Checking the valve mechanism — static (engine off) (Focus 1)

Remove the valve cover. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.

Check all valve train components for damage and wear. Make sure that only genuine components are installed and that all bolts and nuts are tightened to the specified torque.

Camshaft journal diameter

1. Determine the diameters of the camshaft journals

• To determine if the shaft journals are out of round, measure the diameter at 90 degree intervals using a micrometer.
• To determine if there is taper, measure the diameter of each journal at two locations offset from the journal axis.
• If the measurement results are not within the norm, install a new camshaft.

Radial clearance in the camshaft journal

1.

NOTE: Follow the prescribed procedure carefully. The valve lifters must be removed to perform the following measurements.

NOTE: Make sure the camshaft type is correct (as per specification).

NOTE: Bearing caps and camshaft journals must be clean and free of oil.

Place the Plastigage radial clearance measuring device thread on the bearing cap.

• Install the camshaft into the cylinder head without lubricating it.
• Place a Plastigage clearance gauge thread equal in length to the width of the bearing cap on the appropriate journal.

2. Install the camshaft bearing caps following the tightening sequence. Refer to the appropriate Section 303-01.

3.

NOTE: Do not hit the bearing caps.

Remove bearing caps, refer to appropriate Section 303-01.

4. Using Plastigage, take a reading.

• Compare the width of the Plastigage thread with the corresponding scale.
• The scale reading corresponds to the radial clearance in the bearing.

Axial clearance of the camshaft




1.

NOTE: Make sure the camshaft type is correct (to specification).

Using a dial indicator, measure the axial clearance.

• Move the camshaft in both directions. Take readings and record the maximum and minimum values.
• The axial clearance is equal to the difference between the maximum and minimum values.
• If the measurement result is not within the specification, install new elements.

Inspection of the camshaft surface

1. Inspect the camshaft lobe running surfaces for pitting or damage. Minor pitting outside the running surface is acceptable.

Camshaft cam lift height

1. Determine the cam lift height.

• Using a micrometer, measure the cam length in two directions.
• The difference between the two measurements is equal to the cam lift height.

Crankshaft journal diameter

General equipment: Micrometer.

1. Measure the diameters of the main and connecting rod journals of the crankshaft.

• Repeat the measurement with the micrometer offset by 90° to determine if any eccentricity exists.
• Measure the journal diameter in two different places to determine if there is any taper.

Crankshaft axial clearance

General equipment

• Dial indicator
• Dial indicator stand

1.

NOTE: Operation only for vehicles with Zetec-E engine. On Zetec-SE engines, disassembling the crank mechanism is not permitted.

Determine the axial clearance.

• Install the dial indicator and tripod.
• Determine the axial clearance by lifting the crankshaft with a screwdriver.
• If necessary, adjust the axial clearance using new thrust washers.

Cylinder bore taper

1.

NOTE: The main bearing caps must be in place and tightened to the specified torque. However, the bearing shells must not be installed.

Measure the cylinder diameter using an outside micrometer.

• To determine if there is any deviation of the cylinder shape from roundness or taper, take measurements in different directions and at different heights.
• If the measurement result is not within the standard, install a new cylinder block or perform cylinder block honing (if applicable/allowed).

Inspection of the piston

1.

CAUTION: Do not use harsh cleaning fluid or wire brush to clean the piston.

Perform a visual inspection.

• Clean the piston skirt, piston pin bushing, piston grooves and crown and inspect them for wear and cracks.
• If there are signs of wear on the piston skirt, check that the connecting rod is not deformed or twisted.

Matching the piston pin to the piston hole

1.

NOTE: The piston and piston pin form a single pair. Do not confuse these elements.

Measure the piston pin bore diameter.

• The measurement should be carried out in two directions.
• If the values are not within specification, install a new piston and a new piston pin.

Piston diameter

General equipment: Micrometer.

1.

NOTE: Mark the piston to ensure correct piston installation.

Using a micrometer, measure the piston diameter.

Piston ring joint gap

1.

CAUTION: Do not mix up piston rings. Install piston rings in the same position and in the same locations.

Take the piston ring and use the piston without rings to push the piston ring into the cylinder approximately 30mm.





2. Using a set of feeler gauges, measure the gap at the piston ring joint.

Clearance between groove and piston ring

General equipment: Set of feeler gauges.

1.

NOTE: The piston ring should protrude from the piston groove. To determine the height clearance between the groove and the ring, insert a feeler gauge directly into the groove behind the ring.

Using a feeler gauge, measure the height clearance between the groove and the ring.

Piston pin diameter

1.

NOTE: The piston and piston pin form a single pair. Do not confuse these elements.

Measure the piston pin diameter.

• Measure in two directions
• If the values are not within specification, install a new piston and a new piston pin.

Connecting rod lower head bore

1. Measure the connecting rod head bore diameter at two locations. The difference in measurement results is the deviation of the bore circumference from roundness. Check the diameter and deviation from roundness to ensure that they are within specification.

Valve stem diameter

1. Use a micrometer to measure the diameters of the valve stems. If the measurement result is not within the standard, install a new valve.

Flywheel inspection

1. Inspect the flywheel for:

• 1.Presence of cracks
• 2.Wear of the gear ring
• 3. Presence of chips and cracks on the gear ring

Deformation (warping) of the mating surface of the cylinder head

General equipment:

• Set of feeler gauges
• Straight ruler

1.

CAUTION: The mating surface on 2.5L engines should not be reworked.

Using a straight edge and feeler gauge, measure the distortion of the cylinder head mating surface.

• Measure the distortion of the mating surface shape.
• If the value is not within specification, rework the mating surface.

Deformation (warping) of the mating surface of the cylinder block

1. Using a straight edge and feeler gauge, measure the out-of-plane deviation of the cylinder block/cylinder head mating surface.

• Measure the deviation from flatness of the mating surface.
• If the measurement results do not meet the specification, rework the mating surface (if permitted).

Cleaning and inspection of the exhaust manifold

1. Inspect the exhaust manifold flanges that connect to the cylinder head for signs of exhaust leakage.

2. Inspect the exhaust manifold for cracks, damaged gasket surfaces, or other damage that may render the manifold unsuitable for subsequent use.

Bearing inspection

1. Inspect the bearings for the following defects.

• 1. Chipping (cratering) - fatigue wear
• 2. Polished in places - incorrect fit
• 3. Inclusions - dirty motor oil
• 4. Scratches - dirty engine oil
• 5. Scoring - poor lubrication
• 6.Wear of both edges - damage to the neck
• 7.Wear on one edge - neck taper or incorrect fit

Inspection of the valve seat

General equipment: Ruler for measuring valve seat width.

1. Measure the valve seat width.

• Measure the valve seat width; for this purpose, a ruler is used to measure the width of the valve seat.
• If the measurement result is not within specification, rework the valve seat.

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