HSC and Endura-E engines
Cylinder head
The maximum allowable 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 machined with normal tools.
Inlet valve
Valve length - 103.7-104.4 mm
Valve disc diameter - 34.4-34.6 mm
Valve stem diameter - 7.0 mm
Gap between valve stem and guide - 0.020-0.069 mm
Exhaust valve
Valve length - 104.2-104.7 mm
Valve disc 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.
- The 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.
Clearance of the lock of the top sealing ring (installed in the cylinder) - 0.25-0.45 mm
Clearance of the lock of the middle sealing ring (installed in the cylinder) - 0.45-0.75 mm
Clearance of the oil scraper ring lock 0.20-0.40 mm
O-ring clearance in piston grooves - 0.20 mm
The clearance of the oil scraper ring in the piston groove - 0.10 mm
Location of piston ring locks:
Upper seal ring lock - 180°from oil scraper ring
Middle seal ring lock - 90°from 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:
- designation in white - 18.026-18.029 mm
- designation in red - 18.029-18.032 mm
- designation in blue - 18.032-18.035 mm
- designation in yellow - 18.035-18.038 mm
- Clearance in the piston hubs - 0.008-0.014 mm
- Fixed fit in crank - 0.016-0.048 mm
Crankshaft
Diameters of main journals:
- 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
- Clearance in main bearings - 0.009-0.056 mm
Connecting rod 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
- Axial play of the crankshaft 0.075-0.285 mm
Tightening torques
| main bearing cap | 95 Nm |
| * Bolts of fastening of the lower cover of a rod: | |
| Stage 1 | 4 Nm |
| Stage 2 | tighten by 90° |
| Bolts of fastening of a transmission to the engine | 40 Nm |
* Use only new bolts
CVH and PTE engines
Cylinder head
The maximum allowable flatness of the lower surface of the cylinder head is 0.15 mm
Diameters of bearings of a camshaft in a head of the block of cylinders (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 camshaft 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 lifter bore diameter (standard size) - 22.235-22.265 mm
Valve lifter 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 machined with conventional tools
Inlet valve
Length:
- engines with a displacement of 1.4 dm3 - 136.29-136.75 mm
- engines with a displacement of 1.6 dm3 -134.54-135.00 mm
Plate diameter:
- engines with a displacement of 1.4 dm3 - 39.9-40.1 mm
- engines with a displacement of 1.6 dm3 - 41.9-42.1 mm
Rod diameter:
- nominal - 8.025-8.043 mm
- enlarged by 0.2 mm - 8.225-8.243 mm
- enlarged by 0.4 mm - 8.425-8.443 mm
The gap between the valve stem and the guide sleeve - 0.020-0.063 mm
Exhaust valve
Length:
- engines with a displacement of 1.4 dm3 - 132.97-133.43 mm
- engines with a displacement of 1.6 dm3 - 131.57-132.03 mm
Plate diameter:
- engines with a displacement of 1.4 dm3 - 33.9-34.1 mm
- engines with a displacement of 1.6 dm3 - 36.9-37.1 mm
Rod diameter:
- nominal - 7.999-8.017 mm
- enlarged by 0.2 mm - 8.199-8.217 mm
- enlarged by 0.4 mm - 8.399-8.417 mm
The gap between the valve stem and the guide sleeve - 0.046-0.089 mm
Cylinder diameters
Engines with a displacement 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
- enlarged B - 77.520-77.530 mm
- enlarged C - 77.530-77.540 mm
Engines with a displacement 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 displacement 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
- enlarged B - 77.490-77 500 mm
- enlarged C - 77.500-77.510 mm
Engines with carburetor and displacement 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
- enlarged B - 80.210-80.220 mm
- enlarged C - 80.220-80.230 mm
Engines with EFi injection system and displacement 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
- enlarged B - 80.215-80.225 mm
- enlarged C - 80.225-80.235 mm
Piston clearance in cylinder
- engines with a displacement of 1.4 dm3 - 0.02-0.04 mm
- engines with a carburetor and a displacement of 1.6 dm3 - 0.02-0.04 mm
- engines with EFi injection system and a displacement of 1.6 dm3 - 0.015-0.035 mm
O-ring lock gap (installed in the cylinder) - 0.3-0.5 mm
Oil scraper ring clearance:
- engines with a displacement of 1.4 dm3 - 0.4-1.4 mm
- engines with a carburetor and a displacement of 1.6 dm3 - 0.4-1.4mm
- engines with EFi injection system and a displacement of 1.6 dm3 - 0.25-0.4 mm
Piston pins
Length:
- engines with a displacement of 1.4 dm3 - 63.00-63.80 mm
- engines with a carburetor and a displacement of 1.6dm3 - 66.20-67.00 mm
- engines with EFi injection system and a displacement of 1.6 dm3 - 63.00-63.80 mm
Diameter:
- designation in white - 20.622-20.625 mm
- designation in red - 20.625-20.628 mm
- designation in blue - 20.628-20.631 mm
- designation in yellow - 20.631-20.634 mm
- Clearance in the piston hubs - 0.005-0.011 mm
- Fixed fit in the connecting rod - 0.013-0.045 mm
Crankshaft
Diameters of main journals:
- 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
- Clearance in main bearings - 0.011-0.058 mm
Connecting rod 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
- Axial play of the crankshaft - 0.090-0.300 mm
Tightening torques
| Head bolts | 95 Nm |
| Bolts of fastening of a cover of the bottom head of a rod | 33 Nm |
| Bolts of fastening of a transmission to the engine | 40 Nm |
Zetec and Zetec-E engines
Cylinder head
The maximum allowable flatness of the lower surface of the cylinder head is 0.10 mm
Valve seat angle - 90°
Valve guide hole diameter - 6.060-6.091 mm
Inlet valve
Length - 96.870-97.330 mm
Plate diameter:
- engines with a displacement of 1.6 dm3 - 26.0 mm
- engines with a displacement of 1.8 dm3 - 32.0 mm
Rod diameter - 6.028-6.043 mm
The gap between the valve stem and the guide sleeve - 0.017-0.064 mm
Exhaust valve
Length - 96.470-96.930 mm
Plate diameter:
- engines with a displacement of 1.6 dm3 - 24.5 mm
- engines with a displacement of 1.8 dm3 - 28.0 mm
Rod diameter - 6.010-6.025 mm
The gap between the valve stem and the guide sleeve - 0.035-0.081 mm
Cylinder diameters
Engines with a displacement 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 displacement 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 displacement 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 displacement 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
O-ring lock gap (installed in the cylinder) - 0.3-0.5 mm
Oil scraper ring clearance:
- Engines with a displacement of 1.6 dm3 - 0.25-1.0 mm
- Engines with a displacement of 1.8 dm3 - 0.38-1.14mm
Piston pin
Diameter:
- designation in white with label A - 20.622-20.625 mm
- face color designation with label B - 20.625-20.628 mm
- designation in blue with label C - 20.628-20.631 mm
- Clearance in the piston hubs - 0.010-0.016 mm
- Fixed fit in the connecting rod - 0.011-0.042 mm
Crankshaft
- Diameters of main journals - 57.980-58 00 mm
- Clearance in main bearings - 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
- Axial play of the crankshaft - 0.090-0.310 mm
Tightening torques
| Bearing cap bolts | 80 Nm |
| Bolts of fastening of a cover of the lower head of a rod: | |
| Stage 1 | 18 Nm |
| Stage 2 | tighten by 90° |
| Cylinder block and oil groove 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 for fastening the heat-resistant shield to the exhaust manifold | 32 Nm |
| Crankcase ventilation system: | |
| Oil separator | 10 Nm |
| oil pickup tube | 23 Nm |
| Bolts of fastening of a transmission to the engine | 40 Nm |
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