A Ford Joins My Garage: Ford Figo Petrol (1st Gen) Ownership Review

[mayankdixit]

this is my favourite Honda Valkyrie 1998 flat 6 boxer 1520cc, rear wheel 100HP, rear wheel Torque 139nm. Slightly modified imported from USA. 6 carbs (re-jetted), 6 cylinders (true boxer not just flat 6), 6 seperate straight through exhausts (Cobra 6 pack).

All up "wet" cruising weight 487kg, dry weight 310kg.

That is one huge and heavy bike !!. Congrats for keeping it in top shape. Those twin pods on top look cool. And those 3 pipe chrome exhausts are looking very beautiful. I find that bike is looking way more smart without the storge box at the back.

recent hip and knee problems and a broken leg I am now struggling to handle the bike

Same here with me . I cant even imagine working this bike around in my city, what with back problem and all. I moved on to Activas after selling my bike, because I simply was unable to maneuver the bike. Bike driver posture is very different from scooter driving posture . Bad for my back. Activa is light and easily maneuverable.
I can totally understand your difficulty in holding this thing, with those injuries.
But still, this bike is a Keeper. Maybe your son can drive it.

 

[mayankdixit]

After long-long time got some chance to clean the wheels and wheel wells. Actually I was scared, being a 11 years old car, there might be some ugly rust on the underbody. So was avoiding washing and all,so that out of sight remains out of mind(rust).
Really surprised to find none. Underbody is clean, touchwood.


Washing pics (in no particular order)

Rear brake drum

This bush above the shock absorber is intact so far.Ownwers complain it gets torn fast.

Lots of mud and dirt on the floor

Tiles were covered with mud and grime

My trolley jack sitting on the grime

I thoroughly enjoyed the washing and cleaning the car part.
If you ask "What is there to enjoy in washing a car and wheels ?" , well then,what can I say mate, except that you are in the wrong Forum.

 

[mayankdixit]

After a premium wash I started my premium feeling car, headed straightaway to the petrol pump, and to treat Figo more premiumly I filled it with premium fuel. Oh how stupid I was !!
My unfortunate adventure is detailed here.

 

[mayankdixit]

Timing Belt and Tensioner replacement in Figo.

A little bit of background:
During this Holi festival (25th march 2024), I got a window to work on my Figo. Timing belt replacement was looong pending, and it was eating me up from inside, because you see, the Ford Duratec 1.2 litre is an Interference engine. This means that if the belt snaps on a running engine, then Kaboom !!. Valves will bend and piston damages/scoring might happen. And if the engine is already running at a high RPM and speed like on an open highway or such then one can imagine the damages that will occur. Basically I will loose the engine !!
And I have changed pretty much every rubber part and age related degeneration part and every fluid on this car except the damn Timing belt, which if you see from my point of view , is the most important part and should be changed first. And all this was causing me tension.
Tension because I wanted to get this done, but I did not want to go to the Ford ASS for this. I wanted to do it all by myself DIY way . And herein lies the whole problem! It's a big job. Doing it as a DIY will need space.I have 7 feet wide parking space,which is not much considering that the car itself occupies most of it, so doors cannot be opened properly.You have to move around the car for jacking on both wheels,so yes,it was an issue. Moreover I needed tools.and lots of them. And tools specific to my car, not just generic spanners and sockets. also I needed an assistant,which I did not have.Its a 2 man job at the Ford ASS.
And even after all this, if I succeeded in opening the required engine components, and still screwed up the already perfectly timed engine, I will look like the biggest fool on the planet, at least in my eyes! So it has to be done right the first time or don't do it at all ! But I was stubborn.I informed my trusted mechanic at Ford and asked if I can do it at my home.His reply dampened my spirits furthur. "Sir, Nobody in his right minds will think of doing it as a DIY at home, let alone attempt it. It's not possible sir, and ultimately you will be towing your car to us so what's the point."
Well towing the car to the Ford ASS with its engine opened by an oversmart owner will be a laughing point at the ASS. And it would be very insulting to me.So that was also causing tension.

 

[VISHNUCARCRAZY]

@mayankdixit That was one very daring attempt, sir.

Had you replaced the Timing Belt?

 

[mayankdixit]

@mayankdixit That was one very daring attempt, sir.

Actually there were 2 such attempts made. As I have already mentioned ,I was aware that its a very critical component which needed replacement after every 5 years or 60,000kms( whichever earlier), and I was worried how to go about it. My car is already 12 years old .So this job was overdue by 7 years!! And after opening the timing belt cover and inspecting the belt I concluded that timing belt was never changed and the original was still running !! How long it will run further before it snaps. Its a rubber component afterall. Sooner or later it will give way. And there will be no warning whatsoever !!

 

[mayankdixit]

Timing Belt and Tensioner replacement in Figo.(contd)




This is the Ford Figo 1.2 litre Duratec engine.
Timing belt is located deep,and lots and lots of parts need to be removed in order to access it.

Timing belt cover pointed by the screwdriver. As can be seen the alternator is attached to the cover itself, so alternator has to be removed too !

Crankshaft pulley is behind this tyre and brake components. Screwdriver is pointing towards the drive belt cover.

This is the timing belt kit I have assembled for convenience.

Contents of the Timing belt kit

This is the automatic Tensioner for timing belt. Its recommended to be changed along with the timing belt as it gets loose with old belt.
New belt is tighter.Needs newer tight tensioner.

Tensioner and crankshaft bolt. This bolt is very tightly fit(almost welded together) to the crankshaft pulley.Very difficult to remove !

This is the Timing belt !!

Timing tools specific to FIGO Duratec 1.2 engine. It took me a lot of time and effort to procure these.Without it nothing can be done at all no matter how good you are.

 

[mayankdixit]

Timing Belt and Tensioner replacement in Figo.(contd)


DOHC(twin camshaft setup) of duratec 1.2

old timing belt closeup

Please note that camshafts are locked in this pic with the locking tool fitted at the end.
Its very important to lock the timing before loosening everything.

camshaft pulleys and timing belt. Also seen in this pic is the belt tensioner (orange coloured pulley)

old timing belt grooves in closeup

Tappet cover. Note that there is a gasket covering the boundary grooves and the middle lines.
This gasket is rubber and becomes hard with time and leaks. I have changed this too.

Crankshaft bolt is 18mm and very-very tight. I had huge problems opening this bolt.

Timing belt plastic cover. It has 8 bolts covering from all sides.

 

[mayankdixit]

Thank you @ Redex , for your help and positive motivation. This DIY wouldn't have been possible without your guidance. You know your stuff and that is really helpful for forum members.

The Figo is based on the U.K Fiesta. Assuming the basic 1.2 U.K. 2015 model Fiesta cam belt replacement is a fairly complicated task. You would need to be a competent DIYER, with a reasonable selection of tools

I have already dismantled all the parts required for this job. I reached the crankshaft ,locked it by that pin. I used that locking plate above on the camshafts. I locked the engine by putting a screwdriver in the flywheel. Then I tried turning the CRANK-BOLT. No matter what it did not budge. I was really upset and scared that I might rip off the bolt head or something. I mounted every thing back. Took out the locking pins. And the car has been running fine ever since.
But I want to give it a second try. Because timing belt is old and may snap someday

You really need to know what you are doing as this is an interference engine Valve train, valves, cylinder head and piston damage will occur if not done correctly.
Regards Neil. I have been in India since mid November

Don't use the camshaft locking plate unless you have the correct crankshaft locking tool !!!

All things mechanical have been a passion for over 57 years. I love fixing things instead of throwing them away. Especially something with an engine

Leave the cambelt and auxiliary belts fitted and tensioned while trying to loosen the crankshaft bolt. Stand on the brakes, without the camshaft locking plate fitted.

Thank you for your answer. I never expected any lesser from you. Much appreciated.
My Figo is based on Fiesta UK mark 5 model. Parts are similar. This is the first time I am listening this" standing on the brake" thing. I must confess, It sound logical too. This is definitely going to stop rotation of pulley if done correctly.

I cannot thank you enough for your above posts, and your efforts in helping me out. Joined just a week back and already hitting the ball out of the park !!

 

[mayankdixit]

Timing Belt and Tensioner replacement in Figo.(cont.)




more pics from the DIY
timing bely is surprisingly in good condition from outside. No tear, no teeth loss, not even a single crack !!
and its been 12 years already. But it has become hard.

brand new tensioner put in place

All the belts and crankshaft pulley removed

these are the 2 camshaft pulleys. Also can be seen is the water pump pulley and crankshaft pulley in the background below. Not the coolant reservoir has been removed completely.

There is very very little space to work in Figo. As can be seen it becomes difficult sometimes because of wires and hoses coming in between.
Here I have moved the power steering hose and the reservoir away. I have used vise grip plier to grip and block the coolant hose.

Here the ignition coil and cables are being removed to access the tappet cover

Tensioner pulley bolt is 13 size. Very difficult to put normal sockets in the space present to hold it.

Here the engine block can be seen after every belt and tensioner has been moved out of the way. There is a small tiny bit leak at the base of water pump shown in pink colour

Tappet or camshaft cover

There is a gasket running inside the tappet cover which too has been replaced to new.

Zoom out view of engine