Ford Focus>> Engines>> Assembly and engine dismantling>> Digatel Zetec-E 1,8 – 2,0 l
Engine dismantling
Dismantling of the engine carry out in the following sequence:
- establish the engine on the assembly stand or an assembly table;
- remove the catalyst;
- remove the contact socket of the sensor of pressure of oil;
- remove the generator;
- remove an inlet collector;

Fig. 119. Details on the engine from an inlet collector: 1 — the holder of the generator; 2 — the oil filter; 3 — the sensor of pressure of oil



- from an inlet collector remove the holder of the generator 1 (fig. 119) , the oil filter 2, the sensor of pressure of oil 3;

Fig. 120. Hinged knots of the engine from a final collector: 1 — the holder of the pump of the hydraulic booster of a steering; 2 — the holder of the compressor of the conditioner



- from a final collector remove the holder of the pump of the hydraulic booster of a steering 1 (fig. 120) , the holder of the compressor of the conditioner 2;
- remove a hose of system of ventilation of a case;

Fig. 121. Hinged details of the engine: 1 — bolts of fastening of the top cover of a GRM belt; 2 — bolts of fastening of a pulley of the pump of cooling liquid; 3 — a bolt of fastening of a pulley of a cranked shaft; 4 — bolts of fastening of the bottom cover of a GRM belt; 5 — a supporting roller; 6 — bolts of fastening of an average cover of a GRM belt



- turn on: bolts 1 (fig. 121) of fastening of the top cover of a GRM belt, bolts of 2 fastenings of a pulley of the pump of cooling liquid, a bolt of 3 fastenings of a pulley of a cranked shaft, bolts of 4 fastenings of the bottom cover of a GRM belt, bolts of the 6th fastening of an average cover of a GRM belt also remove supporting roller 5;
- remove wires of a high voltage and a spark plug;
- uncover heads of the block of cylinders;

Fig. 122. Removal of details of the engine: 1 — a natyazhitel of a belt; 2 — a gear belt; 3 — the top directing roller; 4 — the bottom directing roller; 5 — a pulley of a cranked shaft with an adjusting washer; 6 — bolts of fastening of the pump of cooling liquid



- weaken the moment of an inhaling of a bolt of a natyazhitel 1 (fig. 122) , rotate it clockwise and remove it;
- remove a gear belt 2;
- remove the top directing roller 3;
- remove the bottom directing roller 4;
- unscrew bolts of the 6th fastening of the pump of cooling liquid and remove it;
- remove a pulley 5 with an adjusting washer from a cranked shaft;
- remove pulleys of camshafts;
- remove the klapanny mechanism and its details spread out one after another that at assembly not to mix in places;
- unscrew bolts of fastening of a head of the block of cylinders. Bolts can be used only two times. This work carry out on the cooled engine;
- remove a head of the block of cylinders;
- remove press and conducted coupling disks;
- remove a flywheel of a cranked shaft;
- carefully remove an oil case, without having damaged details;

Fig. 123. Removal of a maslopriyemnik and amplifier of rigidity of a case: 1 — bolts of fastening of a maslopriyemnik; 2 — bolts of fastening of the amplifier of rigidity of a case



- unscrew bolts 1 (fig. 123) of fastening of a maslopriyemnik and bolts 2 amplifiers of rigidity of a case;

Fig. 124. Removal of the oil pump



- remove the oil pump (fig. 124) ;
- remove a back epiploon of a cranked shaft and the sensor of an angle of rotation of a cranked shaft (SKR) with the holder;
- unscrew bolts of fastening of radical and shatunny bearings and postpone them in a certain order that at the subsequent assembly not to mix in places. Take out a cranked shaft from basic bearings;
- squeeze out pistons together with rods upward from the engine.
Engine assembly
For performance of assembly works on the engine masterful Fords use the following special tool: a flange clamp 205-072 (915-030 And), a stripper of epiploons 303-039 (21-009B) and 303-291 (21-141), a template for installation of camshafts 303-376 (21-162B), the adaptation for blocking of a flywheel 303-254 (21-135), the adaptation for centering of a conducted disk of coupling 308-204 (16-067), a template for installation of a cranked shaft 303-620 (21-163), bolts of a head of the block 303-392 (21-167).
Before assembly clear all condensed surfaces, carving openings, channels of systems of greasing and cooling by the compressed air and check on existence of defects. Remove oil шлам from the top planes of cylinders. Grease all bolts and washers with engine oil.
The Ford plant delivers radical bearings of four groups, depending on thickness: And (2,145 — 2,152 mm); In (2,142 — 2,147 mm); With (2,135 — 2,142 mm); D (2,130 — 2,135 mm). Always use bearings with the corresponding designation. On norms of Ford, the admissible radial gap in bearings should be within 0,020 — 0,040 mm.
Assembly of the engine carry out in the following sequence:
- put loose leaves of radical bearings on seats of the block of cylinders and prepare the corresponding covers of bearings. Moisten loose leaves with new engine oil and establish in them a cranked shaft;
- put covers of radical bearings and wrap bolts by hand. Scroll a cranked shaft so that shatunny necks of the 1st and 4th cylinders appeared in NMT. Grease shatunny necks with fresh engine oil;
- establish pistons together with rods, thus сориентируйте shatunno-piston group so that the arrow indicated the bottom of the piston towards a GRM belt;
- before piston installation together with a rod from above the block of cylinders grease installation sites of piston rings, piston walls, a mirror of the cylinder and previously the dry shatunny bearing inserted into a rod with engine oil. Locks of piston rings сориентируйте so that they were developed relatively each other on 120 °;
- compress the oiled piston rings by means of a tape coupler;
- involve the pistons established in a coupler together with a rod in cylinders while the coupler will not rest against the block of cylinders. Further strike to the piston easy blows with the wooden handle of a hammer, at the same time other hand direct a rod on a bearing seat. Further put a cover of the bearing and a hand tighten fixing bolts of a rod. Do not mix cover places;
- turn a cranked shaft on 180 ° so that pistons of the 2nd and 3rd cylinders appeared in NMT then repeat similar assembly for these cylinders;
- if the cranked shaft freely rotates, can finally tighten bolts of fastening of covers of radical bearings, begin from the average radical bearing. The moment of an inhaling of radical bearings makes 83 N · m. Check again free rotation of a shaft;
- wrap bolts of fastening of shatunny bearings, do it when the piston is in NMT. Wrap bolts in two stages: at first wrap bolts the moment of 15 N · m, then tighten each bolt on 90 °. Again check free rotation of a cranked shaft;
- establish a back cover of the engine and the SKR sensor. Bolts previously tighten by hand;
- arrange a cover so that the condensed surface was lower than an edge of the block of cylinders on 0,3 — 0,8 mm, and tighten bolts;
- establish a new epiploon of a cranked shaft;
- establish the oil pump with new laying. The surface interfaced to an oil case should support evenly a surface of the block of cylinders on 0,3 — 0,8 mm;
- prepare the amplifier of rigidity of a case with new laying for installation, slightly having wrapped bolts. Put hermetic on a joint of the oil pump and the block of cylinders (apply the hermetic recommended by the instruction of Ford). In 10 minutes bolts of fastening of the amplifier of rigidity can be tightened finally. Correctly сориентируйте the amplifier of rigidity of a case concerning the block of cylinders, for this purpose use flat щупы and a ruler so that surfaces of the block and the amplifier were at one level. The following deviations are admissible: c a mechanical transmission of MTH 75 vystupany within 0,10 mm, a gap to 0,25 mm, with an automatic box is allowed a gap 0 — 0,25 mm;
- if the valid sizes do not correspond to these values, adjust by means of washers;
- prepare for installation a maslopriyemnik of system of greasing and establish;
- establish an oil case. Screw previously 10 adjusting hairpins М6х20 in deaf openings. Do not allow hermetic hit in openings;
- on a flange of an oil case put hermetic with a layer in thickness about 3 mm (use Ford hermetic);
- put an oil case and in two steps tighten a fastening bolt, at first the moment of 1 — 6 N · m, and then the moment of 2 — 10 N · m. Tighten cross-wise, beginning from the middle, in both parties;
- establish a flywheel and fix it new bolts. Previously remove the hermetic remains from deaf openings in cranked to a shaft;
- establish the coupling, for this purpose conducted and press disks establish on a flywheel and center a conducted disk concerning an axis of a cranked shaft by means of a special opravka and tighten bolts of fastening of a casing of a press disk cross-wise the moment of 29 N · m. Before installation put a small amount of dense greasing on a shlitsa of a conducted disk;

Fig. 125. Installation of laying of a head of the block of cylinders: 1 and 2 — directing plugs; 3 — laying of a head of the block; 4 — put number



- establish laying of a head of the block. It is important to know that on the forward party of the block around the 1st cylinder the figure according to which you should buy new laying is put. Before installation of laying 3 (fig. 125) check a block surface on lack of agnails. Establish laying on directing plugs 1, it should lie without tension and densely adjoin on all surface of the block of cylinders.
- wrap bolts of fastening of a head of the block. Screw at first bolts in carving openings by hand (bolts it is possible not to grease). After that wrap bolts in the sequence specified above. An inhaling of bolts carry out to three stages: with the moment of 20 N · m, further with the moment of 40 N · m and then tighten bolts on 90 °.
- establish pushers of valves and adjusting washers as they were established before dismantling;
- establish a cranked shaft for 60 ° before position of the piston of the 1st cylinder in VMT;
- arrange both camshafts so that any of cams was not in the provision of complete lifting;

Fig. 126. Installation of covers of bearings of a camshaft



- before putting covers of bearings of camshafts, plentifully grease bearings and cams with fresh engine oil. Put silikonosoderzhashchy hermetic on interfaced surfaces of covers and a head of cylinders of the first bearings of shaft. Marking of covers should be on the outer side (fig. 126) ;
- put covers of bearings and wrap fastening bolts, an inhaling carry out from the middle outside in the sequence specified earlier. Tighten in three stages: evenly on a half of turn while the cover will not lay down on a head of cylinders, then the moment of 10 N · m and the moment of 19 N · m;
- grease with engine oil working edges of epiploons and a neck of camshafts then press epiploons;

Fig. 127. The provision of a cranked shaft corresponding to finding of the piston of the 1st cylinder in VMT at a step of compression



- establish a cranked shaft in the situation corresponding to finding of the piston of the 1st cylinder in VMT at a step of compression (fig. 127) ;
- establish both camshafts so that in grooves at end faces it was possible to establish the special adaptation;
- establish both gear pulleys on camshafts and by hand wrap fastening bolts so that pulleys could rotate on shaft;
- establish the pump of cooling liquid with new laying;

Fig. 128. Installation of a gear belt: 1 — a gear belt; 2 — the top directing roller; 3 — the pump of cooling liquid; 4 — the bottom directing roller; 5 — a pulley of a cranked shaft with an adjusting washer; 6 — a natyazhitel of a belt



- establish a new gear belt, before it establish a pulley 5 (fig. 128) with an adjusting washer on a cranked shaft, bottom 4 and the top 2 directing rollers. Installation of a belt begin with a pulley 5 and put it counter-clockwise, holding it thus tense. Establish a natyazhitel of a belt 6 and wrap a fastening bolt on 5 turns;
- pull a gear belt, for this purpose a natyazhitel rotate counter-clockwise while the arrow and a mark will not coincide then tighten the screw. The wrong tension of a belt breaks gazoraspredeleniye phases;
- check once again for safety the provision of a cranked shaft, it should correspond to finding of the piston of the 1st cylinder in VMT at a compression step;
- tighten finally bolts of fastening of pulleys of camshafts the special tool;
- turn a cranked shaft for a flywheel on two turns clockwise and check gazoraspredeleniye phases. If necessary modify the work;
- check and adjust thermal gaps of valves. Work is carried out, as well as for the Zetec-SE engine;

Fig. 129. Installation of a belt of a drive of auxiliary units: 1 — bolts of fastening of the top cover; 2 — bolts of fastening of an average cover; 3 — bolts of fastening of a pulley of the pump of cooling liquid; 4 — a bolt of fastening of a pulley of a cranked shaft; 5 — a bolt of fastening of the bottom cover; 6 — a bolt of fastening of a directing roller



- wrap bolts 5 (fig. 129) of fastening of the bottom cover of a GRM belt, tighten a bolt of 4 fastenings of a pulley (damper) of a cranked shaft, wrap bolts of 1 top and average 2 covers, establish directing roller 6 and wrap bolts of 3 fastenings of the pump of cooling liquid);
- establish system of ventilation of a case of the engine with new consolidation;

Fig. 130. Fastening of details and engine knots from a final collector: 1 — the holder of the compressor of the conditioner; 2 — the holder of the hydraulic booster of a steering; 3 — the holder of protection of the engine



- fix engine knots from a final collector: holder 1 (fig. 130) of the compressor of the conditioner, holder 2 hydraulic boosters of a steering, holder of 3 protection of the engine;

Fig. 131. Engine details from an inlet collector



- establish details and knots from an inlet collector (fig. 131) ;
- establish an inlet collector, having wrapped 7 bolts and 2 nuts;
- carefully establish catalytic converter, apply only new laying. Establish the heatreflective screen. Wrap bolts and nuts;
- establish the generator;
- establish the sensor of pressure of oil.
Removal and installation of a head of the block of cylinders on the car
Masterful Fords at performance of these works use the following special tool:
- universal flange holder 205-072 (915030);
- stripper of epiploons 303-039 (21009А);
- the elevating device for the engine 303-122 (21068);
- a face key for bolts of a head of the block 303-392 (21167);
- candle key 303-622 (21226);
- adaptation 303-397 (24003).
At acquaintance with this section use the illustrations given earlier.
Removal of a head of the block carry out on the cold engine. Work carry out in the following sequence:
- remove wires from plugs of the storage battery;
- merge cooling liquid from a broad tank of system of cooling;
- remove wires of a high voltage from spark plugs;
- uncover heads of the block of cylinders;
- remove a belt of a drive of auxiliary units as it is described earlier;
- remove a hose from the vacuum amplifier of brakes and a hose of ventilation of a case from an inlet collector;
- disconnect the contact socket from the pressure sensor;
- remove the case of the air filter;
- disconnect a drive of a pedal of an accelerator;
- disconnect the contact socket from the sensor of temperature of a head of the block (SNT);
- remove топливопровод. In топливопроводе there is a residual pressure therefore prepare capacity for the flowed-out fuel;
- remove a wire of connection with "weight";
- remove the heatreflective screen;
- remove the thermostat;
- remove catalytic converter from a final collector;
- remove the pipeline of the hydraulic booster of a steering and a tube of the index of level of oil;
- remove an arm of the pump of the hydraulic booster of a steering;
- remove the generator and unscrew the top bolts of the holder;
- remove the klapanny mechanism and its details spread out one after another not to mix them at the subsequent assembly;
- unscrew bolts of fastening of a head of the block of cylinders in the sequence specified above. Bolts can be used only two times;
- remove a block head.
Installation of a head of the block of cylinders on the car carry out in the following sequence:
- clear interfaced surfaces and blow the compressed air a head, cylinders and an inlet collector. Wipe mirrors of cylinders pure engine oil. To grind a head of the block it is impossible. Apply new laying of a head of the block;
- establish a block head on the block of cylinders, having centered it on two directing plugs, do not damage thus new laying;
- wrap bolts of a head of the block in an order specified above. Bolts tighten in three stages as it is described earlier;
- further installation carry out in sequence, return dismantling;
- check level of oil and replace the filter;
- start up the engine and warm up it to working temperature. Check tightness of connections and reliability of carving fastenings;
- 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.
Camshafts and epiploons
Masterful Fords at works on removal and installation of camshafts and epiploons use the adaptation for removal of epiploons 303-039 (21009В).
Removal of camshafts and epiploons carry out in the following sequence:
- remove a gear belt as it was described earlier;
- remove pulleys of camshafts as it was described earlier;
- remove covers of bearings of camshafts as it was described earlier;
- remove epiploons.
Installation of camshafts and epiploons carry out in the following sequence:
- on interfaced surfaces of forward covers of bearings and a head of the block put hermetic;
- establish camshafts as it was described earlier;
- grease working edges of epiploons and a neck of camshafts with fresh engine oil and establish them;
- establish pulleys of camshafts as it was described earlier;
- check phases of a gazoraspredeleniye and in need of them modify.
Maslosjemnye caps
Working operations on removal and installation of maslosjemny caps are identical to works which were described for the Zetec-SE engine (see section «Maslosjemnye caps»).
GRM belt
Working operations on removal and installation of a GRM belt are identical to works which were described for the Zetec-SE engine (see section. "GRM belt").