Ford Workshop Service and Repair Manuals

Engine

• Cross-mounted 4-cylinder inline engine with an overhead camshaft and 8 valves
• 1.3 l capacity
• 43/50 kW (58/68 PS) at 5500 rev/min
• 100/106 Nm at 2500/2800 rev/min
• Compression ratio 10.2 : 1
• Camshaft drive provided via hydraulically tensioned timing chain
• Valves actuated by roller cam follower with hydraulic clearance adjustment
• Cylinder head made of an aluminium alloy

Engine Management

• SIM 21 engine management system
• Load detection via temperature and intake manifold absolute pressure (T-MAP) sensor
• Sequential multi-port fuel injection (SFI)

Engine Emission Control

• European emissions level IV
• Three-way catalytic converter with two lambda probes integrated in the exhaust manifold

Diagnosis

• Diagnosable with WDS via the data link connector (DLC)

General

The 1.3L Duratec 8V engine is a 4-cylinder inline engine featuring an overhead camshaft and a crossflow cylinder head.

Features of the 1.3L Duratec 8V engine:

• Cast iron cylinder block with integrated timing chain housing
• Crankshaft runs on 5 bearings
• Cast aluminium alloy cylinder head with integrated timing chain housing
• Camshaft runs on 5 bearings
• 2 valves per cylinder
• Roller cam followers
• Valve clearance adjustment via hydraulic tappets
• 2-layer cylinder head gasket
• Aluminium oil pan with reinforcing ribs
• Plastic air intake module with integrated throttle valve housing, throttle valve position (TP) sensor, idle air control (IAC) valve and T-MAP sensor
• Oil pump driven via the crankshaft
• SIM 21 powertrain control module (PCM)

Technical Data and Specifications

Engine views

Cylinder head and valve train

Cylinder head

The cylinder head is made of an aluminium alloy and features two valves per cylinder.

It is laid out as a crossflow cylinder head.

The valve angles on the intake and exhaust valves are asymmetrical. The valve angle of the intake valves is 10°, and the valve angle of the exhaust valves is 6°.

The spark plugs are located on the exhaust side.

The valve guides and valve seats are made of sintered metal.

The timing chain housing is an integral part of the cylinder head and the cylinder block.

Valve train

The camshaft is held in place with five bearing caps, and runs directly in the cylinder head without bearing shells.

An additional reference cam is located on the camshaft for identification of cylinder no. 1.

The camshaft actuates the roller cam followers.

As the cam followers run on rollers, the frictional losses of the valve train are reduced.

As a result of the use of hydraulic tappets, no valve clearance adjustments are required.

Intake and exhaust valves

The intake valve is made entirely from a single material. The valve diameter is 35.1 mm.

The exhaust valve is designed as a bi-metal valve. The valve diameter is 29.7 mm.

Cylinder head gasket

The cylinder head gasket is designed as a 2-layer metal gasket.

Cylinder head cover

The cylinder head cover is bolted to the cylinder head with ten bolts.

The cylinder head cover gasket is T-shaped and is secured in the groove of the cylinder head cover.

The CMP sensor is attached to the cylinder head cover and is used to identify the position of cylinder no. 1.

The EI module is attached with four retaining bolts to the side of the cylinder head cover.

The EVAP solenoid valve is secured to an additional bracket.

Air intake module

The air intake module consists of the following components:

• Intake manifold
• Fuel distribution pipe with four injectors
• Throttle valve housing with TPsensor
• IAC valve
• T-MAP sensor

The intake manifold is attached to the cylinder head with three bolts and two studs.

O-rings are used to seal between the intake manifold and the cylinder head.

The fuel distribution pipe with the four injectors is inserted on the upper side of the intake manifold.

The TP sensor is located on the throttle valve housing.

The IAC valve and the T-MAP sensor are positioned on the inside of the intake manifold.

Exhaust manifold

The exhaust manifold gasket is a specially coated 2-layer metal gasket.

The catalytic converter forms an integral component with the exhaust manifold.

The heat shield serves to protect the adjacent components from excessive heat.

Cylinder block and crank assembly

Cylinder block

CAUTION:The oil gallery plug must not be removed.

The cylinder head is made of cast iron.

The cylinder block does not have any cylinder liners. The running surfaces of the cylinders are worked directly into the cylinder block.

The connection for the positive crankcase ventilation is located on the rear side of the cylinder block.

Crankshaft and bearing caps

The crankshaft runs on five bearings and has four crank webs.

The main bearing caps are numbered and are marked with an arrow to indicate the installation position and orientation. The arrows must point towards the timing chain end after installation.

The main bearing shells which are inserted in the main bearing caps do not have an oil groove.

The main bearing shells which are inserted in the cylinder block do have an oil groove.

Four of the retaining bolts for the main bearing caps feature stud extensions which are used to secure the oil baffle plate and the intake pipe for the oil pump.

The end float of the crankshaft is limited with two thrust washers.

Connecting rod

The connecting rods are made of forged steel.

The connecting rods are available in three different weight classes.

Pistons and piston rings

The lightweight construction pistons are made of aluminium.

The piston recess helps to optimise the swirl of the air/fuel mixture.

The pistons have a special coating at the piston skirt in order to improve their durability.

The pistons are available in service with three different diameters (two oversizes).

The upper compression ring is a rectangular-section ring and is made of steel.

The lower compression ring is an L-section ring and is made of cast iron.

The oil scraper ring consists of 3 parts and is chromium plated.

Crankshaft rear oil seal carrier

The assembly sleeve is made of plastic.

The oil seal is integrated into the oil seal carrier. The oil seal is made of polytetrafluoroethylene (PTFE).

The oil seal carrier is centred with two guide studs and then attached to the cylinder block with four bolts.

Oil baffle plate and oil intake pipe

The oil baffle plate prevents excessive foaming of the engine oil.

The oil baffle plate and the oil intake pipe are attached with the stud extensions of the bearing cap retaining bolts.

The oil intake pipe is sealed at the oil pump by means of an O-ring.

Oil pan

The oil pan is made of an aluminium alloy and features reinforcing ribs.

The bracket for the A/C compressor is integrated into the oil pan.

The oil pan gasket consists of an aluminium base to which a rubber coating is applied.

Flywheel

The flywheel is made of cast iron.

The flywheel is bolted to the crankshaft with 6 bolts and aligned with a centring spigot.

Camshaft drive

Camshaft sprocket and crankshaft sprocket

The camshaft sprocket is made of steel and has 38 teeth.

The crankshaft sprocket is made of sintered steel and has 19 teeth.

The timing mark is stamped on the front.

The installation position of both sprockets is defined by a Woodruff key.

Timing chain

The timing chain is a sleeve type chain with 114 links.

The chain guide rails are made of plastic.

Both chain guide rails are positioned via a retaining bolt.

The chain guide rail on the intake side is also located via a recess in the cylinder head.

The chain guide rail on the exhaust side can slide and is moved via the hydraulic chain tensioner.

Hydraulic chain tensioner

The hydraulic chain tensioner is moved by the engine oil pressure.

The piston pushes against the chain guide rail (exhaust side) and exerts a defined contact pressure on the timing chain.

Oil circuit

Oil pump

The oil pump is a G-rotor pump which is driven directly by the engine.

The crankshaft oil seal (PTFE) is located in the housing of the oil pump.

The gasket of the oil pump housing is a rubber-coated metal gasket.

Oil intake pipe

Engine oil is pumped from the oil pan through the oil intake pipe to the oil pump.

The oil intake pipe is made of steel.

A strainer is located on the underside of the oil intake pipe. This strainer protects the oil pump against damage from particles in the oil.

Oil filter and oil filter adapter

NOTE:The gasket must not be reused after disassembling the oil filter adapter.

The oil filter adapter is made of an aluminium alloy.

The metal gasket of the oil filter adapter is rubber coated.

Positive crankcase ventilation (PCV)

Overview

PCV valve

The PCV valve is located on the upper side of the cylinder head cover.

The crankcase gases are sucked by the PCV valve into the intake manifold.

The PCV valve is opened by the vacuum in the intake manifold.

The amount of crankcase gases depends on the engine speed. The amount of sucked in gases is determined by the spring and the shape of the piston.

Deflection panel

The deflection panel is integrated into the cylinder head cover.

It prevents oil from being sucked in and burned in the combustion process.

The oil droplets condensate on the deflection panel and are then fed back into the oil circuit.