Move the tensioner to the left and remove the toothed belt. Remove the high-voltage wires. distributor cap and unscrew the spark plugs. Remove the crankcase ventilation hose from the branch pipe on the cylinder block (Fig. 2.7,a).
Remove the cylinder head cover. Loosen the mounting bolts in the reverse order shown in Fig. 2.14. and remove the cylinder head assembly with the intake and exhaust manifolds. Remove the cylinder head gasket. Remove the engine oil sump. Remove the pressure and driven clutch plates. then the engine flywheel. Remove the crankshaft oil seal and its holder. Remove the toothed belt tensioner. Loosen the four mounting bolts and remove the water pump. Press the toothed pulley off the crankshaft, using puller 21-098 if necessary. remove the spacer ring. Remove the oil pump oil seal. Loosen the oil intake pipe and oil pump mounting bolts and remove the oil pump assembly with the oil intake. Remove the emergency oil pressure sensor. Set the pistons to an intermediate position between TDC and BDC and use a scraper to remove carbon deposits in the cylinders. Make sure that there are marks on the main and connecting rod bearing caps (Fig. 2.8).
Remove the connecting rod bearing caps together with the liners. Move the pistons with the connecting rods upward, remove the upper connecting rod liners and put them in order together with the caps. Remove the main bearing caps together with the liners. Carefully remove the crankshaft. Remove the upper main bearings and thrust half rings and put the liners in order together with the caps. Remove the deflector (Fig. 2.7, 6) of the crankcase ventilation together with the spring. Alternately remove the pistons assembled with the connecting rods.
Before assembling the engine, measure the clearance in the main bearing cap joints using a calibrated plastic wire, lubricating them with engine oil. Tighten the mounting bolts to a torque of 9.0-10.0 kgf·m. The main bearing caps are numbered. When installing, the arrow on the cap should face forward. Measure the axial clearance of the crankshaft using a dial indicator (Fig. 2.10). Adjust it if necessary. by installing thrust half rings of the appropriate thickness.
Install the rings on the pistons. The compression rings have a molybdenum coating. Take care not to damage it during assembly.
The mark on the second compression ring should be directed toward the piston pin. The ends of the spring expander of the oil scraper ring should be installed end-to-end, not overlapping. The ring locks should be spread 120° around the circumference. Lubricate the pistons with connecting rods and cylinder faces with engine oil. Having compressed the rings with a special clamp (Fig. 2.11), insert the pistons into the cylinders. The arrow on the piston bottom and the mark cast near the hole for the pin should be directed toward the valve timing mechanism drive.
Lubricate the connecting rod bearing shells and install them in the connecting rods and connecting rod caps. Install the connecting rod caps according to the numbers, paying attention to the correct position of the mounting studs. Install the emergency oil pressure sensor. Fill with oil and install the oil pump, turning the gears by hand. Install the oil seal using tool 21-093, lightly lubricating the working edges (Fig. 2.12) Install the spacer washer with the convex side outward, press on the toothed pulley.
Install the water pump with a new gasket. Set the toothed belt tensioner to the extreme left position. Lubricate the working edge of the rear oil seal 5 (Fig. 2.13) of the crankshaft with engine oil and install it in the holder using tool 21-095.
Check the condition of the flywheel mounting bolt threads, apply sealant to the threads and install the flywheel. Install the clutch pressure plate with the drive disk on the flywheel, center the driven disk using the 21-052 mandrel. Install new gaskets on the rear mating surface and in the groove of the oil pump cover. Apply a layer of sealant to the mating surface of the cylinder block with the rear mating surface and with the oil pump cover. Install the toothed belt on the crankshaft pulley, install the gaskets and oil pan. Make sure that the dowel pins are present and install the cylinder head gasket. Turn the crankshaft and set the piston of the first cylinder 2 cm from TDC. Install the cylinder head and tighten the new bolts in four steps: 1st - 2.5 kgf·m; 2nd - 5.5 kgf·m; 3 - turn 90°; 4th - turn 90° in the order shown in Fig. 2.14.
Install the camshaft toothed pulley, aligning its mark with the mark on the cylinder head, the crankshaft toothed pulley key with the mark on the oil pump cover. Perform the valve timing and toothed belt installation operations as described in the chapter "Camshaft and its drive". Apply a 2-3 cm wide layer of sealant (type A 70 SX-19554-BA according to Ford specifications) to the mating surface of the toothed belt cover with the cylinder block and the cylinder head with the valve cover. Install the cylinder head cover with a new gasket and connect the crankcase ventilation hose. Install the toothed belt cover, then install the crankshaft pulley Screw in the spark plugs, install the distributor cover and high-voltage wires Install the oil filter, and on engines with injection and the oil cooler, then the oil drain plug with a new gasket. Install the oil dipstick, connect the heater hose to the water pump. Install the generator with the bracket (and the protective shield on GMA, GPA. GLA engines) and the drive belt.
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