Ford Workshop Service and Repair Manuals

Cylinder head cover

NOTE:The cylinder head cover is made of magnesium, and the gasket is vulcanised onto it and therefore cannot be renewed separately. The cylinder head cover and its gasket do not need to be renewed every time they are removed. Carry out a visual check of the gasket and renew the cylinder head cover only if the gasket is damaged.

The cylinder head cover is attached to four camshaft bearing caps. These studs are sealed with four rubber bungs with torque limiters. If any leaks are detected, the four bungs can be renewed separately. It is permissible to lightly coat the rubber bungs with engine oil for installation. Wipe off any excess oil with a clean cloth. When fitting a new cylinder head cover, use the four new rubber bungs supplied with the new cylinder head cover.

Camshafts

CAUTION:The camshafts must be lubricated with engine oil prior to installation.

CAUTION:The camshaft bearing caps are tightened in three stages to a maximum of 16 Nm following the tightening sequence.

NOTE:The camshaft timing belt pulleys are not positively prevented from turning on the camshafts.

Check the camshaft bearings whenever the camshafts are renewed. In the event of damage renew the cylinder head and, if necessary, the camshaft bearing caps.

The exhaust camshaft is fitted with an additional cam for the camshaft position sensor (CMP sensor).

Both camshafts have a forged hexagon (21 mm) for turning them.

Both camshaft ends have a slot into which the tool for setting TDC fits.

The numbering of the bearing caps starts at the timing belt end with:

I1 on the intake side

E1 on the exhaust side

The front bearing caps are accurately positioned on the cylinder head by means of guide sleeves and must be fitted using sealant.

Cylinder head

CAUTION:Thread repairs are not permitted on the cylinder head.

CAUTION:Do not skim the cylinder head mating face.

CAUTION:Machining the valve seats and stem guides is not permitted.

NOTE:If new valves are installed, they are to be ground in without re- cutting the seats.

The cylinder head is made of aluminium and is accurately positioned on the cylinder block with two guide sleeves.

In service a new cylinder head is supplied complete with installed valves and camshaft bearing caps.

New studs must be installed.

To ensure that the cylinder head is properly sealed, the maximum permitted unevenness on the cylinder block mating face is 0.05 mm.

Cylinder head gasket

NOTE:The cylinder head gasket can only be installed properly in one position.

The cylinder head gasket is a multi-layer steel gasket which must be renewed every time it is disassembled.

Cylinder block

CAUTION:In order to prevent damaging the cylinder block mating face, only ever place it down onto a soft surface.

CAUTION:Thread repairs on the cylinder block are not permitted.

CAUTION:Machining the cylinder block mating faces is not permitted.

CAUTION:Do not damage the impeller of the coolant pump during removal and installation.

The cylinder block is of die-cast aluminium with cylinder liners made of cast iron.

In service a new cylinder block is supplied complete with crank gear and pistons, as well as all oil gallery blanking plugs and coolant drain plugs.

Always renew coolant drain plugs after removal.

To ensure that the cylinder head is properly sealed, the maximum permitted unevenness on the cylinder block mating face is 0.05 mm.

Crankshaft

NOTE:Owing to the very fine tolerances for the bearing clearance and bearing shells, the crankshaft drive components cannot be renewed separately. Bearing clearance measurement (main bearings and big-end bearings) is not possible by traditional methods.

Never disassemble the crank gear.

The crankshaft is attached to the cylinder block by means of a lower crankcase made of aluminium.

Pistons

CAUTION:The pistons must not be removed.

No oversize pistons are available.

The pistons are made of an aluminium alloy and feature three piston rings:

Plain compression ring (top)

Napier ring (middle)

Oil scraper ring (bottom)

Oil pan

Vehicles built up to 12/1999

The oil pan is made of aluminium.

During installation align the oil pan so that it forms a flush surface with the flywheel end of the cylinder block.

Spacer washers are not provided.

Note the tightening sequence and specified tightening torque during installation.

Always renew the oil pan gasket after the oil pan has been removed.

Apply the specified sealant to the cylinder block gaps, the oil pump flange and the contact surface of the crankshaft rear oil seal carrier before attaching the oil pan.

When applied, the specified sealant must extend 10 mm past the joints in the mating faces.

Vehicles built from 12/1999

A liquid gasket is used to form the seal between the oil pan and the cylinder block.

Valve train

CAUTION:The retaining bolts of the timing pulleys can only be re-used once.

The two overhead camshafts are driven by the crankshaft via a timing belt. They control the valves via bucket tappets.

The valve clearances are adjusted by valve adjustment shims located on the top of the bucket tappets. They should be checked every 100,000 km.

Two timing belt tensioners are used.

Timing belt tensioner with cam

Timing belt tensioner with slot

The timing belt should be renewed after 150,000 km or 10 years.

Crankshaft pulley/vibration damper

CAUTION:Check the relative positions of camshafts and crankshaft (i.e. the timing) every time the bolt of the crankshaft pulley/vibration damper is loosened and re-tightened.

CAUTION:Only use the crankshaft pulley/vibration damper bolt once.

Vehicles up to model year 98 1/2

NOTE:The crankshaft pulley/vibration damper bolt must only be pulled on with the special tool. If it is tightened using the bolt, the specified torque is reached before the pulley/vibration damper is fully home.

Vehicles from model year 98 1/2

NOTE:The crankshaft pulley/vibration damper and the crankshaft timing pulley located behind it are free to turn on the crankshaft until the bolt is tightened to the specified torque.

The crankshaft pulley/vibration damper must be properly installed before adjusting and checking the valve timing.