Ford Workshop Service and Repair Manuals

Location of the engine number on the cylinder block

Engine codes

The engine codes for the 2.0L Zetec-E engines are:

• 2,0L Zetec-E-Motor (D3) - EDBA
• 2,0L Zetec-E-Motor (E4) - EBBC
• 2,0L Zetec-E-Motor (Stage II) - EBBD
• 2,0L Zetec-E-Motor (Stage III) - EDBB

Construction of the Zetec-E engine

Basic concept

The Zetec-E engine is an in-line four cylinder engine with two overhead camshafts and 16 valves. The 16 valve cylinder head achieves a better cylinder charge particularly at high engine speeds.

The cylinder head is made of aluminum alloy and the cylinder block of cast iron.

Timing belt center cover/front engine mounting bracket

The new timing belt cover has a vertical rib to increase its rigidity. This means that both the timing belt centre cover and the front engine mounting must be removed at the same time in order to change the timing belt.

Cylinder head

Combustion chamber

The centrally positioned spark plug in the roof shaped combustion chamber causes the mixture found in the combustion chamber to ignite. Positioning the spark plug centrally causes an even spread of the flame front through the combustion chamber and thus at the same time reduces the tendency of the engine to knock.

Valve gear

The two camshafts are driven by one common drive belt and operate four valves per cylinder through adjustable tappets. Because of the exhaust gas stream flowing past them, the exhaust valves are subjected to particularly high temperatures. The exhaust valves are specially coated so that they are better able to dissipate heat. Each valve is closed by its own single valve spring. Adjustment shims in the valve tappets are changed in order to adjust the valve clearance. These are available in 52 different thicknesses. The thickness of the adjusting shim is stamped on the back face as a numerical value accurate to a hundredth of a millimetre (example: the number 222 = 2,22 mm). Because of the limited space in the cylinder head the camshaft must be removed in order to change the adjusting shims. Absolute accuracy is therefore necessary during the adjustment procedure in order to avoid having to remove and install the camshaft more than once. The cams on the camshaft run off-centre on the valve tappets. Because of this, from an engine speed of about 3000 rev/min the tappets are caused to rotate, and they transmit this turning movement to the valves. Turning of the valves is desirable because this leads to an even seating of the valves on their seats and prevents the valves from bedding in at one position and leaking.

Valve gear

Timing belt tensioner

CAUTION:Only tension the timing belt tensioner anticlockwise.

Correct timing belt tension is ensured by the automatic timing belt tensioner. To do this it is set to its base position when a new timing belt is put in place (arrow point (3) and marking (2) line up). This base setting is taken over by a cam (4). A further cam which is under spring pressure ensures the correct timing belt tension during operation. The working range of the timing belt tensioner is 30° either side of the centre position.

NOTE:The timing belt must not be re-tensioned because there is a danger that the working range would be exceeded in one direction. The base setting of the timing belt tensioner is only valid for new timing belts. Re-tensioning can therefore lead to splitting or run-out of the timing belt.

After removing the adjusting tool and the alignment pin the base setting can no longer be checked (the force of the valve springs puts pressure on the timing belt and alters the position of the timing belt tensioner).

Automatic timing belt tensioner

Components Attached to Cylinder Head

Intake manifold

The new Zetec-E engines are equipped with an inlet manifold made of glass fibre reinforced plastic. The channels of the inlet manifold are arranged in such a way that the inlet paths for all cylinders are the same length.

• This gives the following advantages:
  -

  reduced heat transfer to the fuel injectors and therefore prevention of vapor bubbles,
  -

  lighter weight
  -

  reduction of fuel deposits on the intake pipe walls during cold starts
  -

  less heating of the intake air when the engine is hot.

Components attached to the inlet manifold

Cylinder block

Crankshaft

The five main bearing crankshaft has a counterbalance weight for each cylinder. The centre main bearing is provided with two bearing half shells which take the axial thrust of the crankshaft and are also used to adjust the end float.

Crankshaft bearings

Big end bearings

The connecting rods are numbered from one to four in sequence on the side nearest the timing belt. Mixing up the big end bearing caps and connecting rods is almost impossible because the bearing caps are broken away from the connecting rods during production. The fracture profile of the bearing cap therefore only matches one particular connecting rod.

Lower crankcase

Lower crankcase

View of lower crankcase

The purpose of the lower crankcase is to dampen the engine vibrations. This leads to a further reduction in the noise level in the passenger compartment. The joint between the lower crankcase and the cylinder block is sealed using a rubber gasket (from 01/1999 a steel carrier plate gasket is used).

Lower crankcase shims

Shims are to be installed at the lower crankcase in order to level out the gap between the transmission and the lower crankcase if it is too large (see Technical Data and Specifications).

Oil pan

The assembly is closed at the bottom by a pressed steel sump which is attached directly to the lower crankcase. Sealing is achieved using a 3 mm wide bead of sealer.

Engine management

EEC V Module

Engine management of the Zetec-E engines is handled by the EEC V module. To do this it requires a great deal of information about the current operating parameters of the engine and the automatic transmission (CD4E). The EEC V module obtains this information through sensors.

• The EEC V module controls:
  -

  the fully electronic ignition system (EI)
  -

  sequential fuel injection (SEFI),
  -

  the air conditioning system together with the cooling system and
  -

  transmission control of the CD4E automatic transmission (if equipped).