Chapter 1 Routine maintenance and servicing

Engine removal and overhaul procedures 2D•176 Extract each tappet in turn. Keep them inorder of fitting by inserting them in a card witheight holes in it, numbered 1 to 8 (from thetiming chain end of the engine). A valvegrinding suction tool will be found to be usefulfor the removal of tappets (see illustration).Inspection7 Examine the camshaft bearing journals andlobes for damage or excessive wear. Ifevident, the camshaft must be renewed.8 Examine the camshaft bearing internalsurfaces for signs of damage or excessivewear. If evident, the bearings must berenewed by a Ford dealer.9 If not carried out on removal, check thecamshaft endfloat as described in paragraph3. If the endfloat is exceeds thespecified tolerance, renew the thrust plate.10 It is seldom that the tappets wearexcessively in their bores, but it is likely thatafter a high mileage, the cam lobe contactsurfaces will show signs of depression orgrooving.11 Where this condition is evident, renew thetappets. Grinding out the grooves and wearmarks will reduce the thickness of the surfacehardening, and will accelerate further wear.Refitting12 To refit the tappets and the camshaft, it isessential that the crankcase is inverted.13 Lubricate their bores and the tappets.Insert each tappet fully into its original bore inthe cylinder block.14 Lubricate the camshaft bearings,camshaft and thrust plate, then insert thecamshaft into the crankcase from the timingcase end.15 Fit the thrust plate and tighten theretaining bolts to the specified torque setting(see illustration). Check that the camshaft isable to rotate freely, and that the endfloat is asspecified.11 Piston/connecting rodassemblies - removal and4inspectionRemovalHCS engines1 Refer to Part A of this Chapter and removethe cylinder head and sump, then remove theoil pick-up pipe and strainer.2 Temporarily refit the crankshaft pulley, sothat the crankshaft can be rotated. Check thatthe connecting rod big-end caps haveadjacent matching numbers facing towardsthe camshaft side of the engine. If no markscan be seen, make your own before disturbingany of the components, so that you can becertain of refitting each piston/connecting rodassembly the right way round, to its correct(original) bore, with the cap also the right wayround.10.6 Tappet withdrawal using a valvegrinding tool suction cupCVH and PTE engines3 Refer to Part B of this Chapter and removethe cylinder head and sump, then remove theoil pick-up pipe and strainer.4 Temporarily refit the crankshaft pulley, sothat the crankshaft can be rotated. Check thatthe connecting rods have identificationnumbers - these should be found on theexhaust side of the big-ends. No 1 assemblyis at the timing belt end of the engine. If nomarks can be seen, make your own beforedisturbing any of the components, so that youcan be certain of refitting each piston/connecting rod assembly the right way round,to its correct (original) bore, with the cap alsothe right way round.Zetec engines5 Refer to Part C of this Chapter and removethe cylinder head and sump.6 Undo the screws securing the oil pumppick-up/strainer pipe to the pump, thenunscrew the four nuts, and withdraw the oilpump pick-up/strainer pipe and oil baffle (seeillustration).7 Temporarily refit the crankshaft pulley, sothat the crankshaft can be rotated. Note thateach piston/connecting rod assembly can beidentified by its cylinder number (countingfrom the timing belt end of the engine) etchedinto the flat-machined surface of both theconnecting rod and its cap. The numbers arevisible from the front (exhaust side) of theengine (see illustration). Furthermore, each10.15 Refitting the camshaft thrust platepiston has an arrow stamped into its crown,pointing towards the timing belt end of theengine. If no marks can be seen, make yourown before disturbing any of the components,so that you can be certain of refitting eachpiston/connecting rod assembly the right wayround, to its correct (original) bore, with thecap also the right way round.All engines8 Use your fingernail to feel if a ridge hasformed at the upper limit of ring travel (about aquarter-inch down from the top of eachcylinder). If carbon deposits or cylinder wearhave produced ridges, they must becompletely removed with a special tool.Follow the tool manufacturer’s instructionsprovided. Failure to remove the ridges beforeattempting to remove the piston/connectingrod assemblies may result in piston ringbreakage.9 Slacken each of the big-end bearing capbolts half a turn at a time, until they can beremoved by hand. Remove the No 1 cap andbearing shell. Don’t drop the shell out of thecap.10 Remove the upper bearing shell, and pushthe connecting rod/piston assembly outthrough the top of the engine. Use a woodenhammer handle to push on the connectingrod’s bearing recess. If resistance is felt,double-check that all of the ridge wasremoved from the cylinder.11 Repeat the procedure for the remainingcylinders.2D11.6 Removing the oil baffle to provideaccess to crankshaft and bearings11.7 Each connecting rod and big-endbearing cap will have a flat-machinedsurface with the cylinder number etched in it1595Ford Fiesta Remake