Crank mechanism
1 – crankshaft, 2 – main bearing shells, 3 – main bearing cap, 4 – connecting rod, 5 – connecting rod bearing shell, 6 – piston, 7 – piston rings
Gas distribution system
1 – crankshaft pulley, 2 – timing belt, 3 – intermediate shaft pulley, 4 – intermediate shaft, 5 – camshaft pulley, 6 – camshaft, 7 – valve lever, 8 – valve lever spring, 9 – ball-head bolt (valve lever support), 10 – valve, 11 – timing belt tensioner
1. Install the clutch shaft bearing into the hole in the rear of the crankshaft (tool 21.044).
2. Insert dry main bearing shells into the sockets in the cylinder block.
3. Lubricate the working surfaces of the half-liners with oil and install the crankshaft on them.
4. Install the main bearing caps together with the oiled half-liners (see Fig. Crank mechanism - the arrows on the main bearing caps should point towards the pulley on the crankshaft).
5. Tighten the main bearing cap bolts to the specified torque and measure the crankshaft end play.
6. Install a new rear crankshaft seal ring using tool 21.011 A.
7. Coat the groove of the rear crankshaft seal cover with sealing paste (No. A 70 SX-19554-BA) and install the two gasket halves using a screwdriver with a blunt blade; the red marking on the gasket must face the bearing cap.
8. Install the front cylinder block cover with a new gasket.
9. Install a new front sealing ring (tool 21.009 A).
10. Attach the intermediate shaft and its thrust bearing to the cylinder block; install the cover with a new sealing ring.
11.Install the flywheel on the crankshaft, tightening the flywheel mounting bolts (lubricate the threads with oil) to the appropriate torque.
12. Using tool 21.044, center the clutch disc on the flywheel and install the clutch drive part.
13. Lubricate the cylinders and pistons with oil, with piston rings installed correctly.
14. Install the piston-connecting rod units in the cylinders, compressing the piston rings with a special device. Point the arrows on the pistons toward the valve timing system (see Fig. Valve timing system).
15. Install the connecting rod bearings and connecting rod caps, tightening the bolts to the appropriate torque. Check the axial play of the connecting rods on the connecting rod journals.
16. Install the oil pump drive shaft and screw on the oil pump together with the oil supply lines.
Caution! When installing a new pump, fill it with oil and turn its drive shaft by hand several times.
17. Install new gaskets (lubricated with sealing paste) into the grooves of the crankshaft main bearing caps (rear and front), insert new oil pan gaskets and press them into the grooves.
18. Install the oil pan and tighten its bolts in three stages, starting with bolt (A), towards bolt (B), and then from bolt (B) to bolt (A).
19. Install the fuel pump drive pusher and the fuel pump with the gasket.
20. Install the oil sump (secure it with Loctite).
21. Install the coolant pump.
22. Install the oil filter together with the gasket. The oil filter housing should be tightened by hand until it touches, and then another 3/4 turn.
23. Screw in the oil pressure sensor.
24. Install the pulley on the crankshaft (with the reinforced side facing the flywheel).
25. Screw into the cylinder block in place of bolts No.7 and 9 (see Fig. Cylinder Head Bolt Tightening Sequence), pins centering the cylinder head (see subsection 4.1.5.4). Install the cylinder head gasket with the inscription facing up.
26. Set the piston in the 1st cylinder at top dead center (TDC) and the camshaft pulley so that the timing marks are aligned (see Fig. Installation signs of the gas distribution system).
27. Install the cylinder head, insert (except bolts No.7 and 9 – see Fig. Cylinder Head Bolt Tightening Sequence) and slightly tighten the head bolts, remove the bolt centering pins and screw in the remaining two bolts in their place. Tighten the cylinder head mounting bolts accordingly (see subsection 4.2.1.5).
28. Install the pulley (with the concave side facing out), the toothed belt and its cover on the crankshaft (see subsection 4.1.5.4).
29. Install the flexible cooling system pipes and adjust the timing belt tension.
Caution! From now on, the crankshaft should only be rotated in the direction of its rotation while the engine is running.
30. Adjust the position of the generator, install the coolant pump and fan.
31. Install the alternator pulley and tension the V-belt so that its deflection is 10 mm (A) (1 – tensioner bolt).
32. Check whether the piston of the 1st cylinder is set to the TDC position and install the ignition distributor.
33. Connect the vacuum line to the ignition system.
34. Check and, if necessary, adjust the valve clearance.
35. Install the cylinder head cover, paying attention to the correct position of its gasket.
36. Tighten the cylinder head cover mounting bolts in the appropriate sequence (see Fig. Cylinder Head Cover Bolt Tightening Sequence).
37. Screw the spark plugs into the cylinder head and connect the high-voltage wires.
38. Insert a new gasket and screw the drain plug into the oil pan.
39. Connect the flexible crankcase ventilation hose.
40. Insert the oil level indicator into the hole in its guide in the engine cylinder block.
Information for this article was taken from the website (FordBook.ru)