Engine Description
Zetec Engine, (formerly Zeta), with two overhead camshafts and sixteen valves (DOHC), with four cylinders mounted transversely on the front side of the car and the gearbox on the left side. The Zetec-E engine is identical to the Zetec except for changes in the intake system and elements of the exhaust emission reduction system.
All major engine components are made of aluminum alloy except for the plastic timing belt covers and the cast iron cylinder block. The crankshaft is five-bearing, with fixation from axial movement by thrust half rings, which are mounted on the central main bearing.
The pistons are connected to the connecting rods by piston pins, which are installed in a fixed fit in the upper head of the connecting rod. The pistons are made of aluminum alloy and have three rings, two compression and one oil control. During manufacture, the cylinder diameters and pistons are classified into three classes, which must be matched during assembly, for the correct piston clearance in the cylinder. The intake and exhaust valves are closed by coil springs.
The camshafts are driven by a toothed belt. Each camshaft operates eight valves via hydraulic tappets. Thus, valve clearance adjustment is not required. Each camshaft rotates in five bearings, which are made directly in the cylinder head, and are closed by bearing caps. This means that the bearing caps are machined together with the cylinder head and cannot be replaced separately from the cylinder head.
The water pump is bolted to the front of the cylinder block and is driven along with the power steering pump and alternator by a flat multi-groove belt from the crankshaft pulley. Lubrication is carried out by an oil pump. which is mounted on the right end of the crankshaft, and takes oil through a strainer located in the oil pan. The pump supplies oil through an externally mounted full flow oil filter. Some engine models have an oil cooler at the base of the oil filter so that the engine oil entering the engine is cooled by the cooling system.
Repair without removing the engine
On the engine installed in the car, you can perform the following operations:
- compression test
- Removing and installing cylinder head cover
- toothed belt replacement
- removal and installation of the toothed belt tensioner
- replacing camshaft seals
- removal and installation of camshafts and hydraulic tappets
- removal and installation of the cylinder head
- cleaning the cylinder head and pistons
- removal and installation of the oil pan
- replacement of crankshaft seals
- removal and installation of the oil pump
- Removal and installation of the flywheel / drive plate
- inspection and replacement of engine/gearbox mount suspension (power unit)
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