HSC and Endura-E engines
Cylinder head
The maximum permissible non-flatness of the lower surface of the cylinder head is 0.15 mm
Valve seat angle (inlet and outlet) - 45°
Valve seat width (inlet and outlet) - 1.18-1.75 mm *
* The intake and exhaust valves have special inserts that cannot be processed with conventional tools.
Inlet valve
Valve length - 103.7-104.4 mm
Valve plate diameter - 34.4-34.6 mm
Valve stem diameter - 7.0 mm
Clearance between valve stem and guide - 0.020-0.069 mm
Exhaust valve
Valve length - 104.2-104.7 mm
Valve plate diameter - 28.9-29.1 mm
Valve stem diameter: 7.0 mm.
The gap between the valve stem and the guide is 0.046-0.095 mm.
Cylinders
Cylinder diameters:
- standard 1 - 73.940-73.950 mm.
- standard 2 - 73.950-73.960 mm.
- standard 3 - 73.960-73.970 mm.
- repair +0.5 mm - 74.500-74.510 mm.
- repair +1.0 mm - 75.000-75.010 mm.
Pistons and piston rings
Piston diameter:
- nominal size 1 - 73.910-73.920 mm.
- nominal size 2 - 73.920-73.930 mm.
- nominal size 3 - 73.930-73.940 mm.
- increased by 0.5 mm - 74.460-74.485 mm.
- increased by 1.0 mm - 74.960-74.985 mm.
- Piston clearance in the cylinder is 0.015-0.050 mm.
Piston rings
Each piston has three rings: two sealing rings and one oil scraper ring.
The gap of the upper sealing ring lock (installed in the cylinder) is 0.25-0.45 mm
The gap of the middle sealing ring lock (installed in the cylinder) is 0.45-0.75 mm
Oil scraper ring lock gap 0.20-0.40 mm
The gap of the sealing rings in the piston grooves is 0.20 mm
The gap of the oil scraper ring in the piston groove is 0.10 mm
Location of piston ring locks:
Upper seal ring lock - 180° from oil scraper ring
The middle sealing ring lock is 90° from the oil scraper ring
The oil scraper ring lock is aligned with the end of the piston pin.
Piston pins
Length - 63.3-64.6 mm
Diameter:
- white marking - 18.026-18.029 mm
- red marking - 18.029-18.032 mm
- blue marking - 18.032-18.035 mm
- yellow marking - 18.035-18.038 mm
- Piston hub clearance - 0.008-0.014 mm
- Fixed fit in connecting rod - 0.016-0.048 mm
Crankshaft
Main journal diameters:
- nominal size - 56.980-57.000 mm
- repair size -0.254 - 56.726-56.746 mm
- repair size -0.508 - 56.472-56.492 mm
- repair size -0.762 - 56.218-56.238 mm
- Main bearing clearance - 0.009-0.056 mm
Connecting rod journal diameters:
- nominal size - 42.990-43.010 mm
- repair size -0.254 - 42.740-42.760 mm
- repair size -0.508 - 42.490-42.510 mm
- repair size -0.762 - 42.240-42.260 mm
- Clearance in connecting rod bearings - 0.006-0.060 mm
Thickness of thrust half rings:
- nominal size - 2.800-2.850 mm
- repair size - 2.990-3.040 mm
- Crankshaft axial clearance 0.075-0.285 mm
Tightening moments
| Main bearing cap | 95 Nm |
| * Connecting rod lower cover mounting bolts: | |
| Stage 1 | 4 Nm |
| Stage 2 | turn 90° |
| Gearbox to engine mounting bolts | 40 Nm |
* Use only new bolts
CVH and PTE engines
Cylinder head
The maximum permissible non-flatness of the lower surface of the cylinder head is 0.15 mm
Camshaft bearing diameters in cylinder head (standard size):
- bearing 1 - 44.783-44 808 mm
- bearing 2 - 45.033-45.058 mm
- bearing 3 - 45.283-45.308 mm
- bearing 4 - 45.533-45.558 mm
- bearing 5 - 45.783-45.808 mm
Cylinder head distribution bearing diameters (oversized):
- bearing 1 - 45.188-45.163 mm
- bearing 2 - 45.433-45.413 mm
- bearing 3 - 45.663-45.663 mm
- bearing 4 - 45.933-45.913 mm
- bearing 5 - 46.183-46.163 mm
Valve tappet bore diameter (standard size) - 22.235-22.265 mm
Valve tappet bore diameter (oversized) - 22.489-22.519 mm
Valve seat angle (inlet and outlet) - 44°30'
Valve seat width (inlet and outlet) - 1.75-2.32 mm *
* Exhaust valves have special inserts that cannot be processed with conventional tools
Inlet valve
Length:
- engines with a working volume of 1.4 dm³ - 136.29-136.75 mm
- engines with a working volume of 1.6 dm³ -134.54-135.00 mm
Plate diameter:
- engines with a working volume of 1.4 dm³ - 39.9-40.1 mm
- engines with a working volume of 1.6 dm³ - 41.9-42.1 mm
Rod diameter:
- nominal - 8.025-8.043 mm
- increased by 0.2 mm - 8.225-8.243 mm
- increased by 0.4 mm - 8.425-8.443 mm
Clearance between valve stem and guide bushing - 0.020-0.063 mm
Exhaust valve
Length:
- engines with a working volume of 1.4 dm³ - 132.97-133.43 mm
- engines with a working volume of 1.6 dm³ - 131.57-132.03 mm
Plate diameter:
- engines with a working volume of 1.4 dm³ - 33.9-34.1 mm
- engines with a working volume of 1.6 dm³ - 36.9-37.1 mm
Rod diameter:
- nominal - 7.999-8.017 mm
- increased by 0.2 mm - 8.199-8.217 mm
- increased by 0.4 mm - 8.399-8.417 mm
Clearance between valve stem and guide bushing - 0.046-0.089 mm
Cylinder diameters
Engines with a working volume of 1.4 dm³:
- standard 1 - 77.220-77.230 mm
- standard 2 - 77.230-77.240 mm
- standard 3 - 77.240-77.250 mm
- standard 4 - 77.250-77.260 mm
- enlarged A - 77.510-77.520 mm
- increased B - 77.520-77.530 mm
- enlarged C - 77.530-77.540 mm
Engines with a working volume of 1.6 dm³:
- standard 1 - 79.940-79.950 mm
- standard 2 - 79.950-79.960 mm
- standard 3 - 79.960-79.970 mm
- standard 4 - 79.970-79.980 mm
- enlarged A - 80.230-80.240 mm
- enlarged B - 80.240-80.250 mm
- enlarged C - 80.250-80.260 mm
Piston diameter
Engines with a working volume of 1.4 dm³:
- standard 1 - 77,190-77,200 mm
- standard 2 - 77,200-77,210 mm
- standard 3 - 77.210-77.220 mm
- standard 4 - 77.220-77.230 mm
- enlarged A 77.480-77.490 mm
- increased B - 77.490-77 500 mm
- enlarged C - 77.500-77.510 mm
Engines with carburetor and working volume of 1.6 dm³:
- standard 1 - 79.910-79.920 mm
- standard 2 - 79.920-79.930 mm
- standard 3 - 79.930-79.940 mm
- standard 4 - 79.940-79.950 mm
- enlarged A - 80.200-80.210 mm
- increased B - 80.210-80.220 mm
- enlarged C - 80.220-80.230 mm
Engines with EFi injection system and a working volume of 1.6 dm³:
- standard 1 - 79.915-79.925 mm
- standard 2 - 79.925-79.935 mm
- standard 3 - 79.935-79.945 mm
- standard 4 - 79.945-79.955 mm
- enlarged A - 80.205-80.215 mm
- increased B - 80.215-80.225 mm
- enlarged C - 80.225-80.235 mm
Piston clearance in cylinder
- engines with a working volume of 1.4 dm³ - 0.02-0.04 mm
- engines with carburetor and working volume of 1.6 dm³ - 0.02-0.04 mm
- engines with EFi injection system and a working volume of 1.6 dm³ - 0.015-0.035 mm
The gap between the sealing rings (installed in the cylinder) is 0.3-0.5 mm
Oil scraper ring lock clearance:
- engines with a working volume of 1.4 dm³ - 0.4-1.4 mm
- engines with carburetor and working volume of 1.6 dm³ - 0.4-1.4 mm
- engines with EFi injection system and a working volume of 1.6 dm³ - 0.25-0.4 mm
Piston pins
Length:
- engines with a working volume of 1.4 dm³ - 63.00-63.80 mm
- engines with carburetor and working volume of 1.6 dm³ - 66.20-67.00 mm
- engines with EFi injection system and a working volume of 1.6 dm³ - 63.00-63.80 mm
Diameter:
- white marking - 20.622-20.625 mm
- red marking - 20.625-20.628 mm
- blue marking - 20.628-20.631 mm
- yellow marking - 20.631-20.634 mm
- Piston hub clearance - 0.005-0.011 mm
- Fixed fit in connecting rod - 0.013-0.045 mm
Crankshaft
Main journal diameters:
- nominal size - 57.980-58.000 mm
- repair size -0.25 - 57.730-57.750 mm
- repair size -0.50 - 57.4480-57.500 mm
- repair size -0.762 - 57.230-57.250 mm
- Main bearing clearance - 0.011-0.058 mm
Connecting rod journal diameters:
- nominal size 47.890-47.910 mm
- repair size -0.25 - 47.640-47.660 mm
- repair size -0.50 - 47.390-47.410 mm
- repair size -0.75 - 47.140-47.160 mm
- repair size -1.00 - 46.890-46.910 mm
- Clearance in connecting rod bearings - 0.006-0 060 mm
Thickness of thrust half rings:
- nominal size - 2.301-2.351 mm
- repair size - 2.491-2.541 mm
- Crankshaft axial clearance - 0.090-0.300 mm
Tightening moments
| Head mounting bolts | 95 Nm |
| Connecting rod lower head cover mounting bolts | 33 Nm |
| Gearbox to engine mounting bolts | 40 Nm |
Zetec and Zetec-E engines
Cylinder head
The maximum permissible non-flatness of the lower surface of the cylinder head is 0.10 mm
Valve seat angle - 90°
Valve guide bore diameter - 6.060-6.091 mm
Inlet valve
Length - 96.870-97.330 mm
Plate diameter:
- engines with a working volume of 1.6 dm³ - 26.0 mm
- engines with a working volume of 1.8 dm³ - 32.0 mm
Rod diameter - 6.028-6.043 mm
Clearance between valve stem and guide bushing - 0.017-0.064 mm
Exhaust valve
Length - 96.470-96.930 mm
Plate diameter:
- engines with a working volume of 1.6 dm³ - 24.5 mm
- engines with a working volume of 1.8 dm³ - 28.0 mm
Rod diameter - 6.010-6.025 mm
Clearance between valve stem and guide bushing - 0.035-0.081 mm
Cylinder diameters
Engines with a working volume of 1.6 dm³:
- class 1 - 76.000-76.010 mm
- class 2 - 76.010-76.020 mm
- class 3 - 76.020-76.030 mm
Engines with a working volume of 1.8 dm³:
- class 1 - 80.600-80.610 mm
- class 2 - 80.610-80.620 mm
- class 3 - 80.620-80.630 mm
Piston diameter
Engines with a working volume of 1.6 dm³:
- class 1 - 75.975-75.995 mm
- class 2 - 75.985-75.985 mm
- class 3 - 75.995-76.005 mm
Engines with a working volume of 1.8 dm³:
- class 1 - 80.570-80.580 mm
- class 2 - 80.580-80.590 mm
- class 3 - 80.590-80.600 mm
The gap of the sealing ring lock (installed in the cylinder) is 0.3-0.5 mm
Oil scraper ring lock clearance:
- Engines with a working volume of 1.6 dm³ - 0.25-1.0 mm
- Engines with a working volume of 1.8 dm³ - 0.38-1.14 mm
Piston pin
Diameter:
- white marking with mark A - 20.622-20.625 mm
- designation in bold color with mark B - 20.625-20.628 mm
- blue marking with mark C - 20.628-20.631 mm
- Piston hub clearance - 0.010-0.016 mm
- Fixed fit in connecting rod - 0.011-0.042 mm
Crankshaft
- Main journal diameters - 57.980-58 00 mm
- Main bearing clearance - 0.011-0 058 mm
- Diameters of connecting rod journals - 46.890-46.910 mm
- Clearance in connecting rod bearings - 0.016-0.070 mm
- Crankshaft axial clearance - 0.090-0.310 mm
Tightening moments
| Bearing cap mounting bolts | 80 Nm |
| Connecting rod lower head cover mounting bolts: | |
| Stage 1 | 18 Nm |
| Stage 2 | turn 90° |
| Cylinder block and oil groove cover plugs: | |
| M6x10 | 10 Nm |
| M10x11.5 | 24 Nm |
| 1/4PTF | 25 Nm |
| Air conditioning compressor and power steering pump bolts to cylinder block | 47 Nm |
| Bolts securing the heat shield to the exhaust manifold | 32 Nm |
| Crankcase ventilation system: | |
| Oil separator | 10 Nm |
| Oil pickup pipe | 23 Nm |
| Gearbox to engine mounting bolts | 40 Nm |
(The original can be found on the specified resource www.FordBook.ru)