Maintenance service, the device and car repairs Ford Fokus - engine Assemblage//Ford Focus

Ford Fokus>> Engines>> Assemblage and engine dismantling>> Engine assemblage

For performance of assembly works on the engine workshops Ford are equipped with the following special tool:

- Universal key 205-072 (15-030А);

- The device for measurement of corners 303-174 (21540);

- Interlock for a cranked shaft 303-204 (21168);

- The adaptation for installation of a camshaft 303-376 (21-162В);

- Unprofitable a key for bolts of a head of the block of cylinders 303-392 (21167);

- 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);

- оправка for installation of a conducted disk of coupling 308-204 (16067).

Before assemblage all bolts, washers, landing surfaces moisten with engine oil, clear and check up привалочные surfaces. Assemblage 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 gauge of an angle of rotation of a cranked shaft (СКР) (fig. 92);

- Establish gauge SKR;

Fig. 93. Flywheel installation

- Establish a flywheel and fix its bolts. The sequence of an inhaling is shown on fig. 93. An inhaling spend to two stages, at first turn the moment 30 Нм, and then tighten by means of the special adaptation 303-174 on 80 ;

Fig. 94. Installation маслоприемника and the oil pump

- Connect a rotor of the oil pump to cranked shaft then establish the oil pump and маслоприемник with a new lining (fig. 94);

- Establish an epiploon of a cranked shaft, before installation seats moisten with engine oil.

Models of release till 11.1999

Fig. 95. Drawing of special hermetic

Put on interfaced surfaces of the block of cylinders special силиконосодержащий hermetic (fig. 95);

- Establish the bottom part картера on the block of cylinders with a new lining and wrap fastening bolts by hand;

Fig. 97. Sequence of an inhaling of bolts

- Correctly arrange c the help of a ruler the bottom part картера concerning the block of cylinders so that from outside a flywheel of their surface were at one level, and tighten bolts the moment 20 Нм in certain sequence (fig. 97).

Models of release after 12.1999

Fig. 96. Apertures under hairpins М8х20

Screw hairpins М8х20 in deaf apertures (fig. 96). Pay attention to that hermetic has not got to these apertures that can lead to rigidity reduction (fig. 96);

- Put on a flange картера hermetic in the thickness of 3 mm and tighten bolts in two steps: at first the moment 10 Нм, and then the moment 20 Нм (fig. 97 see).

All models

Establish coupling, for this purpose centre a conducted disk by means of centering оправки concerning a cranked shaft and wrap bolts of fastening of a press disk cross-wise the moment 29 Нм;

- Establish a ventilation hose картера and the detonation gauge. Arrange a gauge wire on the corresponding distance from a head of the block of cylinders and a ventilation hose картера;

- Establish the thermostat with new rubber consolidation;

- Establish the gauge of pressure of oil, before it put on a carving hermetic;

- Establish the pump of a cooling liquid with new consolidation. Pay attention on крыльчатку, it is easily deformed;

- Put a lining of a head of the block on the block of cylinders. Pay attention to that directing plugs fixed a lining without pressure;

Fig. 98. An order of a tightening of a head of the block of cylinders

- Establish a head of the block of cylinders. Preliminary clear interfaced surfaces, tighten fastening bolts in certain sequence in three steps, at first the moment 15 Нм, then 30 Нм 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 4 Нм and establish a tube of the index of level of oil;

- Establish pushers of valves and adjusting washers, thus keep their position what was before removal;

Fig. 99. The piston of 1st cylinder is on distance of 25 mm to ВМТ

- Establish the piston of the first cylinder so that it in a compression step did not reach to ВМТ 25 mm, thus a flywheel has occupied the position shown on fig. 99;

- Establish camshafts. The camshaft of final valves has an additional cam on an installation site of the gauge of an angle of rotation (СМР). 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 силиконосодержащий 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 an outer side: E1 — concerns a shaft of final valves, I1 — inlet (fig. 100);

- Establish covers of bearings and tighten bolts in the sequence specified above, in three stages: in regular intervals roll on a half-turn for time while the cover will not lay down on a block head, turn the moment 7 Нм, turn the moment 16 Нм;

- Grease working edges of epiploons of camshafts with engine oil and запрессуйте them;

Fig. 101. Position of camshafts when the piston of 1st cylinder is in position ВМТ. Shaft are established by means of special tool Ford 21-162 Zetec, 21-162A Zetec-SE

- Establish an internal cover of belt ГРМ;

- Establish gear pulleys on camshafts;

- Establish camshafts in position when the piston of 1st cylinder will be in ВМТ. For this purpose turn shaft for шестигранник until the adaptation will not be established in face grooves of shaft;

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

- Establish a cranked shaft in position when the piston of 1st cylinder is in ВМТ. For this purpose wrap the special adaptation in an adjusting aperture. After turn a cranked shaft clockwise cautiously 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 (демпфер крутильных fluctuations) on a cranked shaft. For fastening necessarily use only a new bolt. Tighten a bolt in two steps: at first the moment 40 Нм, and then a special key tighten on 90 ;

- Dress a gear belt on pulleys, begin from below and continue counter-clockwise;

- Establish натяжитель a belt эксцентрикового type. Do not turn at a tightening the clown;

- For a belt tension turn the clown by means of a key with internal шестигранником counter-clockwise while the arrow will not coincide with tetrahedral проточкой;

- Tighten a bolt натяжителя the moment 20 Нм;

- If on the engine it is established натяжитель a belt with a longitudinal groove turn fastening bolts by hand;

- Pull a belt, having turned натяжитель with an arm clockwise so that the index has settled down behind two labels put behind a roller, and tighten bolts of fastening by the moment 20 Нм;

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

- Wrap bolts of fastening of pulleys of camshafts the special tool with the moment 60 Нм, thus do not admit displacement of position of camshafts and a cranked shaft (fig. 103);

- Take out an adjusting pin of a cranked shaft from the block and close an aperture carving заглушкой;

- Check up phases timing;

- Scroll a cranked shaft a hand for a flywheel;

Fig. 104. Adjustment of thermal backlashes of valves

- Adjust thermal backlashes of valves. If you do not have special tool, it is better to you to address in a specialised workshop (fig. 104);

- For adjustment of thermal backlashes of valves workshops Ford use the special tool 303-563 (21218);

Fig. 105. Installation of an assembly support

- Establish an assembly support of the engine (fig. 105);

- Establish клапанную a cover;

- Establish elements of system of ignition;

- Connect топливопровод and fix it;

- Establish the top cover of belt ГРМ.

Models without the conditioner

Establish натяжитель 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 assemblage of a head of cylinders

Dismantling of a head of cylinders spend in a following order:

Fig. 107. Removal of an inlet collector

- Remove an inlet collector with a lining (fig. 107).

Fig. 108. Contact sockets: 1 — a contact socket of the gauge of management of position throttle заслонки; 2 — a contact socket of the valve of adjustment of rotation of a cranked shaft idling

- Disconnect contact sockets from the gauge of management of position throttle заслонки (ТР) 1 (fig. 108) and the valve of adjustment of rotation of a cranked shaft idling (IAC) 2;

Fig. 109. Removal котактных sockets of atomizers

- Remove contact sockets of atomizers (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 ignition coil (EI) 1 (fig. 110), a final collector of 2 systems of cooling with a lining, the condenser 3 assembly eye 4 engines;

Fig. 111. Gauge SMR removal

- Remove the gauge of an angle of rotation of a camshaft (СМР) (fig. 111);

Fig. 112. Gauge SNT removal

- Remove the gauge of temperature of a head of cylinders (СНТ) (fig. 112);

- If the block head is damaged, it is necessary to replace it with the new. According to instruction Ford the further repair of a head is impossible.

Assemblage of a head of the block of cylinders spend in the following sequence:

- Arrange a block head on a soft substrate, for example on a rubber floor-mat. The new head of the block is delivered with клапанным the mechanism without hairpins for a final collector;

- Establish new gauge SNT. Pay attention to that the interfaced surface remained intact;

- Screw new adjusting hairpins for fastening of a final collector;

- Establish the new gauge of an angle of rotation of a camshaft (СМР) with a new ring lining;

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

- Establish the fuel distributor;

- Connect contact sockets of atomizers;

- Connect a contact socket of gauge TR;

- Connect a contact socket of valve IAC;

- Fix wires;

- Establish an inlet collector with a new lining.

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 spend 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 a contact socket from the oxygen gauge;

- Remove a final collector and a lining;

- 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 a contact socket from отдатчика MAF.

- Disconnect a drive of a pedal of an accelerator;

- Remove a hose of system of ventilation картера;

- Disconnect contact socket СМР;

- Disconnect a contact socket from the ignition and condenser coil;

- Remove vacuum hoses from the case with the activated coal of the vacuum amplifier of brakes;

- Disconnect a contact socket of the gauge of a detonation;

- Remove hoses of system of cooling;

- Disconnect топливопровод. Prepare small capacity, the system is under pressure and the fuel part can flow out;

- Uncover heads of cylinders, remove camshafts;

- Turn away 3 bolts from below an inlet collector;

- Lift the receiver the index of level of oil;

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

- Remove a head of the block of cylinders. Fastening bolts 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 spend in the following sequence:

- привалочная the 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 a new lining;

- Establish on the block a head of cylinders, do not damage a new lining;

- Wrap bolts of fastening of a head of the block. The inhaling order is shown in drawing above. An inhaling of bolts spend to three stages;

- The further installation spend in an order, the return to removal;

- Check up level of oil and replace the oil filter. Start up the engine and allow to it to 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. In this time electronic control systems of the engine and the car should be activated. If you find out failures in engine work, for example non-uniformity of rotation of a cranked shaft of the engine idling, поезжайте on specialised station Ford where to you will reprogram the management block anew;

- After a trial trip again check up levels of working liquids, reliability of fixing connections and tightness шланговых.

Epiploons of camshafts

For removal and installation of epiploons workshops Ford 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 spend 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 special adaptation Ford 303-293

- Remove by means of a stripper epiploons of camshafts (fig. 115).

Installation of epiploons spend 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 special adaptation Ford 303-395

- New epiploons establish by means of the special adaptation (fig. 116);

- Establish gear pulleys of camshafts as it is described earlier. Check up and if necessary establish phases timing as it is described earlier

Maslosemnye caps

At removal and installation маслосъемных caps workshops Ford 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); a grip 303-508 (21211).

Works on removal маслосъемных caps spend 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 spring of the valve 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 special цангового the tool remove маслосъемный a cap. The same steps undertake with all cylinders.

- Remove маслосъемные caps on other valves.

Installation маслосъемных caps spend in the following sequence:

- It is important to notice that маслосъемные caps differ on colour: for inlet valves they of green colour, for final — brown;

- Establish the assembly plug on a valve core;

- Before запрессовкой caps grease with engine oil directing plug of the valve and a working edge of a cap;

cнимите the assembly plug;

- Establish a spring of the valve and the top plate of a spring of the valve;

- Compress a spring of the valve by means of the special tool and establish crackers;

- Repeat works on installation for other valves;

- Finish installation in sequence, return to removal.

Belt ГРМ

At performance of works on removal and installation of a belt workshops Ford use the following tool:

- фланцевый a 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 position when the piston of 1st cylinder is in ВМТ at a step of compression 303-507 (21210);

- Grip 303-622 (21226).

Belt removal spend in the following sequence:

- Disconnect wires from plugs of the storage battery;

- ослабьте the moment of an inhaling of bolts of fastening of a pulley of the pump of a cooling liquid;

- Lift a forward part of the car and reliably fix on supports;

- Uncover a belt of a drive of auxiliary units;

- ослабьте a tension of a belt of a drive of auxiliary units also remove it as it has been described earlier;

- Remove a pulley (демпфер) a cranked shaft;

- Remove a pulley of the pump of a 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 a contact socket of the gauge of temperature of a head of the block (СНТ);

- Turn away three top bolts of fastening of a cover of belt ГРМ;

- Remove a broad tank of system of cooling;

- Remove a tank гироусилителя a steering and take aside;

- Remove the generator;

- Unload forward support of the power unit, having substituted a jack under oil картер, thus use wooden plates;

- Remove support;

- ослабьте a tension of belt ГРМ as it is described earlier, and remove it.

Belt installation spend in the following sequence:

- Establish a cranked shaft in the position corresponding ВМТ. By means of an adjusting pin;

- ослабьте 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 position соответствуюшее to a finding of the piston of 1st cylinder in ВМТ at a compression step;

- Establish belt ГРМ as it is described earlier;

- Establish a pulley (демпфер) on a cranked shaft with a new bolt as it is described earlier, and tighten;

- Put on new belt ГРМ as it is described earlier, and pull it;

- Check up and adjust phases timing as it is described earlier;

- The further installation spend to sequences, return to removal;

- After a trial trip again check up levels of working liquids, reliability of fixing connections and tightness шланговых.