Ford Focus>> Engines>> Assembly and engine dismantling>> Engine assembly
For performance of assembly works on the engine masterful Fords are equipped with the following special tool:
- universal key 205-072 (15-030A);
- the device for measurement of corners 303-174 (21540);
- the interlock for a cranked shaft 303-204 (21168);
- the adaptation for installation of a camshaft 303-376 (21-162B);
- a superimposed key for bolts of a head of the block of cylinders 303-392 (21167);
- a stripper for epiploons 303-395 (21171);
- clamp 303-435-06 (21031В);
- elevating support 303-435-1 (21212);
- candle key 303-499 (21202);
- adjusting pin of a cranked shaft 303-507 (21210);
- an opravka for installation of a conducted disk of coupling 308-204 (16067).
Before assembly all bolts, washers, landing surfaces moisten with engine oil, clear and check privalochny surfaces. Assembly carry out in the following sequence:
- establish the block of cylinders on an assembly table or the stand;

Fig. 92. Installation of a cover of a back epiploon of a cranked shaft



- establish a cover of a back epiploon of a cranked shaft and an arm of the sensor of an angle of rotation of a cranked shaft (SKR) (fig. 92) ;
- establish the SKR sensor;

Fig. 93. Flywheel installation



- establish a flywheel and fix it bolts. The sequence of an inhaling is shown on fig. 93 . An inhaling carry out to two stages, at first wrap the moment of 30 N · m, and then tighten by means of the special adaptation 303-174 on 80 °;

Fig. 94. Installation of a maslopriyemnik and oil pump



- connect a rotor of the oil pump to cranked shaft then establish the oil pump and a maslopriyemnik with new laying (fig. 94) ;
- establish an epiploon of a cranked shaft, before installation seats moisten with engine oil.
Release models to 11.1999 g.

Fig. 95. Drawing of special hermetic



Put on interfaced surfaces of the block of cylinders special silikonosoderzhashchy hermetic (fig. 95) ;
- establish the lower part of a case on the block of cylinders with new laying and wrap fastening bolts by hand;

Fig. 97. Sequence of an inhaling of bolts



- correctly arrange c the help of a ruler the lower part of a case concerning the block of cylinders so that from a flywheel of their surface were at one level, and tighten bolts the moment of 20 N · m in a certain sequence (fig. 97) .
Release models after 12.1999 g.

Fig. 96. Openings under hairpins М8х20



Screw hairpins М8х20 in deaf openings (fig. 96) . Pay attention to that hermetic did not get to these openings that can lead to rigidity reduction (fig. 96) ;
- put on a case flange hermetic in thickness of 3 mm and tighten bolts in two steps: at first the moment of 10 N · m, and then the moment of 20 N · m (see fig. 97 ).
All models
Establish coupling, for this purpose center a conducted disk by means of a centering opravka of rather cranked shaft and wrap bolts of fastening of a press disk cross-wise the moment of 29 N · m;
- establish a hose of ventilation of a case and the detonation sensor. Arrange a sensor wire at the corresponding distance from a head of the block of cylinders and a hose of ventilation of a case;
- establish the thermostat with new rubber consolidation;
- establish the sensor of pressure of oil, before it put on a carving hermetic;
- establish the pump of cooling liquid with new consolidation. Pay attention to a krylchatka, it is easily deformed;
- put laying of a head of the block on the block of cylinders. Pay attention to that directing plugs fixed laying without tension;

Fig. 98. Order of a tightening of a head of the block of cylinders



- establish a head of the block of cylinders. Previously clear interfaced surfaces, tighten fastening bolts in a certain sequence in three steps, at first the moment of 15 N · m, then 30 N · m then tighten them by means of the special tool 303-174 on 90 ° (fig. 98) ;
- wrap three bottom bolts of an inlet collector the moment of 4 N · m also establish a tube of the index of level of oil;
- establish pushers of valves and adjusting washers, thus keep their situation what was before removal;

Fig. 99. The piston of the 1st cylinder is at distance of 25 mm to VMT



- establish the piston of the first cylinder so that it in a step of compression did not reach VMT of 25 mm, thus the flywheel occupied the situation shown on fig. 99 ;
- establish camshafts. The camshaft of final valves has an additional cam on an installation site of the sensor of an angle of rotation (SMR). Before installation plentifully grease with engine oil of a surface of bearings and cams;

Fig. 100. Designations of covers of bearings of camshafts: 1 — a cover of a camshaft of inlet valves; 2 — a cover of a camshaft of final valves



- put silikonosoderzhashchy hermetic on interfaced to a head of the block of a surface of covers of the first bearings. Designations of covers of bearings are on outer side: E1 — belongs to a shaft of final valves, I1 — inlet (fig. 100) ;
- establish covers of bearings and tighten bolts in the sequence specified above, in three stages: evenly roll on a half of turn for time while the cover will not lay down on a block head, wrap the moment of 7 N · m, wrap the moment of 16 N · m;
- grease working edges of epiploons of camshafts with engine oil and press them;

Fig. 101. The provision of camshafts when the piston of the 1st cylinder is in situation VMT. Shaft are established by means of the special Ford 21-162 Zetec tool, 21-162A to Zetec-SE



- establish an internal cover of a GRM belt;
- establish gear pulleys on camshafts;
- establish camshafts in situation when the piston of the 1st cylinder will be in VMT. For this purpose turn shaft for a shestigrannik until the adaptation will not be established in face grooves of shaft;

Fig. 102. A cranked shaft in situation when the piston of the 1st cylinder is in VMT. It is established by means of the special Ford 303-507 tool



- establish a cranked shaft in situation when the piston of the 1st cylinder is in VMT. For this purpose wrap the special adaptation in an adjusting opening. After turn a cranked shaft clockwise carefully while the special tool will not rest against a cheek of a cranked shaft (fig. 102) ;
- put on a gear pulley a cranked shaft;
- establish the bottom cover of a belt;
- establish a gear pulley (a damper of krutilny fluctuations) on a cranked shaft. For fastening surely use only a new bolt. Tighten a bolt in two steps: at first the moment of 40 N · m, and then a special key tighten on 90 °;
- dress a gear belt on pulleys, begin from below and continue counter-clockwise;
- establish a natyazhitel of a belt of ekstsentrikovy type. Do not turn at a tightening the clown;
- for a tension of a belt turn the clown by means of a natural an internal shestigrannik counter-clockwise while the arrow will not coincide with a tetrahedral pro-point;
- tighten a bolt of a natyazhitel the moment of 20 N · m;
- if on the engine the natyazhitel of a belt with a longitudinal groove is established, wrap fastening bolts by hand;
- pull a belt, having turned a natyazhitel with an arm clockwise so that the index settled down behind two labels put behind a roller, and tighten bolts of fastening the moment of 20 N · m;

Fig. 103. Installation of pulleys of camshafts. Masterful Fords for fastening of pulleys use the special tool 205-072



- wrap bolts of fastening of pulleys of camshafts the special tool with the moment of 60 N · m, thus do not allow shift of provision of camshafts and a cranked shaft (fig. 103) ;
- take out an adjusting pin of a cranked shaft from the block and close an opening a carving cap;
- check gazoraspredeleniye phases;
- scroll a cranked shaft a hand for a flywheel;

Fig. 104. Adjustment of thermal gaps of valves



- adjust thermal gaps of valves. If you have no special tool, it is better to you to address in a specialized workshop (fig. 104) ;
- for adjustment of thermal gaps of valves masterful Fords use the special tool 303-563 (21218);

Fig. 105. Installation of an assembly support



- establish an assembly support of the engine (fig. 105) ;
- establish a klapanny cover;
- establish elements of system of ignition;
- connect топливопровод and fix it;
- establish the top cover of a GRM belt.
Models without the conditioner
Establish a natyazhitel of a belt of a drive of auxiliary units.
All models

Fig. 106. Generator installation



Establish the generator (fig. 106) ;
- connect the engine to a transmission and prepare for installation on the car.
Dismantling and assembly of a head of cylinders
Dismantling of a head of cylinders carry out in the following order:

Fig. 107. Removal of an inlet collector



- remove an inlet collector with laying (fig. 107) .

Fig. 108. Contact sockets: 1 — the contact socket of the sensor of management of the provision of a butterfly valve; 2 — the contact socket of the valve of adjustment of rotation of a cranked shaft idling



- disconnect contact sockets from the sensor of management of the provision of a butterfly valve (TR) 1 (fig. 108) and the valve of adjustment of rotation of a cranked shaft idling (IAC) 2;

Fig. 109. Removal of kotaktny sockets of nozzles



- remove contact sockets of nozzles (fig. 109) ;
- remove the distributor of fuel and a vacuum hose;

Fig. 110. Removal of knots and details from a head of the block of cylinders: 1 — the ignition coil; 2 — a final collector; 3 — the condenser; 4 — an assembly eye



- remove the coil of ignition (EI) 1 (fig. 110) , a final collector of 2 systems of cooling with laying, the condenser 3 an assembly eye 4 engines;

Fig. 111. SMR sensor removal



- remove the sensor of an angle of rotation of a camshaft (SMR) (fig. 111) ;

Fig. 112. SNT sensor removal



- remove the sensor of temperature of a head of cylinders (SNT) (fig. 112) ;
- if the head of the block is damaged, it is necessary to replace it with the new. According to Ford instruction further repair of a head is impossible.
Assembly of a head of the block of cylinders carry out in the following sequence:
- arrange a block head on a soft substrate, for example on a rubber mat. The new head of the block is delivered with the klapanny mechanism without hairpins for a final collector;
- establish the SNT new sensor. Pay attention to that the interfaced surface remained intact;
- screw new adjusting hairpins for fastening of a final collector;
- establish the new sensor of an angle of rotation of a camshaft (SMR) with new ring laying;
- establish the coil of ignition (EI) 1 (see fig. 110 ), a final collector of 2 systems of cooling with laying, the condenser 3, an assembly eye 4 engines;
- establish the fuel distributor;
- connect contact sockets of nozzles;
- connect the contact socket of the TR sensor;
- connect the contact socket of the IAC valve;
- fix wires;
- establish an inlet collector with new laying.
Removal and installation of a head of cylinders from the car
At acquaintance with this part of repair work use the drawings presented earlier. Removal carry out in the following sequence:
- the head of cylinders should be cold before removal;
- disconnect wires from plugs of the storage battery;
- open a broad tank of system of cooling and merge cooling liquid;
- remove a wire of connection with "weight" and a heat-shielding casing of a final collector;
- remove the contact socket from the oxygen sensor;
- remove a final collector and laying;
- lift a forward part of the car and reliably fix the car on supports;
- disconnect a flange of a reception pipe. Protect сильфон from excesses;
- take out a collector from under the car;
- lower a forward part of the car;
- remove the air filter together with a soaking-up hose and disconnect the contact socket from MAF otdatchik.
- disconnect a drive of a pedal of an accelerator;
- remove a hose of system of ventilation of a case;
- disconnect the SMR contact socket;
- disconnect the contact socket from the ignition and condenser coil;
- remove vacuum hoses from the case with absorbent carbon of the vacuum amplifier of brakes;
- disconnect the contact socket of the sensor of a detonation;
- remove hoses of system of cooling;
- disconnect топливопровод. Prepare small capacity, the system is under pressure and the part of fuel can flow out;
- uncover heads of cylinders, remove camshafts;
- unscrew 3 bolts from below an inlet collector;
- lift the receiver the index of level of oil;

Fig. 113. An order of an otvorachivaniye of fixing bolts at removal of a head of the block



- remove a head of the block of cylinders. Bolts of fastening turn on according to the order shown on fig. 113 . Old bolts can be used.
Installation of a head of the block on the car carry out in the following sequence:
- the privalochny plane of a head of the block is not subject to grinding. For installation of a head of the block two directing hairpins serve. Before installation smooth out all interfaced surfaces and blow cylinders and an inlet collector;
- establish on the block only new laying;
- establish on the block a head of cylinders, do not damage new laying;
- wrap bolts of fastening of a head of the block. The order of an inhaling is shown in drawing above. An inhaling of bolts carry out to three stages;
- further installation carry out as it should be, the return to removal;
- check level of oil and replace the oil filter. Start up the engine and let's to it get warm. Thus pay attention to reliability of an inhaling of all connections and hoses;
- make a trial trip run not less than 20 km. During this time electronic control systems of the engine and the car should be activated. If you find failures in operation of the engine, for example unevenness of rotation of a cranked shaft of the engine idling, go on specialized station Ford where to you will reprogram the control unit anew;
- after a trial trip again check levels of working liquids, reliability of fixing connections and tightness of the shlangovy.
Epiploons of camshafts
For removal and installation of epiploons masterful Fords use the following special tool: a universal key for keeping of flanges 205-072 (15030А), a stripper 303-293 (21143), the adaptation for installation of epiploons 303-395 (21171).
Removal of epiploons carry out in the following sequence:
- remove a gear belt as it is described earlier;

Fig. 114. Removal of gear pulleys



- remove gear pulleys as it is described earlier (fig. 114) ;

Fig. 115. Removal of epiploons of camshafts by means of the special Ford 303-293 adaptation



- remove by means of a stripper epiploons of camshafts (fig. 115) .
Installation of epiploons carry out in the following sequence:
- clear and wipe necks of camshafts and seats of epiploons. Slightly grease necks of shaft and an edge of epiploons with engine oil;

Fig. 116. Installation of new epiploons by means of the special Ford 303-395 adaptation



- new epiploons establish by means of the special adaptation (fig. 116) ;
- establish gear pulleys of camshafts as it is described earlier. Check and if necessary establish gazoraspredeleniye phases as it is described earlier
Maslosjemnye caps
At removal and installation of maslosjemny caps masterful Fords use the following tool: the device for compression of springs of valves 303-361 (22155), the auxiliary tool 303-361 303-361-04 (2115504), 303-361-(2115505), the replacement tool, the assembly adaptation 303-363 (21157); grip 303-508 (21211).
Works on removal of maslosjemny caps carry out in the following sequence:
- remove camshafts as it is described earlier;
- remove the coil of ignition and the condenser;

Fig. 117. Installation of the special tool



- establish the special tool on a head of cylinders (fig. 117) ;
- compress a valve spring by means of the special tool;

Fig. 118. Compression of a spring of the valve by means of the special tool



- remove crackers, the top plate of a spring of the valve and take out from a block head a spring (fig. 118) ;
- by means of the special tsangovy tool remove a maslosjemny cap. The same steps undertake with all cylinders.
- remove maslosjemny caps on other valves.
Installation of maslosjemny caps carry out in the following sequence:
- it is important to note that maslosjemny caps differ on color: for inlet valves they green color, for final — brown;
- establish the assembly plug on a valve core;
- before a press fitting of caps grease with engine oil directing plug of the valve and a working edge of a cap;
cнимите assembly plug;
- establish a spring of the valve and the top plate of a spring of the valve;
- compress a valve spring by means of the special tool and establish crackers;
- repeat works on installation for other valves;
- finish installation in sequence, return to removal.
GRM belt
At works on removal and belt installation masterful Fords use the following tool:
- flange clamp 205-072 (15030);
- measuring instrument of corners 303-174 (21540);
- the adjusting adaptation for installation of camshafts 303-376 (21162);
- candle key 303-499 (21202);
- the adjusting pin of installation of a cranked shaft in situation when the piston of the 1st cylinder is in VMT at a step of compression 303-507 (21210);
- grip 303-622 (21226).
Removal of a belt carry out in the following sequence:
- disconnect wires from plugs of the storage battery;
- weaken the moment of an inhaling of bolts of fastening of a pulley of the pump of cooling liquid;
- lift a forward part of the car and reliably fix on supports;
- uncover a belt of a drive of auxiliary units;
- weaken a tension of a belt of a drive of auxiliary units and remove it as it was described earlier;
- remove a pulley (damper) of a cranked shaft;
- remove a pulley of the pump of cooling liquid and directing roller of a belt of a drive of auxiliary units;
- lower a forward part of the car;
- uncover heads of the block of cylinders;
- disconnect топливопровод;
- disconnect the contact socket of the sensor of temperature of a head of the block (SNT);
- unscrew three top bolts of fastening of a cover of a GRM belt;
- remove a broad tank of system of cooling;
- remove a tank of a girousilitel of a steering and take aside;
- remove the generator;
- unload forward support of the power unit, having substituted a jack under an oil case, thus use wooden plates;
- remove support;
- weaken a GRM belt tension as it is described earlier, and remove it.
Installation of a belt carry out in the following sequence:
- establish a cranked shaft in the situation relevant to VMT. by means of an adjusting pin;
- weaken fastening of pulleys of camshafts as it is described earlier so that pulleys freely rotated on camshafts;
- remove spark plugs;
- establish by means of the adaptation distributive a shaft in situation corresponding to finding of the piston of the 1st cylinder in VMT at a compression step;
- establish a GRM belt as it is described earlier;
- establish a pulley (damper) on a cranked shaft with a new bolt as it is described earlier, and tighten;
- put on the GRM new belt as it is described earlier, and pull it;
- check and adjust gazoraspredeleniye phases as it is described earlier;
- further installation carry out to sequences, return to removal;
- make a trial trip run not less than 20 km. During this time electronic control systems of the engine and the car should be activated. If you find failures in operation of the engine, for example unevenness of rotation of a cranked shaft of the engine idling, go on specialized station Ford where to you will reprogram the control unit anew;
- after a trial trip again check levels of working liquids, reliability of fixing connections and tightness of the shlangovy.