Ford Fokus>> Engines>> Assemblage and engine dismantling>> Engine Endura-DI of 1,8 l
Engine dismantling
Engine dismantling spend in the following sequence:
- Establish the engine on the assembly stand or an assembly table;

Fig. 132. Removal of hoses of system of ventilation картера



- Remove a hose of an oil cooler and hoses of system of ventilation картера (РСV) (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 турбонагнетателя



- Remove tubes of giving of oil to турбонагнетателю (fig. 135);
- Remove a pulley of the pump of a cooling liquid;
- Uncover block heads;
- Remove a forward cover of a belt of drive ГРМ;
- Remove a generator arm;
- Remove forward support of the engine;
- ослабьте a tension of a belt of drive ГРМ also 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 (ТНВД) (fig. 136);
- Turn away 7 bolts of fastening of the case of epiploon ТНВД;
- Remove a back cover of a belt of drive ГРМ;

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. Fastening bolts turn on in 138 sequences presented on fig.;
- Remove the pump of a 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 натяжителя chains and chains ТНВД



- Remove натяжитель chains, chain ТНВД and a chain asterisk (fig. 139);
- Remove топливопровод;

Fig. 140. Removal of arm ТНВД



- Remove arm ТНВД (fig. 140);
- Remove ТНВД, 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 gauge of an angle of rotation of a cranked shaft (СКР);
- Remove a flywheel, coupling and a back epiploon;

Fig. 141. Gauge SKR removal




Fig. 142. Removal маслоохладителя



- Remove маслоохладитель (fig. 142);
- Remove oil картер;
- We separate маслоприемник and a connecting tube;

Fig. 143. Removal intermediate картера



- Remove intermediate картер (fig. 143);
- Remove a cranked shaft and shatunno-piston group, work spend similarly to works described for engine Zetec-E.
Engine assemblage
Workshops Ford at engine assemblage 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);
- Pin for installation of a cranked shaft 303-193 (21104), 310-057 (23049);
- Stripper 303-199 (21110);
- The 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 gauging of corners 303-174 (21540).
Before assemblage clear all interfaced surfaces, carving apertures, oil channels, details of system of cooling by the compressed air and check up, whether they have damages. Wipe rags greasy surfaces to remove deterioration products. Grease all bolts and washers before their installation by engine oil. Ford for assemblage of engines delivers bearings of radical necks of a cranked shaft with internal diameter 53,970—53,990 mm, and bearings шатунных necks — diameter 48,970—48,990 mm.
Engine assemblage spend 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 backlash 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 arrows put on surfaces of covers, should specify towards a belt of drive ГРМ (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 27 Н·м and further доворотом on 75 °. Check up in the end free rotation of a cranked shaft. Add to all radical necks some drops of fresh engine oil;
- Measure an axial backlash of a cranked shaft, it should make 0,11—0,37 mm;
- Pistons with rods establish only on the former places. The arrow should specify in the piston bottom towards a belt of drive ГРМ;
- Scroll a cranked shaft so that шатунные necks of 1st and 4th cylinders have appeared in НМТ. Grease шатунные 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 preliminary inserted into a rod dry шатунный the bearing. 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;
- Definitively tighten bolts of fastening of covers шатунных bearings. Do it in three stages: at first tighten the moment 25 Н·м, then tighten a key on 60 ° then hold on for 20 °;
- Check up ease of moving of a head of a rod in the bearing at a piston finding in НМТ, jammings should not be;
- Establish a casing of a chain with a new lining;
- Establish intermediate картер so that its surface has appeared заподлицо with the block of cylinders;
- Establish маслоприемник with a new sealing ring;
- Establish oil картер, preliminary put special hermetic Ford on a condensed flange and tighten fastening bolts, beginning from the middle, in both parties cross-wise;
- запрессуйте a back epiploon of the engine in a cover also 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 18 Н·м, 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 with the help оправки then turn bolts of fastening of a casing of coupling cross-wise;

Fig. 145. Installation ТНВД



- Establish ТНВД (fig. 145) with a new lining and fix bolts;
- Establish a cranked shaft in position when the piston of 1st cylinder is in ВМТ in the end of a compression step, fix pulley ТНВД a drill of 6 mm, establish a chain and wrap bolts by hand;
- Establish натяжитель chains and tighten bolts of fastening of the pump definitively;

Fig. 146. Installation of the oil pump



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

Fig. 147. A bolshy semicircle of a camshaft above



- Turn a cranked shaft so that the piston of 1st cylinder was in ВМТ in 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 больший the semicircle has been located above (fig. 147);

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



- Establish a new lining on directing plugs 1 (fig. 148). The designation «TOP/OBEN» should be from above. It is necessary to pick up a thickness of a lining correctly. The thickness depends from выступания the piston over a surface of the block of cylinders. The thickness makes 0,500 0,840 mm. Pay attention to that the new lining had the same designation, as old. At the repair engine it is necessary for you to measure выступание the piston and depending on it to pick up a correct thickness of a lining;
- Before head installation establish an oil hose турбонагнетателя;
- 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 10 Н·м, then the moment 100 Н·м after that make endurance of 5 mines that loading has worked on a lining;
- Further release bolts, having turned them on 180 ° and wait for 3 mines, then tighten bolts the moment 70 Н·м and wait for 3 mines and in summary tighten bolts on 120 °. Now the lining is tightened and should not reach further;
- Establish a cover of epiploon ТНВД, centre and wrap nuts the corresponding moment;
- Establish pulley ТНВД, having put preliminary on its surface hermetic, and wrap 3 bolts;
- Establish a cam-shaft epiploon;
- Establish belt ГРМ 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 atomizers and candles накаливания;
- Connect топливопровод to ТНВД, 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 маслопровод with an arm on турбонагнетатель.
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:
- The holder of flanges 205-072 (150300);
- Stripper 303-122 (21068А);
- Adjusting pin of position 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);
- Key for atomizers 310-051 (23045).
At acquaintance with the given part of section use the illustrations resulted earlier.
Works on removal of a head of the block spend 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. Cooler removal наддувочного air



- Remove a cooler branch pipe наддувочного air together with a cooler (fig. 149);
- Uncover heads of the block and a camshaft cover;
- Turn a cranked shaft in position when the piston of 1st cylinder is in ВМТ in the end of a compression step;
- Lift the car;
- Remove the bottom cover of a radiator;
- Remove an arm каталитического neutralizer;
- Remove a returnable hose from турбонагнетателя;
- ослабьте a tension of a belt of a drive of auxiliary units also remove it;
- Remove a generator pulley;
- Lower the car;
- Remove an oil separator;

Fig. 150. Thermostat removal: 1 — a candle wire накаливания; 2 — a vacuum hose; 3 — a contact socket



- Remove the thermostat, before it remove wires 1 (fig. 150) candles накаливания, a vacuum hose 2, a contact socket 3 gauges of pressure of oil and contact socket ТНВД;
- Remove vacuum hoses from the vacuum pump;
- Remove топливопровод a high pressure;
- Remove the pipeline of a high pressure from the steering hydraulic booster, merge a 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 drive ГРМ, ослабьте 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;
- ослабьте 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 an old lining.
Installation of a head of the block of cylinders spend in the following sequence:
- Clear interfaced surfaces, blow cylinders and apertures the compressed air and turn a cranked shaft on 15 ° counter-clockwise from position corresponding ВМТ. Slightly grease cylinders with engine oil and put a new lining (the section «engine Assemblage» see)
- Establish a block head (the section «engine Assemblage» see);
- Finish assemblage in sequence, return to removal;
- Replace the oil filter and check up oil level;
- 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.
Camshaft epiploon
At performance of works on removal and installation of an epiploon workshops Ford use the following special tool:
- Stripper 303-293 (21-143);
- The adaptation 303-199 (21-110А);
- Stripper 303-039 (21009В).
Epiploon removal spend in the following sequence:
- Remove a belt of drive ГРМ 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.
Epiploon installation spend 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 drive ГРМ as it is described earlier, and pull it;
- Check up phases timing and if necessary modify.
Maslosemnye caps
Workshops Ford at performance of works on removal and installation маслосъемных caps use the following special tool:
- Assembly оправка 303-037 (21-007А);
- The adaptation for removal of crackers 303-060 (21-024);
- The adaptation 303-060-05 (21-024-05);
- The lift 303-199 (21-110);
- The assembly adaptation 303-362 (21-156);
- Grip 303-390 (21-165).
Removal маслосъемных caps spend in the following sequence:
- Establish and fix a cranked shaft in position when the piston of 1st cylinder is in ВМТ in the end of a compression step;
- Camshafts should be removed, as is described earlier;
- Note position of pulley ТНВД concerning a chain cover;
cнимите springs of valves of 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 маслосъемные caps.
Installation маслосъемных caps spend in the following sequence:
- Not to damage working edges маслосъемных caps, stick flutes under crackers on valves with a sticky tape;
- Grease маслосъемные caps with fresh engine oil;

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



- Establish маслосъемные caps by means of a special grip (fig. 151);
- Remove a sticky tape from a flute under a cracker;
- Establish a spring and a spring plate 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 spend 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 2nd and 3rd cylinders;
- Check up phases timing and if necessary modify them.
Belt of drive ГРМ
Workshops Ford at performance of works on removal and installation of a belt of drive ГРМ use the following special tool:
- The holder of flanges 205-072 (15-030А);
- Adjusting pin of a cranked shaft 303-193 (21104);
- The 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 (21-162В).
Removal of a belt of drive ГРМ spend on the cold engine in the following sequence:
- Disconnect wires from plugs of the storage battery;
- Remove a cooler наддувочного air as it is described earlier;
- Merge cooling liquid from a broad tank of system of cooling and remove it;
- Disconnect a contact socket of the gauge of temperature воздухозабора (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 position corresponding to a finding of the piston of 1st cylinder in ВМТ in 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;
- ослабьте 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 position corresponding to a finding of the piston of 1st cylinder in ВМТ in the end of a step of compression;
- Lower the car;
- Reliably fix the engine and remove forward support;
- Uncover a belt of drive ГРМ;
- Fix a camshaft by means of the adaptation in the position corresponding to a finding of the piston of 1st cylinder in ВМТ in the end of a step of compression;
- ослабьте a tension of a belt of drive ГРМ as it is described earlier, and remove it;

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



- Turn away a bolt 1 (fig. 152) fastenings 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 drive ГРМ.
Installation of a belt of drive ГРМ spend 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. Натяжитель a belt of drive ГРМ



- Establish натяжитель a belt and wrap a fastening bolt by hand. The adjusting clown should stand in position «three hours» (fig. 153);
- Rotate the adjusting clown counter-clockwise and pull a belt. The belt should be pulled by means of indicator Clavis-Handmessgerat. Be convinced that натяжитель at a bolt inhaling 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 натяжителя 15 Н·м. If you do not have indicator Clavis-Handmessgerat pull a belt so that its deflection on the longest free piece at the effort appendix made 2,5—3 mm;
- Tighten preliminary a bolt of fastening of a gear pulley of a camshaft the moment 15 Н·м;
- Remove the adaptation for camshaft blocking;
- If you have indicator Clavis-Handmessgerat, check up once again a belt tension.
If you have indicator Clavis-Handmessgerat a definitive tension of a belt spend in the following sequence:
- Lift the car on the lift;
- Unblock a cranked shaft;
- Designate a paint current position of a pulley of a cranked shaft and turn it on 6 turns clockwise;
- Again establish a cranked shaft in the position corresponding to a finding of the piston of 1st cylinder in ВМТ in the end of a step of compression, and block it for a flywheel;
- Fix a camshaft by means of the adaptation in the position corresponding to a finding of the piston of 1st cylinder in ВМТ in the end of a step of compression, and turn away a bolt of fastening of a pulley, so, that the pulley freely rotated on a shaft;
- Turn away a fastening bolt натяжителя a belt;
- Tighten fastening bolts натяжителя and a gear pulley of a camshaft by hand;
- Pull a belt so that frequency of its fluctuations on indicator Clavis-Handmessgerat made 98 Hz (натяжитель should be motionless), and tighten fastening bolts натяжителя and a gear pulley of a camshaft the moment 50 Н·м;
- Check up 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 do not have indicator Clavis-Handmessgerat the termination of works spend in the following sequence, recognising that a definitive tension of a belt should be twice less preliminary:
- Establish a cover of a belt of drive ГРМ;
- 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 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.