Engine dismantling
Engine dismantling spend in the following sequence:
- Establish the engine on the assembly stand or an assembly table;
- Remove the catalyst;
- Remove a contact socket of the gauge of pressure of oil;
- Remove the generator;
- Remove an inlet collector;
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Fig. 119. Details on the engine from outside an inlet collector: 1 — the holder of the generator; 2 — the oil filter; 3 — the gauge of pressure of oil
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- From outside an inlet collector remove the holder of the generator 1 (
fig. 119), the oil filter 2, the gauge of pressure of oil 3;
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Fig. 120. Hinged knots of the engine from outside 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
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- From outside 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 картера;
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Fig. 121. Hinged details of the engine: 1 — bolts of fastening of the top cover of belt ГРМ; 2 — bolts of fastening of a pulley of the pump of a cooling liquid; 3 — a bolt of fastening of a pulley of a cranked shaft; 4 — bolts of fastening of the bottom cover of belt ГРМ; 5 — a supporting roller; 6 — bolts of fastening of an average cover of belt ГРМ
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- Turn on: bolts 1 (
fig. 121) fastenings of the top cover of belt
ГРМ, bolts of 2 fastenings of a pulley of the pump of a cooling liquid, a bolt of 3 fastenings of a pulley of a cranked shaft, bolts of 4 fastenings of the bottom cover of belt
ГРМ, bolts of 6 fastenings of an average cover of belt
ГРМ also remove supporting roller 5;
- Remove high voltage and spark plug wires;
- Uncover heads of the block of cylinders;
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Fig. 122. Removal of details of the engine: 1 — натяжитель 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 a cooling liquid
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ослабьте the moment of an inhaling of a bolt
натяжителя 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;
- Turn away bolts of 6 fastenings of the pump of a cooling liquid and remove it;
- Remove a pulley 5 with an adjusting washer from a cranked shaft;
- Remove pulleys of camshafts;
- Remove клапанный the mechanism and its details spread out one after another that at assemblage not to mix in places;
- Turn away 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;
- Cautiously remove oil картер, without having damaged details;
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Fig. 123. Removal маслоприемника and the rigidity amplifier картера: 1 — fastening bolts маслоприемника; 2 — bolts of fastening of the amplifier of rigidity картера
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- Turn away bolts 1 (
fig. 123) fastenings
маслоприемника and bolts 2 amplifiers of rigidity
картера;
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Fig. 124. Removal of the oil pump
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- Remove a back epiploon of a cranked shaft and the gauge of an angle of rotation of a cranked shaft (СКР) with the holder;
- Turn away bolts of fastening radical and шатунных bearings and postpone them in a certain order that at the subsequent assemblage not to mix in places. Take out a cranked shaft from basic bearings;
- Squeeze out pistons together with rods upward from the engine.
Engine assemblage
For performance of assembly works on the engine workshops Ford use the following special tool: фланцевый a clamp 205-072 (915-030), a stripper of epiploons 303-039 (21-009В) and 303-291 (21-141), a template for installation of camshafts 303-376 (21-162В), 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 assemblage clear all condensed surfaces, carving apertures, channels of systems of greasing and cooling by the compressed air and check up on presence of defects. Remove oil шлам from the top planes of cylinders. Grease all bolts and washers with engine oil.
Factory Ford delivers radical bearings of four groups, depending on a 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 a corresponding designation. On norms Ford, the admissible radial backlash in bearings should be within 0,020—0,040 mm.
Engine assemblage spend in the following sequence:
- Put loose leaves of radical bearings on seats of the block of cylinders and prepare 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 шатунные necks of 1st and 4th cylinders have appeared in НМТ. Grease шатунные necks with fresh engine oil;
- Establish pistons together with rods, thus сориентируйте so that the arrow specified shatunno-piston group in the piston bottom towards belt ГРМ;
- 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 preliminary inserted into a rod dry шатунный the bearing with engine oil. Locks of piston rings сориентируйте so that they have been developed rather 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 by the wooden handle of a hammer, simultaneously 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 2nd and 3rd cylinders have appeared in НМТ then repeat similar assemblage for these cylinders;
- If the cranked shaft freely rotates, can definitively 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 Нм. Check up again free rotation of a shaft;
- Wrap fastening bolts шатунных bearings, do it when the piston is in НМТ. Wrap bolts in two stages: at first wrap bolts the moment 15 Нм, then tighten each bolt on 90 . Again check up free rotation of a cranked shaft;
- Establish a back cover of the engine and gauge SKR. Bolts preliminary tighten by hand;
- Arrange a cover so that the condensed surface was below 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 a new lining. Interfaced with oil картером the surface should support in regular intervals a surface of the block of cylinders on 0,3—0,8 mm;
- Prepare the rigidity amplifier картера with a new lining 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 instruction Ford). In 10 minutes bolts of fastening of the amplifier of rigidity can be tightened definitively. Correctly сориентируйте the rigidity amplifier картера concerning the block of cylinders, for this purpose use flat щупы and a ruler so that block and amplifier surfaces were at one level. Following deviations are admissible: c mechanical transmission МТХ 75 выступание within 0,10 mm, a backlash to 0,25 mm, with an automatic box supposes a backlash of 0-0,25 mm;
- If the valid sizes do not correspond to these values, adjust by means of washers;
- Prepare for installation маслоприемник systems of greasing and establish;
- Establish oil картер. Screw preliminary 10 adjusting hairpins М6х20 in deaf apertures. Do not suppose hermetic hit in apertures;
- On a flange oil картера put hermetic a layer in the thickness about 3 mm (use hermetic Ford);
- Put oil картер and in two steps tighten a fastening bolt, at first the moment 1—6 Нм, and then the moment 2—10 Нм. Tighten cross-wise, beginning from the middle, in both parties;
- Establish a flywheel and fix its new bolts. Preliminary remove the rests of hermetic from deaf apertures in cranked to a shaft;
- Establish the coupling, for this purpose conducted and press disks establish on a flywheel and centre a conducted disk concerning an axis of a cranked shaft by means of special оправки and tighten bolts of fastening of a casing of a press disk cross-wise the moment 29 Нм. Before installation put a small amount of dense greasing on шлицы a conducted disk;
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Fig. 125. Installation of a lining of a head of the block of cylinders: 1 and 2 — directing plugs; 3 — a lining of a head of the block; 4 — put number
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- Establish a lining of a head of the block. It is important to know that on the forward party of the block around 1st cylinder the figure according to which you should buy a new lining is put. Before installation of a lining 3 (
fig. 125) check up a block surface on absence of agnails. Establish a lining on directing plugs 1, it should lie without pressure 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 apertures by hand (bolts it is possible not to grease). After that wrap bolts in the sequence specified above. An inhaling of bolts spend to three stages: with the moment 20 Нм, further with the moment 40 Нм and then tighten bolts on 90 .
- Establish pushers of valves and adjusting washers as they have been established before dismantling;
- Establish a cranked shaft for 60 before position of the piston of 1st cylinder in ВМТ;
- Arrange both camshafts so that any of cams was not in position of full lifting;
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Fig. 126. Installation of covers of bearings of a camshaft
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- Before to put covers of bearings of camshafts, plentifully grease bearings and cams with fresh engine oil. Put
силиконосодержащий hermetic on interfaced surfaces of covers and a head of cylinders of the first bearings of shaft. Marks of covers should be on lateral aspect (
fig. 126);
- Put covers of bearings and wrap fastening bolts, an inhaling spend from the middle outside in the sequence specified earlier. Tighten in three stages: in regular intervals on a half-turn while the cover will not lay down on a head of cylinders, then the moment 10 Нм and the moment 19 Нм;
- Grease with engine oil working edges of epiploons and a neck of camshafts, then запрессуйте epiploons;
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Fig. 127. The position of a cranked shaft corresponding to a finding of the piston of 1st cylinder in ВМТ at a step of compression
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- Establish a cranked shaft in the position corresponding to a finding of the piston of 1st cylinder in
ВМТ 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 a cooling liquid with a new lining;
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Fig. 128. Installation of a gear belt: 1 — a gear belt; 2 — the top directing roller; 3 — the pump of a cooling liquid; 4 — the bottom directing roller; 5 — a pulley of a cranked shaft with an adjusting washer; 6 — натяжитель a belt
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- 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. Belt installation begin with a pulley 5 and put it counter-clockwise, holding it thus tense. Establish
натяжитель a belt 6 and wrap a fastening bolt on 5 turns;
- Pull a gear belt, for this purpose натяжитель rotate counter-clockwise while the arrow and a mark will not coincide then tighten the screw. The wrong tension of a belt breaks phases timing;
- Check up once again for safety position of a cranked shaft, it should correspond to a finding of the piston of 1st cylinder in ВМТ at a compression step;
- Tighten definitively bolts of fastening of pulleys of camshafts the special tool;
- Turn a cranked shaft for a flywheel on two turns clockwise and check up phases timing. If necessary modify the work;
- Check up and adjust thermal backlashes of valves. Work is spent, as well as for engine Zetec-SE;
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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 a 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
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- Wrap bolts 5 (
fig. 129) fastenings of the bottom cover of belt
ГРМ, tighten a bolt of 4 fastenings of a pulley
(демпфера) 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 a cooling liquid);
- Establish ventilation system картера the engine with new consolidation;
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Fig. 130. Fastening of details and engine knots from outside 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
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- Fix engine knots from outside a final collector: the holder 1 (
fig. 130) the conditioner compressor, the holder 2 hydraulic boosters of a steering, the holder of 3 protection of the engine;
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Fig. 131. Engine details from outside an inlet collector
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- Establish details and knots from outside an inlet collector (
fig. 131);
- Establish an inlet collector, having wrapped 7 bolts and 2 nuts;
- Cautiously establish каталитический neutralizer, apply only a new lining. Establish теплоотражательный the screen. Wrap bolts and nuts;
- Establish the generator;
- Establish the gauge of pressure of oil.
Removal and installation of a head of the block of cylinders on the car
Workshops Ford at performance of these works use the following special tool:
- Universal фланцевый the holder 205-072 (915030);
- Stripper of epiploons 303-039 (21009А);
- The elevating device for the engine 303-122 (21068);
- Face key for bolts of a head of the block 303-392 (21167);
- Candle key 303-622 (21226);
- The adaptation 303-397 (24003).
At acquaintance with the given section use the illustrations resulted earlier.
Removal of a head of the block spend 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 ventilation hose картера from an inlet collector;
- Disconnect a contact socket from the pressure gauge;
- Remove the case of the air filter;
- Disconnect a drive of a pedal of an accelerator;
- Disconnect a contact socket from the gauge of temperature of a head of the block (СНТ);
- 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 теплоотражательный the screen;
- Remove the thermostat;
- Remove каталитический neutralizer 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 turn away the top bolts of the holder;
- Remove клапанный the mechanism and its details spread out one after another not to mix them at the subsequent assemblage;
- Turn away 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 spend in the following sequence:
- Clear interfaced surfaces and blow compressed air a head, cylinders and an inlet collector. Wipe mirrors of cylinders pure engine oil. To grind a block head it is impossible. Apply a new lining 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 a new lining;
- Wrap bolts of a head of the block in an order specified above. Bolts tighten in three stages as it is described earlier;
- The further installation spend in sequence, return dismantling;
- Check up level of oil and replace the filter;
- Start up the engine and warm up it to working temperature. Check up tightness of connections and reliability of carving fastenings;
- 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.
Camshafts and epiploons
Workshops Ford at performance of works on removal and installation of camshafts and epiploons use the adaptation for removal of epiploons 303-039 (21009В).
Removal of camshafts and epiploons spend 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 spend in the following sequence:
- On interfaced surfaces of forward covers of bearings and a block head 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 up phases timing and in need of them modify.
Maslosemnye caps
Working operations on removal and installation маслосъемных caps are identical to works which have been described for engine Zetec-SE (see section Maslosemnye caps).
Belt ГРМ
Working operations on removal and installation of belt ГРМ are identical to works which have been described for engine Zetec-SE (see section Belt ГРМ).