Chapter 1 Routine maintenance and servicing

Engine removal and overhaul procedures 2D•1912.4 Connecting rod big-end bearing capand main bearing cap markings12.12 Crankshaft main bearing cap arrowspoint to timing belt end of engine (A), andbearing numbers (B) are consecutive fromtiming belt end12.22 Measure the diameter of eachcrankshaft journal at several points, todetect taper and out-of-round conditionsHCS engines4 Check that the main bearing caps havemarks to indicate their respective fittedpositions in the block. They also have arrowmarks pointing towards the timing chain coverend of the engine to indicate correctorientation (see illustration).5 Unscrew the retaining bolts, and removethe main bearing caps. If the caps arereluctant to separate from the block face,lightly tap them free using a plastic- orcopper-faced hammer. If the bearing shellsare likely to be used again, keep them withtheir bearing caps for safekeeping. However,unless the engine is known to be of lowmileage, it is recommended that they berenewed.6 Lift the crankshaft out from the crankcase,then extract the upper bearing shells and sidethrustwashers. Keep them with theirrespective caps for correct repositioning ifthey are to be used again.7 Remove the crankshaft oil seals from thetiming cover and the rear oil seal housing.CVH and PTE engines8 Check that each main bearing cap isnumerically marked for position. Each capshould also have an arrow marking to indicateits direction of fitting (arrow points to thetiming belt end).9 Unscrew the retaining bolts, and removethe main bearing caps. As they are removed,keep each bearing shell with its cap (in casethey are to used again). Note that the bearingshells in the main bearing caps are plain (nogroove). It is recommended that the shells berenewed, unless the engine is known to be oflow mileage.10 Lift out the crankshaft from the crankcase.11 Remove each bearing shell in turn fromthe crankcase, and keep them in order offitting. Note that the upper shell halves aregrooved. Also remove the semi-circularthrustwasher from each side of the centralmain bearing web, and keep them in theirorder of fitting.Zetec engines12 Check the main bearing caps, to see ifthey are marked to indicate their locations(see illustration). They should be numberedconsecutively from the timing belt end of theengine - if not, mark them with numberstampingdies or a centre-punch. The capswill also have an embossed arrow pointing tothe timing belt end of the engine. Noting thedifferent fasteners (for the oil baffle nuts) usedon caps 2 and 4, slacken the cap bolts aquarter-turn at a time each, starting with theleft- and right-hand end caps and workingtoward the centre, until they can be removedby hand.13 Gently tap the caps with a soft-facedhammer, then separate them from the cylinderblock/crankcase. If necessary, use the boltsas levers to remove the caps. Try not to dropthe bearing shells if they come out with thecaps.14 Carefully lift the crankshaft out of theengine.15 Remove each bearing shell in turn fromthe cylinder block/crankcase, and keep themin order of fitting.Inspection16 Clean the crankshaft, and dry it withcompressed air if available.Warning: Wear eye protectionwhen using compressed air! Besure to clean the oil holes with apipe cleaner or similar probe.17 Check the main and crankpin (big-end)bearing journals for uneven wear, scoring,pitting and cracking.18 Big-end bearing wear is accompanied bydistinct metallic knocking when the engine isrunning (particularly noticeable when theengine is pulling from low speed) and someloss of oil pressure.19 Main bearing wear is accompanied bysevere engine vibration and rumble - gettingprogressively worse as engine speedincreases - and again by loss of oil pressure.20 Check the bearing journal for roughnessby running a finger lightly over the bearingsurface. Any roughness (which will beaccompanied by obvious bearing wear)indicates that the crankshaft requiresregrinding (where possible) or renewal.21 Remove all burrs from the crankshaft oilholes with a stone, file or scraper.22 Using a micrometer, measure thediameter of the main bearing and crankpin(big-end) journals, and compare the resultswith the Specifications at the beginning of thisChapter (see illustration).23 By measuring the diameter at a number ofpoints around each journal’s circumference,you will be able to determine whether or notthe journal is out-of-round. Take themeasurement at each end of the journal, nearthe webs, to determine if the journal istapered.24 If the crankshaft journals are damaged,tapered, out-of-round, or worn beyond thelimits specified in this Chapter, the crankshaftmust be taken to an engine overhaulspecialist, who will regrind it, and who cansupply the necessary undersize bearingshells.25 Check the oil seal journals at each end ofthe crankshaft for wear and damage. If eitherseal has worn an excessive groove in itsjournal, consult an engine overhaul specialist,who will be able to advise whether a repair ispossible, or whether a new crankshaft isnecessary.13 Cylinder block/crankcase -cleaning and inspection2Cleaning1 Prior to cleaning, remove all externalcomponents and senders. On HCS engines,make sure that the camshaft and tappets areremoved before carrying out thoroughcleaning of the block. On the CVH and PTEengines, remove the engine ventilation capfrom the recess in the rear corner of thecylinder block and if still fitted, undo theretaining screw and withdraw the enginespeed sensor from the bellhousing face. OnZetec engines, unbolt the piston-cooling oiljets or blanking plugs (as applicable); notethat Ford state that the piston-cooling oil jets(where fitted) must be renewed whenever the2D1595Ford Fiesta Remake