting bracket.

48.Coat the spark plug threads with lubricant and install them using the special
tool.
49. NOTICE:
When installing a new cylinder head, check the cylinder head cover for
damage and use a new cylinder head cover if necessary.
Use a blunt object (e.g. plastic cable tie) to apply the silicone grease to
avoid damaging the spark plug connector seals.
Push on the spark plug connectors, keeping them in line with the spark
plugs.
NOTE: Coat the inside of the spark plug connector with silicone grease to a
depth of 5-10 mm.
Install the cylinder head cover.
1. Screw on the cylinder head cover nuts.
2. Push on the spark plug connectors until they click in place.
3. Insert the ignition cable clip.
50. Attach the cylinder head cover top plate (if removed).
51. Install the engine wiring harness.
52. Install the upper timing belt cover.

 Timing belt cover
 Idler pulley
 Coolant pump belt pulley

53. Attach the generator.
1. Install the three bolts.
2. Connect the lead.
3. Connect the plug.

54. Attach the generator.
All vehicles
55.Hook the engine into the workshop crane using the special tool.

56. Take the engine off the assembly stand.
 Remove the special tools.

Engine - 1.7L - Specifications

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Engine - 1.7L - Specifications

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Engine - 1.

7L - Specifications Puma 1998 (06/1997-12/2001)

Description 1,7 Zetec-S VCT

Description 1,7 Zetec-S VCT

Description 1,7 Zetec-S VCT

Description 1,7 Zetec-S VCT

Description 1,7 Zetec-S VCT

Description 1,7 Zetec-S VCT

Description Nm lb-ft lb-in

Engine - 1.7L - Engine Puma 1998 (06/1997-12/2001)

Description and Operation

An electronically controlled hydraulic adjustment unit provides variable adjustment of

Location of serial number, engine code and engine number

Always place the cylinder block down on a rubber mat to prevent

Thread repairs on the cylinder block are not permissible.

NOTE: Do not dismantle the crank gear.

The crankshaft has eight counterbalances and runs on five bearings.

The cylinder head is made of an aluminium-silicium alloy and is accurately

The intake camshaft is equipped with variable camshaft timing.

An additional coolant duct is located between the exhaust valve guides to

The material used is an aluminium alloy.

For manufacturing reasons the oil pan consists of two parts.

Timing belt tensioner

Timing belt tensioner adjustment. For additional information, refer to Section

Crankshaft pulley/vibration damper

After undoing and tightening the crankshaft pulley/vibration damper

Only use the crankshaft pulley/vibration damper bolt once.

There are no oversize pistons available.

The pistons cannot be renewed separately.

As a result of the variable camshaft timing it has become necessary to

The valve clearance should be checked every 150,000 km.

The timing belt should be renewed after 150,000 km or 10 years.

The tappets are mechanical bucket tappets.

This arrangement has the following advantages:

 smaller and therefore lighter adjustment shims.

Lubricate the camshafts with engine oil before installing them.

NOTE: Always renew the hollow bolt after removal.

The camshaft adjustment is map-controlled, but also responds to mass air

Depending on the required setting of the camshaft, pressurised engine oil is

Adjustment angle of the intake camshaft

The adjustment angle depends on the operating conditions of the engine.

Oil circuit of the VCT adjustment unit

Advancing the camshaft

The adjustment piston is moved axially on the helical gears.

The camshaft timing is advanced.

The adjustment piston is moved axially on the helical gears.

The camshaft timing is retarded.

Engine - 1.7L - Cylinder Head Puma 1998 (06/1997-12/2001)

Disassembly and Assembly of Subassemblies

4. Detach the exhaust manifold together with the gasket.

5. NOTE: Adjustment shims underneath the bucket tappets.

3. Attach the exhaust manifold with the gasket.

Engine - 1.7L - Engine Puma 1998 (06/1997-12/2001)

Universal Flange Holding Wrench

Aligner, Clutch Disk

Mounting Bracket for 303-435

Socket, Cylinder Head Bolt

Locking Tool, Flywheel

Installer, Crankshaft Oil Seal

Crankshaft TDC setting

Mounting Plate for 303-435-06

Replacer, vibration damper