Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2D•20 Engine removal and overhaul procedures13.1a Unbolt blanking plugs (where fitted)to clean out oilways . . .engine is dismantled for full overhaul (seeillustrations).2 Remove all oil gallery plugs (where fitted).The plugs are usually very tight - they mayhave to be drilled out, and the holes retapped.Use new plugs when the engine isreassembled. Drill a small hole in the centre ofeach core plug, and pull them out with a carbodywork dent puller.Caution: The core plugs (also known asfreeze or soft plugs) may be difficult orimpossible to retrieve if they are driveninto the block coolant passages.3 If any of the castings are extremely dirty, allshould be steam-cleaned.4 After the castings are returned from steamcleaning,clean all oil holes and oil galleriesone more time. Flush all internal passageswith warm water until the water runs clear,then dry thoroughly, and apply a light film ofoil to all machined surfaces, to preventrusting. If you have access to compressed air,use it to speed the drying process, and toblow out all the oil holes and galleries.Warning: Wear eye protectionwhen using compressed air!5 If the castings are not very dirty, you can doan adequate cleaning job with hot soapywater (as hot as you can stand!) and a stiffbrush. Take plenty of time, and do a thoroughjob. Regardless of the cleaning method used,be sure to clean all oil holes and galleries very13.12 Measure the diameter of eachcylinder just under the wear ridge (A), atthe centre (B) and at the bottom (C)13.1b . . . but note that piston-cooling oiljets (where fitted) must be renewedwhenever engine is overhauled - Zetecenginesthoroughly, and to dry all componentscompletely; protect the machined surfaces asdescribed above, to prevent rusting.6 All threaded holes must be clean and dry,to ensure accurate torque readings duringreassembly; now is also a good time to cleanand check the threads of all principal bolts -however, note that some, such as the cylinderhead and flywheel/driveplate bolts, are to berenewed as a matter of course whenever theyare disturbed. Run the proper-size tap intoeach of the holes, to remove rust, corrosion,thread sealant or sludge, and to restoredamaged threads (see illustration). Ifpossible, use compressed air to clear theholes of debris produced by this operation; agood alternative is to inject aerosol-appliedwater-dispersant lubricant into each hole,using the long spout usually supplied.Warning: Wear eye protectionwhen cleaning out these holesin this way, and be sure to dryout any excess liquid left in theholes.7 When all inspection and repair proceduresare complete (see below) and the block isready for reassembly, apply suitable sealantto the new oil gallery plugs, and insert theminto the holes in the block. Tighten themsecurely. After coating the sealing surfaces ofthe new core plugs with suitable sealant,install them in the cylinder block/crankcase.Make sure they are driven in straight and13.13 Measure the piston skirt diameter atright-angles to the gudgeon pin axis, justabove the base of the skirt13.6 All bolt holes in the block should becleaned and restored with a tapseated properly, or leakage could result.Special tools are available for this purpose,but a large socket with an outside diameterthat will just slip into the core plug, used withan extension and hammer, will work just aswell.8 On Zetec engines, refit the blanking plugsor (new) piston-cooling oil jets (as applicable),tightening their Torx screws to the torquewrench setting specified. On all engines, refitall other external components removed,referring to the relevant Chapter of thismanual for further details where required.Refit the main bearing caps, and tighten thebolts finger-tight.9 If the engine is not going to be reassembledright away, cover it with a large plastic bag tokeep it clean; protect the machined surfacesas described above, to prevent rusting.Inspection10 Visually check the castings for cracks andcorrosion. Look for stripped threads in thethreaded holes. If there has been any historyof internal coolant leakage, it may beworthwhile having an engine overhaulspecialist check the cylinder block/crankcasefor cracks with special equipment. If defectsare found, have them repaired, if possible, orrenew the assembly.11 Check each cylinder bore for scuffing andscoring.12 The cylinder bores must be measuredwith all the crankshaft main bearing capsbolted in place (without the crankshaft andbearing shells), and tightened to the specifiedtorque wrench settings. Measure the diameterof each cylinder at the top (just under theridge area), centre and bottom of the cylinderbore, parallel to the crankshaft axis. Next,measure each cylinder’s diameter at the samethree locations across the crankshaft axis(see illustration). Note the measurementsobtained.13 Measure the piston diameter at rightanglesto the gudgeon pin axis, just above thebottom of the skirt; again, note the results(see illustration).14 If it is wished to obtain the piston-to-boreclearance, measure the bore and piston skirtas described above, and subtract the skirt