Chapter 1 Routine maintenance and servicing

Engine removal and overhaul procedures 2D•2317.5 Place the crankshaft thrustwashersinto position in the crankcase so that theiroil grooves are facing outwards17.6 Fit the bearing shells to the mainbearing housings in the crankcase17.7 Fit the crankcase ventilation cap andits retaining springthem (the lower half bearings are plain). Theupper and lower front shells are narrower insection, and both have an oil groove in them.Where the old main bearings are beingrefitted, ensure that they are located in theiroriginal positions (see illustration). Make surethat the tab on each bearing shell fits into thenotch in the block or cap.Caution: Don’t hammer the shells intoplace, and don’t nick or gouge the bearingfaces. No lubrication should be used atthis time.7 Relocate the crankcase ventilation cap andits retaining spring into position in thecrankcase (see illustration).8 Place the crankshaft thrustwashers intoposition in the crankcase so that their oilgrooves are facing outwards (away from thecentral web).Zetec engines9 Wipe clean the main bearing shell seats inthe crankcase, and clean the backs of thenew main bearing shells. Fit the shells with anoil groove in each main bearing location in theblock; note the thrustwashers integral with theNo 3 (centre) main bearing upper shell. Fit theother shell from each bearing set in thecorresponding main bearing cap. Make surethe tab on each bearing shell fits into thenotch in the block or cap. Also, the oil holes inthe block must line up with the oil holes in thebearing shell (see illustration).Caution: Don’t hammer the shells intoplace, and don’t nick or gouge the bearingfaces. No lubrication should be used atthis time.All engines10 Clean the bearing surfaces of the shells inthe block, and the crankshaft main bearingjournals with a clean, lint-free cloth. Check orclean the oil holes in the crankshaft, as anydirt here can go only one way - straightthrough the new bearings.11 Once you’re certain the crankshaft isclean, carefully lay it in position in the mainbearings. Trim several pieces of theappropriate-size Plastigauge (they must beslightly shorter than the width of the mainbearings), and place one piece on eachcrankshaft main bearing journal, parallel withthe crankshaft centre-line (see illustration).12 Clean the bearing surfaces of the capshells, and install the caps in their respectivepositions (don’t mix them up) with the arrowspointing to the timing chain/belt end of theengine. Don’t disturb the Plastigauge.13 Working on one cap at a time, from thecentre main bearing outwards (and ensuringthat each cap is tightened down squarely andevenly onto the block), tighten the mainbearing cap bolts to the specified torquewrench setting. Don’t rotate the crankshaft atany time during this operation!14 Remove the bolts, and carefully lift off themain bearing caps. Keep them in order. Don’tdisturb the Plastigauge or rotate thecrankshaft. If any of the main bearing caps aredifficult to remove, tap them gently fromside-to-side with a soft-faced mallet to loosenthem.15 Compare the width of the crushedPlastigauge on each journal with the scaleprinted on the Plastigauge envelope to obtainthe main bearing running clearance (seeillustration). Check the Specifications tomake sure that the clearance is correct.16 If the clearance is not as specified, seekthe advice of a Ford dealer or similar enginereconditioning specialist - if the crankshaftjournals are in good condition, it may bepossible simply to renew the shells to achievethe correct clearance. If this is not possible,the crankshaft must be reground by aspecialist who can supply the necessaryundersized shells. First though, make surethat no dirt or oil was between the bearingshells and the caps or block when theclearance was measured. If the Plastigauge isnoticeably wider at one end than the other,the journal may be tapered.17 Carefully scrape all traces of thePlastigauge material off the main bearingjournals and the bearing surfaces. Be very2D17.9 Tab on each bearing shell mustengage with notch in block or cap, and oilholes in upper shells must align with blockoilways17.11 Lay the Plastigauge strips (arrowed)on the main bearing journals, parallel tothe crankshaft centre-line17.15 Compare the width of the crushedPlastigauge to the scale on the envelope todetermine the main bearing runningclearance1595Ford Fiesta Remake