General appearance
General information
The Duratec 8V engine is an in-line, transversely mounted, four-cylinder engine with a single overhead camshaft and a cross-flow cylinder head (the intake and exhaust ports are located on opposite sides).
Duratec 8V engine features:
- Cast iron cylinder block with integral timing chain housing
- The crankshaft is supported by 5 bearings
- Cylinder head made from cast aluminum alloy with integral timing chain housing
- Camshaft drive provided by timing chain with hydraulic tensioner
- The camshaft is supported by 5 bearings
- Two valves per cylinder
- Roller valve tappets
- Valve clearance adjustment using hydraulic tappets
- Double layer cylinder head gasket
- Aluminum oil pan with stiffening ribs
- Crankshaft driven oil pump
Engine Identification
The engine serial number is indicated on the flywheel housing on the exhaust side.
In addition, the chassis number (VIN) and a warning sign are indicated in short form in the same place.
| Pos. | Spare Part No | Name |
| 1 | - | Warning sign |
| 2 | - | VIN |
| 3 | - | Engine code |
Engine types
| Pos. | Spare Part No | Name |
| 1 | - | Camshaft Position (CMP) Sensor |
| 2 | - | Electronic Ignition Module (EI) |
| 3 | - | Thermostat housing |
| 4 | - | Flywheel |
| 5 | - | Oil filter |
| 6 | - | Air intake module |
| Pos. | Spare Part No | Name |
| 1 | - | Exhaust manifold |
| 2 | - | Hydraulic chain tensioner |
| 3 | - | Timing chain |
| 4 | - | Air intake module |
| 5 | - | Oil filter |
| Pos. | Spare Part No | Name |
| 1 | - | Camshaft |
| 2 | - | Inlet valve |
| 3 | - | Exhaust valve |
| 4 | - | Thermostat housing |
| 5 | - | Pistons |
| 6 | - | Flywheel |
| 7 | - | Intake oil line |
| 8 | - | Belt pulley |
| 9 | - | Coolant pump |
Cylinder head cover
| Pos. | Spare Part No | Name |
| 1 | - | Oil filler cap |
| 2 | - | CMP sensor |
| 3 | - | Positive Crankcase Ventilation (PCV) Valve |
| 4 | - | EI module |
| 5 | - | Evaporative Emission (EVAP) Control System Solenoid Valve |
The cylinder head cover is secured to the cylinder head with ten bolts.
The cylinder head cover gasket has a T-shaped cross-section and is fixed in the groove of the cylinder head cover.
The CMP sensor is mounted on the cylinder head cover and is used to determine the position of cylinder #1.
The EI module is secured to the cylinder head cover wall with four bolts.
The EVAP solenoid valve is mounted on an additional bracket.
The cylinder head is made of aluminum alloy and is characterized by the presence of two valves per cylinder.
This is the so-called cross-flow cylinder head, i.e. the intake and exhaust valves are located on opposite sides.
The angles of the intake and exhaust valves are asymmetrical. The angle of the intake valves is 10°, and the angle of the exhaust valves is 6°.
Spark plugs are located on the exhaust side.
Valve guides and valve seats are made of sintered metal.
The timing chain housing is an integral part of the cylinder head and cylinder block.
Valve mechanism
| Pos. | Spare Part No | Name |
| 1 | - | Camshaft Bearing Cap |
| 2 | - | Camshaft |
| 3 | - | Basic cam |
| 4 | - | Roller valve tappet |
| 5 | - | Hydraulic pusher |
| 6 | - | Cylinder head |
The camshaft is held in position by five bearing caps and rests directly on the cylinder head - without bearing shells.
The camshaft has an additional base cam to identify cylinder No.1.
The camshaft drives the roller tappets of the valves.
Due to the fact that the valve tappets are supported by rollers, friction losses in the valve mechanism are reduced.
The use of hydraulic tappets means that no valve clearance adjustment is required.
Inlet and outlet valves
| Pos. | Spare Part No | Name |
| 1 | - | Inlet valve |
| 2 | - | Exhaust valve |
The inlet valve is made entirely of one material. The outlet valve is a bimetallic valve.
Cylinder head gasket
The cylinder head gasket is a two-layer metal gasket.
Cylinder block
| Pos. | Spare Part No | Name |
| 1 | - | Connection for forced crankcase ventilation |
| 2 | - | Oil gallery plug |
CAUTION: The oil gallery plug should not be removed.
The cylinder head is made of cast iron.
The cylinder block does not have any special cylinder liners.
The working surfaces of the cylinders are formed directly in the cylinder block.
The connection for forced crankcase ventilation is located on the rear side of the cylinder block.
Crankshaft and bearing caps
| Pos. | Spare Part No | Name |
| 1 | - | Bolts (6 pcs.) |
| 2 | - | Bolts combined with studs (4 pcs.) |
| 3 | - | Main bearing caps |
| 4 | - | Main bearing shells (without lubricating oil groove) |
| 5 | - | Crankshaft |
| 6 | - | Main bearing shells (with lubricating oil groove) |
| 7 | - | Thrust washers |
| 8 | - | Beveled edge |
| 9 | - | Cylinder block |
| 10 | - | Oil injectors |
The crankshaft is supported by five bearings and has four cheeks.
The main bearing caps are numbered and marked with arrows to indicate installation position and orientation. After the caps are installed, the arrows should point in the direction of the timing chain.
The main bearing shells, which are inserted into the main bearing caps, do not have an oil groove.
The main bearing shells, which are inserted into the cylinder block, have a lubrication groove.
Four of the main bearing cap bolts are continued by studs after the heads, which are used to secure the oil deflector plate and the oil pump inlet pipe.
The axial clearance of the crankshaft is limited by two thrust washers.
Connecting rod
The connecting rods are made of forged steel. The connecting rods are divided into three different weight classes.
Pistons and piston rings
| Pos. | Spare Part No | Name |
| 1 | - | Notch in the piston |
| 2 | - | Upper compression ring |
| 3 | - | Lower compression ring |
| 4 | - | Oil scraper ring |
| 5 | - | Coating |
Lightweight pistons are made of aluminum. The piston skirt has a special coating that increases the service life of the piston. Pistons are available in only one diameter. The upper compression ring has a rectangular cross-section and is made of steel. The lower compression ring has an L-shaped cross-section and is made of cast iron. The oil scraper ring consists of three parts and has a chrome coating.
Crankshaft Rear Oil Seal Holder
| Pos. | Spare Part No | Name |
| 1 | - | Sealant |
| 2 | - | Oil Seal Holder |
| 3 | - | Bolt |
| 4 | - | Mounting sleeve |
The mounting sleeve is made of plastic. The oil seal is built into the oil seal holder. The oil seal is made of polytetrafluoroethylene (PTFE). The oil seal holder is centered on two guide pins and then secured to the cylinder block with four bolts.
Oil deflector plate and oil intake pipe
| Pos. | Spare Part No | Name |
| 1 | - | Intake oil line |
| 2 | - | Screw |
| 3 | - | Oil deflector plate |
| 4 | - | O-ring |
| 5 | - | Bolt |
The oil deflector plate prevents excessive foaming of engine oil.
The oil deflector plate and the oil intake pipe are secured by means of studs, which are a continuation of the bearing cap mounting bolts.
The oil inlet line is sealed against the oil pump by means of a circular cross-section sealing ring.
Oil pan
| Pos. | Spare Part No | Name |
| 1 | - | Oil pan gasket |
| 2 | - | Oil pan |
The oil pan is made of aluminum alloy and has stiffening ribs. The oil pan has a built-in bracket for the A/C compressor. The oil pan gasket consists of an aluminum base with a rubber coating applied to it.
Flywheel
| Pos. | Spare Part No | Name |
| 1 | - | Centering sleeve |
| 2 | - | Flywheel |
| 3 | - | Bolts |
The flywheel is made of cast iron. The flywheel is attached to the crankshaft with six bolts and is centered by means of a special centering sleeve.
Camshaft drive
| Pos. | Spare Part No | Name |
| 1 | - | Camshaft Sprocket |
| 2 | - | Crankshaft sprocket |
| 3 | - | Front chain guide |
| 4 | - | Rear chain guide |
| 5 | - | Timing chain |
| 6 | - | Hydraulic chain tensioner |
Camshaft Sprocket and Crankshaft Sprocket
| Pos. | Spare Part No | Name |
| 1 | - | Installation mark |
| 2 | - | Segment key |
The camshaft sprocket is made of steel and has 38 teeth. The timing mark is stamped on the front. The crankshaft sprocket is made of sintered steel and has 19 teeth. The installation position of both sprockets is determined by a woodruff key.
Timing chain
| Pos. | Spare Part No | Name |
| 1 | - | Timing chain |
| 2 | - | Chain guide (intake side) |
| 3 | - | Chain guide (outlet side) |
| 4 | - | Hydraulic chain tensioner |
The timing chain is a sleeve type chain with 114 links. The chain guides are made of plastic. Both chain guides are secured with a bolt. The chain guide on the intake side also passes through a recess in the cylinder head. The chain guide on the exhaust side can slide and move with a hydraulic chain tensioner.
Hydraulic chain tensioner
| Pos. | Spare Part No | Name |
| 1 | - | Oil supply |
| 2 | - | Pistons |
The hydraulic chain tensioner moves under the influence of engine oil pressure. The piston rests against the chain guide (from the exhaust side) and ensures the creation of a certain contact pressure on the timing chain.
Oil circuit
| Pos. | Spare Part No | Name |
| 1 | - | From the oil intake line to the oil pump |
| 2 | - | From oil pump to oil filter |
| 3 | - | From the oil filter to the main oil gallery |
| 4 | - | From the main oil gallery to the main bearings |
| 5 | - | Oil gallery leading to the cylinder head and to the camshaft |
| 6 | - | Return oil channel |
| 7 | - | Oil splashing |
| Pos. | Spare Part No | Name |
| 1 | - | From the oil intake line to the oil pump |
| 2 | - | From oil pump to oil filter |
| 3 | - | From the oil filter to the main oil gallery |
| 4 | - | Oil gallery leading to the cylinder head and to the camshaft |
| 5 | - | Oil supply to the hydraulic chain tensioner |
| 6 | - | Return oil channel |
| 7 | - | Oil splashing |
Oil pump
| Pos. | Spare Part No | Name |
| 1 | - | Cylinder block |
| 2 | - | Oil pump and coolant pump gasket |
| 3 | - | Oil pump |
| 4 | - | Oil pump pulley |
The oil pump is a G-rotor type pump which is directly driven by the engine. The crankshaft oil seal (PTFE) is located in the oil pump housing. The oil pump housing gasket is a rubberized metal gasket.
Intake oil line
| Pos. | Spare Part No | Name |
| 1 | - | Mesh oil filter |
The engine oil is pumped from the oil pan to the oil pump via the oil intake pipe. The oil intake pipe is made of steel. A mesh filter is located on the bottom of the oil intake pipe. This mesh filter protects the oil pump from damage by particles present in the oil.
Oil filter and oil filter adapter
| Pos. | Spare Part No | Name |
| 1 | - | Pad |
| 2 | - | Oil filter and oil filter adapter |
| 3 | - | Bolt |
NOTE: Once the oil filter adapter has been disassembled, the gasket cannot be reused.
The oil filter adapter is made of aluminum alloy. The metal gasket of the oil filter adapter is rubberized.
General view of PCV
| Pos. | Spare Part No | Name |
| 1 | - | Cylinder head cover with integrated oil separator |
| 2 | - | From the EVAP solenoid valve |
| 3 | - | From PCV |
| 4 | - | To the intake manifold |
PCV valve
| Pos. | Spare Part No | Name |
| 1 | - | Spring |
| 2 | - | Pistons |
The PCV valve is located on the top side of the cylinder head cover. The gases from the engine crankcase are sucked by the PCV valve into the intake manifold. The PCV valve opens under the influence of the vacuum present in the intake manifold. The amount of gases present in the engine crankcase depends on the engine crankshaft speed. The amount sucked is determined by the spring and the shape of the piston.
Reflective plate
| Pos. | Spare Part No | Name |
| 1 | - | Reflective plate |
The deflector plate is built into the cylinder head cover. This prevents oil from being sucked in and burned during combustion. Oil droplets condense on the deflector plate and are then returned to the oil circuit.
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