Ford Focus>> Engines>> Assembly and engine dismantling>> Endura-DI engine of 1,8 l
Engine dismantling
Dismantling of the engine carry out in the following sequence:
- establish the engine on the assembly stand or an assembly table;

Fig. 132. Removal of hoses of system of ventilation of a case



- remove a hose of an oil cooler and hoses of system of ventilation of a case (PCV) (fig. 132) ;

Fig. 133. Removal of the vacuum pump: 1 — a bolt; 2 and 3 — collars



- remove the vacuum pump (fig. 133) ;
- remove топливопровод;
- remove the thermostat together with a hose;

Fig. 134. Generator removal



- remove the generator together with a power shaft (fig. 134) ;

Fig. 135. Removal of tubes of a turbonagnetatel



- remove tubes of supply of oil to a turbonagnetatel (fig. 135) ;
- remove a pulley of the pump of cooling liquid;
- uncover block heads;
- remove a forward cover of a belt of a drive of GRM;
- remove a generator arm;
- remove forward support of the engine;
- weaken a tension of a belt of a drive of GRM and remove it;
- remove a gear pulley of a camshaft;

Fig. 136. Removal of a pulley of the fuel pump of a high pressure



- remove a pulley of the fuel pump of a high pressure (TNVD) (fig. 136) ;
- unscrew 7 bolts of fastening of the case of an epiploon of TNVD;
- remove a back cover of a belt of a drive of GRM;

Fig. 137. Removal of a cover of a camshaft



- uncover a camshaft (fig. 137) ;

Fig. 138. Removal of a head of the block of cylinders



- remove a head of the block of cylinders. Bolts of fastening turn on in 138 sequences presented on fig.;
- remove the pump of cooling liquid;
- remove a gear pulley of a cranked shaft, thus fix a flywheel by means of a screw-driver;
- remove the oil pump and a chain casing;

Fig. 139. Removal of a natyazhitel of a chain and TNVD chain



- remove a natyazhitel of a chain, a chain of TNVD and a chain asterisk (fig. 139) ;
- remove топливопровод;

Fig. 140. Removal of an arm of TNVD



- remove TNVD arm (fig. 140) ;
- remove TNVD, probably, it is required to remove the bent tube of the oil pump and a casing of chain transfer;
- remove a pipe of system of cooling;
- remove the sensor of an angle of rotation of a cranked shaft (SKR);
- remove a flywheel, coupling and a back epiploon;

Fig. 141. SKR sensor removal




Fig. 142. Removal of a maslookhladitel



- remove a maslookhladitel (fig. 142) ;
- remove an oil case;
- we separate a maslopriyemnik and a connecting tube;

Fig. 143. Removal of an intermediate case



- remove an intermediate case (fig. 143) ;
- remove a cranked shaft and shatunno-piston group, work carry out similar to works described for the Zetec-E engine.
Engine assembly
Masterful Fords at assembly of the engine use the following special tool:
- the adaptation for fixing of flanges 205-072 (15030А);
- the adaptation for a centering of a conducted disk of coupling 308-204 (16067);
- a pin for installation of a cranked shaft 303-193 (21104), 310-057 (23049);
- stripper 303-199 (21110);
- demountable adaptation 303-318 (21148А), 303-513 (212170), 303-652 (21230);
- adjusting template 303-652 (21168);
- the adaptation for fixing 303-393 (21168);
- the adaptation for measurement of corners 303-174 (21540).
Before assembly clear all interfaced surfaces, carving openings, oil channels, details of system of cooling by the compressed air and check, whether they have damages. Wipe rags greasy surfaces to remove wear products. Grease all bolts and washers before their installation by engine oil. Ford for assembly of engines delivers bearings of radical necks of a cranked shaft with internal diameter 53,970 — 53,990 mm, and bearings of shatunny necks — diameter 48,970 — 48,990 mm.
Assembly of the engine carry out in the following sequence:
- establish and fix the block of cylinders at the assembly stand or an assembly table;
- before installation of a cranked shaft grease with fresh engine oil radical necks of a cranked shaft, loose leaves and persistent half rings of the third radical bearing;
- insert one loose leaves of radical bearings into the block of cylinders, others — in covers of bearings. Persistent half rings of the third radical bearing establish in a nest of the block of cylinders a flute for greasing outside and in a bearing cover. They limit an axial gap of a cranked shaft;

Fig. 144. Installation of a cranked shaft



- put a cranked shaft in the block of cylinders, put from above a cover of bearings and tighten bolts of fastening of covers. Pay attention that the shooters put on a surfaces of covers, should specify towards a belt of a drive of GRM (fig. 144) ;
- if the cranked shaft rotates freely, it is possible to tighten bolts of fastening of covers of all bearings. Begin with the average bearing, moving outside. Bolts tighten in two stages, at first the moment of 27 N · m and further dovoroty on 75 °. Check at the end free rotation of a cranked shaft. Add to all radical necks some drops of fresh engine oil;
- measure an axial gap of a cranked shaft, it should make 0,11 — 0,37 mm;
- pistons with rods establish only on the former places. The arrow should indicate the bottom of the piston towards a belt of a drive of GRM;
- scroll a cranked shaft so that shatunny necks of the 1st and 4th cylinders appeared in NMT. Grease shatunny necks with fresh engine oil;
- before piston installation together with a rod from above the block of cylinders grease with engine oil of an installation site of piston rings, piston walls, a mirror of the cylinder and previously the dry shatunny bearing inserted into a rod. 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;
- finally tighten bolts of fastening of covers of shatunny bearings. Do it in three stages: at first tighten the moment of 25 N · m, then tighten a key on 60 ° then hold on for 20 °;
- check ease of moving of a head of a rod in the bearing when finding the piston in NMT, jammings should not be;
- establish a chain casing with new laying;
- establish an intermediate case so that its surface appeared aflush with the block of cylinders;
- establish a maslopriyemnik with a new sealing ring;
- establish an oil case, previously put special Ford hermetic on a condensed flange and tighten fastening bolts, beginning from the middle, in both parties cross-wise;
- press a back epiploon of the engine in a cover and establish and fix it on the engine, having centered concerning a neck of a cranked shaft;
- establish a flywheel with new bolts. Bolts tighten in three stages: tighten the moment of 18 N · m, tighten bolts on 45 °, tighten bolts for 45 °;
- establish conducted and press coupling disks, having centered a conducted disk concerning an axis of a cranked shaft by means of an opravka then wrap bolts of fastening of a casing of coupling cross-wise;

Fig. 145. TNVD installation



- establish TNVD (fig. 145) with new laying and fix bolts;
- establish a cranked shaft in situation when the piston of the 1st cylinder is in VMT at the end of a compression step, fix TNVD pulley a drill of 6 mm, establish a chain and wrap bolts by hand;
- establish a natyazhitel of a chain and tighten bolts of fastening of the pump finally;

Fig. 146. Installation of the oil pump



- establish the oil pump together with metal laying and a sealing ring. Tighten bolts and nuts in the sequence specified fig. 146 : at first moment of 10 N · m, and then moment of 23 N · m;
- establish a forward casing with an epiploon;
- establish a gear pulley (damper) on a cranked shaft, fix a flywheel and tighten a bolt of fastening the moment of 90 N · m then tighten a key on 90 °;
- establish the pump of cooling liquid fastening by 7 bolts. Bolts М8 wrap the moment of 23 N · m, the others — the moment of 9 N · m;
- establish TNVD arm, camshafts and pulleys;

Fig. 147. Bigger semicircle of a camshaft above



- turn a cranked shaft so that the piston of the 1st cylinder was in VMT at the end of a compression step, further turn a camshaft so that the groove at its end face was parallel to a surface of a head of the block, thus the bigger semicircle was located above (fig. 147) ;

Fig. 148. Laying of a head of the block: 1 — the directing plug; 2 — designation of thickness of laying



- establish new laying on directing plugs 1 (fig. 148) . Designation of "TOP/OBEN" should be from above. It is necessary to pick up thickness of laying correctly. The thickness depends on a piston vystupaniye over a surface of the block of cylinders. The thickness makes 0,500 — 0,840 mm. Pay attention to that new laying had the same designation, as old. At the repair engine it is necessary for you to measure a vystupaniye of the piston and depending on it to pick up the correct thickness of laying;
- before installation of a head establish an oil hose of a turbonagnetatel;
- at installation of a head of the block apply only new dry bolts. Tighten bolts in two stages from the middle in both parties cross-wise: at first the moment of 10 N · m, then the moment of 100 N · m after that make endurance of 5 mines that loading worked on laying;
- further release bolts, having turned them on 180 ° and wait for 3 mines, then tighten bolts the moment of 70 N · m also wait for 3 mines and in summary tighten bolts on 120 °. Now laying is tightened and should not reach further;
- establish a cover of an epiploon of TNVD, center and wrap nuts the corresponding moment;
- establish TNVD pulley, having put previously on its surface hermetic, and wrap 3 bolts;
- establish a cam-shaft epiploon;
- establish a GRM belt as it was described earlier, and put the top cover;
- establish a cover of a camshaft and a cover of a head of the block;
- establish the thermostat with new consolidation;
- establish nozzles and glow plugs;
- connect топливопровод to TNVD, at damage of a tube it is necessary to replace it;
- establish the vacuum pump;
- wrap by hand assembly eyes of the engine;
- fix an oil separator on eyes. Further fix eyes and an oil separator. A clip establish at an angle 45 ° across;
- establish an oil radiator with new details;
- establish an oil pipeline with an arm on a turbonagnetatel.
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:
- holder of flanges 205-072 (150300);
- stripper 303-122 (21068А);
- adjusting pin of provision of a cranked shaft;
- the adaptation for installation of a camshaft 303-376 (21162В);
- the adaptation for measurement of corners 303-174 (21540);
- adjusting pin 310-018 (23019);
- a key for nozzles 310-051 (23045).
At acquaintance with this part of the section use the illustrations given earlier.
Works on removal of a head of the block carry out on the cold engine in the following sequence:
- remove wires from the storage battery and the battery;
- remove a broad tank of system of cooling and merge cooling liquid for its further use;

Fig. 149. Removal of a cooler of nadduvochny air



- remove a branch pipe of a cooler of nadduvochny air together with a cooler (fig. 149) ;
- uncover heads of the block and a camshaft cover;
- turn a cranked shaft in situation when the piston of the 1st cylinder is in VMT at the end of a compression step;
- lift the car;
- remove the bottom cover of a radiator;
- remove an arm of catalytic converter;
- remove a returnable hose from a turbonagnetatel;
- weaken a tension of a belt of a drive of auxiliary units and remove it;
- remove a generator pulley;
- lower the car;
- remove an oil separator;

Fig. 150. Thermostat removal: 1 — a glow plug wire; 2 — a vacuum hose; 3 — the contact socket



- remove the thermostat, before it remove wires 1 (fig. 150) of candles of an incandescence, a vacuum hose 2, the contact socket 3 sensors of pressure of oil and the TNVD contact socket;
- remove vacuum hoses from the vacuum pump;
- remove топливопровод a high pressure;
- remove the pipeline of a high pressure from the hydraulic booster of a steering, merge liquid from a tank of the hydraulic booster and take him aside;
- remove a final collector;
- remove a hose of system of cooling;
- unload a forward support of the engine and remove it;
- uncover a belt of a drive of GRM, weaken a tension of a belt and remove it from a gear pulley of a camshaft;
- remove a gear pulley of a camshaft;
- temporarily establish forward support of the engine;
- weaken the moment of an inhaling of bolts of fastening of a head of the block cross-wise, since both parties and moving to the middle, and then turn out them;
- remove a head from the block of cylinders and old laying.
Installation of a head of the block of cylinders carry out in the following sequence:
- clear interfaced surfaces, blow cylinders and openings the compressed air and turn a cranked shaft on 15 ° counter-clockwise from the provision of the corresponding VMT. Slightly grease cylinders with engine oil and put new laying (see section. «Engine assembly»)
- establish a block head (see section. «Engine assembly»);
- finish assembly in sequence, return to removal;
- replace the oil filter and check oil level;
- 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.
Camshaft epiploon
At works on removal and epiploon installation masterful Fords use the following special tool:
- stripper 303-293 (21-143);
- adaptation 303-199 (21-110A);
- stripper 303-039 (21009В).
Removal of an epiploon carry out in the following sequence:
- remove a belt of a drive of GRM as it is described earlier;
- remove a gear pulley of a camshaft as it is described earlier;
- remove a camshaft as it is described earlier;
- remove cальник.
Installation of an epiploon carry out in the following sequence:
- clear working surfaces of a camshaft and a landing surface of an epiploon. Slightly grease before installation a working edge of an epiploon and a camshaft neck;
- establish an epiploon, using the adaptation;
- establish a camshaft;
- establish a gear pulley of a camshaft as it is described earlier;
- establish a belt of a drive of GRM as it is described earlier, and pull it;
- check phases of a gazoraspredeleniye and if necessary modify.
Maslosjemnye caps
Masterful Fords at works on removal and installation of maslosjemny caps use the following special tool:
- assembly opravka 303-037 (21-007A);
- the adaptation for removal of crackers 303-060 (21-024);
- adaptation 303-060-05 (21-024-05);
- lift 303-199 (21-110);
- assembly adaptation 303-362 (21-156);
- grip 303-390 (21-165).
Removal of maslosjemny caps carry out in the following sequence:
- establish and fix a cranked shaft in situation when the piston of the 1st cylinder is in VMT at the end of a compression step;
- camshafts should be removed, as is described earlier;
- note the provision of a pulley of TNVD concerning a chain cover;
cнимите of a spring of valves of the 1st and 4th cylinders. For this purpose squeeze springs and remove crackers, a plate of springs of the valve and a spring;
- by means of a special grip remove from a valve core maslosjemny caps.
Installation of maslosjemny caps carry out in the following sequence:
- not to damage working edges of maslosjemny caps, stick flutes under crackers on valves with a sticky tape;
- grease maslosjemny caps with fresh engine oil;

Fig. 151. Installation of maslosjemny caps with use of the special Ford 303-390 tool



- establish maslosjemny caps by means of a special grip (fig. 151) ;
- remove a sticky tape from a flute under a cracker;
- establish a spring and a plate of a spring on a valve core, squeeze a spring by means of the adaptation and establish crackers in a flute of a core of the valve. The same operations carry out with other valves;
- remove a clamp of a cranked shaft and turn it clockwise on 180 ° then fix it;
- repeat the same operations with valves of the 2nd and 3rd cylinders;
- check phases of a gazoraspredeleniye and if necessary modify them.
Belt of a drive of GRM
Masterful Fords at works on removal and installation of a belt of a drive of GRM use the following special tool:
- holder of flanges 205-072 (15-030A);
- adjusting pin of a cranked shaft 303-193 (21104);
- adaptation 303-290 (21-140);
- extras 303-290-01 (21-140-01), 303-290-02 (21-140-02), 303-290-03 (21-140-03);
- stripper 303-651 (21-229);
- clamp of a flywheel 303-393 (21-168);
- the adaptation for installation of a camshaft 303-376 (21-162B).
Removal of a belt of a drive of GRM carry out on the cold engine in the following sequence:
- disconnect wires from plugs of the storage battery;
- remove a cooler of nadduvochny air as it is described earlier;
- merge cooling liquid from a broad tank of system of cooling and remove it;
- disconnect the contact socket of the sensor of temperature of the air intake (IAT);
- uncover heads of the block of cylinders;
- remove an arm of fastening of the pipeline of the hydraulic booster of a steering;
- disconnect топливопровод;
- establish a cranked shaft in the situation corresponding to finding of the piston of the 1st cylinder in VMT at the end of a step of compression;
- lift the car on the lift;
- remove the bottom cover of a belt of a drive of auxiliary units;
- weaken a tension of a belt of a drive of auxiliary units as it is described earlier, and remove it;
- remove a generator pulley as it is described earlier;
- remove a starter;
- block a flywheel by means of the adaptation 303-393 (21-168), thus the cranked shaft should be established in the situation corresponding to finding of the piston of the 1st cylinder in VMT at the end of a step of compression;
- lower the car;
- reliably fix the engine and remove forward support;
- uncover a belt of a drive of GRM;
- fix a camshaft by means of the adaptation in the situation corresponding to finding of the piston of the 1st cylinder in VMT at the end of a step of compression;
- weaken a tension of a belt of a drive of GRM as it is described earlier, and remove it;

Fig. 152. Otvorachivaniye of a bolt of fastening of a gear pulley of a camshaft by means of a special key: 1 — a special key; 2 — a bolt



- unscrew a bolt 1 (fig. 152) of fastening of a gear pulley of a camshaft by means of a special key 205-072 (15-229);
- remove a gear pulley of a camshaft, using a stripper 303-651 (21-229);
- remove a belt of a drive of GRM.
Installation of a belt of a drive of GRM carry out in the following sequence:
- put only a new belt and pay attention to the set direction of rotation;
- establish a gear pulley of a camshaft and by hand wrap a fastening bolt;

Fig. 153. Natyazhitel of a belt of a drive of GRM



- establish a natyazhitel of a belt and wrap a fastening bolt by hand. The adjusting clown should stand in situation «three hours» (fig. 153) ;
- rotate the adjusting clown counter-clockwise and pull a belt. The belt should be pulled by means of the Clavis-Handmessgerat indicator. Be convinced that the natyazhitel at an inhaling of a bolt does not move;
- frequency of fluctuations of a belt at a preliminary tension should make 145 — 160 Hz, the preliminary moment of an inhaling of a bolt of a natyazhitel of 15 N · m. If you have no Clavis-Handmessgerat indicator, pull a belt so that its deflection on the longest free piece at the appendix of effort made 2,5 — 3 mm;
- tighten previously a bolt of fastening of a gear pulley of a camshaft the moment of 15 N · m;
- remove the adaptation for camshaft blocking;
- if you have a Clavis-Handmessgerat indicator, check once again a belt tension.
If you have a Clavis-Handmessgerat indicator, the final tension of a belt is carried out in the following sequence:
- lift the car on the lift;
- unblock a cranked shaft;
- designate paint the current provision of a pulley of a cranked shaft and turn it on 6 turns clockwise;
- again establish a cranked shaft in the situation corresponding to finding of the piston of the 1st cylinder in VMT at the end of a step of compression, and block it for a flywheel;
- fix a camshaft by means of the adaptation in the situation corresponding to finding of the piston of the 1st cylinder in VMT at the end of a step of compression, and unscrew a bolt of fastening of a pulley, so, that the pulley freely rotated on a shaft;
- unscrew a bolt of fastening of a natyazhitel of a belt;
- tighten bolts of fastening of a natyazhitel and a gear pulley of a camshaft by hand;
- pull a belt so that frequency of its fluctuations on the Clavis-Handmessgerat indicator made 98 Hz (the natyazhitel should be motionless), and tighten bolts of fastening of a natyazhitel and a gear pulley of a camshaft the moment of 50 N · m;
- check a belt tension. Frequency of its fluctuations should be in limits of 85 — 110 Hz if is not present, repeat operations on a belt tension.
If you have no Clavis-Handmessgerat indicator, the completion of works is carried out in the following sequence, recognizing that a final tension of a belt should be twice less preliminary:
- establish a cover of a belt of a drive of GRM;
- establish engine support;
- establish a generator pulley;
- establish a belt of a drive of auxiliary units and pull it;
- establish the bottom cover of a belt of a drive of auxiliary units;
- lower the car;
- finish installation in sequence, return to removal;
- 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.