| Description and Operation The Endura‐E engine is introduced into the Escort range from '96 MY. The familiar 1,3 litre HCS engine has been reworked. The main changes compared with the previous model are among others a sequential, electronically controlled multiport fuel injection system, a new sump made of aluminium and an inlet manifold made of thermoplastic. The following picture shows the engine as fitted in Fiesta '96. | | 1. Cylinder block • Thread repairs on the cylinder block are allowed, provided Helicoil thread repairs are used. The remaining material thickness for diameters up to 9,5 mm must be at least 3,2 mm; for larger diameters at least 4,8 mm. • Core plugs must not be removed. | | | 2. Crank gear The crankshaft runs on five bearings. The bearing caps have been numbered in production and they should be re‐used accordingly during fitting. The first main bearing has a mounting for the tensioning arm of the timing chain tensioner. |  | NOTE: The arrows on the bearing caps point forwards. | | | NOTE: When measuring the crankshaft pay attention to the paint marks. | The crank shaft and also the main bearing caps are colour coded corresponding to production dimensions. For bearing caps this colour coding is found on the caps themselves; for the crankshaft the marking is on the crank web. |  | CAUTION: The main bearing bolts and the big‐end bearing bolts must not be re‐used. | | | | 3. Cylinder head The cast iron cylinder head is positioned on the cylinder block with two sleeves and is secured with ten bolts. | | CAUTION: The cylinder head bolts may be re‐used once, but must be clearly marked for re‐use with centre punch markings. | | | NOTE: The cylinder head bolts must be tightened in three stages following the correct tightening sequence. | • The maximum allowable unevenness of the cylinder head sealing surface is 0,15 mm over the whole length. • Thread repairs are permitted provided Helicoil thread inserts are used. | | NOTE: The cylinder head mating face must not be re‐worked. | 4. Cylinder head gasket The cylinder head gasket is made of aramide fibre with filler, and must be renewed every time the cylinder head is removed. To protect the gasket, it is plated with steel and copper around the oil pressure bore and cylinder bore respectively. | | | 5. Piston The piston is made of an aluminium‐silicon alloy and is fitted with three piston rings: • Barrel faced plane ring (top). • Napier ring (middle). • Oil control ring (bottom). | | NOTE: The piston rings can be changed separately without re‐working the cylinder liner. | • The piston ring gaps should be fitted at least at 90_ intervals around the circumference. • The arrows on the piston crown point forwards. | | | 6. Sump The sump is made of aluminium. | | CAUTION: The sump should be fitted flush with the rear side of the cylinder block. | | | NOTE: The timing cover and the crankshaft oil seal carrier must not be offset to the cylinder block. | • When installing the sump, the bolt‐tightening sequence must be followed. • If there is any visible damage to the sump gasket then it must be changed. • Sealer must be applied to the cylinder block when installing the sump. • Thread repairs on the sump are permitted provided Helicoil thread repairs are used. | | | 7. Inlet manifold • The inlet manifold is made of thermoplastic. This method of manufacture not only reduces the weight, but also reduces heat conduction compared with the cast iron version. • The use of plastic also improves the flow characteristics, reduces the tendency towards condensation during a cold start and lets the engine respond better during a warm start. | | | 8. Valve train | | NOTE: When removing and installing the rocker shaft, do not disturb the rocker bolts. | The engine timing is controlled from the crankshaft by a single roller chain to the lower lying camshaft. The camshaft transmits the timing actions to the valves via tappets, push rods and a rocker shaft. | | | 9. Thermostat | | CAUTION: To ensure that the thermostat works correctly, it must be installed in the correct position. | The thermostat housing gasket must be renewed during every installation. | Location of engine code and serial number. | | 10. Identification 1. Serial number. 2. Engine code. | |
