General Specifications Escort/Orion 1991 (08/1990-09/2001)

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Specifications
Engine Data
1,4 PTE
Engine management EEC IV/SEFI
Emission standard 93 EEC/96 EEC
95 ROZ Super
Fuel
unleaded
Engine code F4B
Firing order 1‐3‐4‐2
Bore mm 77,24
Stroke mm 74,30
Cubic capacity cm3 1392
Compression ratio 9,5 : 1
Compression pressure at starter motor speed bar 12‐14
Power output (DIN) kW 54
Power output (DIN) PS 73
at
Power output (DIN) 5500
rev/min
Torque (DIN) Nm 105
Idle speed rev/min 875
Maximum engine speed, continuous rev/min 6100
Maximum engine speed, intermittent rev/min 6325
Spark plugs AGPR 32 C1
Key to Engine Code on Cylinder Block

1. Engine code F4B

 1st letter: cubic capacity (F = 1,4 litres)

 2nd number/letter: engine type (4 = PTE SFI version)
 3rd letter: vehicle model: vehicle model (B = installed in Escort)
2. Engine serial number

Dimensions
Cylinder block 1,4 PTE
Cast mark 88SM‐6015‐AA
Number of main bearings 5
Cylinder bore ∅, standard class 1 (production) mm 77,22 ‐ 77,23
Cylinder bore ∅, standard class 2 (production) mm 77,23 ‐ 77,24
Cylinder bore ∅, standard class 3 (production) mm 77,24 ‐ 77,25
Cylinder bore ∅, standard class 4 (production) mm 77,25 ‐ 77,26
Cylinder bore ∅, oversize class A (production) mm 77,51 ‐ 77,52
Cylinder bore ∅, oversize class B (production) mm 77,52 ‐ 77,53
Cylinder bore ∅, oversize class C (production) mm 77,53 ‐ 77,54
Cylinder bore ∅, standard (Service) mm 77,245 ‐ 77,255
Cylinder bore ∅, 1st oversize 0,29 (Service) mm 77,525 ‐ 77,535
Cylinder bore ∅, 2nd oversize 0,50 (Service) mm 77,745 ‐ 77,755
Main bearing clearance mm 0,011 ‐ 0,058
Main bearing parent bore, standard mm 62,287 ‐ 62,300
Main bearing parent bore, oversize mm 62,687 ‐ 62,700
Dimensions
Crankshaft 1,4 PTE
Main bearing journal Ø, standard mm 57,98 ‐ 58,00
Main bearing journal Ø, 1st undersize 0,50 mm 57,73 ‐ 57,75
Main bearing journal Ø, 2nd undersize 0,50 mm 57,48 ‐ 57,50
Main bearing journal Ø, 3rd undersize 0,75 mm 57,23 ‐ 57,25
Centre main bearing width, standard mm 28,825 ‐ 28,875
Centre main bearing width, oversize mm 29,255 ‐ 29,205
Thickness of thrust half rings, standard mm 2,301 ‐ 2,351
Thickness of thrust half rings, oversize mm 2,491 ‐ 2,541
Main bearing journal end float mm 0,09 ‐ 0,30
Big‐end bearing journal Ø, standard mm 47,89 ‐ 47,91
Big‐end bearing journal Ø, undersize 0,25 mm 47,64 ‐ 47,66
Big‐end bearing journal Ø, undersize 0,50 mm 47,39 ‐ 47,41
Big‐end bearing journal Ø, undersize 0,75 mm 47,14 ‐ 47,16
Big‐end bearing journal Ø, undersize 1,00 mm 46,89 ‐ 46,91
Dimensions
Connecting rods 1,4 PTE
Bore Ø, big‐end mm 50,89 ‐ 50,91
Bore Ø, small end mm 20,589 ‐ 20,609
Inner ∅ of big‐end bearing shells (fitted), standard mm 47,916 ‐ 47,950
Inner ∅ of big‐end bearing shells (fitted), 1st undersize 0,25 mm 47,666 ‐ 47,700
Inner ∅ of big‐end bearing shells (fitted), 2nd undersize 0,50 mm 47,416 ‐ 47,450
Inner ∅ of big‐end bearing shells (fitted), 3rd undersize 0,75 mm 47,166 ‐ 47,200
Inner ∅ of big‐end bearing shells (fitted), 4th undersize 1,00 mm 46,916 ‐ 46,950
Big‐end bearing clearance (radial) mm 0,006 ‐ 0,060
Dimensions
Pistons 1,4 PTE
Piston Ø (production), standard class 1 mm 77,190 ‐ 77,200
Piston Ø (production), standard class 2 mm 77,200 ‐ 77,210
Piston Ø (production), standard class 3 mm 77,210 ‐ 77,220
Piston Ø (production), standard class 4 mm 77,220 ‐ 77,230
Piston Ø (production), oversize class A mm 77,480 ‐ 77,490
Piston Ø (production), oversize class B mm 77,490 ‐ 77,500
Piston Ø (production), oversize class C mm 77,500 ‐ 77,510
Clearance in bore, production mm 0,020 ‐ 0,040
Piston Ø (Service), standard mm 77,210 ‐ 77,235
Piston Ø (Service), oversize 0,29 mm 77,490 ‐ 77,515
Piston Ø (Service), oversize 0,50 mm 77,710 ‐ 77,735
Clearance in bore (Service) mm 0,01 ‐ 0,045
Piston ring gap (fitted), upper compression ring mm 0,30 ‐ 0,50
Piston ring gap (fitted), lower compression ring mm 0,30 ‐ 0,50
Piston ring gap (fitted), oil scraper ring mm 0,40 ‐ 1,40
The piston ring gaps must be evenly spaced around the piston circumference. This also
applies to each part of the oil scraper ring. Arrange the gaps at 120° to each other.

Dimensions
Piston pins 1,4 PTE
Piston pin length mm 63,00 ‐ 63,80
Piston pin Ø, white mm 20,622 ‐ 20,625
Piston pin Ø, red mm 20,625 ‐ 20,628
Piston pin Ø, blue mm 20,628 ‐ 20,631
Piston pin Ø, yellow mm 20,631 ‐ 20,634
Piston pin clearance in piston mm 0,005 ‐ 0,011
Interference fit in connecting rod mm 0,013 ‐ 0,045
Dimensions
Cylinder head 1,4 PTE
Cast mark 945M‐6090‐AB
Combustion chamber volume cm3 38,88 ‐ 41,88
Valve seat angle 44°30' ‐45°30'
Valve seat width mm 1,75 ‐ 2,32
Upper correction angle (production), inlet/exhaust ° 30
Service correction cutter, inlet/exhaust ° 15
Lower correction angle (production), inlet ° 77
Lower correction angle (production), exhaust ° 70
Service correction cutter, inlet ° 75
Service correction cutter, exhaust ° 70
Stem bore, inlet and exhaust valves, standard mm 8,063 ‐ 8,094
Stem bore, inlet and exhaust valves, 1st oversize 0,2 mm 8,263 ‐ 8,294
Stem bore, inlet and exhaust valves, 1st oversize 0,4 mm 8,463 ‐ 8,494
Cylinder head bore (standard), camshaft bearing 1 mm 44,783 ‐ 44,808
Cylinder head bore (standard), camshaft bearing 2 mm 45,033 ‐ 45,058
Cylinder head bore (standard), camshaft bearing 3 mm 45,283 ‐ 45,308
Cylinder head bore (standard), camshaft bearing 4 mm 45,533 ‐ 45,558
Cylinder head bore (standard), camshaft bearing 5 mm 45,783 ‐ 45,808
Cylinder head bore (oversize), camshaft bearing 1 mm 45,188 ‐ 45,163
Cylinder head bore (oversize), camshaft bearing 2 mm 45,438 ‐ 45,413
Cylinder head bore (oversize), camshaft bearing 3 mm 45,688 ‐ 45,663
Cylinder head bore (oversize), camshaft bearing 4 mm 45,938 ‐ 45,913
Cylinder head bore (oversize), camshaft bearing 5 mm 46,188 ‐ 46,163
Valve tappet bore (standard) mm 22,235 ‐ 22,265
Valve tappet bore (oversize) mm 22,489 ‐ 22,519
Max. permissible cylinder head unevenness mm 0,15
Cylinder head mating face skimming (maximum) mm 0,30
Min. combustion chamber depth mm 17,40
Dimensions
Camshaft 1,4 PTE
Number of camshaft bearings 5
Drive Timing belt
Camshaft retaining plate (thickness) mm 4,99 ‐ 5,01
Cam lift (inlet/exhaust) mm 5,79
Cam length (between heel and tip), inlet mm 38,305
Cam length (between heel and tip), exhaust mm 37,289
Bearing journal Ø, camshaft bearing 1 mm 44,75
Bearing journal Ø, camshaft bearing 2 mm 45,00
Bearing journal Ø, camshaft bearing 3 mm 45,25
Bearing journal Ø, camshaft bearing 4 mm 45,50
Bearing journal Ø, camshaft bearing 5 mm 45,75
Valve timing, inlet valve opens after TDC °CS 15
Valve timing, inlet valve closes after BDC °CS 30
Valve timing, exhaust valve opens before BDC °CS 28
Valve timing, exhaust valve closes before TDC °CS 13
Camshaft end float mm 0,05 ‐ 0,15
Dimensions
Valves 1,4 PTE
Valve lift, inlet mm 9,3 ‐ 9,7
Valve lift, exhaust mm 9,3 ‐ 9,7
Free valve spring length (with varying colour code depending
mm 47,20
on the manufacturer)
Colour code, valve spring blue‐blue
Valve length, inlet mm 136,29 ‐ 136,75
Valve length, exhaust mm 132,97 ‐ 133,43
Valve head Ø, inlet mm 39,90 ‐ 40,10
Valve head Ø, exhaust mm 33,90 ‐ 34,10
Valve stem Ø (standard), inlet mm 8,025 ‐ 8,043
Valve stem Ø (standard), exhaust mm 7,999 ‐ 8,017
Valve stem Ø (oversize 0,2), inlet mm 8,225 ‐ 8,243
Valve stem Ø (oversize 0,2), exhaust mm 8,199 ‐ 8,217
Valve stem Ø (oversize 0,4), inlet mm 8,425 ‐ 8,443
Valve stem Ø (oversize 0,4), exhaust mm 8,399 ‐ 8,417
Clearance in valve stem guide, inlet mm 0,020 ‐ 0,063
Clearance in valve stem guide, exhaust mm 0,046 ‐ 0,089
Dimensions
Timing belt tension Scale divisions on
test gauge 21‐113
New timing belt 10 ‐ 11
Used timing belt 4‐6
Check used timing belt 4‐6
Dimensions
Drive belt tension N
New drive belt 400 ‐ 500
Used drive belt 300 ‐ 400
Engine oil up to '99 MY (up to 07.98)
Description Viscosity/Ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil
over 40 degrees Centigrade M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 to over ACEA A1/B1, A2/B2 or
Ford Super Multigrade Engine Oil
40 degrees Centigrade A3/B3
Ford XR+ High‐performance High‐ SAE 10W40 / ‐20 to above
ACEA A3/B3
lubricity Motor Oil 40 degrees Centigrade
SAE 5W40 / below ‐20 to
Ford Formula S Synthetic Motor Oil above 40 degrees ACEA A3/B3
Centigrade
Engine oil from '99 MY (from 08.98)
Description Viscosity/Ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil
over 40 degrees Centigrade M2C912‐A1
Engine oils for topping up only:
Ford XR+ High‐performance High‐ SAE 10W40 / ‐20 to above
ACEA A3/B3
lubricity Motor Oil 40 degrees Centigrade
SAE 5W40 / below ‐20 to
Ford Formula S Synthetic Motor Oil above 40 degrees ACEA A3/B3
Centigrade
Lubricants, Fluids and Sealants
Ford
Specification
Ford transmission fluid SAE 75 W 90 WSD‐M2C200‐B
Coolant Super Plus 4 (blue/green) (Do not mix together coolants of different
ESD‐M97B49‐A
colours/specifications)
Coolant Super Plus 2000 (orange) (Do not mix together coolants of different
WSS‐M97B44‐D
colours/specifications)
High‐temperature grease: transmission input shaft, clutch release bearing
ESD‐M1C220‐A
guide sleeve, crankshaft guide bearing, clutch splines
Spark plug threads: Never Seeze ESE‐M1244‐A
Sealant, sump mating face intersections, oil pressure switch thread (Hylosil
WSK‐M4G320‐A
502)
Sealant for sump mating face intersections (Hylosil 502) WSK‐M4G320‐A
Fill capacities/filling levels
Description Litres
Engine oil, initial fill including filter 3,86
Engine oil, oil change including filter change 3,50
Engine oil, oil change without filter change 3,25
Coolant 7,1
Fill capacity, manual transmission (iB5) 2,8
10 ‐ 15 mm
below lower
Filling level, manual transmission (iB5)
edge of level
check bore
Engine lubrication
Description
Oil pressure approx. 80 °C at idle speed bar 1,0
Oil pressure approx. 80 °C at 2000 rev/min bar 2,8
Pressure relief valve opening pressure bar 4,7 ‐ 6,0
Oil pressure warning light comes on at bar 0,3 ‐ 0,5
Oil pump, rotor/housing (clearance) mm 0,060 ‐ 0,190
Oil pump, inner to outer rotor gap mm 0,050 ‐ 0,180
Oil pump, rotor to mating face (end float) mm 0,014 ‐ 0,100
Torques
General Nm lbf.ft
Wheel nuts 85 63
Intake pipe to cylinder head cover 10 7
Intake air temperature sensor (IAT sensor) 15 11
Lower suspension arm to spindle carrier 80 59
Shift rod stabiliser to transmission 55 41
Shift rod clamp bolt 16 12
Accelerator cable bracket 10 7
Air conditioning compressor 25 18
Torques
Intake manifold Nm lbf.ft
Intake manifold to cylinder head 18 13
Upper intake manifold to lower intake manifold (nut) 18 13
Coolant hose connector to lower intake manifold 15 11
Intake manifold studs to cylinder head 5 4
Fuel rail to lower intake manifold 23 17
Torques
Exhaust system Nm lbf.ft
Exhaust manifold studs to cylinder head 5 4
Exhaust manifold to cylinder head 16 12
Exhaust pipe to exhaust manifold 38 28
Bracket for exhaust pipe rubber retaining loop 44 32
Exhaust manifold heat shield 17 13
Rear exhaust pipe to catalytic converter 47 35
Exhaust manifold nut, Stage 1 16 12
Exhaust manifold nut, wait five mins. Stage 2 7 5
Torques
Transmission Nm lbf.ft
Clutch housing cover plate (two bolts) 40 30
Starter motor 40 30
Transmission flange bolts to engine 40 30
Clutch pressure plate 30 22
Torques
Coolant circuit Nm lbf.ft
Coolant pump 9 7
Thermostat housing 9 7
Temperature gauge sender unit 6 4
Engine coolant temperature sensor (ECT sensor) 19 14
Ground lead to transmission 24 18
Torques
Oil circuit Nm lbf.ft
Oil pressure switch 20 15
Oil level check plug to transmission 27 20
Oil pump to cylinder block 10 7
Oil filter adapter to cylinder block 22 16
Oil pump cover plate 10 7
Oil intake pipe to cylinder block 20 15
Oil intake pipe to oil pump 10 7
Sump (with one‐piece sump gasket), Stage 1 7 5
Sump (with one‐piece sump gasket), Stage 2 7 5
Oil drain plug 25 18
Torques
Engine mounting Nm lbf.ft
Front engine mounting to suspension strut dome console 85 63
Front engine mounting bracket to cylinder block 90 66
Manifold absolute pressure sensor (MAP sensor) bracket 24 18
Brace to right‐hand engine mounting (two nuts) 70 52
Brace to front crossmember 70 52
Strut to engine mounting bracket 50 37
Front left‐hand bracket to rubber mounting 70 52
Rear right‐hand engine mounting bracket to transmission (lower
72 53
nuts)
Rear right‐hand engine mounting shackle 69 51
Rear right‐hand engine mounting bracket 83 61
Rear left‐hand engine mounting to side member 69 51
Brace to rear right‐hand engine mounting bracket 69 51
Strut to transmission (two bolts) 44 32
Torques
Cylinder block Nm lbf.ft
Timing belt tensioner 18 13
Upper and lower timing belt cover 10 7
Drive belt lower cover 11 8
Crankshaft position sensor (CKP sensor) 5 4
Crankshaft rear oil seal carrier 10 7
Engine/transmission flange bolts 40 30
Camshaft thrust plate 11 8
Main bearing cap 95 70
Big‐end bearing cap 33 24
Pulley/vibration damper on crankshaft 108 80
Flywheel 87 64
Special tool 21‐168 to cylinder block 40 30
Reinforcement struts to cylinder block 45 33
Torques
Power‐assisted steering Nm lbf.ft
Bracket for power steering pump and alternator 24 18
Power steering pump to bracket 24 18
Alternator to bracket 24 18
Belt pulley to power steering pump 24 18
Torques
Cylinder head Nm lbf.ft
Cylinder head cover 7 5
Cylinder head bolts, Stage 1 30 22
Cylinder head bolts, Stage 2 50 37
Cylinder head bolts, Stage 3 905 905
Cylinder head bolts, Stage 4 905 905
Camshaft timing belt pulley 57 42
Engine lifting eye to cylinder head 44 32
Camshaft bearing thrust plate 11 8
Rocker nuts 27 20
Cylinder head ground cable 24 18
Sealing flange studs 5 4
Rocker stud to cylinder head 21 15
Torques
Ignition system Nm lbf.ft
EI coil to bracket 6 4
EI coil bracket to cylinder head 10 7
Spark plugs 25 19

General Specifications Escort/Orion 1991 (08/1990-09/2001)

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Specifications
Engine data
1,4  CVH 1,6 EFI
Engine Management EEC IV/CFI EEC IV/EFI
Emission standard 93 EEC 96 EEC
Premium 95 RON Premium 95 RON
Fuel
unleaded unleaded
Engine code F6D/F6B LJD / LJE
Firing order 1‐3‐4‐2 1‐3‐4‐2
Bore mm 77,24 79,96
Stroke mm 74,30 79,52
Cubic capacity cm3 1392 1596
Compression ratio 9,5 : 1 9,75 : 1
Compression pressure at starter motor
bar 12‐14 12‐14
speed
Power output (DIN) kW 54 77 / 79
Power output (DIN) PS 73 105 / 108
Power output (DIN) at 1/min 5600 6000
Torque (DIN) Nm 103 138 / 141
Idle speed rev/min 900 900
Maximum engine speed, continuous rev/min 6050 6250
Maximum engine speed, intermittent rev/min 6275 6450
Spark plugs AGPR 32 C1 AGPR 22 C1
Key to Engine Code on Cylinder Block

1. Engine code
  1st letter: cubic capacity (F = 1,4 litres; L = 1,6 litres)
 2nd number/letter: engine type (6 = CFI version; J = EFI version)
 3rd letter: vehicle model
2. Engine serial number

Dimensions
Cylinder block 1,4 CVH 1,6 EFI
Cast mark 88SM‐6015‐AA 88SM‐6015‐BA
Number of main bearings 5 5
Cylinder bore ∅, Standard class 1 (Production) mm 77,22 ‐ 77,23 79,94 ‐ 79,95
Cylinder bore ∅, Standard class 2 (Production) mm 77,23 ‐ 77,24 79,95 ‐ 79,96
Cylinder bore ∅, Standard class 3 (Production) mm 77,24 ‐ 77,25 79,96 ‐ 79,97
Cylinder bore ∅, Standard class 4 (Production) mm 77,25 ‐ 77,26 79,97 ‐ 79,98
Cylinder bore ∅, Oversize class A (Production) mm 77,51 ‐ 77,52 80,23 ‐ 80,24
Cylinder bore ∅, Oversize class B (Production) mm 77,52 ‐ 77,53 80,24 ‐ 80,25
Cylinder bore ∅, Oversize class C (Production) mm 77,53 ‐ 77,54 80,25 ‐ 80,26
77,245 ‐ 79,965 ‐
Cylinder bore ∅, Standard (Service) mm
77,255 79,975
77,525 ‐ 79,245 ‐
Cylinder bore ∅, 1st oversize 0,29 (Service) mm
77,535 80,255
77,745 ‐ 80,465 ‐
Cylinder bore ∅, 2nd oversize 0,50 (Service) mm
77,755 80,475
Main bearing clearance mm 0,011 ‐ 0,058 0,011 ‐ 0,058
62,287 ‐ 62,287 ‐
Main bearing parent bore, Standard mm
62,300 62,300
62,687 ‐ 62,687 ‐
Main bearing parent bore, Oversize mm
62,700 62,700
Dimensions
Crankshaft 1,4 CVH 1,6 EFI
Main bearing journal diameter, Standard mm 57,98 ‐ 58,00 57,98 ‐ 58,00
Main bearing journal diameter, 1st undersize 0,25 mm 57,73 ‐ 57,75 57,73 ‐ 57,75
Main bearing journal diameter, 2nd undersize 0,50 mm 57,48 ‐ 57,50 57,48 ‐ 57,50
Main bearing journal diameter, 3rd undersize 0,75 mm 57,23 ‐ 57,25 57,23 ‐ 57,25
28,825 ‐ 28,825 ‐
Centre main bearing width, Standard mm
28,875 28,875
29,255 ‐ 29,255 ‐
Centre main bearing width, Oversize mm
29,205 29,205
Thickness of thrust half rings, Standard mm 2,301 ‐ 2,351 2,301 ‐ 2,351
Thickness of thrust half rings, Oversize mm 2,491 ‐ 2,541 2,491 ‐ 2,541
Main bearing journal end float mm 0,09 ‐ 0,30 0,09 ‐ 0,30
Big‐end bearing journal diameter, Standard mm 47,89 ‐ 47,91 47,89 ‐ 47,91
Big‐end bearing journal diameter, Undersize 0,25 mm 47,64 ‐ 47,66 47,64 ‐ 47,66
Big‐end bearing journal diameter, Undersize 0,50 mm 47,39 ‐ 47,41 47,39 ‐ 47,41
Big‐end bearing journal diameter, Undersize 0,75 mm 47,14 ‐ 47,16 47,14 ‐ 47,16
Big‐end bearing journal diameter, Undersize 1,00 mm 46,89 ‐ 46,91 46,89 ‐ 46,91
Dimensions
Connecting rods 1,4 CVH 1,6 EFI
Bore diameter, Big end mm 50,89 ‐ 50,91 50,89 ‐ 50,91
20,589 ‐ 20,589 ‐
Bore diameter, Small end mm
20,609 20,609
47,916 ‐ 47,916 ‐
Inside ∅ of big‐end bearing shells, Standard mm
47,950 47,950
Inner ∅ of big‐end bearing shells (installed), 1st 47,666 ‐ 47,666 ‐
mm
undersize 0,25 47,700 47,700
Inner ∅ of big‐end bearing shells (installed), 2nd 47,416 ‐ 47,416 ‐
mm
undersize 0,50 47,450 47,450
Inner ∅ of big‐end bearing shells (installed), 3rd 47,166 ‐ 47,166 ‐
mm
undersize 0,75 47,200 47,200
Inner ∅ of big‐end bearing shells (installed), 4th 46,916 ‐ 46,916 ‐
mm
undersize 1,00 46,950 46,950
Big‐end bearing clearance (radial) mm 0,006 ‐ 0,060 0,006 ‐ 0,060
Dimensions
Pistons 1,4 CVH 1,6 EFI
77,190 ‐ 79,915 ‐
Piston diameter (Production), Standard grade 1 mm
77,200 79,925
77,200 ‐ 79,925 ‐
Piston diameter (Production), Standard grade 2 mm
77,210 79,935
77,210 ‐ 79,935 ‐
Piston diameter (Production), Standard grade 3 mm
77,220 79,945
77,220 ‐ 79,945 ‐
Piston diameter (Production), Standard grade 4 mm
77,230 79,955
77,480 ‐ 80,205 ‐
Piston diameter (Production), Oversize class A mm
77,490 80,215
77,490 ‐ 80,215 ‐
Piston diameter (Production), Oversize class B mm
77,500 80,225
77,500 ‐ 80,225 ‐
Piston diameter (Production), Oversize class C mm
77,510 80,235
Clearance in bore, Production mm 0,020 ‐ 0,040 0,015 ‐ 0,035
77,210 ‐ 79,935 ‐
Piston diameter (Service), Standard mm
77,235 79,955
77,490 ‐ 79,215 ‐
Piston diameter (Service), Oversize 0,29 mm
77,515 79,235
77,710 ‐ 80,435 ‐
Piston diameter (Service), Oversize 0,50 mm
77,735 80,455
Clearance in bore (Service) mm 0,01 ‐ 0,045 0,010 ‐ 0,040
Piston ring gap (installed), upper compression ring mm 0,30 ‐ 0,50 0,30 ‐ 0,50
Piston ring gap (installed), lower compression ring mm 0,30 ‐ 0,50 0,30 ‐ 0,50
Piston ring gap (installed), oil scraper ring mm 0,40 ‐ 1,40 0,25 ‐ 0,40
The piston ring gaps must be evenly spaced around the piston circumference. This also
applies to each part of the oil scraper ring. Arrange the gaps at 120 degrees to each other.

Dimensions
Piston pins 1,4 CVH 1,6 EFI
Piston pin length mm 63,00 ‐ 63,80 63,00 ‐ 63,80
20,622 ‐ 20,622 ‐
Piston pin diameter, white mm
20,625 20,625
20,625 ‐ 20,625 ‐
Piston pin diameter, red mm
20,628 20,628
20,628 ‐ 20,628 ‐
Piston pin diameter, blue mm
20,631 20,631
20,631 ‐ 20,631 ‐
Piston pin diameter, yellow mm
20,634 20,634
Piston pin clearance in piston mm 0,005 ‐ 0,011 0,005 ‐ 0,011
Interference fit in connecting rod mm 0,013 ‐ 0,045 0,013 ‐ 0,045
Dimensions
Cylinder head 1,4 CVH 1,6 EFI
Cast mark 89SM6090CA 89SM6090BB
Combustion chamber volume cm3 38,88 ‐ 41,88 53,36 ‐ 55,38
44°30' ‐ 44°30' ‐
Valve seat angle
45°30' 45°30'
Valve seat width mm 1,75 ‐ 2,32 1,75 ‐ 2,32
Upper correction angle (Production) ° 30 30
Service correction cutter ° 15 15
Lower correction angle (Production) ° 77 70
Service correction cutter ° 75 70
Stem bore, inlet and exhaust valve, Standard mm 8,063 ‐ 8,094 8,063 ‐ 8,094
Stem bore, inlet and exhaust valves, 1st oversize 0,2 mm 8,263 ‐ 8,294 8,263 ‐ 8,294
Stem bore, inlet and exhaust valves, 2nd oversize 0,4 mm 8,463 ‐ 8,494 8,463 ‐ 8,494
44,783 ‐ 44,783 ‐
Cylinder head bore (standard), Camshaft bearing 1 mm
44,808 44,808
45,033 ‐ 45,033 ‐
Cylinder head bore (standard), Camshaft bearing 2 mm
45,058 45,058
45,283 ‐ 45,283 ‐
Cylinder head bore (standard), Camshaft bearing 3 mm
45,308 45,308
45,533 ‐ 45,533 ‐
Cylinder head bore (standard), Camshaft bearing 4 mm
45,558 45,558
45,783 ‐ 45,783 ‐
Cylinder head bore (standard), Camshaft bearing 5 mm
45,808 45,808
45,188 ‐ 45,188 ‐
Cylinder head bore (oversize), Camshaft bearing 1 mm
45,163 45,163
45,438 ‐ 45,438 ‐
Cylinder head bore (oversize), Camshaft bearing 2 mm
45,413 45,413
45,688 ‐ 45,688 ‐
Cylinder head bore (oversize), Camshaft bearing 3 mm
45,663 45,663
45,938 ‐ 45,938 ‐
Cylinder head bore (oversize), Camshaft bearing 4 mm
45,913 45,913
46,188 ‐ 46,188 ‐
Cylinder head bore (oversize), Camshaft bearing 5 mm
46,163 46,163
22,235 ‐ 22,235 ‐
Valve tappet bore (standard) mm
22,265 22,265
22,489 ‐ 22,489 ‐
Valve tappet bore (oversize) mm
22,519 22,519
Max. permissible cylinder head unevenness over
mm 0,15 0,15
entire section
Cylinder head mating face skimming (maximum) mm 0,30 0,30
Min. combustion chamber depth mm 17,40 19,10
Dimensions
Camshaft 1,4 CVH 1,6 EFI
Number of camshaft bearings 5 5
Drive Timing belt Timing belt
Camshaft retaining plate (thickness) mm 4,99 ‐ 5,01 4,99 ‐ 5,01
Cam lift (inlet/exhaust) mm 5,79 6,57
Cam length (between heel and tip), Inlet mm 38,305 37,559
Cam length (between heel and tip), Exhaust mm 37,289 37,559
Bearing journal diameter, Camshaft bearing 1 mm 44,75 44,75
Bearing journal diameter, Camshaft bearing 2 mm 45,00 45,00
Bearing journal diameter, Camshaft bearing 3 mm 45,25 45,25
Bearing journal diameter, Camshaft bearing 4 mm 45,50 45,50
Bearing journal diameter, Camshaft bearing 5 mm 45,75 45,75
Valve timings, Inlet valve opens after TDC °CS 15
Valve timings, Inlet valve opens before TDC °CS 4
Valve timings, Inlet valve closes after BDC °CS 30 30
Valve timings, Exhaust valve opens before BDC °CS 28 44
Valve timings, Exhaust valve closes before TDC °CS 13 10
Camshaft end float mm 0,05 ‐ 0,13 0,05 ‐ 0,13
Dimensions
Valves 1,4 CVH 1,6 EFI
Valve lift, Inlet mm 9,3 ‐ 9,7 10,3 ‐ 10,7
Valve lift, Exhaust mm 9,3 ‐ 9,7 10,3 ‐ 10,7
Free valve spring length (with varying colour code
mm 47,20 46,90
depending on manufacturer)
Colour code, Valve spring blue‐blue red‐red
136,29 ‐ 134,54 ‐
Valve length, Inlet mm
136,75 135,00
132,97 ‐ 131,57 ‐
Valve length, Exhaust mm
133,43 132,03
Valve head diameter, Inlet mm 39,90 ‐ 40,10 41,90 ‐ 42,10
Valve head diameter, Exhaust mm 33,90 ‐ 34,10 36,90 ‐ 37,10
Valve stem diameter (standard), Inlet mm 8,025 ‐ 8,043 8,025 ‐ 8,043
Valve stem diameter (standard), Exhaust mm 7,999 ‐ 8,017 7,999 ‐ 8,017
Valve stem diameter (oversize 0,2), Inlet mm 8,225 ‐ 8,243 8,225 ‐ 8,243
Valve stem diameter (oversize 0,2), Exhaust mm 8,199 ‐ 8,217 8,199 ‐ 8,217
Valve stem diameter (oversize 0,4), Inlet mm 8,425 ‐ 8,443 8,425 ‐ 8,443
Valve stem diameter (oversize 0,4), Exhaust mm 8,399 ‐ 8,417 8,399 ‐ 8,417
Clearance in valve stem guide, Inlet mm 0,020 ‐ 0,063 0,020 ‐ 0,063
Clearance in valve stem guide, Exhaust mm 0,046 ‐ 0,089 0,046 ‐ 0,089
Dimensions
Timing belt tension Scale divisions on
test gauge 21‐113
New timing belt 10 ‐ 11
Tension used timing belt 4‐6
Check used timing belt 4‐6
Dimensions
Multi‐groove belt tension N
New multi‐groove belt 400 ‐ 500
Used multi‐groove belt 300 ‐ 400
Engine oil up to '99 MY (up to 07.98)
Description Viscosity/Ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil
over 40 degrees Centigrade M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 to over 40 ACEA A1/B1, A2/B2 or
Ford ”Super" Multigrade Motor Oil
degrees Centigrade A3/B3
Ford XR+High‐performanceHigh‐ SAE 10W40 / ‐20 to over 40 ACEA A3/B3
lubricity Motor Oil degrees Centigrade
Ford Formula S Synthetic Motor SAE 5W40 / below ‐20 to
ACEA A3/B3
Oil over 40 degrees Centigrade
Engine oil from '99 MY (from 08.98)
Description Viscosity/Ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil
over 40 degrees Centigrade M2C912‐A1
Engine oils for topping up only:
Ford XR+High‐performanceHigh‐ SAE 10W40 / ‐20 to over 40
ACEA A3/B3
lubricity Motor Oil degrees Centigrade
Ford Formula S Synthetic Motor SAE 5W40 / below ‐20 to
ACEA A3/B3
Oil over 40 degrees Centigrade
Lubricants, Fluids and Sealants
Ford
Specification
Transmission fluid SQM‐2C‐9008‐A
Coolant Super Plus 4 (blue/green) (Do not mix together coolants of different
ESD‐M97B‐49A
colours/specifications)
Coolant Super Plus 2000 (orange) (Do not mix together coolants of different
WSS‐M97B44‐D
colours/specifications)
High‐temperature grease for transmission input shaft splines, release
ESD‐M1C‐220‐A
bearing guide sleeve
Spark plug threads: Never Seeze ESE‐M1244‐A
Sealant for sump mating face intersections (Hylosil 502) WSK‐M4G320‐A
Sealant for flywheel bolts (Hylosil 502) WSK‐M4G320‐A
Fill capacities
Description Litres
Engine oil, initial fill with filter 3,86
Engine oil, Oil change incl. filter 3,50
Engine oil, Oil change excl. filter 3,25
Coolant 7,1
Transmission fluid B5 3,1
Engine lubrication
Description
Oil pressure with oil temperature approx. 80°C at idle speed bar 1,00
Oil pressure with oil temperature approx. 80°C, at 2000
bar 2,80
rev/min
Pressure relief valve opening pressure bar 4,70 ‐ 6,00
Oil pressure warning light comes on at bar 0,3 ‐ 0,5
Oil pump, rotor/housing (clearance) mm 0,060 ‐ 0,190
Oil pump, inner/outer rotor (clearance) mm 0,050 ‐ 0,180
Oil pump, rotor/mating face (end float) mm 0,014 ‐ 0,100
Torques
General Nm lbf.ft
Wheel nuts 85 63
Intake pipe to cylinder head cover 10 7
Intake air temperature sensor (IAT sensor) 15 11
Lower suspension arm ball joint to spindle carrier 80 59
Track rod end to spindle carrier 28 21
Torques
Inlet manifold Nm lbf.ft
Inlet manifold to cylinder head 18 13
Upper part of inlet manifold to lower part of inlet manifold (nut) 18 13
Coolant hose connector to lower part of inlet manifold 15 11
Studs ‐ inlet manifold to cylinder head 5 4
Fuel rail to lower part of inlet manifold 23 17
Torques
Exhaust manifold Nm lbf.ft
Exhaust manifold studs to cylinder head 5 4
Exhaust manifold to cylinder head 16 11
Exhaust pipe to exhaust manifold 38 28
Exhaust manifold heat shield 17 12
Rear exhaust pipe to catalytic converter 47 35
Exhaust manifold nut, Stage 1 16 11
Exhaust manifold nut, wait five minutes, Stage 2 7 5
Torques
Transmission Nm lbf.ft
Clutch housing cover plate (two bolts) 40 30
Starter motor 40 30
Transmission flange bolts to engine 40 30
Clutch pressure plate 30 22
Torques
Coolant circuit Nm lbf.ft
Coolant pump 9 6
Thermostat housing 11 8
Temperature gauge sender unit 6 4
Engine coolant temperature sensor (ECT sensor) 15 11
Ground lead to transmission 24 18
Torques
Oil circuit Nm lbf.ft
Oil pressure switch 20 14
Oil level check plug to transmission 27 20
Oil pump to cylinder block 10 7
Oil filter adapter to cylinder block 22 16
Oil pump cover 10 7
Oil intake pipe to cylinder block 20 15
Oil intake pipe to oil pump 10 7
Sump (with one‐piece sump gasket), Stage 1 7 5
Sump (with one‐piece sump gasket), Stage 2 7 5
Engine oil drain plug 25 19
Torques
Engine mounting, right‐hand side Nm lbf.ft
Front engine mounting to suspension strut top mount bracket 85 63
Front engine mounting bracket to cylinder block 90 66
MAP sensor bracket 24 18
Brace to right‐hand engine mounting (two nuts) 70 52
Brace to front crossmember 70 52
Torques
Engine mounting, front left‐hand side Nm lbf.ft
Brace to engine/transmission mounting bracket 50 37
Front left‐hand bracket to rubber mounting 70 52
Torques
Engine mounting, rear left‐hand side Nm lbf.ft
Vertical bracket to transmission (three nuts) 72 53
Engine mounting to vertical bracket (one nut) 83 61
Engine mounting bracket to crossmember 83 61
Engine mounting to bracket (two bolts) 47 35
Transverse brace to vertical bracket (two bolts) 68 50
Transverse brace to transmission (two bolts) 44 33
Torques
Transmission mounting Nm lbf.ft
Transmission mounting, rear left‐hand side 70 52
Transmission mounting, rear right‐hand side 50 37
Torques
Cylinder block Nm lbf.ft
Timing belt tensioner 18 13
Timing belt cover 10 7
Multi‐groove belt lower cover 11 8
Lower timing belt cover 10 7
Crankshaft position sensor (CKP sensor) 5 4
Crankshaft rear oil seal housing 10 7
Engine/transmission flange bolts 40 30
Camshaft thrust plate 11 8
Main bearing cap 95 70
Big‐end bearing cap 33 24
Crankshaft pulley 108 80
Flywheel 87 64
Special Tool 21‐168 to cylinder block 40 30
Torques
Power steering Nm lbf.ft
Bracket for power steering pump and alternator 24 18
Power steering pump to bracket 24 18
Alternator to bracket 24 18
Belt pulley to power steering pump 24 18
Torques
Cylinder head Nm lbf.ft
Cylinder head cover 7 5
Cylinder head bolts, Stage 1 30 22
Cylinder head bolts, Stage 2 50 37
Cylinder head bolts, Stage 3 905 905
Cylinder head bolts, Stage 4 905 905
Camshaft timing belt pulley 57 42
Engine lifting eye to cylinder head 44 33
Rocker nuts 27 20
Torques
Ignition system Nm lbf.ft
EI ignition coil to bracket 6 4
EI ignition coil bracket to cylinder head 10 7
Spark plugs 25 19
Rocker bolts to cylinder head 21 15

Engine ‐ Dismantle and Assemble (Engine

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 134 8)
 Print

Removal and Installation

Special Tools

16‐067 Clutch disc locator

21‐064 Mounting bracket

21‐064‐01 Retaining bolts for

21‐064

21‐093A Crankshaft front oil

seal installer

21‐095 Crankshaft rear oil

seal installer

21‐096 Remover, oil seal

21‐098 Remover, timing belt

pulley

21‐113 Tension gauge, timing

belt

21‐150A Mounting plate

21‐168 Locking tool,

crankshaft

21‐179 Separator, sump

 21‐540 Angle gauge

24‐003 Remover/installer,
coolant hose clips

Materials
Description
From: Replacement
Services Limited, 30,
Euston Street,
Plastigage
Freemans Industrial
Estate, Leicester, LE2
7ST
Sealant (Hylosil 502) WSK‐M4G320‐A
Lubricant for spark
ESE‐M1244‐A
plugs (Never Seeze)
Engine oil WSS‐M2C912‐A1
Proprietary Tools
Description
Dial gauge
Magnetic fixture
Piston ring compressor
Oil filter strap wrench
Steel straight edge
Piston ring expander
Micrometer
Depth gauge
Feeler gauges
12 workshop‐made studs (M6 x 30)
1. General notes.
• Use Special Tool 24‐003 as required when
disconnecting and connecting coolant and ventilation
hoses.
Dismantle
2. Mount the engine on an assembly stand.
3. Preparations.
1. Drain the engine oil.
2. Unscrew the oil filter with a strap wrench.
3. Remove the oil pressure switch.
4. Remove the oil dipstick and oil dipstick tube.

4. Release the bolts of the power steering belt pulley.

5. Release the belt tensioner and remove the multi‐
groove belt.
6. Disconnect the coolant hose.

7. Detach the belt pulley from the power steering

pump.

8. Remove the power steering pump.

9. Remove the alternator.

10. Remove the bracket of the power steering pump

and the alternator.

11. Detach the front engine mounting bracket from

the cylinder block.

12. Remove the adapter plate.

13. Immobilise the flywheel with the special tool.

 14. Detach the crankshaft pulley/vibration damper.

15. Remove the upper and lower timing belt cover

(two parts).

16. Remove the timing belt and the timing belt

tensioner.
1. Slacken the bolts of the timing belt tensioner.
2. Remove the timing belt.
3. Detach the timing belt tensioner.

17. Pull off the spark plug connectors.

CAUTION:
Do not pull on the cable when disconnecting
the spark plug connectors. Twist the spark
plug connectors slightly before pulling them
off.
CAUTION:
Pull off the spark plug connectors in line
with the axis of the spark plug.

18. Remove the spark plugs (16 mm socket wrench).

19. Detach the hose for the positive crankcase
ventilation (PCV).
 20. Detach the cylinder head cover.
   Remove the gasket.

NOTE:
Slacken the cylinder head bolts in the
indicated order and remove them.
21. Remove the cylinder head.

22. Remove the cylinder head gasket and the two

guide sleeves.

NOTE:
Evenly loosen the bolts on the clutch
pressure plate.
23. Remove the clutch.

24. Detach the crankshaft position sensor (CKP

sensor).
 NOTE:
Mark the installation position.

25. Remove the flywheel.

   Remove the special tool.

NOTE:
Remove the sump downwards to prevent oil
sludge and abraded particles from entering
the engine.
NOTE:
Follow specified bolt slackening order.

26. Remove the sump.

27. Separate the sump from the cylinder block using

the special tool.

28. Remove the crankshaft rear oil seal.

1. Special tool
2. Radial oil seal
29. Remove the oil seal carrier.
30. Detach the bracket for the CKP sensor.

31. Remove the oil baffle.

32. Detach the coolant pump.

33. Detach the crankshaft timing belt pulley.

   Remove the thrust washer.

34. Turn the cylinder block through 1805.

35. Remove the crankshaft front oil seal.
 36. Remove the oil pump with the oil intake pipe.
1. Detach the oil intake pipe bracket.
2. Remove the oil pump.

CAUTION:
Do not touch the piston ring area.

37. Remove the ring of carbon from the top edge of

the cylinder.
• Set the piston to the half stroke position.
• Remove the ring of carbon carefully with a suitable
scraper.

NOTE:
Put down the big‐end bearing shells in order
for reuse.
38. Remove the pistons with the connecting rods.
• Detach the big‐end bearing caps.
• Press the pistons with the connecting rods out of the
cylinder block.

39. Remove the crankshaft.

   Detach the main bearing caps.

NOTE:
Put down the main bearing shells in order for
reuse.
40. Remove the main bearing shells and the thrust
washers.
 41. Remove all the blanking plugs and covers.
   Clean all the oil passages thoroughly.

Assemble
42. Preparations.
• Clean the seats of the removed blanking plugs and
covers.
• Thoroughly clean all the mating faces and reusable
parts and check them for damage.
• Install new blanking plugs and covers using sealant
(WSK‐M4G320‐A).
NOTE:
Compare the measured values with the
values in the ”General Specifications" and if
necessary regrind or renew the crankshaft.
43. Measure the diameter of the main and big‐end
bearing journals using a micrometer.
   Take two measurements in each case, with the
second measurement at 905 to the first.

44. Paint marks on the main and big‐end bearing

journals (production repair sizes).
   Standard main and big‐end bearing journals do not
have any paint mark.
1. Main bearing journals which are 0,25 mm
undersize have a green mark.
2. Big‐end bearing journals which are 0,25 mm
undersize have a green mark on the first crank web
adjoining the big‐end bearing journal.
45. Paint marks on the bearing shells (production
repair sizes).
• Standard main and big‐end bearing shells do not
have any paint mark.
• Standard main and big‐end bearing shells (+ 0,01
mm) have a yellow paint mark.
• Standard main bearing shells for oversize cylinder
blocks and standard main bearing journals have a
black mark.
• Standard main bearing shells for standard cylinder
blocks and undersize main bearing journals have a
green mark.
46. Paint marks on main bearing caps (production
repair sizes).
• Standard main bearing caps do not have any paint
mark.
• Oversize main bearing caps (+ 0,4 mm) have a
black mark.
47. Service bearing shells.
   Bearing shells for undersize crankshafts or oversize
cylinder blocks are identified in writing on the rear
side (see Parts Microfiche).

48. Preparations for measuring the bearing clearance.

NOTE:
Carry out the following steps exactly as
described.
• Measure each bearing individually with a length of
Plastigage thread.
• The bearing shells and journals must be free from oil
• In each case only the bearing cap of the bearing
being measured is installed and tightened.
• The measurement should be carried out near the
respective dead centre position.
49. Measure the crankshaft main bearing clearance.
CAUTION:
Do not turn the crankshaft during the
measuring procedure. Do not strike the
bearing caps.
• Lay the associated bearing shells in the cylinder
block unoiled.
• Place the crankshaft unoiled in the cylinder block.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.

50. Measure the crankshaft main bearing clearance

(continued).
NOTE:
Lubricate the bolt threads with oil.

NOTE:
The numbering of the bearing caps starts at
the timing belt end.
NOTE:
Measure the bearing clearances in turn in
numerical order (one to five).
• Install each bearing cap with its associated bearing
shell making sure the arrow is pointing towards the
timing belt end and tighten it.
• Remove the bearing cap.
51. Measure the crankshaft main bearing clearance
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• Renew the bearing shells as necessary and repeat
the measurement as described in the previous step.

52. Install the crankshaft.

   Lubricate all the main bearing journals, thrust
washers and bearing shells as well as all the bolt
threads and the undersides of the bolt heads with
engine oil.
1. Insert the bearing shells.
2. Insert the thrust washers into the centre main
bearing.
3. Oil grooves of the thrust washers.

53. Install the crankshaft (continued).

   Insert the crankshaft.
NOTE:
Coat the surfaces of the main bearings with
engine oil.
NOTE:
The bearing cap numbering starts at the
timing belt end indicated by the arrows.
• Install the crankshaft main bearing caps with the
associated bearing shells.
• Tighten the bolts.
NOTE:
Compare the measurement with the values
given in the General Specifications and
correct, if necessary, with thrust washers.
54. Check the crankshaft end float.
• Set up the dial gauge.
• Measure the end float by lifting the crankshaft with a
screwdriver.

55. Measure the piston ring gaps

   Install the piston ring 12 mm below the cylinder
block mating surface.
56. Measure the piston ring gaps (continued).
   Compare the measurement with the values given in
the General Specifications and, if necessary, renew the
piston ring.

NOTE:
Connecting rod numbering (numbering starts
at the timing belt end). The cast pip next to
the piston pin bore also points to the timing
belt end.
57. Install the pistons.
1. Cast pip.
2. Connecting rod numbering.

58. Install the pistons (continued).

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference. In the case of the oil scraper ring, the
intermediate ring gaps should each be set 120 degrees
from the expander gap.
• Compress the piston rings using a piston ring
compressor.
• Press piston nos. 1 and 4 into the cylinders using the
handle of the hammer. The crank pin must be at TDC.
• Install the clean, oil‐free bearing shells in their
associated connecting rods and bearing caps.
• Install the bearing caps.
• Turn the crankshaft through 1805 and install piston
nos. 2 and 3.
59. Measure the big‐end bearing clearances.
   Measure the big‐end bearing clearance as described
in steps to
 NOTE:
The numbers on the connecting rods and big
end bearing caps must tally.
60. Install the big‐end bearing caps.
• Lubricate the bearing shells and bearing journals
with engine oil.
• Install the appropriate big‐end bearing caps and
bearing shells and tighten the bolts.

NOTE:
Fill new or overhauled oil pumps with engine
oil before installation.
NOTE:
The mating faces of the oil pump and gasket
must be flush with the sump mating face.
61. Install the oil pump with the oil intake pipe and a
new gasket.

CAUTION:
Insert the oil seal as far as it will go.

62. Insert the oil seal in the special tool.

   For correct installation in accordance with the
specifications, hold the special tool in a vice and press
the oil seal in using the handle of a hammer.
1. Wrong way.
2. Right way.

NOTE:
Lubricate the oil seal lip and the crankshaft
running face with engine oil.
63. Install the crankshaft front oil seal
   Using the pulley bolt, draw the oil seal into the oil
pump housing as far as the stop.
 NOTE:
The thrust face of the timing belt pulley must
face outwards.
64. Install the timing belt pulley.
• Grease the crankshaft journal.
1. Slide on the thrust washer with the convex side
facing outwards.
2. Tighten the timing belt pulley.
• Remove the belt pulley.
• Remove Special Tool 21‐168.

65. Install the coolant pump with a new gasket.

CAUTION:
The mating face of the oil seal carrier and its
gasket must be flush with the sump mating
face.
66. Install the crankshaft rear oil seal carrier with a
new gasket.
67. Install the bracket of the CKP sensor.

NOTE:
Lubricate the oil seal lip and the crankshaft
running face with engine oil.
68. Install the rear oil seal.
• Insert the oil seal into the special tool (see earlier
step).
• Draw in the oil seal with two flywheel bolts.

NOTE:
The installation position is marked.

NOTE:
Renew the bolts

NOTE:
Apply sealant (WSK‐M4G320‐A) to the bolt
threads.
69. Install the flywheel.
• Immobilise the flywheel.
• Tighten the bolts uniformly, working diagonally.
70. Centre the clutch disc on the clutch pressure plate
using the special tool.

71. Install the clutch.

• Tighten the bolts uniformly, working diagonally.
• Remove the special tool.

72. Install the CKP sensor.

73. Install the baffle.

74. Install the sump.

• Apply sealant (WSK‐M4G320‐A) to the joins of the oil
seal carrier and oil pump housing.
• Lay the one‐piece sump gasket in place and install it
in the groove of the oil seal carrier and the oil pump
housing.
75. Install self‐made studs (M6 x 30).

NOTE:
Tightening sequence.

76. Install the sump (continued).

• Install the sump and screw in the bolts.
• Install sump bolts in place of the self‐made studs.
• Tighten the bolts in the indicated sequence (two
stages).
• Screw in the oil drain plug with a new seal.

NOTE:
If the maximum permitted cylinder head
unevenness is exceeded, rework the mating
face (see General Specifications).
77. Check the cylinder head unevenness with a steel
straight edge.

78. Install the cylinder head gasket.

1. Insert the guide bushes.
2. Choose the new cylinder head gasket by comparing
it with the old gasket (identification teeth).
3. Install the cylinder head gasket.
 CAUTION:
Renew the cylinder head bolts.

NOTE:
Before installing the cylinder head, turn the
crankshaft so that cylinder no. 1 is approx.
20 mm before TDC.
79. Install the cylinder head.
• Install the cylinder head.
• Tighten the new cylinder head bolts in the indicated
sequence in four stages.

CAUTION:
The cylinder head bolts must not be
retorqued.
80. Install the cylinder head (continued).

81. Turn the camshaft timing belt to the TDC mark.

1. TDC mark on cylinder head.
2. TDC mark on camshaft timing belt pulley.
 CAUTION:
The crankshaft should be turned in the
direction with the shorter distance to the
mark.
82. Turn the crankshaft to the TDC mark.
1. TDC mark on cylinder block.
2. TDC mark on crankshaft timing belt pulley.

83. Install the timing belt tensioner and the timing

belt.
   Screw in the bolts.
1. Press the timing belt tensioner all the way to the
left.
2. Install the timing belt starting at the crankshaft,
working anti‐clockwise.
   Adjust the timing belt tension as described in the
following step.
3. Tighten the bolts.

CAUTION:
Check the timing belt tension again after 500
km.
84. Adjust the timing belt tension.
• Pretension the timing belt with the timing belt
tensioner.
• Turn the crankshaft clockwise at least two turns to
the TDC position for cylinder no. 1.
1. Turn the crankshaft back anti‐clockwise approx. 605
(three tooth divisions on the camshaft timing belt
pulley).
2. Install the special tool and read off the timing belt
tension.
• If the timing belt tension does not correspond to the
values stated in the General Specifications (new timing
belt 10 to 11 scale divisions, used timing belt 4 to 6
scale divisions), turn the crankshaft clockwise to the
TDC position for cylinder no. 1.
• Release the timing belt tensioner and adjust the
timing belt as required.
• Turn the crankshaft 90° further in a clockwise
direction.
• Turn the crankshaft anti‐clockwise to 605 before TDC
position (measuring position).
• Install the special tool and read off the timing belt
tension.
• Repeat the procedure until the timing belt tension is
correct.
85. Install the cylinder head cover.
• Install the cylinder head cover with a new gasket.
• Install the reinforcing panels with the rippled side
upwards.
• Tighten the bolts uniformly.

86. Install the timing belt cover (two parts).

87. Connect the PCV hose.

NOTE:
Apply spark plug lubricant `Never Seeze'
(ESE‐M1244‐A) to the threads of the spark
plugs.
88. Install the spark plugs (16 mm socket).

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) to avoid
damaging the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in line with
the axis of the spark plug.
NOTE:
Coat the inside of the spark plug connectors
to a depth of 5‐10 mm with silicone grease.
89. Push on the spark plug connectors until they
engage.
 NOTE:
Dowel pins.

90. Install the adapter plate.

91. Attach the crankshaft pulley/vibration damper.

   Immobilise the flywheel.

92. Attach the front engine mounting bracket to the

cylinder block.

93. Install the power steering pump and alternator

bracket.

94. Install the alternator.

95. Install the power steering pump (four bolts).

NOTE:
Do not tighten the bolts.

96. Attach the belt pulley to the power steering

pump.

97. Install the coolant hose and the multi‐groove belt.

1. Coolant hose
2. Release the belt tensioner.
3. Install the multi‐groove belt and tension it.
4. Secure the power steering pump belt pulley.

NOTE:
Renew the O‐ring.

98. Finishing operations.

1. Install the oil dipstick tube with an O‐ring and
insert the oil dipstick.
NOTE:
Lubricate the oil filter seal with engine oil.

2. Install the new oil filter using an oil filter strap

wrench.
3. Install the oil pressure switch using sealant (WSK
M4G320‐A).
    Fill up with oil.
99. Detach the engine from the assembly stand.

General Specifications Escort/Orion 1991 (08/1990-09/2001)

 Print

Specifications
Engine Data
1,3 HCS‐CFI
Engine management EEC IV
Emission standard 15.04/93EEC
Engine code J6A
Firing order 1‐2‐4‐3
Bore mm 73,96
Stroke mm 75,48
Effective
Cubic capacity 1297
cc
Effective
Fiscal capacity 1299
cc
Compression ratio 8,8 : 1
Compression pressure at starter motor speed bar 13 ‐ 16
Max. continuous engine speed rev/min 5450
Max. intermittent engine speed rev/min 5675
kW
Power output (DIN) at 44 (5000)
(rev/min)
PS
Power output (DIN) at 60 (5000)
(rev/min)
Nm
Torque (DIN) at 101 (2500)
(rev/min)
Dimensions
Cylinder block 1,3 HCS‐CFI
Cast mark 1,3 89BM‐6015‐FA
Number of main bearings 5
Cylinder liner bore diameter in the cylinder block mm 77,086 ‐ 77,112
Cylinder bore diameter ‐ standard class 1 mm 73,940 ‐ 73,950
Cylinder bore diameter ‐ standard class 2 mm 73,950 ‐ 73,960
Cylinder bore diameter ‐ standard class 3 mm 73,960 ‐ 73,970
Cylinder bore diameter ‐ oversize 0,5 mm 74,500 ‐ 74,510
Cylinder bore diameter ‐ oversize 1,0 mm 75,000 ‐ 75,010
Centre main bearing width (without thrust half rings) mm 22,04 ‐ 22,10
Fitted main bearing shells, standard mm 57,009 ‐ 57,036
Vertical inside diameter, undersize 0,254 mm 56,755 ‐ 56,782
Vertical inside diameter, undersize service 0,508 mm 56,501 ‐ 56,528
Vertical inside diameter, undersize 0,762 mm 56,247 ‐ 56,274
Main bearing parent bore diameter, standard mm 60,623 ‐ 60,636
Main bearing parent bore diameter, oversize mm 61,003 ‐ 61,016
Camshaft bearing parent bore diameter, standard mm 42,888 ‐ 42,918
Camshaft bearing parent bore diameter, oversize mm 43,396 ‐ 43,420
Camshaft bearing bush diameter, standard mm 39,662 ‐ 39,682
Camshaft bearing bush diameter, oversize cylinder block mm 39,662 ‐ 39,682
Camshaft bearing bush diameter, standard and oversize
mm 39,662 ‐ 39,713
service
Dimensions
Crankshaft 1,3 HCS‐CFI
Main bearing journal diameter, standard mm 56,980 ‐ 57,000
Main bearing journal diameter, yellow mm ‐
Main bearing journal diameter, undersize (green) 0,254 mm 56,726 ‐ 56,746
Main bearing journal diameter, undersize service 0,508 mm 56,472 ‐ 56,492
Main bearing journal diameter, undersize 0,762 mm 56,218 ‐ 56,238
Main bearing shell width mm 18,29 ‐ 18,69
Main bearing clearance mm 0,009 ‐ 0,056
Big‐end bearing journal diameter, standard mm 40,99 ‐ 41,01
Big‐end bearing journal diameter, undersize (green) 0,254 mm 40,74 ‐ 40,76
Big‐end bearing journal diameter, undersize service 0,508 mm 40,49 ‐ 40,51
Big‐end bearing journal diameter, undersize 0,762 mm 40,24 ‐ 40,26
End float mm 0,075 ‐ 0,285
Thrust half washer thickness, standard mm 2,80 ‐ 2,85
Thrust half washer thickness, oversize mm 2,99 ‐ 3,04
Dimensions
Connecting rods 1,3 HCS‐CFI
Bore diameter, big‐end mm 43,99 ‐ 44,01
Bore diameter, small end mm 17,99 ‐ 18,01
Fitted big‐end bearing shell, vertical inside diameter, standard mm 41,016 ‐ 41,050
Fitted big‐end bearing shell, vertical inside diameter,
mm 40,766 ‐ 40,800
undersize 0,254
Fitted big‐end bearing shell, vertical inside diameter,
mm 40,516 ‐ 40,550
undersize 0,508
Fitted big‐end bearing shell, vertical inside diameter,
mm 40,266 ‐ 40,300
undersize 0,762
Fitted big‐end bearing shell, vertical inside diameter,
mm 40,016 ‐ 40,050
undersize 1,016
Clearance between big‐end bearing journal and bearing shell mm 0,006 ‐ 0,060
End float mm 0,100 ‐ 0,250
Dimensions
Pistons 1,3 HCS‐CFI
Piston diameter, standard class 1 mm 73,91 ‐ 73,92
Piston diameter, standard class 2 mm 73,92 ‐ 73,93
Piston diameter, standard class 3 mm 73,93 ‐ 73,94
Piston diameter, standard service mm 73,93 ‐ 73,95
Piston diameter, standard oversize 0,5 mm 74,46 ‐ 74,49
Piston diameter, standard oversize 1,0 mm 74,96 ‐ 74,99
Piston clearance ‐ production mm 0,020 ‐ 0,040
Piston clearance ‐ service mm 0,015 ‐ 0,050
Piston ring gap (fitted), top and middle mm 0,25 ‐ 0,45
Piston ring gap (fitted), middle (from 4/96) mm 0,45 ‐ 0,75
Piston ring gap (fitted), lower mm 0,20 ‐ 0,50
Ring gap position, top 180° from the oil control ring gap
Ring gap position, middle 90° from the oil control ring gap
Ring gap position, bottom in alignment with piston pin
Piston pin length mm 63,6 ‐ 64,4
Piston pin diameter, white mm 18,026 ‐ 18,029
Piston pin diameter, red mm 18,029 ‐ 18,032
Piston pin diameter, blue mm 18,032 ‐18,035
Piston pin diameter, yellow mm 18,035 ‐ 18,038
Piston pin interference fit at 21°C mm 0,016 ‐ 0,048
Piston pin clearance at 21°C mm 0,008 ‐ 0,014
Dimensions
Cylinder head 1,3 HCS‐CFI
Cast mark 1,3 CFI 92BM‐6090‐AA
Combustion chamber volume cm3 31,79 ‐ 33,79
Max. permissible distortion of cylinder head, measured over a
mm 0,04
length of 26 mm
Max. permissible distortion of cylinder head, measured over a
mm 0,08
length of 152 mm
Max. permissible distortion of cylinder head, measured over
mm 0,15
the whole length
Milling the cylinder mating face
After milling the combustion chamber must have a depth of at
mm 14,4 ‐ 14,55
least
Stem bore (inlet and exhaust valve), standard mm 7,063 ‐ 7,094
Stem bore (inlet and exhaust valve), 1st oversize 0,2 mm 7,263 ‐ 7,294
Stem bore (inlet and exhaust valve), 2nd oversize 0,4 mm 7,463 ‐ 7,494
Upper correction angle (A), production ° 30
Upper correction angle (A), service correction cutter ° 30
Valve seat angle (B) ° 45
Lower correction angle (C), production (inlet) ° 60
Service correction cutter ° 75
Valve seat width (D) inlet/exhaust mm 1,18 ‐ 1,75
Dimensions
Camshaft 1,3 HCS‐CFI
Drive Timing chain
Chain length 46 links
Valve timing, inlet valve opens before TDC °CS 12
Valve timing, inlet valve closes after BDC °CS 48
Valve timing, exhaust valve opens before TDC °CS 47
Valve timing, exhaust valve closes after BDC °CS 13
Cam lift, inlet mm 5,70
Cam lift, exhaust mm 5,76
Cam length (base to nose), inlet mm 32,586 ‐ 39,814
Cam length (base to nose), exhaust mm 32,646 ‐ 33,874
Camshaft bearing diameter mm 39,615 ‐ 39,635
Bearing bush inner diameter mm 39,662 ‐ 39,682
Bearing bush inner diameter, service mm 39,662 ‐ 39,713
Camshaft thrust plate thickness mm 4,457 ‐ 4,508
Camshaft end float mm 0,02 ‐ 0,19
Dimensions
Valves 1,3 HCS‐CFI
via tappets,
Valve control push rods and
rocker arms
Valve clearance (engine cold), inlet mm 0,20
Valve clearance (engine cold), exhaust (engines built in production
mm 0,30
up to 20.11.96)
Valve clearance (engine cold), exhaust (engines built in production
mm 0,50
from 21.11.96, identified by a sticker on the cylinder head cover)
13,081 ‐
Valve tappet diameter mm
13,094
Tappet clearance in cylinder block mm 0,016 ‐ 0,062
Valve spring free length (inlet/exhaust) mm 41,0
Valve spring inner diameter mm 20,25 ‐ 20,75
Valve spring wire diameter mm 3,77 ‐ 3,83
Number of turns mm 6
103,70 ‐
Valve length, inlet mm
104,40
104,02 ‐
Valve length, exhaust mm
104,72
Valve head diameter, inlet mm 34,40 ‐ 34,60
Valve head diameter, exhaust mm 28,90 ‐ 29,10
Valve stem diameter, standard inlet mm 7,025 ‐ 7,043
Valve stem diameter, standard exhaust mm 6,999 ‐ 7,017
Valve stem diameter, oversize 0,20 inlet mm 7,225 ‐ 7,243
Valve stem diameter, oversize 0,20 exhaust mm 7,199 ‐ 7,217
Valve stem diameter, oversize 0,40 inlet mm 7,425 ‐ 7,443
Valve stem diameter, oversize 0,40 exhaust mm 7,399 ‐ 7,417
Valve stem guide clearance, inlet mm 0,020 ‐ 0,069
Valve stem guide clearance, exhaust mm 0,046 ‐ 0,095
Valve lift (without clearance), inlet mm 8,86 ‐ 9,26
Valve lift (without clearance), exhaust mm 8,96 ‐ 9,36
Engine Oil
Viscosity/ ambient Designation Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to over Ford Formula E Economy ACEA A1/B1 and WSS‐
40 degrees Centigrade Motor Oil M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 to over 40 Ford ”Super" Multigrade Motor ACEA A1/B1 or A2/B2 or
degrees Centigrade Oil API/SH/CD EC
SAE 10W40 / ‐20 to over 40 Ford XR+ High‐performance
ACEA A3/B3 or API/SH/CD EC
degrees Centigrade High‐lubricity Motor Oil
SAE 5W40 / below ‐20 to over Ford Formula S Synthetic
ACEA A3/B3 or API/SH/CD EC
40 degrees Centigrade Motor Oil
If engine oils with these specifications are not available, only engine oils which at least meet
the API/SH/CD EC specification may be used.
Engine Lubrication
Description 1,3 HCS‐CFI
Oil pressure (minimum, oil temperature approx. 80 5C), at
bar 0,6
750 rev/min
Oil pressure (minimum, oil temperature approx. 80 5C), at
bar 1,5
2000 rev/min
Pressure relief valve opening pressure bar 2,41 ‐ 2,96
Oil pump, max. gap between outer and inner rotor mm 0,051 ‐ 0,127
Oil pump (clearance between outer rotor and housing) mm 0,14 ‐ 0,26
End float, outer/inner rotor to oil pump cover mm 0,025 ‐ 0,06
Engine Lubrication
Description 1,3 HCS‐CFI
Minimum oil pressure at idle speed bar 0,6
Minimum oil pressure at 2000 rev/min bar 1,5
Oil pressure warning lamp lights up at bar 0,32 ‐ 0,53
Pressure relief valve opens at bar 2,41 ‐ 2,96
Oil pump (clearance between outer rotor and housing) mm 0,14 ‐ 0,26
Clearance between inner and outer rotor mm 0,051 ‐ 0,127
End float between outer and inner rotor and oil pump cover mm 0,025 ‐ 0,06
Lubricants, Fluids and Sealers
Description Ford
Specification
Coolant (Ford Super Plus 4 coolant concentrate) ESD‐M97B‐49A
Transmission fluid SQM‐2C‐9008‐A
Lubricant ‐ spark plug threads ('Never Seeze') ESE‐M1244‐A
Sealer, sump mating face intersections (Hylosil 502) WSK‐M4G320‐A
Sealer, flywheel bolts (Hylosil 502) WSK‐M4G320‐A
Capacities
Description Litres
Coolant 7,1
Engine oil ‐ initial fill with oil filter 3,4
Engine oil ‐ oil change with filter change 3,25
Engine oil ‐ oil change without filter change 2,75
Transmission fluid (B5) 3,1
Drive belt tension
N
New drive belt (with tension gauge) 350 ‐ 450
Run‐in drive belt (run for at least 10 minutes) (with tension
250 ‐ 350
gauge)
Torques
General Nm lbf.ft
Track rod to spindle carrier 36 27
Lower suspension arm to spindle carrier 52 38
Intake air temperature (IAT) sensor 23 17
Exhaust manifold to cylinder head 23 17
Exhaust pipe to exhaust manifold 38 28
Heated oxygen sensor (HO2S) 60 44
Adapter plate ‐ engine/transmission 40 30
Starter motor 40 30
Front exhaust pipe to rear exhaust pipe 47 35
Torques
Engine mountings Nm lbf.ft
Front engine mounting 84 62
Engine mounting brace ‐ rear right‐hand side 69 51
Front engine mounting to cylinder block bracket 120 89
Front engine mounting bracket to cylinder block 69 51
Front engine mounting brace 69 51
Torques
Cylinder head Nm lbf.ft
Inlet manifold 24 18
Catalytic converter to exhaust manifold 37 27
Spark plugs 17 13
Exhaust manifold to cylinder head 23 17
Engine coolant temperature sensor (ECT sensor) 23 17
Coolant temperature gauge sender unit 6 4
Inlet manifold to cylinder head 18 13
Cylinder head (Stage 1) 30 22
Cylinder head (Stage 2) 90° 90°
Cylinder head (Stage 3) 90° 90°
Rocker shaft 43 32
Cylinder head cover 6 4
Torques
Cylinder block Nm lbf.ft
Main bearing cap 95 70
Big‐end bearing caps (stage 1) 4 3
Big‐end bearing caps (stage 2) 90° 90°
Camshaft thrust plate 11 8
Camshaft sprocket 28 21
Timing chain tensioner 8 6
Timing cover 9 7
Hexagonal headed bolts, rear crankshaft oil seal carrier 22 16
Torx bolts, rear crankshaft oil seal carrier 18 13
Crankshaft pulley 115 85
Torques
Oil circuit Nm lbf.ft
Sump (stage 1) 7 5
Sump (stage 2) 10 7
Retighten sump (stage 3) (engine at operating temperature ‐ 15
10 7
minutes at 1000 rev/min)
Oil drain plug 25 18
Oil pressure switch 14 10
Oil pump 18 13
Torques
Clutch/transmission Nm lbf.ft
Flywheel 67 49
Clutch pressure plate 30 22
Flange bolts ‐ engine/transmission 44 32
Torques
Coolant circuit Nm lbf.ft
Thermostat housing 20 15
Coolant pump 8 6
Engine coolant temperature sensor (ECT sensor) 23 17
Coolant pump pulley 10 7

Description and Operation Escort/Orion 1991 (08/1990-09/2001)

 Print

Description and Operation

The Escort/Orion '91 is equipped with the following familiar and reliable Valencia HCS
engines:

1,1 2V engine (Euronorm)

1,3 2V engine (15.04)

1,3 2V engine (Euronorm)

1,3 CFI engine (83 US)

The 1,3 HCS‐CFI engine also belongs to this group.

All engine variants are equipped with a distributerless and fully electronic ignition system,
and because of the use of hardened valve seat rings on the inlet and exhaust valves they
can be run on unleaded fuel.

Engine code
1. Location of engine code and serial number
1. Engine code.
2. Serial number.
Item Description
1 Front engine mounting brace
2 Front engine mounting
3 Rear right‐hand side engine mounting
Engine mounting strut ‐ rear right‐
4
hand side
5 Rear left‐hand engine mounting
6 Transmission
7 Engine

Engine ‐ Dismantle and Reassemble

Escort/Orion 1991 (08/1990-09/2001)
(engine removed) (21 134 8)
 Print

Removal and Installation

Special Tools

16‐067Locator, clutch disc

21‐046Installer, crankshaft
front oil seal

21‐050AMounting bracket,
engine

21‐102Installer/aligner, oil
seal
 21‐102‐01Adapter for 21‐102

21‐102‐02AAdapter for 21‐102

21‐102‐04Bolts for 21‐102‐

02A

21‐168Installer, oil seal

21‐187Assembly stand

21‐540Angle gauge

Proprietary tools
Description
Oil filter strap wrench
Piston ring compressor
Piston ring pliers
Micrometer
Two‐legged puller
Three‐legged puller
Torque wrench
Steel rule
Internal gauge
Feeler gauges
Dial gauge
Measuring fixture
Plastic scraper
Materials
Description
Obtainable from:
Replacement Services
Limited, 16 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST
Sealer, sump to
cylinder block, oil WSK‐M4G320‐A
pressure switch
Lubricant ‐ spark plugs ESE‐M1244‐A
refer to General
Engine Oil
Specifications
Dismantle
1. Mount the engine on the assembly stand.
CAUTION:
Do not pull on the lead when removing the
spark plug connectors. If necessary,
disconnect the HT lead from the ignition coil
to prevent the lead from getting kinked.
Before removing it, turn the spark plug
connector slightly to loosen the seal.
CAUTION:
Pull off the spark plug connector in a
direction in line with the spark plug axis.
   Pull off the spark plug connectors and unclip the HT
leads.
2. Detach the alternator.
1. Undo the bolts on the coolant pump pulley.
2. Slacken the drive belt by undoing the locking bolt
and swivelling the alternator, and then remove the
drive belt.
3. Remove the bolts and take off the alternator.
4. Remove the tensioning bracket.

3. Detach the alternator bracket.

NOTE:
Loosen the bolts evenly.

4. Remove the clutch and undo the flywheel bolts.

1. Mount the special tool.
2. Remove the clutch.
NOTE:
Only undo the bolts and do not remove them.

3. Undo the flywheel bolts.

5. Remove the ancillary components.
1. Drain the engine oil.
2. Remove the oil filter.
3. Remove the oil pump (three bolts).
4. Remove the EI coil (three bolts).
5. Detach the intake manifold (five bolts, one stud).
• Detach the hose from the oil filler cap.
• Remove the seals.

6. Remove the oil pressure switch.

NOTE:
Do not remove the gasket.

7. Remove the coolant pump.

1. Remove the coolant pump pulley (three bolts).
2. Remove the coolant pump (three bolts).

NOTE:
Immobilise the crankshaft using Special Tool
21‐168.
8. Remove the crankshaft pulley bolt and tighten it a
few turns.
9. Remove the crankshaft pulley.
• Pull off the pulley using a three‐legged puller.
• Unscrew the pulley bolt.

10. Remove the cylinder head cover.

1. Pull off the oil filler cap.
2. Remove the cylinder head cover (four bolts and four
extended washers).
NOTE:
Do not adjust the rocker arm bolts.

3. Remove the rocker shaft (four bolts).

NOTE:
Lay the push rods in order to one side ready
for re‐use.
4. Take out the push rods and set them aside in the
correct order.

11. Remove the thermostat housing.

1. Remove the thermostat housing.
   Remove the thermostat and the gasket.
2. Remove the coolant temperature gauge sender unit.
3. Remove the spark plugs.
 CAUTION:
Mark the bolts for re‐use with centre punch
markings. The bolts can only be re‐used
once. Remove the bolts following the
indicated sequence.
12. Remove the cylinder head (ten bolts).
   Take off the cylinder head together with the exhaust
manifold.

13. Remove the flywheel.

   Remove the flywheel bolts and take off the flywheel.
NOTE:
Only remove the sump downwards to prevent
any abraded particles or oil sludge from
getting in to the engine.
14. Remove the sump (18 bolts).

15. Detach the crankshaft rear oil seal carrier (four

bolts).
• Remove the gasket.
• Tap out the radial seal on a flat surface.

16. Remove the timing cover.

• Remove the gasket.
• Tap out the radial seal on a flat surface.
 17. Remove the timing chain.
1. Remove the oil slinger from the crankshaft.
2. Remove the timing chain tensioning arm from the
pin of the front main bearing.
3. Remove the timing chain tensioner (two bolts).
4. Destake the bolts on the camshaft sprocket and
remove them.
   Remove the camshaft sprocket together with the
lock tab and the timing chain.

CAUTION:
Rotate the engine into the indicated position.

18. Remove the camshaft.

• Turn the camshaft through 360_ to position the
valve tappets to TDC.
• Destake the camshaft bolts.
• Remove the camshaft bolts and thrust plate.
• Carefully pull the camshaft out of the cylinder block.
NOTE:
Lay the valve tappets in order to one side
ready for re‐use.
   Remove the valve tappets.
19. Remove the crankshaft sprocket with a two‐legged
puller.

CAUTION:
Do not damage the cylinder liners.

NOTE:
Carefully decarbonise with a plastic scraper.
Do not damage the piston ring running
surfaces.
20. Remove the pistons and the connecting rods.
NOTE:
Set aside the connecting rods, the big‐end
bearing caps and the bearing shells in the
correct order.
• Remove the big‐end bearing caps.
• Press out the connecting rods with the pistons from
the cylinder block.
 NOTE:
Set aside the main bearing caps and the
bearing shells in the correct order. Mark the
position of the centre thrust half rings on
the centre main bearing.
21. Remove the crankshaft.
• Detach the main bearing caps.
• Lift the crankshaft out of the cylinder block.
• Take out the bearing shells and the thrust half rings
and set them aside in the correct order.

Reassemble
22. Thoroughly clean all mating faces and re‐usable
parts and check them for damage.
23. All oil ways, e.g. those of the cylinder block,
cylinder head etc., must be free of dirt and swarf.
NOTE:
The main bearing caps must be fitted without
the main bearing shells, and tightened to the
specified torque.
24. Measure the cylinder bores using an internal
gauge.
   If the measured cylinder bore diameter is too large
for the piston classification, then the cylinder block
must be overhauled or renewed.

NOTE:
Measure the piston diameter at a distance of
42 mm to the piston crown.
NOTE:
Piston classification, in case a piston must be
renewed.
25. Measure the piston diameters.
 CAUTION:
Do not mix up the piston rings. Replace the
rings in the same grooves and at the same
position.
26. Measure the piston ring gaps.
   The values given in the General Specifications apply
to a gauge ring used in production. When measured in
the cylinder, the values may be exceeded by 0,15 mm.

NOTE:
The piston ring axial clearance must be
measured with the ring projecting from its
groove.
27. Measure the piston ring clearance.
• The maximum clearance for the upper compression
ring is 0,2 mm.
• The maximum clearance for the second compression
is 0,1 mm.

NOTE:
Perform two measurements in each case,
90° opposed to each other.
28. Measure the crankshaft.
   Measure the main and big‐end bearing journals
using a micrometer.

29. Paint markings on the main bearing caps.

• The standard sized parent bore has no identification
marking.
• On a 0,38 mm oversize parent bore the bearing caps
have a white paint marking.

30. Paint markings on the main and big‐end bearing

shells.
• Standard bearing shells are either unmarked or have
a yellow (0,010 mm wide) paint mark.
• Bearing shells for an oversize cylinder block or
undersize crankshaft are marked accordingly on the
rear faces (see Parts Microfiche).
• For production repairs, the shells are paint marked
as illustrated.
31. Paint markings on the main and big‐end bearing
journals.
• Standard diameter main bearing journals are
unmarked.
• A crankshaft with 0,25 mm undersize main bearing
journals is marked at the first crankshaft web with a
green paint stripe.
• Standard diameter big‐end bearing journals are
unmarked.
• On 0,25 mm undersize big‐end bearing journals the
first crankshaft web adjacent to the bearing journal
has a green paint mark.
CAUTION:
Take care not to damage the journals when
laying the crankshaft in place.
32. Lay the crankshaft in place.
• Position the main bearing shells in the cylinder block.
• Lay the crankshaft oil dry in place.
NOTE:
Measure the bearing clearance in numerical
sequence (1 to 5). The numbering starts at
the front face.
33. Measure the main bearing clearance.
   Lay a length of Plastigage thread across the bearing
on the bearing journal.
CAUTION:
Do not turn the crankshaft during the
measuring procedure. Do not strike the
bearing caps.
34. Measure the main bearing clearance (continued).
• Lay the bearing caps in place with their matching
bearing shells and tighten them to the specified
torque.
• Remove the bearing cap.

NOTE:
If the specified clearance is not achieved, the
bearing shells must be changed and the
measuring procedure repeated.
35. Measure the main bearing clearance (continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The measured value shows the bearing clearance.

36. Install the crankshaft.

• Lubricate the main bearing journal, all bearing shells
and all bolts (on the thread and on the underside of
the head) with engine oil.
NOTE:
The oil grooves on the thrust half rings must
be visible.
• Place the bearing shells and the thrust half rings in
position on the cylinder block.
37. Install the crankshaft (continued).
• Install the crankshaft.
NOTE:
Arrows must point towards the front.

• Put the main bearing caps in place together with

their bearing shells and thrust half washers.
• Tighten the bolts.

NOTE:
If necessary correct the end float by fitting
new thrust half washers.
38. Check the crankshaft end float.
• Fit dial‐gauge.
• Measure end float by lifting the crankshaft.

39. Install the pistons and connecting rods.

   Pull the piston rings onto the piston using piston ring
pliers.
NOTE:
Fit the piston rings with the manufacturer's
markings towards the top. If the
manufacturer's markings are not present,
install the Napier ring and the oil scraper ring
as shown in the diagram.
NOTE:
Distribute the piston ring gaps as detailed in
General Specifications.
   Lubricate the pistons and cylinder bores with engine
oil.
40. Install the pistons and connecting rods
(continued).
   Compress the piston rings using a piston ring
compressor.
NOTE:
The marking arrow on the piston points
towards the front. The connecting rods are
marked at the base with the cylinder number
in which they should be fitted.
NOTE:
Guide each connecting rod with the hand so
as not to damage the bearings.
   Push the piston into the cylinder bore with a
hammer handle. The relevant big‐end journal must be
at BDC.
41. Measure the big‐end bearing clearances.
• Measure the big‐end bearing clearance as described
in the previous job steps.
• If necessary fit different bearing shells.
 CAUTION:
Renew the bolts.

NOTE:
The numbering of the connecting rods and
the bearing caps must correspond. Ensure
that the connecting rods have enough axial
clearance.
42. Fit big‐end bearing caps.
• Lubricate the bearing shells and bearing journals, as
well as the bolt threads and bolt head contact areas
with engine oil.
• Fit big‐end bearing shells and caps and tighten
them.
NOTE:
The marking on the sprocket must be visible.

43. Install the crankshaft sprocket.

• Fit the sprocket with the aid of the pulley, the bolt
and the washer.
• Lubricate the valve tappets with engine oil and insert
them (x8).

44. Install the camshaft.

• Lubricate camshaft bearing, camshaft and thrust
plate with engine oil.
• Insert the camshaft from the front and position the
thrust plate.
• Tighten and secure the bolts.

45. Install the chain tensioner.

• Fit the chain tensioner to the cylinder block (two
bolts).
• Check for parallel at two points across ”A".
• If the tolerance is exceeded, undo, align and tighten
the timing chain tensioner and repeat the
measurement.

NOTE:
The marks on the sprockets must line up.

46. Install the timing chain.

1. Place the camshaft timing chain and sprocket in
position.
2. Put on the lock tab, tighten the bolts and secure
them.
3. Slide the chain tensioner arm onto the studs.
 CAUTION:
Coat the outer rubber of the oil seal with a
drop of engine oil to prevent it from skewing
when pressing it in. Never coat the sealing
lip with engine oil.
47. Install the crankshaft front oil seal.
1. Slide the special tool onto the hub of the
crankshaft pulley.
2. Place the oil seal on the hub of the crankshaft
pulley.
3. Locate the crankshaft pulley in position and pull
the oil seal in by tightening the bolt.
NOTE:
The mating surface to the sump must be
flush with that of the cylinder block.
48. Fit the timing cover.
• Centre the timing cover together with the pulley and
tighten the four bolts.
• Take off the belt pulley and the special tool.
• Tighten the fifth bolt.

49. Install the crankshaft rear oil seal

   Locate the oil seal carrier in position with a new seal
and screw in the bolts.

50. Install the crankshaft rear oil seal.

 CAUTION:
Do not remove the support ring until after
installation. Coat the outer rubber of the oil
seal with a drop of engine oil to prevent it
from skewing when pressing it in. Never coat
the sealing lip with engine oil.
1. Push the crankshaft rear oil seal onto the
crankshaft.
NOTE:
The crankshaft guide pin must be aligned
with the bore of the special tool.
NOTE:
The special tool must be centred on the oil
seal to prevent the oil seal from skewing
when being pressed in.
2. Attach the special tool.
• Draw in the oil seal up to the stop by tightening the
nut.
• Detach the special tool and remove the support ring.
51. Tighten the crankshaft rear oil seal carrier.
• Torx bolts: 18 Nm
• Hexagonal headed bolts: 22 Nm

NOTE:
Apply sealer (WSK‐M4G320‐A) to the areas
marked.
52. Apply sealer to the cylinder block.

NOTE:
Locate the lugs on the cork gaskets
underneath the recesses in the rubber seals.
53. Put on the sump gasket.
• Insert the rubber seals into the oil seal carrier
grooves.
• Put on the cork gaskets.
 NOTE:
The arrow on the side nearest the clutch
points towards the front of the car.
54. Fit the sump.
   Position the sump and tighten the bolts in three
stages.
1. In alphabetic sequence to 7 Nm.
2. In numeric sequence to 10 Nm.
3. After warming up the engine for 15 minutes,
retorque the bolts to 10 Nm.

55. Fit the flywheel (6 bolts).

• Immobilise the crankshaft.
• Coat the bolts with engine oil and tighten them
working diagonally.

NOTE:
Immobilise the crankshaft using Special Tool
21‐168.
56. Install the crankshaft pulley.
57. Install the cylinder head.
• Lay a new cylinder head gasket in place.
• Lay the cylinder head in place and screw in (but do
not tighten) the cylinder head bolts.
• Tighten the cylinder head bolts in three stages
according to the tightening sequence shown.

58. Fit the thermostat housing.

1. Insert the thermostat with a new gasket.
   Fit the thermostat housing.
2. Coolant temperature gauge sender unit
NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
3. Fit the spark plugs.

59. Fit the rocker shaft.

1. Insert the push rods.
2. Fit the rocker shaft (4 bolts).
60. Set the valve clearances as described in Operation
No. 21 213 0.

NOTE:
Renew the gasket.

61. Fit the cylinder head cover.

1. Fit the cylinder head cover (four bolts and four
extended washers).
2. Push on the oil filler cap and connect the crankcase
ventilation hose.
62. Fit the coolant pump.
1. Fit the coolant pump (three bolts).
2. Fit the coolant pump pulley (three bolts).

NOTE:
Apply sealer (WSK‐M4G320‐A) to the thread
of the oil pressure switch.
63. Fit the oil pressure switch.

64. Fill the oil pump with 0,15 l of engine oil before
fitting.
   Turn the oil pump input shaft one turn anti‐
clockwise.

65. Fit the attaching parts.

1. Fit the oil drain plug with a new seal.
2. Install the intake manifold with a new gasket (five
bolts, one stud).
NOTE:
Previous job step.

3. Fit the oil pump with a new gasket (three bolts).

4. Fit the EI coil (three bolts).
NOTE:
Lubricate the seal lip with oil.

5. Fit the oil filter.

66. Centre the clutch disc.
   Centre the clutch disc on the clutch pressure plate
and secure it using the special tool.

67. Install the clutch disc with the clutch pressure

plate.
1. Locate the clutch pressure plate with the special tool
and the centred clutch disc on the guide pegs on the
flywheel.
2. Tighten down the clutch pressure plate evenly,
working diagonally.
3. Remove the special tool.

68. Fit the alternator bracket.

69. Fit the generator.

1. Fit the tensioning bracket.
2. Tighten the alternator bolt.
3. Screw in the tensioning bolt.
• Lay the drive belt in place and swivel the alternator
to tension it.
• Tighten all bolts.
 70. Remove the engine from assembly stand.
   Push on the spark plug connectors, lay the HT leads
in place and clip them into the wiring bracket.

71. Standard finishing operations.

• Top up with engine oil.
• Remove the special tools.
• Remove the engine from assembly stand.

Cylinder Head ‐ Remove and Install (21

Escort/Orion 1991 (08/1990-09/2001)
163 0)
 Print

Removal and Installation

Special Tools

24‐003Remover and installer

for radiator hose clips

21‐540Angle gauge

Materials
Spark plug lubricant ESE‐M1244‐A
Cable ties
Silicone grease A960‐M1C171‐AA
Coolant ESD‐M97B‐49A
Remove
1. Standard preparatory measures.
• Make a note of the radio keycode.
• Make a note of the pre‐set radio stations.
CAUTION:
Disconnect the battery negative lead.

• When removing the coolant and ventilation hoses,

use remover 24‐003 as necessary.
2. Drain the coolant.
WARNING:
Before opening up the cooling system, cover
up the coolant expansion tank cover with a
thick cloth to avoid scalding.
• Remove the coolant drain plug.
• Unscrew and remove the coolant expansion tank cap.
• After the coolant has been drained, retighten the
drain plug.
3. Remove the air cleaner housing.
1. Remove the bolts.
2. Unclip the fuel separator from the air cleaner
housing.
   Slightly lift the air cleaner housing and pull off the
crankcase ventilation hose downwards.

4. Detach the coolant hoses from the thermostat

housing and disconnect the plugs.
1. Cooling fan motor temperature switch
2. Coolant temperature gauge sender unit

5. Detach the coolant hoses from the throttle body

assembly and from the inlet manifold.

6. Pull off the vacuum hoses and disconnect the

ground cable from the inlet manifold.
1. To the pulse air system.
2. To the brake servo.

7. Disconnect the vacuum hoses.

1. To the fuel separator.
2. To the manifold absolute pressure (MAP) sensor.
 NOTE:
Watch out for escaping fuel.

8. Disconnect the fuel pipes.

1. Return pipe from the throttle body assembly.
2. Quick‐release coupling on the feed pipe.

9. Detach the throttle cable from the throttle body

assembly.

10. Disconnect the plugs.

1. Throttle valve stepper motor.
2. Throttle position sensor (TP sensor)
3. Throttle body assembly
4. Intake air temperature (IAT) sensor

11. Disconnect the plug of the engine coolant

temperature sensor (ECT sensor).
   

NOTE:
Installation position of the thermostat.

12. Remove the thermostat housing.

• Remove the thermostat.
• Raise the vehicle.
 13. Remove the front exhaust pipe and disconnect the
heated oxygen sensor plug (HO2S).
   Lower the vehicle.

CAUTION:
Do not pull on the lead when removing the
spark plug connectors. If necessary,
disconnect the HT lead from the ignition coil
to prevent the lead from getting kinked.
Before removing it, turn the spark plug
connector slightly to loosen the seal.
CAUTION:
Pull off the spark plug connector in a
direction in line with the spark plug axis.
14. Pull off the spark plug connectors and unclip the
HT leads.
15. Detach the cylinder head cover.
16. Remove the spark plugs.

NOTE:
Do not mix up the push rods during
removal/installation.
NOTE:
Do not turn the rocker arm bolts.

17. Remove the rocker shaft.

CAUTION:
If no colour markings or punch marks are
present, punch mark the cylinder head bolts
and re‐use them. If the cylinder head bolts
are marked use new bolts.
18. Detach the cylinder head.
   Remove the cylinder head bolts in the indicated
sequence.

Install
CAUTION:
Check whether the old cylinder head bolts are
marked (punch mark). If markings are
 present, use new bolts.
CAUTION:
Do not retighten the cylinder head bolts.

19. Fit the cylinder head.

• Lay a new cylinder head gasket in place.
• Tighten the cylinder head bolts in the specified
sequence.

NOTE:
Do not mix up the push rods during
removal/installation.
20. Install the rocker shaft.
• Lubricate the ends of the push rods with engine oil
and insert them.
• Insert the rocker arm adjusting screws into the push
rod end‐cups.

21. Set the valve clearances as described in Operation

No. 21 213 0.
NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
22. Fit the spark plugs.
23. Fit the cylinder head cover.
CAUTION:
To apply the silicone grease, use a blunt
object (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push the spark plug connector on in a
direction in line with the spark plug axis.
NOTE:
Coat the inside of the spark plug connector,
down to a depth of 5‐10 mm, with silicone
grease (A960‐M1C171‐AA).
24. Clip the HT leads in place and push the spark plug
connectors on to the spark plugs.
   Raise the vehicle.
25. Fit the exhaust pipe and connect the HO2S plug.
   Lower the vehicle.
 NOTE:
Renew the thermostat gasket.

NOTE:
Installation position of the thermostat.

26. Fit the thermostat housing.

   Insert the thermostat with the gasket.

27. Connect the ECT sensor plug.

28. Connect the plugs.

1. Throttle valve stepper motor.
2. TP sensor
3. Throttle body assembly
4. IAT sensor

29. Hook the throttle cable onto the throttle body

assembly.
30. Attach/connect the fuel pipes.
1. Return pipe to throttle body assembly.
2. Quick‐release coupling on the feed pipe.

31. Push on the vacuum hoses.

1. To the fuel separator.
2. To the MAP sensor.
32. Push on the vacuum hoses and bolt the ground
cable to the inlet manifold.
1. To the pulse air system.
2. To the brake servo.

33. Attach the coolant hoses to the throttle body

assembly and to the inlet manifold.

34. Attach the coolant hoses to the thermostat housing

and connect the plugs.
1. Cooling fan motor temperature switch.
2. Coolant temperature gauge sender unit

35. Install the air cleaner housing.

   Push on the crankcase ventilation hose.
1. Clip the fuel separator onto the air cleaner housing.
2. Tighten the bolts.

36. Standard finishing operations.

• Fill up with coolant.
• Connect the battery negative lead.
• Bleed the cooling system.
• Check the engine and cooling system for leaks.
• Fix the cables and hoses in place with cable ties.
• Remove the protective covers.
• Enter the radio keycode.
• Reprogram the pre‐set radio stations.
• Reset the clock.
• Carry out a road test to allow the PCM (EEC IV) to re
learn values.
• Check and correct the fluid levels as necessary.

Escort/Orion 1991 (08/1990-09/2001)

 Print
Specifications
NOTE:
Only Operation No. 21 134 8 is covered in this section. Other work relevant to the
Endura‐E engine, is covered in Section 21‐03 (1,3 HCS engine).
Engine data
1,3 Endura‐E
Engine management EEC V
Emissions standard 96 EEC, Stage II
Fuel 95 RON
Engine code J4B
Firing order 1‐2‐4‐3
Bore mm 73,96
Stroke mm 75,48
Cubic capacity cm3 1297,9
Compression ratio 9,5:1
Compression pressure at starter motor speed bar 13‐16
Power Output (EEC) kW 44
Power Output (EEC) (PS) 60
Power Output (EEC), at rev/min 5000
Torque Nm 103
Torque, at rev/min 2500
Dimensions
Crankshaft 1,3 Endura‐E
Main bearing journal diameter, standard mm 56,980 ‐ 57,000
Main bearing journal diameter, undersize (green) 0,254 mm 56,726 ‐ 56,746
Main bearing shell width mm 18,29 ‐ 18,69
Big‐end bearing journal diameter, standard mm 40,99 ‐ 41,01
Big‐end bearing journal diameter, undersize (green) mm 40,74 ‐ 40,76
Big‐end bearing journal diameter, undersize (service) 0,508 mm 40,49 ‐ 40,51
Big‐end bearing journal diameter, undersize (service) 0,762 mm 40,24 ‐ 40,26
Crankshaft end float mm 0,05 ‐ 0,26
Thrust half‐ring thickness, standard mm 2,80 ‐ 2,85
Thrust half‐ring thickness, oversize mm 2,99 ‐ 3,04
The crankshaft must not be reworked.
Dimensions
Cylinder block 1,3 Endura‐E
Number of main bearings 5
Cylinder sleeve bore mm 77,086 ‐ 77,127
Cylinder bore diameter, Standard Class 1 mm 73,940 ‐ 73,950
Cylinder bore diameter, Standard Class 2 mm 73,950 ‐ 73,960
Cylinder bore diameter, Standard Class 3 mm 73,960 ‐ 73,970
Cylinder bore diameter, Oversize 0,5 mm 75,000 ‐ 75,010
Centre main bearing width (without thrust half rings) mm 22,040 ‐ 22,100
Main bearing shell, standard, vertical inside ∅ mm 57,009 ‐ 57,056
Main bearing shell, undersize 0,254, vertical inside ∅ mm 56,755 ‐ 56,802
Main bearing shell, undersize service 0,508, vertical inside ∅ mm 56,501 ‐ 56,548
Main bearing shell, undersize service 0,762, vertical inside ∅ mm 56,247 ‐ 56,294
Main bearing parent bore diameter, standard mm 60,623 ‐ 60,636
Main bearing parent bore diameter, oversize mm 61,003 ‐ 61,016
Camshaft bearing parent bore diameter, standard mm 42,888 ‐ 42,918
Camshaft bearing parent bore diameter, oversize mm 43,396 ‐ 43,420
Camshaft bearing bush diameter, standard mm 39,662 ‐ 39,682
Camshaft bearing bush diameter, oversize cyl. block mm 39,662 ‐ 39,682
Camshaft bearing bush diameter, standard and oversize
mm 39,662 ‐ 39,713
(service)
Main bearing clearance (radial) mm 0,009 ‐ 0,056
Dimensions
Connecting rod 1,3 Endura‐E
Bore diameter, big‐end mm 43,99 ‐ 44,01
Bore diameter, small end mm 17,99 ‐ 18,01
Fitted big‐end bearing shells, vertical inner diameter,
mm 41,016 ‐ 41,050
standard
Fitted big‐end bearing shells, vertical inner diameter,
mm 40,966 ‐ 41,000
undersize 0,254
Fitted big‐end bearing shells, vertical inner diameter,
mm 40,516 ‐ 40,550
undersize 0,508
Fitted big‐end bearing shells, vertical inner diameter,
mm 40,266 ‐ 40,300
undersize 0,762
Fitted big‐end bearing shells, vertical inner diameter,
mm 40,016 ‐ 40,050
undersize 1,016
Big‐end bearing clearance (radial) mm 0,006 ‐ 0,060
Big‐end bearing clearance (axial) mm 0,100 ‐ 0,250
Dimensions
Pistons 1,3 Endura‐E
Piston diameter, standard class 1 mm 73,91 ‐ 73,92
Piston diameter, standard class 2 mm 73,92 ‐ 73,93
Piston diameter, standard class 3 mm 73,93 ‐ 73,94
Piston diameter, standard (service) mm 73,93 ‐ 73,955
Piston diameter, oversize 0,5 mm 74,46 ‐ 74,485
Piston diameter, oversize 1,0 mm 74,96 ‐ 74,985
Piston clearance, (initial fit) mm 0,020 ‐ 0,040
Piston clearance, (service) mm 0,015 ‐ 0,050
Piston ring gap (installed), top mm 0,25 ‐ 0,45
Piston ring gap (installed), middle mm 0,45 ‐ 0,75
Piston ring gap (installed), bottom mm 0,2 ‐ 0,5
Piston ring in groove clearance, top mm max 0,2
Piston ring in groove clearance, bottom mm max 0,1
180_ from oil control
Ring gap position, top
ring gap
90_ from oil control
Ring gap position, middle
ring gap
in alignment with
Ring gap position, bottom
piston pin
Bore diameter, big‐end mm 43,99 ‐ 44,01
Piston pin length mm 63,6 ‐ 64,4
Piston pin diameter, white mm 18,026 ‐ 18,029
Piston pin diameter, red mm 18,029 ‐ 19,032
Piston pin diameter, blue mm 18,032 ‐ 18,035
Piston pin diameter, yellow mm 18,035 ‐ 18,038
Piston pin interference fit (in connecting rod) at 21°C mm 0,016 ‐ 0,048
Piston pin clearance (in piston) at 21°C mm 0,008 ‐ 0,014
Dimensions
Camshaft 1,3 Endura‐E
Drive Chain
Chain length (46 links) mm 438,15
Valve timing, inlet opens BTDC °CS 18
Valve timing, inlet closes ABDC °CS 38
Valve timing, exhaust opens BBDC °CS 45
Valve timing, exhaust closes ATDC °CS 7
Camshaft cam lift, inlet mm 5,25
Camshaft cam lift, exhaust mm 5,14
Camshaft bearing diameter mm 39,615 ‐ 39,635
Inner diameter ‐ bearing bush, standard mm 39,662 ‐ 39,682
Inner diameter ‐ bearing bush, oversize (service) mm 39,662 ‐ 39,713
Camshaft thrust plate thickness mm 4,457 ‐ 4,508
Camshaft end float mm 0,02 ‐ 0,19
Dimensions
Valves 1,3 Endura‐E
via tappets, push rods
Valve control
and rocker arms
Valve clearance (engine cold), inlet mm 0,20
Valve clearance (engine cold), exhaust (engines built in
mm 0,30
production up to 20.11.96)
Valve clearance (engine cold), exhaust (engines built in
production from 21.11.96, identified by a sticker on the mm 0,50
cylinder head cover)
Valve tappet diameter mm 13,081 ‐ 13,094
Tappet clearance in cylinder block mm 0,016 ‐ 0,062
Valve spring free length mm 41,0
Valve spring inner diameter mm 20,25 ‐ 20,75
Valve spring wire diameter mm 3,77 ‐ 3,83
Number of turns 6
Valve length, inlet mm 103,70 ‐ 104,40
Valve length, exhaust mm 104,02 ‐ 104,72
Valve head diameter, inlet mm 34,4 ‐ 34,6
Valve head diameter, exhaust mm 28,90 ‐ 29,10
Valve stem diameter (inlet), standard mm 7,025 ‐ 7,043
Valve stem diameter (inlet), oversize 0,2 mm 7,225 ‐ 7,243
Valve stem diameter (inlet), oversize 0,4 mm 7,425 ‐ 7,443
Valve stem diameter (exhaust), standard mm 6,999 ‐ 7,017
Valve stem diameter (exhaust), oversize 0,2 mm 7,199 ‐ 7,217
Valve stem diameter (exhaust), oversize 0,4 mm 7,399 ‐ 7,417
Valve stem guide clearance, inlet mm 0,020 ‐ 0,069
Valve stem guide clearance, exhaust mm 0,046 ‐ 0,095
Valve lift (without clearance), inlet mm 8,35
Valve lift (without clearance), exhaust mm 8,17
Engine oil
Viscosity/ambient Designation Specifications
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to over Ford Formula E Economy ACEA A1/B1 and WSS‐
40 degrees Centigrade Motor Oil M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 to over 40 Ford ”Super" Multigrade Motor ACEA A1/B1 or A2/B2 or
degrees Centigrade Oil API/SH/CD EC
SAE 10W40 / ‐20 to over 40 Ford XR+ High‐performance
ACEA A3/B3 or API/SH/CD EC
degrees Centigrade High‐lubricity Motor Oil
SAE 5W40 / below ‐20 to over Ford Formula S Synthetic
ACEA A3/B3 or API/SH/CD EC
40 degrees Centigrade Motor Oil
If engine oils with these specifications are not available, only engine oils which at least meet
the API/SH/CD EC specification may be used.
Engine Lubrication
Description
Oil pressure (minimum, oil temperature about 80 5C), at 750
bar 0,6
rev/min
Oil pressure, (minimum, oil temperature about 80 5C), at
bar 1,5
2000 rev/min
Relief valve opening pressure bar 2,41 ‐ 2,96
Oil pump max. inner/outer rotor clearance mm 0,051 ‐ 0,127
Oil pump (outer rotor casing clearance) mm 0,14 ‐ 0,26
Inner/outer rotor end float, oil pump cover mm 0,025 ‐ 0,06
Lubricants, Adhesives and Sealers
Description Ford
Specification
Sump to cylinder block, oil pressure switch WSE‐M4G320‐A2
Spark plug lubricant ("Never Seeze") ESE‐M1244‐A
Transmission fluid WSD‐M2C200‐B
Capacity
Description Litres
Engine oil, initial fill with filter 3,40
Engine oil, with filter change 3,25
Engine oil, without filter change 2,75
Transmission fluid, initial fill 2,8
Transmission fluid, change Not required
Coolant (50% water + 50% Motorcraft coolant concentrate Super‐Plus 4, ESD
7,1
M97B‐49A)
Torques
General Nm lbf.ft
Clutch to flywheel 30 22
Alternator to bracket 24 18
Alternator bracket 47
Torques
Cylinder block Nm lbf.ft
Main bearing cap 95 70
Big‐end bearing cap, 1st stage (use new bolts) 4 3
Big‐end bearing caps, 2nd stage 90° 90°
Rear oil seal carrier 18 13
Flywheel 67 49
Clutch pressure plate 30 22
Timing chain tensioner 8 6
Camshaft thrust plate 11 8
Camshaft sprocket 28 21
Timing cover 9 7
Crankshaft pulley 115 85
Starter motor 40 30
Timing chain tensioner 8 6
Crankshaft position sensor (CKP sensor) 5 4
Torques
Coolant circuit Nm lbf.ft
Coolant pump 8 6
Coolant pump pulley 10 7
Thermostat housing 19 14
Torques
Oil circuit Nm lbf.ft
Oil pump 18 13
Oil pump cover plate 10 7
Sump, stage 1 7 5
Sump, stage 2 10 7
After the engine has warmed up (15 min at 1000 rev/min), stage 3 10 7
Oil pressure switch 14 10
Oil drain plug 25 18
Torques
Cylinder head Nm lbf.ft
Rocker shaft 43 32
Cylinder head, 1st stage (the bolts must not be re‐torqued! The bolts
may be re‐used once, but must however be clearly marked that they 30 22
have been re‐used (centre punch mark)).
Cylinder head, stage 2 90_ 90_
Cylinder head, stage 3 90_ 90_
Cylinder head cover 6 4
Inlet manifold to cylinder head 18 13
Spark plugs 17 13
Camshaft position sensor (CMP sensor) 10 7
Cylinder head mounting to cylinder head 69 51

Description and Operation Escort/Orion 1991 (08/1990-09/2001)

 Print

Description and Operation

The Endura‐E engine is introduced into the Escort range from '96 MY. The familiar 1,3 litre
HCS engine has been reworked. The main changes compared with the previous model are
among others a sequential, electronically controlled multiport fuel injection system, a new
sump made of aluminium and an inlet manifold made of thermoplastic. The following picture
shows the engine as fitted in Fiesta '96.
1. Cylinder block
• Thread repairs on the cylinder block are allowed,
provided Helicoil thread repairs are used. The
remaining material thickness for diameters up to 9,5
mm must be at least 3,2 mm; for larger diameters at
least 4,8 mm.
• Core plugs must not be removed.

2. Crank gear
   The crankshaft runs on five bearings. The bearing
caps have been numbered in production and they
should be re‐used accordingly during fitting. The first
main bearing has a mounting for the tensioning arm of
the timing chain tensioner.
NOTE:
The arrows on the bearing caps point
forwards.
NOTE:
When measuring the crankshaft pay attention
to the paint marks.
   The crank shaft and also the main bearing caps are
colour coded corresponding to production dimensions.
For bearing caps this colour coding is found on the
caps themselves; for the crankshaft the marking is on
the crank web.
CAUTION:
The main bearing bolts and the big‐end
bearing bolts must not be re‐used.
3. Cylinder head
   The cast iron cylinder head is positioned on the
cylinder block with two sleeves and is secured with ten
bolts.
CAUTION:
The cylinder head bolts may be re‐used once,
but must be clearly marked for re‐use with
centre punch markings.
NOTE:
The cylinder head bolts must be tightened in
three stages following the correct tightening
sequence.
• The maximum allowable unevenness of the cylinder
head sealing surface is 0,15 mm over the whole
length.
• Thread repairs are permitted provided Helicoil thread
inserts are used.
NOTE:
The cylinder head mating face must not be
re‐worked.
4. Cylinder head gasket
   The cylinder head gasket is made of aramide fibre
with filler, and must be renewed every time the
cylinder head is removed. To protect the gasket, it is
plated with steel and copper around the oil pressure
bore and cylinder bore respectively.
5. Piston
   The piston is made of an aluminium‐silicon alloy and
is fitted with three piston rings:
• Barrel faced plane ring (top).
• Napier ring (middle).
• Oil control ring (bottom).
NOTE:
The piston rings can be changed separately
without re‐working the cylinder liner.
• The piston ring gaps should be fitted at least at 90_
intervals around the circumference.
• The arrows on the piston crown point forwards.
6. Sump
   The sump is made of aluminium.
CAUTION:
The sump should be fitted flush with the rear
side of the cylinder block.
NOTE:
The timing cover and the crankshaft oil seal
carrier must not be offset to the cylinder
block.
• When installing the sump, the bolt‐tightening
sequence must be followed.
• If there is any visible damage to the sump gasket
then it must be changed.
• Sealer must be applied to the cylinder block when
installing the sump.
• Thread repairs on the sump are permitted provided
Helicoil thread repairs are used.
 7. Inlet manifold
• The inlet manifold is made of thermoplastic. This
method of manufacture not only reduces the weight,
but also reduces heat conduction compared with the
cast iron version.
• The use of plastic also improves the flow
characteristics, reduces the tendency towards
condensation during a cold start and lets the engine
respond better during a warm start.

8. Valve train
NOTE:
When removing and installing the rocker
shaft, do not disturb the rocker bolts.
   The engine timing is controlled from the crankshaft
by a single roller chain to the lower lying camshaft.
The camshaft transmits the timing actions to the
valves via tappets, push rods and a rocker shaft.

9. Thermostat
CAUTION:
To ensure that the thermostat works
correctly, it must be installed in the correct
position.
   The thermostat housing gasket must be renewed
during every installation.

Location of engine code and serial number.

10. Identification
1. Serial number.
2. Engine code.

Engine ‐ Dismantle and Reassemble Escort/Orion 1991 (08/1990-09/2001)

(engine removed) (21 134 8)
 Print

Removal and Installation

Special Tools

16‐067Aligner, clutch plate

21‐046Installer, crankshaft
front oil seal

21‐050 AMounting bracket,

engine

21‐102Installer/aligner, oil
seal

21‐102‐01Adapter for 21‐102

21‐102‐02AAdapter for 21‐102

21‐102‐04Bolts for 21‐102‐

02A

21‐168Locking Tool,
Crankshaft

21‐187Assembly stand

21‐540Angle gauge

Proprietary tools
Description
Oil filter strap wrench
Piston ring compressor
Piston ring pliers
Micrometer
Two‐legged puller
Three‐legged puller
Torque wrench
Steel rule
Internal gauge
Dial gauge
Plastic scraper
Dial gauge stand
Feeler gauges
Materials
Description
from: Replacement
Services Ltd., 30,
Euston Street,
Plastigage
Freemans Industrial
Estate, Leicester, LE2
7ST
Sealant, sump to
cylinder block, oil WSK‐M4G320‐A
pressure switch
Spark plug thread
ESE‐M1244‐A
lubricant
Dismantle
1. Mount the engine on an assembly stand.
   Disconnect the spark plug connectors and unclip
the ignition leads from their retainers.

2. Remove the alternator (four bolts).

3. Remove the alternator support bracket together

with the pulley tensioner and the idler pulley.
4. Remove the clutch and loosen the flywheel bolts.
1. Fit the special tool.
2. Remove the clutch.
NOTE:
Only loosen the bolts, do not remove them.

3. Loosen the flywheel bolts.

5. Remove the ancillary components.

1. Drain the engine oil.
2. Remove the oil filter.
3. Remove the EI coil (three bolts).
4. Detach the dipstick tube and pull it out of the
cylinder block.

6. Remove the ancillary components (continued).

1. Pull off the camshaft position (CMP) sensor
connector.
2. Pull off the oil pressure switch connector.
3. Remove the oil pressure switch.
4. Remove the oil pump (two bolts and one nut).
   Remove the gasket.
5. Detach the intake manifold (seven bolts).
   Remove the gasket.
 NOTE:
Do not remove the gasket.

7. Detach the coolant pump.

1. Remove the coolant pump pulley (three bolts).
2. Remove the coolant pump (three bolts).

NOTE:
Lock the crankshaft.

8. Unscrew the crankshaft pulley bolt and screw it

back in a few turns.

9. Remove the crankshaft pulley.

• Pull off the pulley using a three‐legged puller.
• Unscrew the pulley bolt.

10. Remove the cylinder head cover.

1. Pull off the oil filling cap.
2. Remove the cylinder head cover (four bolts and four
washers).
NOTE:
Do not turn the rocker arm bolts.

3. Remove the rocker shaft (four bolts).

4. Take out the push rods and lay them in order to one
side ready for re‐use.
11. Remove the thermostat housing.
1. Remove the thermostat housing.
   Remove the thermostat and the gasket.
2. Remove the spark plugs.

CAUTION:
Mark the bolts for re‐use with centre punch
markings. The bolts can be re‐used once.
Remove the bolts following the indicated
sequence.
12. Detach the cylinder head.
   Take off the cylinder head together with the exhaust
manifold.

13. Remove the flywheel.

   Remove the flywheel bolts and take off the
flywheel.
NOTE:
Only remove the sump downwards to
prevent any abraded particles or oil sludge
from getting into the engine.
14. Remove the sump (18 bolts).

15. Detach the crankshaft rear oil seal carrier.

• Remove the gasket.
• Tap out the radial seal on a flat surface.
16. Remove the timing cover.
• Remove the gasket.
• Tap out the radial seal on a flat surface.

17. Remove the timing chain.

1. Pull the oil baffle off the crankshaft.
2. Remove the timing chain tensioning arm from the
peg on the front main bearing.
3. Remove the chain tensioner (two bolts).
4. Unscrew and remove the bolts from the camshaft
timing sprocket and take off the CMP sensor.
   Remove the camshaft sprocket with the timing
chain.

CAUTION:
Turn the engine into the position shown.

18. Remove the camshaft.

• Turn the camshaft through 360_ to position the
valve tappets to TDC.
• Carefully remove the camshaft from the cylinder
block.
NOTE:
Set the valve tappets aside in the correct
order.
   Remove the valve tappets.
19. Remove the crankshaft sprocket using a two
legged puller.

CAUTION:
Do not damage the cylinder bores.

NOTE:
Carefully decarbonise with a plastic scraper.
Do not damage the piston ring running
surfaces.
20. Remove the pistons and the connecting rods.
NOTE:
Lay the connecting rods, big‐end bearing
caps and bearing shells in order to one side
for re‐use.
• Remove the big‐end bearing caps.
• Press the pistons and the connecting rods out of the
cylinder block.
 NOTE:
Set aside the main bearing caps and the
bearing shells in the correct order. Mark the
position of the centre thrust half rings on
the centre main bearing.
21. Remove the crankshaft.
• Detach the main bearing caps.
• Lift the crankshaft out of the cylinder block.
• Take out the bearing shells and the thrust half rings
and set them aside in the correct order.

Reassemble
22. Thoroughly clean all mating faces and re‐usable
parts and check them for damage.
23. All oil ways, e.g. those of the cylinder block,
cylinder head etc., must be free of dirt and swarf.
NOTE:
The main bearing caps must be fitted without
the main bearing shells, and tightened to the
specified torque.
24. Measure the cylinder bores using an internal
gauge.
   If the measured diameter of the cylinder bores is too
large for the piston class, then the cylinder block must
be overhauled or renewed.

NOTE:
Measure the piston diameter at a distance of
42 mm to the piston crown.
NOTE:
Piston classification, in case a piston must be
replaced.
25. Measure the piston diameters.
 CAUTION:
Do not mix up the piston rings. Replace the
rings in the same grooves and at the same
position.
26. Measure the piston ring gaps.
   The figures given in General Specifications apply to a
gauge ring used in production. When measured in the
cylinder, the values may be exceeded by 0,15 mm.

NOTE:
The piston ring axial clearance must be
measured with the ring projecting from its
groove.
27. Measure the piston ring clearance.
• The maximum clearance for the top compression ring
is 0,2 mm.
• The maximum clearance for the second compression
ring is 0,1 mm.

28. Measure the crankshaft.

• Measure the main and big‐end bearing journals
using a micrometer.
• Perform two measurements in each case, 90_
opposed to each other.

29. Paint marking of main bearing cap.

• Standard size parent bores are unmarked.
• On parent bores which are 0,38 mm oversize the
bearing caps are marked with a white paint stripe.

30. Paint marking of main and big‐end bearing

journals.
• Main bearing journals of standard diameter are
unmarked.
• A crankshaft with 0,25 mm undersize main bearing
journals is marked at the first crankshaft web with a
green paint stripe.
• Standard diameter big‐end bearings are not marked
• For big‐end bearings which are 0,25 mm undersize
there is a green dot marked on the crankshaft web.
 CAUTION:
Avoid damaging the journals when inserting
the crankshaft.
31. Lay the crankshaft in place.
• Position the main bearing shells in the cylinder block.
• Fit the crankshaft dry.
32. Measure the main bearing clearance
• Measure the bearing clearance in numerical
sequence (1 to 5). The numbering starts at the front
end of the engine.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
CAUTION:
Do not turn the crankshaft during the
measuring procedure. Do not strike the
bearing caps.
33. Measure the main bearing clearance (continued).
• Fit the bearing cap with its matching bearing shell
and tighten it down.
• Remove the bearing cap.

NOTE:
If the specified clearance is not achieved, the
bearing shells must be changed and the
measuring procedure repeated.
34. Measure the main bearing clearance (continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The measured value shows the bearing clearance.

35. Install the crankshaft.

• Coat the main bearing journals, all bearing shells and
all bolt threads and bolt contact faces with engine oil.
NOTE:
The oil grooves on the thrust half rings must
be visible.
• Place the bearing shells and the thrust half rings in
position on the cylinder block.

36. Install the crankshaft (continued).

• Install the crankshaft.
NOTE:
Arrows must point towards the front.

• Fit the main bearing caps with the bearing shells and
thrust half rings.
• Tighten the bolts.
37. Measure the crankshaft end float.
• Fit a dial‐gauge.
• Measure the end float by lifting the crankshaft with a
screwdriver.
• If necessary adjust the end float by fitting new thrust
washers.

38. Install the pistons and connecting rods.

• Pull the piston rings onto the piston using piston
pliers.
NOTE:
Fit the piston rings with the manufacturer's
markings towards the top. If no
manufacturer's markings are present, take
care that the Napier ring and oil control ring
are fitted according to the picture shown
here.
NOTE:
Arrange the piston ring gaps according to the
details in the General Specifications.
• Lubricate the pistons and cylinder bores with engine
oil.
39. Install the pistons and connecting rods
(continued).
• Compress the piston rings using a piston ring
compressor.
NOTE:
The marking arrow on the piston points
towards the front. The connecting rods are
marked at the base with the cylinder number
in which they should be fitted.
NOTE:
Guide each connecting rod with the hand so
as not to damage the bearings.
• Push the piston into the cylinder bore with a hammer
handle. The relevant big‐end bearing journal must be
at BDC.
40. Measure the big‐end bearing clearances.
• Measure the big‐end bearing clearance as described
in the previous job steps.
• If necessary install different bearing shells.
CAUTION:
Renew the bolts.

41. Fit big‐end bearing caps.

• Lubricate all bearing shells, bearing journals and
bolts (on the thread and the underside of the head)
with engine oil.
NOTE:
The numbering of the connecting rod and
the bearing caps must correspond. Ensure
that the connecting rods have enough axial
clearance.
• Fit big‐end bearing shells and caps and tighten
them.
42. Install the crankshaft sprocket.
• Position the sprocket.
NOTE:
The marking on the sprocket must be visible.

• Fit the sprocket with the aid of the pulley, the bolt
and the washer.
• Coat the valve tappets with engine oil and put them
in place (x 8).

43. Install the camshaft.

• Lubricate the camshaft bearings, the camshaft and
the thrust plate with engine oil.
• Slide in the camshaft from the front bearing and
attach the thrust plate.
• Tighten the bolts (x 2).

44. Install the chain tensioner.

• Fit the chain tensioner to the cylinder block (two
bolts).
• Check for parallel at two points across "A".
• If the tolerance is exceeded, loosen the chain
tensioner, align it, re‐fit it and repeat the
measurement procedure.

45. Install the timing chain.

1. Place the camshaft timing chain and sprocket in
position.
NOTE:
The markings on the timing sprockets must
line up.
2. Put the CMP sensor in place and tighten the two
bolts.
3. Slide the chain tensioner arm onto the peg on the
front main bearing.

CAUTION:
Lubricate the outer rubber surface of the oil
seal with a drop of engine oil to prevent it
being skewed when it is pressed home. Do
not lubricate the oil seal lip with engine oil
under any circumstances.
46. Install the crankshaft front oil seal.
1. Slide the special tool onto the hub of the
crankshaft pulley.
2. Place the oil seal on the hub of the crankshaft
pulley.
3. Locate the crankshaft pulley in place and draw in
the oil seal by tightening the bolt.
47. Install the rear crankshaft oil seal housing.
   Locate the oil seal carrier in position with a new oil
seal and screw in the bolts.

48. Install the crankshaft oil seal.

CAUTION:
Do not remove the support ring until after
fitting. Lubricate the outer rubber surface of
the oil seal with a drop of engine oil to
prevent it being skewed when it is pressed
home. Do not lubricate the oil seal lip with
engine oil under any circumstances.
1. Place the crankshaft rear oil seal onto the
crankshaft.
NOTE:
The crankshaft locating pin must align with
the hole in the special tool.
NOTE:
The special tool must be centred on the oil
seal to prevent it being skewed when pressed
home.
2. Install the special tools.
• Draw in the oil seal up to the stop by tightening the
nut.
• Remove the special tools together with the support
ring.
 NOTE:
The mating surfaces to the sump must be
flush with those of the cylinder block.
49. Tighten the rear crankshaft oil seal.
• Torx bolts: 18 Nm
• Hexagon headed bolts: 22 Nm

NOTE:
The mating surfaces to the sump must be
flush with those of the cylinder block.
50. Fit the timing cover.
• Position the timing cover using the pulley and
tighten the four bolts.
• Remove the pulley and the special tool.
• Tighten the fifth bolt.

NOTE:
Apply sealer (WSK‐M4G320‐A) to the
surfaces indicated.
51. Apply sealer to the cylinder block.

CAUTION:
The surfaces of the sump and transmission
side of the cylinder block must be flush.
52. Align the sump flush with the cylinder block.
53. Fit the sump.
NOTE:
The arrow points to the front of the car.

   Position the sump and tighten the bolts in three

stages.
• In alphabetic sequence to 7 Nm.
• In numeric sequence to 10 Nm.
• Run the engine for 15 minutes, and then re‐tighten
the bolts in alphabetic sequence to 10 Nm.

54. Fit the flywheel.

• Immobilise the crankshaft.
• Coat the bolts with engine oil and tighten them down
working diagonally.

55. Install the crankshaft pulley.

   Immobilise the crankshaft using Special Tool 21‐
168.
56. Install the cylinder head.
• Lay a new cylinder head gasket in place.
• Lay the cylinder head in place and screw in the
cylinder head bolts.
• Tighten the cylinder head bolts in three stages
according to the tightening sequence shown.

57. Fit the thermostat housing.

1. Position the thermostat and the gasket.
   Fit the thermostat housing.
NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
2. Fit the spark plugs.

58. Install the rocker shaft.

1. Place the push rods in position.
2. Fit the rocker shaft (4 bolts).
59. Adjust the valve clearances as described in
Operation Number 21 213 0.

NOTE:
Use a new gasket.

60. Fit the cylinder head cover.

1. Fit the cylinder head cover (four bolts and four
rectangular washers).
2. Push on the oil filler cap and connect the crankcase
ventilation.
61. Fit the coolant pump.
1. Install the coolant pump (three bolts).
2. Fit the coolant pump pulley wheel (three bolts).

62. Before fitting, fill the oil pump with 0,15 litres of
engine oil.
   Turn the oil pump driveshaft one rotation
anticlockwise.

63. Fit the ancillary components.

1. Attach the intake manifold with a new gasket
(seven bolts).
NOTE:
Previous job step.

2. Fit the oil pump using a new gasket (two bolts).

NOTE:
Apply sealer (WSK‐M4G320‐A) to the oil
pressure switch.
3. Fit the oil pressure switch.
4. Connect the multiplug to the CKP sensor.
5. Push the connector onto the oil pressure switch.
 64. Attach the ancillary components (continued).
1. Guide the dipstick tube into the cylinder block and
secure it in place.
2. Fit the oil filter.
3. Fit the EI coil (three bolts).
NOTE:
Use a new sealing ring.

4. Fit and tighten the oil drain plug.

65. Centralise the clutch disc.

   Centre the clutch disc on the clutch pressure plate
and secure it using the special tool.

66. Install the clutch disc and the clutch pressure

plate.
1. Locate the pressure plate, special tool and centred
clutch disc in position on the flywheel guide pegs.
2. Tighten the pressure plate evenly, working
diagonally.
3. Remove the special tool.
 67. Fit the generator mounting together with the belt
tensioner and idler pulley.

NOTE:
Tighten the front bolts first.

68. Fit the alternator (four bolts).

69. Detach the engine from the mounting bracket and

the assembly stand.
   Connect spark plugs, lay the ignition leads in place
and clip into the holder.

70. Standard finishing operations:

• Fill with engine oil to the correct level.
• Remove the special tools.
• Remove the engine from assembly stand.

General Specifications Escort/Orion 1991 (08/1990-09/2001)

 Print

Specifications
Engine data
1,6 l DOHC 16V 1,8 l DOHC 16V 1,8 l DOHC 16V
Engine management EEC IV/SEFI EEC IV/SEFI EEC IV/SEFI
Emissions standard 83 US/93/59 EEC 83 US/93/59 EEC 83 US/93/59 EEC
Super 95 RON Super 95 RON Super 95 RON
Fuel
lead free lead free lead free
Engine code L1E RDA RQB
Firing order 1‐3‐4‐2 1‐3‐4‐2 1‐3‐4‐2
Bore 76,0 80,6 80,6
Stroke 88,0 88,0 88,0
Cubic capacity 1597 1796 1796
Compression ratio 10,3 : 1 10 : 1 10 : 1
Power output (EEC) (kW)
Power output (EEC) (at rev/min)
Power output (DIN) (kW) 66 77 96
Power output (DIN) (PS) 90 105 130
Power output (DIN) (at rev/min) 5500 5500 6250
Torque (DIN) (Nm) 134 153 162
Torque (DIN) (at rev/min) 3000 4000 4500
Idle speed (rev/min) 875 875 875
Max. engine speed (rev/min) 7100 7100 7100
Engine Data (Zetec‐E)
1,6 l DOHC 16V 1,6 l DOHC 16V 1,8 l DOHC 16V
Engine management EEC IV/SFI EEC IV/SFI EEC IV/SFI
93/59 EEC 93/59 EEC 93/59 EEC
(conforms to EEC (conforms to EEC (conforms to EEC
Emissions standard
1996 emission 1996 emission 1996 emission
standards) standards) standards)
Super 95 RON Super 95 RON Super 95 RON
Fuel
lead free lead free lead free
Engine code L1H L1K RKC
Firing order 1‐3‐4‐2 1‐3‐4‐2 1‐3‐4‐2
Bore 76,0 76,0 80,6
Stroke 88,0 88,0 88,0
Cubic capacity 1597 1597 1796
Compression ratio 10,3 : 1 9,8 : 1 9,8 : 1
Power output (EEC) (kW)
Power output (EEC) (at rev/min)
Power output (DIN) (kW) 66 66 85
Power output (DIN) (PS) 90 90 115
Power output (DIN) (at rev/min) 5500 5500 5500
Torque (DIN) (Nm) 134 134 159
Torque (DIN) (at rev/min) 3000 3000 4500
Idle speed (rev/min) 875 875 800
Max. engine speed (rev/min) 7100 7100 7100
Cylinder block
1,6 l DOHC 1,8 l DOHC
16V 16V
Number of main bearings 5 5
76,000 ‐ 80,600 ‐
Cylinder bore ‐ class 1 mm
76,010 80,610
76,010 ‐ 76 80,610 ‐
Cylinder bore ‐ class 2 mm
020 80,620
76 020 ‐ 80,620 ‐
Cylinder bore ‐ class 3 mm
76,030 80,630
58,011 ‐ 58,011 ‐
Inner main bearing shells (fitted) mm
58,038 58,038
Inner main bearing shells (fitted) (main bearings 58,008 ‐ 58,008 ‐
mm
shells with stepped sizes) 58,031 58,031
Main bearing radial clearance mm 0,011 ‐ 0,058 0,011 ‐ 0,058
Main bearing radial clearance (main bearing shells
mm 0,020 ‐ 0,040 0,020 ‐ 0,040
with stepped sizes)
62,287 ‐ 62,287 ‐
Main bearing parent bore mm
62,300 62,300
Crankshaft
 1,6 l DOHC 1,8 l DOHC
16V 16V
57,980 ‐ 57,980 ‐
Main bearing journals mm
58,000 58,000
Main bearing journal end float mm 0,09 ‐ 0,26 0,09 ‐ 0,26
Big‐end bearing journals mm 46,89 ‐ 49,91 46,89 ‐ 49,91
Connecting rods
1,6 l DOHC 1,8 l DOHC
16V 16V
Bore diameter ‐ big‐end mm 49,89 ‐ 49,91 49,89 ‐ 49,91
20,589 ‐ 20,589 ‐
Bore diameter ‐ small end mm
20,609 20,609
46,926 ‐ 46,926 ‐
Inner big‐end bearing shells (fitted) mm
46,960 46,960
Big‐end bearing clearance (radial) mm 0,016 ‐ 0,070 0,016 ‐ 0,070
Pistons (engine codes L1E, RDA, RQB and L1H)
1,6 l DOHC 1,8 l DOHC
16V 16V
75,975 ‐ 80,570 ‐
Piston Ø ‐ class 1 (new condition) mm
75,985 80,580
75,985 ‐ 80,580 ‐
Piston Ø ‐ class 2 (new condition) mm
75,995 80,590
75,995 ‐ 80,590 ‐
Piston Ø ‐ class 3 (new condition) mm
76,005 80,600
Piston ring gaps (fitted), upper compression ring mm 0,30 ‐ 0,50 0,30 ‐ 0,50
Piston ring gaps (fitted), lower compression ring mm 0,30 ‐ 0,50 0,30 ‐ 0,50
Piston ring gaps (fitted), oil scraper ring mm 0,25 ‐ 1,00 0,38 ‐ 1,14
Ring gap position: The piston ring gaps must be
Gaps measured with the ring
distributed uniformly around the circumference of
gauge. When measured in the
the piston. This also applies to the elements of the
cylinder, these values may be
oil scraper ring. Stagger the piston ring gaps at
exceeded by up to 0,15.
intervals of 120°.
Pistons (engine codes L1K and RKC)
1,6 l DOHC 1,8 l DOHC
16V 16V
75,965 ‐ 80,560 ‐
Piston Ø ‐ class 1 (new condition) mm
75,975 80,570
75,975 ‐ 80,570 ‐
Piston Ø ‐ class 2 (new condition) mm
75,985 80,580
75,985 ‐ 80,580 ‐
Piston Ø ‐ class 3 (new condition) mm
75,995 80,590
Piston ring gaps (fitted), upper compression ring mm 0,025 ‐ 0,035 0,025 ‐ 0,035
Piston ring gaps (fitted), lower compression ring mm 0,30 ‐ 0,50 0,30 ‐ 0,50
Piston ring gaps (fitted), oil scraper ring mm 0,25 ‐ 1,00 0,38 ‐ 1,14
Ring gap position: The piston ring gaps must be
Gaps measured with the ring
distributed uniformly around the circumference of
gauge. When measured in the
the piston. This also applies to the elements of the
cylinder, these values may be
oil scraper ring. Stagger the piston ring gaps at
exceeded by up to 0,15.
intervals of 120°.
Piston pins
1,6 l DOHC 1,8 l DOHC
16V 16V
Piston pin length mm 63,00 ‐ 63,80 63,00 ‐ 63,80
 20,622 ‐ 20,622 ‐
Piston pin diameter ‐ white mm
20,625 20,625
20,625 ‐ 20,625 ‐
Piston pin diameter ‐ red mm
20,628 20,628
20,628 ‐ 20,628 ‐
Piston pin diameter ‐ blue mm
20,631 20,631
Piston pin clearance in piston mm 0,010 ‐ 0,016 0,010 ‐ 0,016
Interference fit in small end bore mm 0,013 ‐ 0,042 0,013 ‐ 0,042
Camshaft
1,6 l DOHC 1,8 l DOHC
16V 16V
Number of camshaft bearings 5 5
Drive Timing belt Timing belt
25,960 ‐ 25,960 ‐
Bearing journal diameter mm
25,980 25,980
Camshaft bearing radial clearance mm 0,020 ‐ 0,070 0,020 ‐ 0,070
Camshaft end‐float mm 0,080 ‐ 0,220 0,080 ‐ 0,220
Cylinder head
1,6 l DOHC 1,8 l DOHC
16V 16V
Maximum distortion (mating faces) mm 0,1 0,1
Mating face height mm 2,0 ± 0,12 2,0 ± 0,12
Peak‐to‐valley height of the mating face (reference
R3z = 6,0 R3z = 6,0
length 2,5 mm at right angles to the direction of the mm
microns microns
grooves)
Oil pressure at 800‐850 rev/min bar 1,3 ‐ 2,5 1,3 ‐ 2,5
Oil pressure at 4000 rev/min bar 3,7 ‐ 5,5 3,7 ‐ 5,5
Engine oil ‐ Zetec/Zetec‐E up to '99 MY (up to 07.98, build code WM)
Description Viscosity/ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to
WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil above 40 degrees
M2C912‐A1
Centigrade
Alternative engine oils:
SAE 10W30 / ‐20 to above ACEA A1/B1, A2/B2 or
Ford "Super" Multigrade Motor Oil
40 degrees Centigrade A3/B3
Ford XR+ High‐performance High‐ SAE 10W40 / ‐20 to above
ACEA A3/B3
lubricity Motor Oil 40 degrees Centigrade
SAE 5W40 / below ‐20 to
Ford Formula S Synthetic Motor Oil above 40 degrees ACEA A3/B3
Centigrade
Engine oil ‐ Zetec‐E from '99 MY (from 08.98, build code WP)
Description Viscosity/ambient Specification
temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to
WSS‐M2C913‐A or WSS‐
Ford Formula E Economy Motor Oil above 40 degrees
M2C912‐A1
Centigrade
Engine oils for topping up only:
Ford XR+ High‐performance High‐ SAE 10W40 / ‐20 to above
ACEA A3/B3
lubricity Motor Oil 40 degrees Centigrade
Ford Formula S Synthetic Motor Oil SAE 5W40 / below ‐20 to ACEA A3/B3
 above 40 degrees
Centigrade
Lubricants, Adhesives and Sealants
Ford
Specification
Transmission fluid (B5) WSD‐M2C200‐C
Transmission fluid (IB5) WSD‐M2C200‐C
Transmission fluid (MTX 75) ESD‐M2C186‐A
Transmission fluid (CTX) ESPM‐2C166‐H
Transmission fluid (CTX), after repairs to transmission WSD‐M2C199‐A
Ford hypoid oil SQM‐2C9002‐AA
Power steering hydraulic fluid ESPM‐2C166‐H
Coolant Super Plus 4 (blue/green) (Do not mix together coolants of
ESD‐M97B49‐A
different colours/specifications)
Coolant Super Plus 2000 (orange) (Do not mix together coolants of
WSS‐M97B44‐D
different colours/specifications)
Sealant, camshaft bearing caps WSK‐M2G348‐A5
Sealant, cylinder block WSE‐M4G323‐A4
High‐temperature grease ESD‐M1C220‐A
Spark plug thread lubricant ESE‐M1244‐A
Thread locking compound SDM‐4G9107‐A
Oil pressure switch sealant WSK‐M2G349‐A7
Fill Capacity
Litres
Engine oil, initial fill with filter 4,50
Engine oil, oil change with filter change 4,25
Engine oil, oil change without filter change 3,75
Transmission fluid ‐ B5 3,10
Transmission fluid ‐ IB5 3,10
Transmission fluid ‐ CTX 3,60
Transmission fluid ‐ MTX 75 2,60
Coolant 7,00
Torques
General Nm lbf.ft
Cable to starter motor 6 4
Radiator crossmember to body 24 18
Heat shield to starter motor 10 7
Cable to alternator 11 8
Retaining plate, alternator bracket to sump 24 18
Gear shift lever cover to body 10 7
Shift rod clamp bolt 16 12
Front exhaust pipe to exhaust manifold 18 13
Catalytic converter to rear exhaust pipe 41 30
Adapter plate 11 8
Torques
Cylinder Head Nm lbf.ft
Cylinder head bolts ‐ Stage 1 25 18
Cylinder head bolts ‐ Stage 2 45 33
Cylinder head bolts ‐ Stage 3 105° 105°
Camshaft bearing caps ‐ Stage 1 10 7
Camshaft bearing caps ‐ Stage 2 19 14
Cylinder head cover ‐ Stage 1 2 1
Cylinder head cover ‐ Stage 2 7 5
Spark plugs 15 11
Camshaft position sensor (CMP sensor) 21 15
Camshaft timing pulley 68 50
Upper timing belt cover 4 3
Thermostat housing 20 15
Bracket, EI coil 21 15
Exhaust manifold nuts 16 12
Exhaust manifold studs 5 4
Inlet manifold nuts and bolts 18 13
Inlet manifold studs 5 4
Intake air pipe to inlet manifold 6 4
Throttle valve housing 9 7
Exhaust gas return (EGR) valve to inlet manifold 9 7
Engine lifting eye to cylinder head 16 12
Ground cable to engine lifting eye 7 5
Timing belt idler pulley 40 30
Bracket, oil dipstick tube 11 8
Rear timing belt cover 14 10
Torques
Cylinder block Nm lbf.ft
Main bearing cap 80 59
Big‐end bearing cap ‐ Stage 1 15 11
Big‐end bearing cap ‐ Stage 2 90° 90°
Positive crankcase ventilation 10 7
Crankcase breather pipe bracket 23 17
Alternator bracket to cylinder block 47 35
Alternator to bracket 25 18
Coolant pump 18 13
Coolant pump pulley 10 7
Air conditioning compressor bracket to cylinder block 68 50
Air conditioning compressor bracket to sump 25 18
Bracket, air conditioning compressor 47 35
Rear crankshaft oil seal carrier (8.8 tensile strength) 22 16
Rear crankshaft oil seal carrier (10.9 tensile strength) 30 22
Lower adapter plate 11 8
Flywheel 112 83
Clutch pressure plate 29 21
Retaining pin, timing belt tensioner spring 10 7
Timing belt tensioning pulley 38 28
Lower and centre timing belt cover 7 5
Pulley/vibration damper on crankshaft 115 85
Pulley cover to engine 10 7
Idler pulley, multi‐groove belt 48 35
Bracket, crankshaft position sensor (CKP sensor) 8 6
Bracket, power steering pressure pipe to cylinder block 7 5
Special Tool 21‐168 to cylinder block 32 24
Starter motor to cylinder block 32 24
Torques
Oil circuit Nm lbf.ft
Oil pump 11 8
Oil pressure switch 27 20
Oil spray jets and blanking plugs 10 7
Oil intake pipe to oil pump 10 7
Bracket, oil dipstick tube 9 7
Sump 22 16
Oil drain plug 25 18
Oil level check plug 45 33
Oil baffle and oil intake pipe bracket to studs 19 14
Oil drain plug 25 18
Torques
Wheel suspension Nm lbf.ft
Lower suspension arm to spindle carrier 70 52
Track rod end to spindle carrier 26 19
Torques
Transmission Nm lbf.ft
Transmission to engine 45 33
Transmission fluid check/filler plug 27 20
Ground cable to transmission housing 26 19
Ground cable to transmission flange 45 33
Starter motor to transmission 35 26
Special tool 21‐168 to transmission 35 26
Shift rod to transmission 23 17
Shift rod stabiliser to transmission 55 41
Torques
Steering Nm lbf.ft
Retaining plate, power steering pump to cylinder head 47 35
Power steering pump to bracket 25 18
Bracket, power steering pressure pipe to cylinder block 7 5
Pulley to power steering pump 35 26
Pulley cover to power steering pump 10 7
Bracket, power steering pump to cylinder head 25 18
Torques
Engine mountings Nm lbf.ft
Rear right‐hand engine mounting to body 83 61
Rear left‐hand engine mounting to body 69 51
Rear left‐hand engine mounting to transmission 58 43
Front engine mounting 83 61
Front engine mounting bracket 90 67
Strut, rear left‐hand engine mounting to transmission 44 32
Strut, rear right‐hand engine mounting to cylinder block 44 32
Strut, rear right‐hand engine mounting to engine mounting 69 51
Rear right‐hand engine mounting shackle 69 51
Bracket, rear right‐hand engine mounting to transmission 72 53
Left‐hand engine mounting bracket to cylinder block, bolt 90 67
Left‐hand engine mounting bracket nuts in transmission (B5) 24 18
Left‐hand engine mounting bracket nuts in transmission (iB5) 33 24
Left‐hand engine mounting bracket nuts in transmission (MTX 75) 33 24
Front support strut 69 51

Description and Operation Escort/Orion 1991 (08/1990-09/2001)

 Print

Description and Operation

Engine code location on cylinder block
1. Engine code
• 1,6 l Zetec (90 PS): L1E
• 1,6 l Zetec (90 PS): L1H
• 1,6 l Zetec (90 PS): L1K
• 1,8 l Zetec (105 PS): RDA
• 1,8 l Zetec (130 PS): RQB
• 1,8 l Zetec (115 PS): RKC
2. Engine serial number
3. Engine flange
   A sticker on the upper timing belt cover shows the
engine cubic capacity (shown as 1,6 or 1,8).
CAUTION:
Do not over‐bore the cylinders. Oversize
pistons are not provided.
4. Cylinder block

CAUTION:
Do not reduce the mating face height to less
than 1,76 mm when machining the cylinder
head mating face.
5. Measure the cylinder head mating face height
Item Description
1 Front engine mounting
2 Rear right‐hand engine mounting
3 Rear left‐hand engine mounting
4 Transmission
5 Engine

Engine ‐ Dismantle and Assemble (Engine

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 134 8)
 Print

Removal and Installation

Special Tools

15030A Universal flange

holding wrench

16‐067 Locator, clutch disc

21009B Installer, camshaft oil

seal

21‐064 Mounting bracket

21068A Engine lifting tackle

 21‐093 A Installer, crankshaft
front oil seal

21‐141 Crankshaft rear oil

seal installer

21150A Mounting plate

21‐162B Timing tool,

camshaft TDC position

21‐167 Wrench, cylinder head

bolts

21‐168 Immobilising tool,

crankshaft

21‐540 Angle gauge

Workshop Equipment
Assembly stand with
21‐187
geared drive
Workshop hoist
Assembly stand with
GV‐2166
retaining straps
Proprietary Tools
Dial gauge
Magnetic fixture
Piston ring compressor
Piston ring pliers
Internal gauge
Micrometer screw
Feeler gauge
8 mm Allen key
Oil filter strap wrench
Workshop straight edge
Materials
See General
Engine oil
Specifications
Sealant, oil pressure
WSK‐M2G349‐A7
switch
Sealant, camshaft
WSK‐M2G348‐A5
bearing caps
Sealant for joints in WSE‐M4G323‐A4
cylinder block mating
faces
Spark plug thread
ESE‐M1244‐A
lubricant
Obtainable from:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST
Threaded bolt (two) M10 x 90
Bolt M10 x 70
Dismantle
1. Detach the front engine mounting bracket.
1. Disconnect the oil pressure switch plug and remove
the oil pressure switch.
2. Remove the oil filter.
3. Remove the front engine mounting bracket.

2. Mount the engine on an assembly stand.

1. Attach Special Tool 21‐150A to the engine.
2. Attach Special Tool 21‐064 to Special Tool 21‐150A
• Lift the engine using Special Tool 21‐068A and the
workshop hoist from the assembly table onto the
assembly stand.
3. Drain the engine oil.
   Screw in the oil drain plug again to 37 Nm.

4. Separate the plugs.

1. From crankshaft position (CKP) sensor
2. From temperature gauge sender
3. From coolant temperature (ECT) sensor
5. Remove the oil dipstick tube and bracket.

6. Disconnect the plug from the camshaft position

(CMP) sensor.
7. Pull off the crankcase breather hose from the inlet
manifold.
   

8. Remove the clutch.

NOTE:
Use washers between the special tool and
the transmission flange.
• Immobilise the flywheel.
• Undo the clutch pressure plate bolts uniformly.
• Remove the clutch pressure plate and clutch disc.
• Remove the upper adapter plate.

NOTE:
Mark the position of the flywheel in relation
to the crankshaft.
9. Undo the bolts and remove the flywheel.

10. Remove the pulley from the coolant pump and

remove the vibration damper.
11. Remove Special Tool 21‐168.
 12. Remove the timing belt cover (three parts).

13. Remove the cylinder head cover and the spark

plugs.
1. Bolts for cylinder head cover
2. Spark plugs

14. Remove the timing belt.

1. Loosen the tensioner pulley bolt.
2. Turn the tensioner pulley clockwise using an Allen
key to slacken the timing belt.
• Remove the timing belt.

15. Remove the crankshaft timing belt pulley.

1. Remove the timing belt pulley.
2. Remove the thrust washer.

Remove the camshafts.

 NOTE:
Use the special tool to stop the camshaft
pulleys from turning.
16. Remove the camshaft timing pulleys.

NOTE:
Follow the loosening sequence shown.

17. Remove the camshafts.

• Slacken each pair of camshaft bearing caps half a
turn until they are completely loose.
• Lay the bearing caps and camshafts down in
sequence.
• Remove the oil seals.
NOTE:
Lay the hydraulic valve tappets in
installation order to one side.
18. Remove the hydraulic tappets.
CAUTION:
Mark the bolts to be reused with one or two
punch marks as applicable. Bolts can be
reused twice. Discard bolts as necessary.
NOTE:
Observe the loosening sequence shown.

19. Remove the cylinder head bolts.

   Lift off the cylinder head and lay it on a soft
surface.

20. Remove the positive crankcase ventilation.

21. Disconnect the CKP sensor.

22. Remove the lower adapter plate (two bolts) (left‐
hand side shown).
23. Remove the coolant pump.

NOTE:
Remove the sump downwards to prevent oil
sludge and abraded particles from entering
the engine.
24. Remove the sump.

25. Remove the rear oil seal carrier together with the
oil seal.
   Prise out the oil seal from the oil seal carrier.

26. Remove the oil intake pipe and the oil baffle.
1. Oil intake pipe
2. Unscrew the nuts and the oil baffle

27. Remove the oil pump.

   Prise out the radial oil seal.
 CAUTION:
Do not damage the cylinder running surfaces.

28. Remove the pistons.

NOTE:
Lay the big‐end bearing shells down in
sequence.
• Remove the oil carbon around the upper edge of the
cylinder.
• Remove the big‐end bearing caps.
• Press out the pistons with the connecting rods and
bearing shells.
NOTE:
Lay the main bearing shells down in
sequence.
29. Remove the crankshaft.
• Remove the main bearing caps.
• Remove the crankshaft.

Vehicles with 1,8l engine only (engine code RQB)

30. Remove the piston cooling oil spray jets and the
blanking plugs.

Reassemble
31. Preparatory measures.
• Pre‐prepare two guide studs as shown in the
diagram.
• Thoroughly clean all mating faces.
• Use new self‐locking nuts.

32. Thoroughly clean all mating faces and re‐useable

parts and check them for any damage.
 33. Measure the cylinder bore diameter with a
proprietary internal gauge.
NOTE:
The piston classification is stamped on the
piston crown.
   If the measured cylinder diameter is too large for
the piston classification, then the cylinder block and
pistons (short engine) must be renewed.

NOTE:
Do not mix up the piston rings. Refit the
rings in the same grooves and at the same
position.
34. Measure the piston ring gaps.
   The values given in the General Specifications are
for the gauge ring used in production. When measured
in the cylinder, the values may be exceeded by 0,15
mm.

Vehicles with 1,8l engine only (engine code RQB)

NOTE:
Use new bolts for the oil spray jets.

35. Install the piston cooling oil spray jets and the
blanking plugs.

36. Measure the diameter of the main and big‐end

bearing journals using a proprietary micrometer
screw.
• Repeat each measurement procedure again, 90
degrees displaced from the previous one.
• If the measured values do not conform to the
required values as given in the General
Specifications, then the crankshaft must be machined
or renewed.

37. Main bearing shell availability.

 NOTE:
Main bearing shells with stepped sizes are
installed in Zetec E engines. These may also
be used in service. They are colour coded.
   Available sizes:
   Size A: 2,152 mm to 2,145 mm (green)
   Size B: 2,147 mm to 2,140 mm (brown)
   Size C: 2,142 mm to 2,135 mm (yellow)
   Size D: 2,137 mm to 2,130 mm (blue)
CAUTION:
Do not damage the bearing area of the
crankshaft when putting it in place.
38. Install the crankshaft.
• Install bearing shells of size "B" or "C" (see previous
step).
• Place the crankshaft dry in the cylinder block.

Measure the main bearing clearance

CAUTION:
The crankshaft must not be turned during
the measurement. Do not hit the bearing
caps.
NOTE:
The point of measurement must be free of
oil.
39. Measure the main bearing clearance
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
• Install the main bearing caps (see following step).
NOTE:
Measure each bearing clearance in numerical
sequence (one to five).
40. Measure the main bearing clearance (cont.).
NOTE:
The bearing cap numbering starts at the
timing belt end of the engine.
• Put each bearing cap in place together with its
corresponding bearing shell, with the arrow pointing
towards the timing belt end of the engine and tighten
them down.
• Remove the bearing cap.
41. Measure the main bearing clearance (cont.).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
• Select the main bearing shell, based on the results of
the previous step, to achieve a main bearing clearance
of 0,020 to 0,042 mm.
 42. Install the crankshaft.
NOTE:
The bearing cap numbering starts at the
timing belt end, to which the arrows also
point.
• Coat the main bearing journals and shells with
engine oil.
• Put on the main bearing caps with their
corresponding shells.
NOTE:
Install bolts with threaded stud extension
heads at bearing positions '2' and '4'.
   Tighten the bolts.
43. Check the crankshaft end float.
• Set up the dial gauge.
• Measure end float by lifting the crankshaft.

44. Install the pistons.

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil scraper ring.
NOTE:
The numbering on the connecting rods begins
at the timing belt end. The arrow on the
piston crown points to the timing belt end.
• Compress the piston rings using a proprietary piston
ring compressor.
• Push pistons number one and four into their
cylinders using a hammer handle. The crank pin must
be at BDC.
• Take the correct bearing shells, make sure they are
dry and free of oil, put them in the connecting rod and
lay the bearing cap in place.
• Install the bearing caps.
• Turn the crankshaft through 180° and insert pistons
numbers two and three.
45. Measure the big end bearing clearances.
   Measure the big‐end bearing clearances as described
in previous steps.
CAUTION:
Only use new bolts.

46. Install the big‐end bearing caps.

NOTE:
The numbers on the connecting rods and
big‐end bearing caps must be the same.
• Lubricate the bearing shells and journals with
engine oil.
• Install the corresponding big‐end bearing caps and
bearing shells and tighten the bolts.
Align the oil pump.
 47. Install the oil pump.
NOTE:
Use a new gasket.

• Position the oil pump.

• Line up the oil pump rotor with the cut outs on the
crankshaft.
• Put in the bolts.
1. Align the oil pump so that the sealing faces of the
oil pump housing lie 0,3 ‐ 0,8 mm below the cylinder
block.
2. Tighten the bolts.
   
48. Install the oil intake
pipe and the oil baffle.
   Lay the oil baffle in
place.
1. Install the oil intake
pipe using a new gasket.
2. Install the oil baffle and
oil intake pipe bracket.

Install the front crankshaft oil seal

49. Press the front crankshaft oil seal into place.
   Press the oil seal in using the special tool and the
vibration damper bolt.

50. Install the coolant pump using a new gasket.

Install the crankshaft rear oil seal

51. Install the oil seal carrier.
   Install the oil seal carrier using a new gasket and
tighten bolts finger tight.
1. Align the oil seal carrier so that the mating face of
the oil seal carrier lies 0,3 ‐ 0,8 mm below the cylinder
block.
CAUTION:
Tightening torques: bolts with 8,8 tensile
strength: 22 Nm; bolts with 10,9 tensile
strength: 30 Nm.
NOTE:
The tensile strength is embossed on the head
of the bolt.
2. Tighten the bolts.
 52. Press the oil seal into the oil seal carrier.
   Press the oil seal in using the special tool and two
flywheel bolts.

NOTE:
The sump bolts must be tightened within 10
minutes of applying the sealant.
53. Apply sealant (WSE‐M4G323‐A4) to the joints in
the mating face on the cylinder block.

Align the sump.

54. Align the sump.
• Put the sump into assembly position using a new
gasket and tighten the bolts.
• Using a workshop straight edge, align the sump so
that there is no step between it and the cylinder block.

55. Tighten the sump bolts.

   Check the alignment of the sump as described in the
previous step.

NOTE:
The installation position is marked.

NOTE:
Use new bolts (bolts are supplied with
sealant ready applied).
56. Install the flywheel.
• Remove any traces of sealant from the threaded
bores in the crankshaft.
• Install the flywheel and screw in the bolts finger
tight.
• Lock the flywheel using the Special Tool .
• Tighten the bolts.
 NOTE:
The installation position is marked.

NOTE:
Use new bolts (bolts are supplied with sealant
ready applied).
57. Install the flywheel.
• Immobilise the flywheel.
• Tighten the bolts.

58. Install the clutch.

   Centre the clutch plate on the clutch pressure plate
and fix it in place using the special tool.

59. Install the clutch (cont.).

• Install the pressure plate with centred clutch disc to
the flywheel.
1. Tighten the bolts uniformly, working diagonally.
2. Remove the special tools.
3. Install the upper adapter plate.

60. Install the CKP sensor.

61. Install the lower adapter plate (two bolts) (left‐
hand side shown).

62. Install the positive crankcase ventilation.

 CAUTION:
Set the first cylinder piston about 20 mm
before TDC.
63. Install the crankshaft timing belt pulley.
1. Install the thrust washer.
NOTE:
The marking: FRONT.

2. Slide the pulley in place.

64. Install the cylinder head.

NOTE:
The marking 'TOP' and the gasket
identification.
1. Check that the locating sleeves are seated
correctly.
2. Install the new cylinder head gasket.
3. Screw in the pre‐prepared guide studs (two M10 x
90 studs).
• Install the cylinder head.
• Remove the guide studs.
NOTE:
Use new, dry cylinder head bolts.

NOTE:
Tightening sequence.

65. Install the cylinder head (cont.).

   Screw in the cylinder head bolts and tighten them
down in two stages in the tightening sequence.

CAUTION:
The cylinder head bolts must not be re‐
tightened.
NOTE:
Tightening sequence.

66. Install the cylinder head (cont.).

   Tighten the cylinder head bolts (stage 3).

CAUTION:
Move the timing belt together with the
crankshaft when turning it, to avoid
damaging the belt.
67. Turn the crankshaft to approx. 60° before TDC.

Install the camshaft.

 NOTE:
Removal sequence.

68. Coat the hydraulic tappets with engine oil and

insert them.
NOTE:
The inlet camshaft has an additional cam at
the end of the shaft for the CMP sensor. Place
the camshaft in such a way that none of the
cams is at full lift.
69. Install the camshafts.
• Coat the bearing surfaces on the cylinder head and
the camshaft with engine oil.
• Apply sealant (WSK‐M2G348‐A5) to the sealing
surface between the cylinder head and the bearing
caps at the timing belt end.
• Lay the camshafts in place.
NOTE:
The numbering begins on the exhaust side
with '0', with the numbers facing outwards.
70. Install the bearing cap.
   Coat the surfaces of the bearing caps with engine
oil.

CAUTION:
After tightening the bolts, do not turn the
crankshaft or camshafts for approx. 15
minutes.
NOTE:
Tightening sequence.

71. Install the camshaft bearing caps (cont.).

• Turn the bolts in pairs, half a turn at a time, until
the bearing caps touch the cylinder head.
• Tighten the bolts in pairs and in two stages.
Install the camshaft oil seal.
72. Install the camshaft oil seals.
• Coat the sealing lip on the oil seals and the
camshafts with engine oil.
• Press in the new oil seals using the special tool, a
washer and an M10x70 bolt.
NOTE:
The camshaft timing pulleys must turn freely
on the camshafts; do not tighten the bolts.
73. Install the camshaft timing pulleys.
74. Align the camshafts.
   Put the special tool on the camshafts.

NOTE:
To make the sump marking more readable,
extend the mark using a small piece of sheet
metal strip (around 25 mm wide).
75. Set the crankshaft to TDC.

76. Tension the tensioning pulley against the spring.

1. Install the retaining bolt (if not already fitted).
2. Hook the tensioning spring of the timing belt
tensioner in place (if not already fitted).
3. Tension the tensioning pulley against the spring and
secure it by turning the Allen key clockwise.

CAUTION:
Do not kink the timing belt (bend diameter
must not be less than 35 mm).
77. Lay the new timing belt in place.
• Check the crankshaft TDC position.
NOTE:
Turn the camshaft timing pulleys so that the
teeth on the timing belt engage properly in
all the pulleys.
1. Starting at the crankshaft timing pulley and working
anti‐clockwise, lay the timing belt in place.
NOTE:
The side of the timing belt taking the load
(between the crankshaft timing pulley and
the camshaft timing pulley) must be taut.
2. Undo the tensioning pulley bolt. The belt is then
tensioned.
78. Tighten the tensioning pulley bolt.

NOTE:
The crankshaft must remain at TDC.

CAUTION:
Do not tighten the camshaft timing pulley
bolts using special tool 21‐162B; use special
tool 15‐030A to prevent movement.
79. Tighten the camshaft timing pulley bolts.
   Remove special tool 21‐162B.
80. Turn the crankshaft clockwise (in engine running
direction), two complete revolutions and then through
to TDC.
81. Check the alignment of the camshafts.
NOTE:
If the alignment is only slightly incorrect:
Adjust the camshaft using special tool 15‐
030A so that special tool 21‐162B can be
inserted for testing purposes. The crankshaft
must remain at TDC.
• Insert special tool 21‐162B.
• Check that the crankshaft is at TDC.
• Remove the special tool.
82. Correct the camshaft alignment (if Special Tool 21
162B cannot be fitted).
CAUTION:
Do not remove or tighten the camshaft
timing pulley bolts using Special Tool 21‐
162B; use Special Tool 15‐030A to prevent
movement.
NOTE:
The crankshaft must stay at TDC.

• Slacken the camshaft timing pulley of the relevant

camshaft.
• Turn the camshaft with an open‐ended spanner until
Special Tool 21‐162B can be fitted.
• Tighten the central bolt of the camshaft timing
pulley.
• Remove the special tool.
• Again turn the engine clockwise through two full
rotations to TDC and check the alignment of the
camshafts.
83. Install the cylinder head cover and the spark
plugs.
NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
1. Install the spark plugs and tighten them.
2. Install the cylinder head cover using a new gasket.
• Tighten the cylinder head cover bolts in two stages.

NOTE:
Make sure that the middle cover is correctly
located in the lower cover.
84. Install the timing belt cover (three parts).

85. Immobilise the flywheel with Special Tool 21‐168.

86. Install the coolant pump pulley and the crankshaft
vibration damper.

87. Connect the plug for the CMP sensor.

88. Install the crankcase breather hose onto the inlet
manifold.
   
 89. Install the oil dipstick tube and bracket.

90. Connect the plugs.

1. To the CKP sensor
2. To the temperature gauge sender
3. To the ECT sensor

91. Remove the engine from assembly stand.

• Lift the engine onto the assembly stand using the
workshop hoist and Special Tool 21‐068A, and secure
with a retaining strap.
• Detach Special Tools 21‐064, 21‐150A and 21‐068A
from the engine.

92. Install the front engine mounting bracket.

1. Front engine mounting bracket.
NOTE:
Coat the oil filter gasket with engine oil.

2. Screw in the oil filter, and after it makes contact

with the sealing surface tighten it a further 1/2 to 3/4
turn.
3. Apply sealant (WSK‐M2G349‐A7) onto the threads
of the oil pressure switch, install it and attach the
electrical connector.

Cylinder Head ‐ Remove and Install (21

Escort/Orion 1991 (08/1990-09/2001)
163 0)
 Print

Removal and Installation

Special Tools

15030A Universal flange

holding wrench

21009B Installer, oil seal

21‐162B Timing tool,

camshaft TDC position

21‐167 Socket wrench,

cylinder head bolts

21068A Engine lifting tackle

21‐226 Pliers, spark plug

connectors

21‐540 Angle gauge

24‐003 Remover and installer,

radiator hose clip

Workshop Equipment
Workshop hoist
Proprietary Tools
8 mm Allen key
Materials
Sealant, camshaft
WSK‐M2G348‐A5
bearing caps
Spark plug thread
ESE‐M1244‐A
lubricant
See General
Engine Oil
Specifications
Bolt M10 X 70
Coolant (blue/green) ESD‐M97B49‐A
Coolant (orange) WSS‐M97B44‐D
Two guide studs M10 x 90
Cable ties
Sheet metal strips approx. 25 mm wide
Silicone grease A960‐M1C171‐AA
Remove
1. General Notes.
• When connecting and disconnecting coolant or
breather hoses, use Special Tool 24‐003 as necessary
2. Standard preparatory measures.
• Make a note of the radio keycode.
• Make a note of the pre‐set radio stations.
CAUTION:
Disconnect the battery negative lead.

WARNING:
There is a risk of scalding when the engine is
warm.
• Unscrew the coolant expansion tank cap.
3. Remove the air cleaner with the intake air pipe.
1. Disconnect the mass air flow (MAF) sensor plug.
2. Unscrew and remove the nut.
3. Remove the crankcase breather tube.
4. Pull out the air intake.
5. Disconnect the plug for the intake air temperature
(IAT) sensor.
6. Undo the pipe clamp, disconnect the intake air pipe
and remove the air cleaner.

WARNING:
There is a risk of scalding when the engine is
warm.
4. Drain the coolant.
   Retighten the drain plug.

5. Remove the coolant expansion tank.

   Lay the reservoir to one side (the hoses remain
connected).

6. Detach the throttle cable.

7. Disconnect the plugs.
1. From EI coil
2. From radio interference suppressor
• Unclip the wiring.

WARNING:
Escaping fuel. Observe safety regulations
regarding the handling of fuel.
8. Separate the fuel pipes.

9. Disconnect the ground cable, the vacuum hose and

the main wiring harness plug.
1. Ground lead.
2. EVAP system vacuum tube
3. Separate the main wiring loom plug (see following
step).

10. Separate the main wiring loom plug.

1. Detach the main wiring harness from the bracket.
2. Push the clip downwards and pull the plug from the
bracket.
3. Press the clip on the plug down and separate the
plug.

11. Raise the vehicle.

12. Remove the front exhaust pipe from the exhaust
manifold.
1. Take off the two nuts.
2. Take off the two compression springs.
3. Unclip the two sleeves (shown without nuts and
compression springs).
• Tie up the front exhaust pipe.
• Remove the gasket and dispose of it.

13. Lower the vehicle.

14. Remove the timing belt as described in Operation
No. 21 304 0.
15. Remove the power steering pump bracket and the
oil dipstick tube.
   One nut, two bolts (one bolt shown)

16. Remove the coolant hose and the thermostat

housing.
   Unclip the coolant hoses.

CAUTION:
Do not undo the camshaft timing pulley bolts
using Special Tool 21‐162B; use Special Tool
15‐030A to prevent movement.
17. Remove the camshaft timing pulleys.

NOTE:
Loosening sequence.

18. Remove the camshafts.

• Slacken the bolts of all the camshaft bearing caps in
pairs by half a turn until they are completely loose.
• Put the bearing caps and camshafts down in
sequence.
• Dispose of the oil seals.
NOTE:
Put down the hydraulic tappets in sequence.

19. Remove the hydraulic tappets.

CAUTION:
Mark the bolts to be reused with one or two
punch marks as applicable. Bolts can be
reused twice. Discard bolts as necessary.
NOTE:
Loosening sequence.

20. Remove the cylinder head bolts.

 21. Lift off the cylinder head.
• Lift off the cylinder head using Special Tool 21‐068A
and the workshop hoist.
• Remove the cylinder head gasket.
• Lay the cylinder head down on a soft surface.

Install
22. Preparatory measures.
• Pre‐prepare two guide studs as shown in the
diagram.
• Thoroughly clean all mating faces.
• Use new self‐locking nuts.

CAUTION:
Move the timing belt together with the
crankshaft when turning it.
23. Turn the crankshaft to approx. 60° before TDC.

24. Prepare the cylinder block for fitting the cylinder

head.
NOTE:
The "TOP" marking and gasket identification.

1. Install the new cylinder head gasket.

2. Put the two pre‐prepared guide studs in place.
3. Check that the locating sleeves are seated
correctly.

25. Install the cylinder head.

• Use the crane to move the cylinder head into
position, locate it on the guide studs, then lower it
into place.
• Remove the lifting gear.
• Unscrew and remove the guide studs.
 NOTE:
Use new, dry cylinder head bolts.

NOTE:
Tightening sequence.

26. Install the cylinder head (cont.).

   Screw in the cylinder head bolts and tighten them
down in two stages in the tightening sequence.

CAUTION:
The cylinder head bolts must not be re‐
torqued.
NOTE:
Tightening sequence.

27. Install the cylinder head (cont.).

   Tighten the cylinder head bolts (third stage).

NOTE:
Sequence

28. Coat the hydraulic tappets with engine oil and

insert them.
NOTE:
Marking of the inlet camshaft: The inlet
camshaft has extra cams for the camshaft
position (CMP) sensor. Lay the camshaft in
place in such a way that no cam is on
maximum lift.
29. Install the camshafts.
• Apply sealant (WSK‐M2G348‐A5) to the sealing
surface between the cylinder head and the camshaft
bearing caps at the timing belt end.
• Coat the bearing surfaces on the cylinder head and
the camshaft with oil.
NOTE:
The numbering begins on the exhaust side
with '0', with the numbers facing outwards.
30. Install the bearing caps.
   Coat the bearing cap running surfaces with oil.

CAUTION:
After tightening the bolts, do not turn the
crankshaft or camshafts for approx. 15
minutes.
NOTE:
Tightening sequence.

31. Install the bearing caps (cont.).

• Turn the bolts in pairs, half a turn at a time, until
the bearing caps touch the cylinder head.
• Fully tighten the bolts in pairs following the
 tightening sequence.
32. Install the camshaft oil seals.
• Coat the sealing lip on the oil seals and the
camshafts with engine oil.
• Press in the new oil seals using the special tool, a
washer and an M10x70 bolt.

NOTE:
The camshaft timing pulleys must turn freely
on the camshafts; do not tighten the bolts.
33. Install the camshaft timing pulleys.
34. Install the timing belt as described in Operation
No. 21 304 0.
NOTE:
The fuel pipes are colour coded.

35. Connect the fuel pipes.

36. Install the power steering pump bracket and the oil
dipstick tube.
   One nut, two bolts (one shown).

37. Connect the plugs.

1. To EI coil
2. From radio interference suppressor
• Clip the wire in place.

38. Install the throttle cable and the bracket.

 39. Connect the ground cable, the vacuum hose and
the main wiring harness plug.
1. Ground lead.
2. EVAP system vacuum tube
3. Main wiring loom plug

40. Raise the vehicle.

41. Install the multi‐groove belt and tension it.
• Pretension the tensioner pulley (clockwise).
• Locate the multi‐groove belt in position.
• Release the tensioner pulley.

42. Install the front exhaust pipe onto the exhaust

manifold using a new gasket.
1. Clip the two sleeves into position (shown without
nuts and compression springs).
2. Put the two compression springs in place.
3. Screw on the two nuts.

43. Lower the vehicle.

44. Install the coolant reservoir.
 45. Install the air cleaner and the intake air pipe.
1. Put the air cleaner air intake in place.
2. Connect the intake air pipe and tighten the clamp.
3. Tighten the nut.
4. Push on the crankcase breather tube.
5. Connect the MAF sensor plug.
6. Connect the IAT sensor plug.

46. Standard finishing operations.

• Change the oil.
CAUTION:
Do not mix together coolant Super Plus 4
(blue/green) and coolant Super Plus 2000
(orange).
• Fill with coolant to the correct level.
• If necessary, fix the cables and hoses with cable ties.
• Connect the battery negative lead.
• Bleed the cooling system.
• Bleed the power steering system as described in
Operation No. 13 416 1.
• Enter the radio keycode.
• Reprogram the pre‐set radio stations.
• Adjust the clock.
• Carry out a road test to enable the PCM (EEC IV or
EEC V) to collect data.
• Check the fluid levels and rectify as necessary.
• Check the engine and cooling system for leaks
(visual inspection).

Cylinder Head ‐ Renew (New Head

Supplied With Valves) (Cylinder Head Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 165 6)
 Print

Removal and Installation

Materials
Thread locking
compound (medium SDM‐M4G9107‐A
setting)
Renew
1. Remove the inlet manifold assembly (eight bolts,
two nuts).
   Remove the gasket.
2. Remove the camshaft position (CMP) sensor and the
engine lifting eye.

3. Remove the thermostat housing and the EI coil and

bracket.
1. Thermostat housing
• Remove the seal ring.
2. Bracket, EI coil

4. Remove the heat shield.

5. Remove the exhaust manifold, the power steering

pump strut and the engine lifting eye.
   Remove the gasket.
 6. Remove the ancillary components.
1. Inner timing belt cover.
2. Centring bushes for the camshaft bearing caps
3. Exhaust manifold studs

7. Install the ancillary components on the new cylinder

head.
NOTE:
Apply thread locking compound (SDM‐
M4G9107‐A) to the studs and install them.
1. Exhaust manifold studs (x 9).
2. Put new camshaft cap centering bushes in place.
3. Inner timing belt cover.

8. Install the engine lifting eye and the power steering

pump strut, and install the exhaust manifold using a
new gasket.

9. Install the heat shield.

 10. Install the thermostat housing and the EI coil and
bracket.
1. Install the thermostat housing using a new gasket.
2. Bracket, EI coil

11. Install the CMP sensor and the engine lifting eye.

12. Install the inlet manifold using a new gasket (eight

bolts, two nuts).

Valve Stem Seals ‐ Renew (21 238 0) Escort/Orion 1991 (08/1990-09/2001)

 Print

Removal and Installation

Special Tools

21‐155 Valve spring

compressor

21‐155‐02A Adapter for 21‐

155
 21‐157 Adapter, air supply
cylinder

21‐160 Remover, valve stem

seal

21‐161 Installer, valve collets

Proprietary Tools
Valve stem removing sleeve
Materials
Ford hypoid oil SQM‐2C9002‐AA
Remove
1. Remove the camshafts as described in Operation
No. 21 284 0.
CAUTION:
Turn the crankshaft to 180 degrees before
TDC before connecting the compressed air
line to cylinders numbers 1 and 4, and to
TDC when connecting it to cylinders numbers
2 and 3. Move the timing belt together with
the crankshaft when turning it.
NOTE:
Carry out the following steps for each
cylinder individually.
2. Screw the compressed air line into the spark plug
bore.
   Connect up the compressed line using an air
pressure of 7 to 10 bar.

3. Install the special tool and the adapter.

NOTE:
Store all parts in the sequence in which they
are removed.
 4. Remove the valve springs.
1. Compress the valve spring.
2. Remove the valve collets.
• Release the valve spring, remove the spring retainer
and the spring.

5. Pull out the valve stem oil seals.

1. Push on the valve stem seal remover.
2. Turn the remover and pull out the oil seal.
   
Install
6. Coat the valve stem with Ford hypoid oil (SQM‐
2C9002‐AA).
7. Slide the fitting sleeve on the valve stem.
 CAUTION:
The valve stem oil seals for the inlet and
exhaust valves are different.
NOTE:
The valve stem oil seals will be pushed in by
the valve spring pressure.
8. Install the valve stem oil seals.
• Coat the sealing lip of the valve stem oil seals with
engine oil.
• Slide the valve stem oil seal onto the valve stem.
• Remove the fitting sleeve from the valve stem.
1. Put on the valve spring with the valve spring
retainer and compress it.
2. Put the valve collets in place.
9. Remove the compressed air line.
10. Install the camshafts as described in Operation No.
21 284 0.

Escort/Orion 1991 (08/1990-09/2001)

 Print

Specifications
NOTE:
This section only contains Operation Number 21 134 8. Other operations for the 1.8l
diesel engine can be found in Section 21‐08 (1,8l Endura DE (TCI) engine).
Engine data 1,8 diesel engine
Engine management ‐‐‐
Engine code RTE, RTF, RTH
Emission standard (RTH with open loop catalytic converter) 93EEC/96EEC
Fuel Diesel
Firing order 1‐3‐4‐2
Bore mm 82,5
Stroke mm 82,0
Cubic capacity (effective) cc 1753
Compression ratio 21,5:1
Compression pressure at starter motor speed bar 28 ‐ 34
Power output (EEC) kW 44
Power output (EEC) (PS) 60
Power output (EEC), at rev/min 4800
Torque Nm 110
Torque, at rev/min 2500
Idle speed rev/min 800 ‐ 900
Maximum engine speed ‐ continuous rev/min 4800
Maximum engine speed ‐ intermittent rev/min 5300 ‐ 5400
Dimensions
Cylinder block
Number of main bearings 5
Cylinder bore diameter, standard class A mm 82,500 ‐ 82,515
Cylinder bore diameter, standard class B mm 82,515 ‐ 82,530
Cylinder bore diameter, standard class C mm 82,660 ‐ 82,675
Cylinder bore diameter, standard class D mm 82,675 ‐ 82,690
Cylinder bore diameter, standard class E mm 83,000 ‐ 83,015
Cylinder bore diameter, standard class F mm 83,500 ‐ 83,515
Main bearing clearance (radial) mm 0,025 ‐ 0,085
Dimensions
Crankshaft
Main bearing journal diameter, standard mm 53,970 ‐ 53,990
Main bearing journal diameter, undersize 1 = 0,25 mm 53,720 ‐ 53,740
Main bearing journal diameter, undersize 2 = 0,50 mm 53,470 ‐ 53,490
Big‐end bearing journal diameter, standard mm 48,970 ‐ 48,990
Big‐end bearing journal diameter, undersize 1 = 0,25 mm 48,720 ‐ 48,740
Big‐end bearing journal diameter, undersize 2 = 0,50 mm 48,470 ‐ 48,490
Big‐end bearing clearance mm 0,016 ‐ 0,074
Crankshaft end float mm 0,09 ‐ 0,37
Dimensions
Connecting rods
Bore diameter, big‐end mm 52,000 ‐ 52,020
Bore diameter, small‐end mm 26,012 ‐ 26,020
Distance between centre lines of connecting rod bearings,
mm 129,880 ‐ 129,940
class A
Distance between centre lines of connecting rod bearings,
mm 129,941 ‐ 130,000
class B
Distance between centre lines of connecting rod bearings,
mm 130,001 ‐ 130,060
class C
Distance between centre lines of connecting rod bearings,
mm 130,061 ‐ 130,120
class D
Big‐end bearing clearance (radial) mm 0,016 ‐ 0,074
NOTE:
The piston ring gaps must be evenly spaced around the piston circumference. This also
applies to each part of the oil scraper ring. Arrange the ring gaps 120 degrees to each
other.
Dimensions
Pistons
Piston diameter (measured at right angles to piston pin
mm 82,460 ‐ 82,475
bore),class A
Piston diameter (measured at right angles to piston pin mm 82,475 ‐ 82,490
bore),class B
Piston diameter (measured at right angles to piston pin
mm 82,620 ‐ 82,635
bore),class C
Piston diameter (measured at right angles to piston pin
mm 82,635 ‐ 82,650
bore),class D
Piston diameter (measured at right angles to piston pin
mm 82,961 ‐ 82,979
bore),class E (Note: only in service)
Piston diameter (measured at right angles to piston pin
mm 83,461 ‐ 83,479
bore),class F (Note: only in service)
Piston clearance (initial installation), class A ‐ D mm 0,022 ‐ 0,055
Piston clearance (initial installation), class E/F 0,021 ‐ 0,054
Piston protrusion at TDC mm 0,500 ‐ 0,840
Piston ring gap (fitted), upper compression ring mm 0,3 ‐ 0,5
Piston ring gap (fitted), lower compression ring mm 0,3 ‐ 0,5
Piston ring gap (fitted), oil control ring mm 0,25 ‐ 0,580
Piston ring clearance in piston groove, upper compression
mm 0,09 ‐ 0,122
ring
Piston ring clearance in piston groove, lower compression
mm 0,05 ‐ 0,082
ring
Piston ring clearance in piston groove, oil control ring mm 0,03 ‐ 0,065
Piston pin diameter mm 25,996 ‐ 26,000
”Floating" in piston
Piston pin type
and connecting rod
Piston pin retention Circlip
Dimensions
Camshaft
Drive Timing Belt
Valve timing, inlet valve opens before TDC °C/S 6
Valve timing, inlet valve closes after BDC °C/S 32
Valve timing, exhaust valve opens before BDC °C/S 57
Valve timing, exhaust valve closes after TDC °C/S 7
Cam lift, inlet mm 9
Cam lift, exhaust mm 10
End float mm 0,100 ‐ 0,240
Bearing journal diameter mm 27,960 ‐ 27,980
Bearing clearance mm 0,020 ‐ 0,079
Dimensions
Cylinder head
Camshaft bearing diameter, standard mm 30,500 ‐ 30,525
Camshaft bearing diameter, oversize mm 30,575 ‐ 30,600
Valve tappet bore diameter, standard mm 35,00 ‐ 35,03
Valve tappet bore diameter, oversize mm 35,50 ‐ 35,53
Valve guide bore diameter, standard mm 8,000 ‐ 8,025
Valve guide bore diameter, oversize 1 mm 8,263 ‐ 8,288
Valve guide bore diameter, oversize 2 mm 8,463 ‐ 8,488
Thickness of cylinder head gasket with piston protrusion of
mm 3
0,500 ‐ 0,680 mm
Thickness of cylinder head gasket with piston protrusion of
mm 3
0,681 ‐ 0,740 mm
Thickness of cylinder head gasket with piston protrusion of
mm 4
0,741 ‐ 0,840 mm
Maximum permitted cylinder head distortion over the whole
mm 0,08
cylinder head
Valve clearance, inlet (cold) mm 0,35 ± 0,05
Valve clearance, exhaust (cold) mm 0,50 ± 0,05
Shim thicknesses mm 3,00 ‐ 4,75
Shim thicknesses are graded in steps of mm 0,05
Engine oil up to model year 1999
Viscosity / Ambient Description Specification
temperature
Recommended engine oil:
SAE 10W40 /‐20 °C to over Ford XR+ High‐performance High‐
ACEA A3/B3
40 °C lubricity Motor Oil
Alternative engine oils:
SAE 5W40 / under‐20 °C to
Ford Formula S Synthetic Motor Oil ACEA A3/B3
over 40 °C
If engine oils to this specification are not available, only other oils which at least conform to
the API/SH/CD EC (Energy Conserving) and CCMC PD2 specifications may be used.

Engine oil from model year 1999

Viscosity / Ambient Description Specification
temperature
Recommended engine oil:
SAE 5W 30 /‐20 °C to WSS‐M2C912‐A1 or WSS‐
Ford Formula E Motor Oil
above 40 °C M2C913‐A
Alternative engine oils:
SAE 5W40 /‐20 °C to over
Ford Formula S Synthetic Motor Oil ACEA A3/B3
40 °C
SAE 10W40 /‐20 °C to over Ford XR+ High‐performance High‐
ACEA A3/B3
40 °C lubricity Motor Oil
If engine oils to this specification are not available, only other oils which at least conform to
the API/SH/CD EC (Energy Conserving) and CCMC PD2 specifications may be used.

Engine Lubrication
Description
Oil pressure (minimum, oil temperature approx.805C), at
bar 0,75
750 rev/min
Oil pressure (minimum, oil temperature approx.805C), at
bar 1,5
2000 rev/min
Pressure relief valve opening pressure bar 2‐4
Oil pump max. inner/outer rotor clearance mm max. 0,174
Oil pump (outer rotor casing clearance) mm 0,14 ‐ 0,26
Inner/outer rotor end float, oil pump cover mm 0,025 ‐ 0,06
Lubricants, Adhesives and Sealers
Description Ford
Specification
Sump to cylinder block, camshaft bearing cap no. 1 (Hylomar SQ321H) SPM 4G9114
Coolant ESD‐M97B‐49A
Sealant, cylinder block mating face intersections SPM‐4G‐9112‐H
Capacity
Description Litres
Engine oil, first fill including filter 5,0
Engine oil, with filter change 5,0
Engine oil, without filter change 4,5
Torques
Cylinder block Nm lbf.ft
Main bearing caps, stage 1 27 20
Main bearing caps, stage 2 75° 75°
Big‐end bearing, stage 1 25 18
Big‐end bearing, stage 2 60° 60°
Big‐end bearing, stage 3 20° 20°
Rear oil seal carrier 20 15
Flywheel, stage 1 18 13
Flywheel, stage 2 45° 45°
Flywheel, stage 3 45° 45°
Clutch pressure plate 30 22
Auxiliary shaft thrust plate 9 7
Auxiliary shaft oil seal carrier 23 17
Front plate to cylinder block 24 18
CKP sensor bracket 21 15
Crankshaft vibration damper to flange 35 26
Crankshaft vibration damper hub, 1st stage 150 111
Crankshaft vibration damper hub, 2nd stage ‐905 ‐665
Crankshaft vibration damper hub, 3rd stage 120 89
Crankshaft vibration damper hub, 4th stage 605 446
Bolt ‐ rear timing belt cover to cylinder block 24 18
Generator bracket 46 34
Generator on bracket 25 18
Plug ‐ crankshaft TDC timing peg bore 24 18
Bracket ‐ fuel‐injection pump/cylinder block 23 17
Torques
Coolant circuit Nm lbf.ft
Coolant pump 23 17
Coolant pump pulley 11 8
Thermostat housing 20 15
Coolant hose ‐ coolant pump/thermostat housing 3 2
Fuel regulation thermostat to thermostat housing 23 17
Coolant pipe to cylinder block 25 18
Torques
Oil circuit Nm lbf.ft
Oil pump 18 13
Sump 11 8
Oil pressure switch to cylinder head 20 15
Oil drain plug ‐ sump 25 18
Blanking plugs, cylinder block oil passages 22 16
Oil intake pipe bracket to cylinder block 22 16
Camshaft oil baffle plate 20 15
Engine oil dipstick tube 10 7
Oil pump to cylinder block 23 17
Torques
Cylinder head Nm lbf.ft
Cylinder head, stage 1 10 7
Cylinder head, stage 2 100 74
Cylinder head, wait 3 minutes
Cylinder head, stage 3 ‐180° ‐180°
Cylinder head, stage 3 70 52
Cylinder head, stage 3 120° 120°
Glow plug power supply 2 1
Glow plugs 28 21
Fuel filter to bracket 23 17
Injectors 70 52
Vacuum pump to cylinder head 22 16
Fuel‐injection pump to front plate 24 18
Vacuum pipe bracket to thermostat housing 9 7
Fuel filter bracket to cylinder head/lifting eye 23 17
Vacuum pipe bracket to cylinder head 22 16
Fuel‐injection pipe to injector/fuel‐injection pump 25 18
Timing belt idler pulley to cylinder head 45 33
Camshaft pulley with flange to camshaft 30 22
Auxiliary shaft timing pulley 45 33
Camshaft timing belt tensioner clamp bolt 9 7
Fuel‐injection pump pulley to flange 23 17
Fuel‐injection pump pulley to flange 45 33
Camshaft toothed belt tensioner bolt 50 37
Camshaft pulley to camshaft flange 9 7
Timing belt cover 8 6
Injection pump belt pulley 25 18
Camshaft bearing caps 23 17
Cylinder head cover 5 4
Engine bearing bracket 24 18
Exhaust manifold on cylinder head 24 18
EGR valve 20 15
EGR valve connecting pipe clip 10 7
Cam shaft timing belt pulley M8 35 26
Cam shaft timing belt pulley M10 48 35

Engine ‐ Disassemble and Assemble

Escort/Orion 1991 (08/1990-09/2001)
(engine removed) (21 134 8)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange

holding wrench

16‐067Locator, clutch disc

21‐011 FCrankshaft rear oil

seal installer
 21‐031 BMounting bracket,
engine

21‐104Timing peg, TDC

21‐148 AAligner/installer, oil

seal

21‐162ATiming tool, camshaft

alignment

21‐164Socket, cylinder head

bolts

21‐168Locking tool,
crankshaft

21‐200Remover, crankshaft
timing pulley

21‐217Aligner, crankshaft rear

oil seal

21‐540Angle gauge

23‐019Timing pin, camshaft

toothed belt

23‐029Timing pin, injection

pump

23‐03427 mm socket for

injectors

Proprietary tools
Description
Dial gauge
Measuring fixture
Piston ring compressor
Oil filter strap wrench
New 6 mm drill bit
Two‐legged puller
Micrometer (25 ‐ 50 mm)
Micrometer (50 ‐ 75 mm)
Steel straight edge
Feeler gauges
Internal gauge
Light‐metal drift
Plastic scraper
Workshop Equipment
Description
Mounting stand with
21‐187
geared drive
Materials
Description
Obtainable through:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST
Sealant, cylinder block
mating face SPM‐4G‐9112‐H
intersections
Engine oil SAE 5W‐30 WSS‐M2C912‐A1
Dismantle
1. General note.
CAUTION:
In MJ '96 the camshaft timing belt was
revised. Coolant pumps and timing belt
tensioners with different idler pulleys are
fitted in production. In service there are now
only coolant pumps with two edges on the
idler pulley available. It should be noted that
when renewing the timing belt tensioner, a
tensioner without an edge must not be fitted
in conjunction with a coolant pump without
edges. Converting a mechanical timing belt
tensioner to an automatic timing belt
tensioner is NOT permissible. In addition,
since MY '96 PTFE oil seals have been fitted
at the front and rear of the crankshaft instead
of the familiar Viton oil seals.
CAUTION:
Since 08.98 (build code WP), a revised oil
pump has been fitted in conjunction with a
revised oil pressure switch (green cover), and
5W 30 engine oil has been used. It should be
noted that up to and including 07.98 (build
code WM), an oil pressure switch with a black
cover was fitted, and 10W‐40 engine oil was
used.
NOTE:
Installation position of the timing belt
tensioner spring and the fuel‐injection pump
spring. DO NOT mix up the springs.
 2. Detach the exhaust gas recirculation valve (EGR
valve).
1. Disconnect the hose.
2. Unscrew the bolts.

3. Detach the exhaust manifold.

4. Mount the engine on an assembly stand.

• Fit the mounting bracket.
• Mount the engine on the assembly stand.
5. Drain the engine oil.

6. Detach the engine mounting.

NOTE:
Watch out for escaping oil.

7. Detach the oil pump with the oil filter.

8. Detach the alternator.

1. Undo the bolts.
2. Slacken the timing belt and remove it.
   Detach the alternator.
 9. Detach the injection pump belt pulley.

10. Detach the upper and lower timing belt covers.

11. Detach the crankcase ventilation hose.

1. To the cylinder block.
2. To the turbocharger.

12. Detach the cylinder head cover.

• Remove the gasket.

Engines fitted with an automatic camshaft timing belt tensioner.

13. Undo the bolt of the adjusting cam.
   Turn the adjusting cam to 6 o'clock.

Engines fitted with an automatic camshaft timing belt tensioner.

 14. Undo the camshaft timing pulley.
NOTE:
Stop the camshaft timing pulley from turning
using the special tool.
• Undo the camshaft timing pulley bolt three turns.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
The timing belt must not be reused.

15. Remove the camshaft timing pulley.

• Detach the camshaft timing pulley and take it off
with the camshaft timing belt.
• Discard the timing belt.

Engines fitted with a mechanical camshaft timing belt tensioner.

16. Detach the camshaft timing belt.
• Undo the timing belt tensioner clamp bolt and
slacken the timing belt.
• Remove the timing belt.
• Tighten the timing belt tensioner clamp bolt.
• Discard the timing belt.

Engines fitted with a mechanical camshaft timing belt tensioner.

CAUTION:
The timing belt tensioner is spring‐loaded.

17. Detach the timing belt tensioner and thecamshaft

timing pulley.
1. Timing belt tensioner bolt
NOTE:
Remove the timing pulley using a two‐legged
puller.
2. Timing pulley bolt.

18. Detach the injection pump timing belt.

• Undo the timing belt tensioner clamp bolt and
slacken the timing belt.
• Tighten the timing belt tensioner clamp bolt.
• Remove the timing belt.
 CAUTION:
The timing belt tensioner is spring‐loaded.

19. Detach the timing belt tensioner and the injection

pump timing pulley.
1. Timing belt tensioner
2. Timing belt pulley

CAUTION:
The timing belt tensioner is spring‐loaded.

20. Detach the timing belt tensioner and the camshaft

timing pulley.
1. Detach the camshaft timing belt tensioner.
NOTE:
Remove the camshaft timing pulley using a
two‐legged puller.
2. Detach the camshaft timing pulley.

NOTE:
Lock the flywheel using the Special Tool.

21. Detach the crankshaft vibration damper.

22. Remove the rear timing belt covers.

1. Detach the timing pulley.
2. Remove the rear cover bolt.
   Remove the covers.

23. Remove the oil dipstick tube together with the

mounting.
24. Detach the crankcase ventilation hose.
25. Detach the fuel delivery pipe.
1. Disconnect the hose.
2. Undo the quick‐release coupling by pressing it
together.
3. Unclip the pipe.

26. Detach the injection pipes and leak‐off hoses.

27. Remove the fuel‐injection pump bracket.

1. Slacken the two bolts.
2. Unscrew the two bolts.

28. Detach the injection pump.

29. Detach the thermostat housing and the coolant

hose.
30. Detach the alternator bracket.
 31. Detach the vacuum pump.
   Detach the vacuum pump oil return hose.

32. Detach the fuel filter.

1. Detach the diesel fuel heater from the bracket.
2. Detach the diesel fuel heater and the bracket.

33. Remove the auxiliary shaft timing pulley and oil

seal carrier.
1. Remove the auxiliary shaft timing pulley.
2. Remove the auxiliary shaft oil seal carrier.

34. Remove the auxiliary shaft.

• Unscrew the thrust plate bolts.
• Withdraw the auxiliary shaft with the thrust plate.

NOTE:
One bolt holds the bracket for the timing belt
tensioner spring.
35. Detach the coolant pump.
 CAUTION:
Insert the expanding part of the puller only,
without the centre spindle.
36. Remove the timing pulley from the crankshaft.
1. Insert the expanding puller.
2. Pull back the expanding puller until it reaches the
stop.

37. Remove the timing pulley from the crankshaft

(cont.).
   Insert the puller spindle and pull the timing pulley
off the crankshaft.

38. Remove the injectors and glow plugs.

1. Remove the injectors.
   Remove the heat shields.
2. Remove the glow plug power supply.
3. Remove the glow plugs.

39. Detach the oil baffle.

 40. Detach the cylinder head.
• Undo and remove the cylinder head bolts in the
specified order.
• Remove the cylinder head and put it down on a soft
surface.
• Remove the gasket.

41. Remove the crankshaft position sensor with its

bracket.

NOTE:
Lock the flywheel using the Special Tool.

42. Remove the clutch.

43. Remove the flywheel.

Viton oil seals only

 44. Remove the crankshaft rear radial oil seal carrier.
   Drive out the oil seal on a flat surface.

PTFE oil seals only

NOTE:
The oil seal carrier is renewed as a unit with
the oil seal.
45. Remove the crankshaft rear radial oil seal carrier.

NOTE:
Remove the sump downwards so that no oil
sludge or debris can enter the engine.
46. Detach the sump (14 bolts).

47. Detach the front plate.

   Prise out the radial oil seal.

48. Remove the oil intake pipe with its bracket.

   Remove the O‐ring.
 CAUTION:
Do not damage the cylinder bore.

49. Remove the pistons with the connecting rods.

• Detach the big‐end bearing caps.
• Remove the crown of carbon around the top of the
cylinders using a plastic scraper.
NOTE:
Keep the big‐end shells and caps in removal
order, ready for re‐fitting.
• Push the pistons and bearing shells out and keep
them in order.
NOTE:
Keep the bearing shells and caps in removal
order, ready for re‐fitting.
50. Remove the crankshaft.
• Detach the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half washers
and set them aside in order for re‐use.

Reassemble
CAUTION:
A revised timing belt drive has been fitted in
production since '96 MY. The timing pulleys,
the timing belt tensioner and the timing belt
cannot be replaced by components from
previous years.
51. Thoroughly clean all mating faces and re‐useable
parts and check them for damage.
52. Clean the piston cooling oil splash nozzles and
oilways.
 NOTE:
The main bearing caps must be fitted without
the main bearing shells, and tightened to the
specified torque.
53. Measure the cylinder bores using an internal
gauge.
   If the measured cylinder bore diameter is too large
for the piston classification then the cylinder block
must be overhauled or renewed.

NOTE:
Repeat the measuring operation at intervals
of 90°.
54. Measure the diameters of the main and big‐end
bearing journals.
• Different sizes of crankshaft are used in production.
The different crankshafts are not marked.
• If the measurements do not agree with those given
in the General Specifications, then the crankshaft
must be overhauled or renewed.

55. Preparations for measuring the bearing clearance.

NOTE:
Carry out the following steps exactly as
described.
• Measure each bearing surface individually with
Plastigage.
• Only the bearing cap of the bearing being measured
is fitted and torqued down to specification.
• The bearing shells and the journals must be free of
oil.
• The measurement should be carried out near the
respective dead centre position.
56. Measure the crankshaft main bearing clearances.
• Place the matching bearing shells in the cylinder
block, free of oil.
• Place the crankshaft in the cylinder block, free of oil.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
 NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
57. Measure the main bearing clearances (continued).
• Locate each bearing cap in place with its associated
bearing shell and tighten it up.
• Detach the bearing cap.

58. Measure the main bearing clearances (continued).

• The measured value shows the bearing clearance.
• Renew the bearing shells as necessary.

NOTE:
Coat the main bearing journals, the bearing
shells and the thrust half washers with
engine oil.
59. Install the crankshaft.
• Place the thrust half washers in the second main
bearing, with the lubrication groove facing outwards.
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point. Do not strike the bearing caps.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
• Tighten the bolts.
NOTE:
Correct any end float as necessary with the
thrust washers at the second main bearing.
60. Check the crankshaft end float.
• Set up the dial gauge.
• Measure the end float by lifting the crankshaft with a
screwdriver.

61. Piston classification.

1. Cylinder bore classification.
2. Piston diameter classification.
3. The weight classes are marked with `+' and `‐'.
 NOTE:
Piston classification, in case a piston must be
replaced.
62. Measure the piston diameters.

CAUTION:
Do not mix up the piston rings. Replace the
rings in the same grooves and at the same
position.
63. Measure the piston ring gaps.
   The values given in General Specifications were
obtained with a gauge ring used in production. When
measured in the cylinder, the values may be exceeded
by 0,15 mm.

NOTE:
The piston ring axial clearance must be
measured with the ring projecting from its
groove.
64. Measure the piston ring clearance.
• The maximum piston ring clearance in the piston
groove for the upper compression ring is 0,2 mm.
• The maximum clearance in the groove for the second
compression ring is 0,1 mm.

NOTE:
Lubricate the pistons and cylinder bores with
engine oil.
65. Install the pistons and connecting rods.
• Distribute the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil control ring.
NOTE:
The numbering of the connecting rods starts
at the timing belt end. The arrow on the
piston crown points to the timing belt end.
• Compress the piston rings using a piston ring
compressor.
CAUTION:
Do not damage the cylinder bores and
bearing surfaces.
NOTE:
The big‐end journal must be at BDC position.

• Press the pistons on cylinders 1 and 4 into the

cylinder with the handle of a hammer while guiding the
connecting rods onto the big‐end bearing journals.
• Place the clean and oil‐free bearing shells in their
matching big‐ends.
• Fit the pistons on cylinders 2 and 3 in the way
described above.
 66. Measure the big‐end bearing clearances and fit
the bearing caps.
   Measure the big end bearing clearances as
described in steps to above.
67. Coat the bearing shells and journals with engine
oil.
NOTE:
The numbering of the connecting rods and
big‐end bearing caps must be the same.
   Fit the appropriate big‐end bearing caps and
bearing shells and tighten the bolts.
NOTE:
Make sure the O‐ring is seated
correctly.
68. Fit the oil intake pipe with its bracket.
1. Fit the oil intake pipe using a new O‐ring.
2. Fit the bracket.

NOTE:
The mating face of the front plate must be
flush with the lower edge of the cylinder
block (tolerance ± 0,1mm).
69. Fit the front plate.
   Fit the front plate with a new gasket and new
rubber oil seals for the oil channels.
1. Centre the front plate using the special tool.
2. Tighten the front plate (4 bolts).

CAUTION:
If a PTFE oil seal (teflon ring) is used, step
should be carried out immediately to stop
the oil seal from contracting. Do not remove
the support ring from the oil seal until it is
about to be fitted.
70. Install the crankshaft front oil seal.
   Fit the oil seal using the special tool and the bolt of
the vibration damper.

CAUTION:
A revised timing belt drive has been fitted in
production since'96 MY. The timing pulleys,
the timing belt tensioner and the timing belt
cannot be replaced by components from
previous years.
71. Fit the crankshaft timing pulley.
NOTE:
Condition of O‐ring in timing pulley.

• Lubricate the O‐ring and the end of the crankshaft

with engine oil.
• Carefully slide on the pulley as far as it will go.
• The locating pin on the end of the crankshaft and the
hole in the timing pulley must line up.
 NOTE:
The sump bolts must be tightened within 20
minutes of applying the sealer.
72. Apply sealer (SPM‐4G‐9112‐H) to the joints on the
cylinder block mating face.

73. Fit the sump.

• Locate the sump in place with a new gasket and
screw in the bolts (x14) finger tight.
• Make sure that the sump is flush with the cylinder
block.

74. Tighten the sump bolts.

PTFE oil seals only

CAUTION:
The seal lip of the oil seal and the sealing
surface on the crankshaft must be free of
oil.
CAUTION:
The support ring is automatically pushed out
of the oil seal when the oil seal carrier is
fitted in place. Do not remove it beforehand.
75. Fit a new crankshaft rear oil seal carrier.
• Locate a new oil seal carrier with integrated oil seal
together with the bolts in installation position.
• Insert the bolts.
• Insert the special tool and centrally align the oil
seal carrier on the crankshaft.
PTFE oil seals only
CAUTION:
If the special tool cannot be removed, then
the sump must be re‐aligned.
76. Tighten the bolts on the crankshaft oil seal
carrier.
   Remove the special tool.
 CAUTION:
Renew the bolts.

77. Fit the flywheel (8 bolts).

   Lock the crankshaft using
Special Tool 21‐168.

78. Fit the CKP sensor together with its bracket.

79. Fit the coolant pump.

   Locate the coolant pump in installation position,
together with a new gasket and the bracket for the
timing belt tensioner spring.

NOTE:
The lubricating grooves on the thrust plate
must face outwards.
80. Fit the auxiliary shaft.
• Lubricate the auxiliary shaft, the bearing bush in the
cylinder block and the thrust plate with engine oil.
• Fit the auxiliary shaft with the thrust plate.

CAUTION:
If the plastic fitting bush is removed from the
oil seal carrier before assembly then the oil
seal is rendered useless.
81. Fit the auxiliary shaft oil seal carrier.
• Lubricate the end of the auxiliary shaft with engine
oil.
• Push a new oil seal carrier with an integrated oil seal
and plastic fitting bush onto the end of the auxiliary
shaft.
• Tighten the bolts on the oil seal carrier.
• After securing the oil seal housing, detach the plastic
fitting bush and check that the seal is seated correctly.
 NOTE:
Make two measurements per cylinder, five
millimetres in from the piston edge.
82. Measure the piston protrusion.
• Measure the piston protrusion of each cylinder when
it is at TDC
• Measure the difference in height between the piston
crown and the cylinder block.
• The largest measurement decides the thickness of
the cylinder head gasket (see General Specifications).
83. Line up the crankshaft and camshaft.
• Turn the crankshaft until the piston of cylinder no. 1
is at TDC.
• Turn the camshaft until the slot in the eccentric on
the camshaft is parallel with the upper edge of the
cylinder head (with the larger semi‐circle at the top).
• The crankshaft and camshaft must not be turned any
further.

NOTE:
The cylinder head gasket is marked
”TOP/OBEN".
84. Fit the new cylinder head gasket.
1. Check that the locating sleeves are seated
correctly.
2. Thickness identification notches.

NOTE:
Renew the cylinder head bolts.

85. Tighten the cylinder head bolts.

• Screw in the cylinder head bolts.
• Tighten the cylinder head bolts in two stages in the
specified sequence.
 NOTE:
The cylinder head bolts must not be re‐
tightened.
86. Tighten the cylinder head bolts (cont.).
CAUTION:
For the third stage, first undo one bolt by the
angle shown, then tighten it to the specified
torque and then apply the angular torque.
Only then move on to the next bolt.
   Wait three minutes and then tighten the cylinder
head bolts to stage 3 in the specified sequence.

NOTE:
The heat shield is correctly installed with the
conical side downwards. Use new heat
shields.
87. Install the injectors and glow plugs.
1. Install the injectors with the heat shields.
2. Install the glow plugs.
3. Install the glow plug power supply.

88. Fit the fuel filter.

1. Fit the bracket with the fuel filter.
2. Attach the diesel fuel heater to the bracket.

89. Fit the vacuum pump.

• Connect the oil return hose.
• Place the vacuum pump and new O‐ring, glow plug
bracket and vacuum pump bolts in position.
• Tighten the bolts.
90. Fit the thermostat housing and the coolant hose.
91. Fit the alternator bracket.

92. Fit the fuel‐injection pump.

93. Fit the fuel‐injection pump bracket.

94. Connect the injection pipes and the leak‐off

hoses.

95. Install the fuel feed pipe.

1. Fuel pipe quick‐release coupling
2. Clip the pipe in place.
3. Connect the hose.
 96. Fit the dipstick tube together with its bracket.
97. Install the crankcase ventilation hose.

98. Fit the rear timing belt covers.

   Locate the covers in installation position.
1. Install the timing pulley.
2. Screw in the bolt.

NOTE:
The auxiliary shaft locating pin and the hole
in the timing pulley must line up.
99. Fit the pulleys and the camshaft timing belt
tensioner.
1. Fit the camshaft timing pulley.
2. Fit the auxiliary shaft pulley (one bolt).
3. Secure the timing belt tensioner (2 bolts).
4. Compress timing belt tensioner spring and lock it
using a bolt.

NOTE:
Do not tighten the bolts.

100. Fit the injection pump timing pulley.

   Set the pulley so that the bolts are central in the
slots.

101. Fit the injection pump timing belt tensioner.

   Compress timing belt tensioner spring and lock it
using a bolt.
 NOTE:
Use a new bolt.

102. Fit the crankshaft vibration damper.

• Lock the crankshaft.
NOTE:
The lug and the notch must line up.

• Coat the underside of the bolt head on the vibration

damper with engine oil and tighten it to the specified
torque.
Engines fitted with an automatic camshaft timing belt tensioner.
103. Fit the special tool in the camshaft groove.

104. Set the crankshaft to TDC.

• Remove the retaining bolt from the cylinder block.
NOTE:
Screw in the special tool as far as it will go.

• Fit Special Tool 21‐104 and carefully turn the

crankshaft in the direction of rotation of the engine
until it comes up against the special tool.
Engines fitted with an automatic camshaft timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the fuel pump timing belt.
CAUTION:
Only carry out work on the timing belt at
workshop temperature.
NOTE:
The crankshaft must be touching Special
Tool 21‐104 and Special Tool 21‐162B must
be inserted in the camshaft.
NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated
correctly.
105. Fit the new camshaft timing belt.
1. Install the camshaft timing belt tensioner.
2. Install the adjusting cam.
3. Locate the timing belt in position.
   Slide the camshaft timing pulley onto the taper and
tighten the bolt until the pulley only just turns on the
camshaft.
Engines fitted with an automatic camshaft timing belt tensioner.
 106. Pre‐tension the camshaft timing belt.
NOTE:
Coat the bolt contact surface of the adjusting
cam with engine oil.
   Turn the adjusting cam clockwise to 9 o'clock and
tighten the adjuster bolt.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
Stop the camshaft timing pulley from turning
using the special tool.
107. Tighten the camshaft timing pulley bolt.

Engines fitted with an automatic camshaft timing belt tensioner.

CAUTION:
Remove Special Tools 21‐104 and 21‐
162B.
108. Turn the crankshaft six turns in its running
direction.
Engines fitted with an automatic camshaft timing belt tensioner.
109. Preparations for tensioning the timing belt.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in as far as
it will go.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Engines fitted with an automatic camshaft timing belt tensioner.
110. Undo the bolt on the adjusting cam half a turn.

Engines fitted with an automatic camshaft timing belt tensioner.

 NOTE:
Stop the camshaft timing pulley from turning
using the special tool.
111. Undo the camshaft timing pulley bolt three turns.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
Insert a screwdriver between the camshaft
timing pulley and the timing belt rear cover.
112. Loosen the camshaft timing pulley from the taper
by lightly tapping the light‐metal drift.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
If necessary, rotate the camshaft until the
timing tool can be inserted.
113. Insert the special tool.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
Check that the camshaft timing pulley is still
free to turn on the camshaft.
114. Tighten the camshaft timing pulley bolt finger
tight and loosen one half turn.

Engines fitted with an automatic camshaft timing belt tensioner.

 115. Tension the camshaft timing belt.
NOTE:
The adjustment range of the adjusting cam
lies between 6 o'clock (MIN) and 12 o'clock
(MAX).
   Tension the camshaft timing belt by turning the
adjusting cam clockwise so that the arrow of the
automatic camshaft timing belt tensioner is located in
the right‐hand corner of the adjustment range.

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
Hold the adjusting cam in position.

116. Tighten the adjusting cam bolt evenly.

Engines fitted with an automatic camshaft timing belt tensioner.

117. Checking the position of the automatic camshaft
timing belt tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A, tension the
camshaft timing belt again as described.
CAUTION:
To avoid damage to the engine, make sure
that the pointer is in range "A".

Engines fitted with an automatic camshaft timing belt tensioner.

NOTE:
Stop the camshaft timing pulley from turning
using the special tool.
118. Tighten the bolt of the camshaft timing pulley.
• Tightening torque for M8 bolt: 35 Nm
• Tightening torque for M10 bolt: 48 Nm

Engines fitted with an automatic camshaft timing belt tensioner.

119. Remove Special Tools 21‐104 and 21‐162B.
Engines fitted with an automatic camshaft timing belt tensioner.
 120. Checking the valve timing.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in as far as
it will go.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Engines fitted with an automatic camshaft timing belt tensioner.
121. Install the special tool. If the special tool cannot
be inserted, tension the camshaft timing belt again as
described.

Engines fitted with an automatic camshaft timing belt tensioner.

122. Checking the position of the automatic timing belt
tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A, tension the
camshaft timing belt again as described.
CAUTION:
To avoid damage to the engine, ensure that
the pointer is located within range ”A".

Engines fitted with an automatic camshaft timing belt tensioner.

123. Remove Special Tools 21‐162B and 21‐104.
Engines fitted with a mechanical camshaft timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the injection pump timing belt.
NOTE:
The springs of the timing belt tensioners are
not interchangeable.
124. Fit the new camshaft timing belt.
• Insert Special Tool 23‐019.
NOTE:
Make sure the timing belt is seated correctly
and positioned in the correct direction of
rotation.
NOTE:
Slots. The bolts of the camshaft timing belt
pulley must be central in the slots.
• Fit a new camshaft timing belt anti‐clockwise
starting from the crankshaft.
• Undo the mechanical belt tensioner clamp bolt and
allow the tensioner to snap against the belt.
1. Tighten the bolt of the mechanical timing belt
tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
Engines fitted with a mechanical camshaft timing belt tensioner.
125. Preparations for tensioning the timing belt.
CAUTION:
Remove Special Tools 21‐104 and 23‐
019.
• Carefully turn the crankshaft six revolutions in the
normal direction of rotation.
1. Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
2. It must be possible to insert the special tool into
the camshaft timing pulley.
3. Undo the bolts of the camshaft timing belt pulley.

Engines fitted with a mechanical camshaft timing belt tensioner.

CAUTION:
A used timing belt cannot be re‐tensioned.

126. Tension the timing belt.

• Slacken the bolts of the mechanical camshaft timing
belt tensioner a quarter of a turn so that the timing
belt tensioner presses against the timing belt.
NOTE:
Check the special tools are seated correctly.

1. Tighten the bolts of the mechanical camshaft

timing belt tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
3. Remove the special tool.
4. Remove the special tool and tighten the retaining
bolt to 24 Nm.
 127. Align the injection pump timing belt pulley.
1. Using the special tool or a new 6 mm drill bit, align
the injection pump timing belt pulley through the
timing pulley recess and the hole in the injection
pump housing.
   Unscrew the blanking plug from the hole for TDC
adjustment in the cylinder block.
2. Screw the special tool into the cylinder block.
NOTE:
The special tool must be screwed in as far as
it will go. The crankshaft must be touching
the special tool.
   Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
CAUTION:
Use a new timing belt.

NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated correctly.

128. Fit the injection pump timing belt.

• Fit a new timing belt anti‐clockwise starting from the
crankshaft.
• Undo the belt tensioner clamp bolt and allow the
tensioner to snap against the belt.
1. Tighten the belt tensioner clamp bolt.
NOTE:
The bolts must not be at the ends of the
slots.
2. Tighten the bolts of the fuel‐injection pump pulley.
• Remove the special tool.
129. Check the valve clearances and adjust them if
necessary as described in Operation Number 21 213 0.
130. Fit the oil baffle.

NOTE:
Clean the gasket, check it for damage and
coat it with engine oil. If necessary, renew it
(it can be used several times).
131. Fit the cylinder head cover.
 132. Insert the plastic tray in the alternator bracket.

133. Install the upper and lower timing belt covers.

134. Fit the injection pump belt pulley.

135. Fit the alternator.

• Insert the bolts.
• Lay the drive belt in place.
1. Tension the drive belt.
2. Tighten the bolt.
3. Tighten the remaining bolts.

136. Centre the clutch disc on the clutch pressure

plate.
 137. Install the clutch.
1. Install the clutch pressure plate/centred clutch disc
assembly.
2. Tighten the six bolts uniformly, working diagonally.
3. Remove the special tool.

NOTE:
Use a new gasket.

NOTE:
Coat the oil pump drive gear with oil.

138. Fit the oil pump and oil filter.

139. Remove engine mounting bracket.

140. Remove the engine from assembly stand.

NOTE:
Tightening order.

NOTE:
Plastic sleeve on right‐hand upper stud (no.
7).
141. Fit the exhaust manifold with a new gasket.

142. Fit the EGR valve with a new seal.

1. Tighten the bolts.
2. Tighten the clamp bolt.
3. Connect the hose.

Escort/Orion 1991 (08/1990-09/2001)

 Print

Specifications
NOTE:
This group only contains Operation Number 21 134 8. Other Operation Numbers for
the 1,8l Endura‐DE (TC) engine can be found in group 21‐08 (1,8l Endura‐DE (TCI)
engine).
Engine Data 1,8 Endura‐DE (TC)
Engine
Engine management EEC V
Emission standard 96 EEC
Fuel Diesel
Engine code RVA
Firing order 1‐3‐4‐2
Bore mm 82,5
Stroke mm 82,0
Cubic capacity (effective) cc 1753
Compression ratio 21,5:1
Compression pressure at starter motor speed bar 28 ‐ 34
Power output (EC) kW 51
Power output (EC) (PS) 70
Power output (EC), at rev/min 4500
Torque Nm 135
Torque, at rev/min 2500
Idle speed rev/min 830 ‐ 860
Idle speed, with air conditioning rev/min 855 ‐ 885
Max. continuous engine speed rev/min 5200 ‐ 5300
Dimensions
Cylinder block 1,8 Endura‐DE (TC)
engine
Number of main bearings 5
Cylinder bore dia., standard class A mm 82,500 ‐ 82,515
Cylinder bore dia., standard class B mm 82,515 ‐ 82,530
Cylinder bore dia., standard class C mm 82,660 ‐ 82,675
Cylinder bore dia., standard class D mm 82,675 ‐ 82,690
Main bearing clearance (radial) mm 0,025 ‐ 0,085
Dimensions
Crankshaft 1,8 Endura‐DE (TC)
Engine
Main bearing journal dia., standard mm 53,970 ‐ 53,990
Main bearing journal dia., 1st undersize 0,25 mm 53,720 ‐ 53,740
Main bearing journal dia., 2nd undersize 0,50 mm 53,470 ‐ 53,490
Big‐end bearing journal dia., standard mm 48,970 ‐ 48,990
Big‐end bearing journal dia., 1st undersize 0,25 mm 48,720 ‐ 48,740
Big‐end bearing journal dia., 2nd undersize 0,50 mm 48,470 ‐ 48,490
Big‐end bearing clearance mm 0,025 ‐ 0,085
Crankshaft end float mm 0,14 ‐ 0,37
Dimensions
Connecting rod 1,8 Endura‐DE (TC)
Engine
Bore dia., big end mm 52,000 ‐ 52,020
Bore dia., small end mm 26,012 ‐ 26,020
Distance between connecting rod bores, class A mm 129,872 ‐ 129,948
Distance between connecting rod bores, class B mm 129,932 ‐ 130,008
Distance between connecting rod bores, class C mm 129,992 ‐ 130,068
Distance between connecting rod bores, class D mm 130,052 ‐ 130,128
Big‐end bearing clearance (radial) mm 0,016 ‐ 0,074
NOTE:
The piston ring gaps must be evenly spaced around the piston circumference. This also
applies to each part of the oil scraper ring. Displace the ring gaps 120 degrees to each
other.
Dimensions
Pistons 1,8 Endura‐DE (TC)
Engine
Piston dia. (measured at right‐angles to piston pin
mm 82,461 ‐ 82,479
bore),class A
Piston dia. (measured at right‐angles to piston pin
mm 82,479 ‐ 82,497
bore),class B
Piston clearance (initial fit), class A/B mm 0,021 ‐ 0,054
Piston protrusion at TDC mm 0,500 ‐ 0,840
Piston ring gap (fitted), upper compression ring mm 0,3 ‐ 0,5
Piston ring gap (fitted), lower compression ring mm 0,3 ‐ 0,5
Piston ring clearance in piston groove, upper compression
mm 0,00 ‐ 0,04
ring
Piston ring clearance in piston groove, lower compression
mm 0,070 ‐ 0,102
ring
Piston ring clearance in piston groove, oil control ring mm 0,05 ‐ 0,08
Piston pin dia. mm 25,996 ‐ 26,000
”Floating" in piston
Piston pin type
and connecting rod
Piston pin retention Circlip
Dimensions
Camshaft 1,8 Endura‐DE (TC)
Engine
Drive Timing Belt
Valve timings, inlet opens before TDC °CS 6
Valve timings, inlet closes after BDC °CS 32
Valve timings, exhaust opens before BDC °CS 57
Valve timings, exhaust closes after TDC °CS 7
Cam lift, inlet mm 9
Cam lift, exhaust mm 10
End float mm 0,100 ‐ 0,240
Bearing journal dia. mm 27,960 ‐ 27,980
Bearing clearance mm 0,020 ‐ 0,079
Dimensions
Cylinder head 1,8 Endura‐DE (TC)
engine
Camshaft bearing dia., standard mm 30,500 ‐ 30,525
Camshaft bearing dia., oversize mm 30,575 ‐ 30,600
Tappet bore dia., standard mm 35,00 ‐ 35,03
Tappet bore dia., oversize mm 35,50 ‐ 35,53
Valve guide bore dia., standard mm 8,000 ‐ 8,025
Valve guide bore dia., 1st oversize mm 8,263 ‐ 8,288
Valve guide bore dia., 2nd oversize mm 8,463 ‐ 8,488
Thickness of cylinder head gasket, with piston protrusion of
3
0,500 ‐ 0,680 mm
Thickness of cylinder head gasket, with piston protrusion of
3
0,681 ‐ 0,740 mm
Thickness of cylinder head gasket, with piston protrusion of
4
0,741 ‐ 0,840 mm
Max. permissible unevenness over entire cylinder head area mm 0,08
Do not overhaul cylinder head mating face!
Dimensions
Valves 1,8 Endura‐DE (TC)
Engine
Valve clearance, inlet (cold) mm 0,35 ± 0,05
Valve clearance, exhaust (cold) mm 0,50 ± 0,05
Adjustment shim thickness mm 3,00 ‐ 4,75
Shims available in steps of mm 0,05
Engine oil from model year 1999
Viscosity / Ambient Designation Specification
temperature
Recommended Engine Oil:
SAE 5W 30 /‐20 °C to WSS‐M2C912‐A1 or WSS‐
Ford Formula E Motor Oil
above 40 °C M2C913‐A
Alternative engine oils:
SAE 5W 40 /‐20 °C to
Ford Formula S Synthetic Motor Oil ACEA A3/B3
above 40 °C
SAE 10W 40 /‐20 °C to Ford XR+ High‐performance High‐
ACEA A3/B3
above 40 °C lubricity Motor Oil
If engine oils to this specification are not available, only other oils which at least conform to
the API/SH/CD EC (Energy Conserving) and CCMC PD2 specifications may be used.

Engine oil up to model year 1999

Viscosity / Ambient Designation Specification
temperature
Recommended Engine Oil:
SAE 10W 40 /‐20 °C to Ford XR+ High‐performance High‐
ACEA A3/B3
above 40 °C lubricity Motor Oil
Alternative engine oils:
SAE 5W40 / under‐20 °C to
Ford Formula S Synthetic Motor Oil ACEA A3/B3
above 40 °C
If engine oils to this specification are not available, only other oils which at least conform to
the API/SH/CD EC (Energy Conserving) and CCMC PD2 specifications may be used.

Engine Lubrication
Description
Oil pressure (minimum, oil temperature approx.805C), at
bar 0,75
750 rev/min
Oil pressure (minimum, oil temperature approx.805C), at
bar 1,5
2000 rev/min
Relief valve opening pressure bar 2‐4
Oil pump max. inner/outer rotor clearance mm max. 0,174
Oil pump (outer rotor casing clearance) mm 0,14 ‐ 0,26
Inner/outer rotor end float, oil pump cover mm 0,025 ‐ 0,06
Lubricants, Adhesives and Sealers
Description Ford
Specification
Sump to cylinder block, camshaft bearing cap no. 1 (Hylomar SQ321H) SPM 4G9114
Coolant ESD‐M97B‐49A
Sealer, cylinder block mating face intersections SPM‐4G‐9112‐4
Capacity
Description Litres
Engine oil, initial fill with oil filter 5,4
Engine oil, with oil filter change 5,1
Engine oil, without filter change 4,5
Torques
Cylinder block Nm lbf.ft
Main bearing caps, stage 1 27 20
Main bearing caps, stage 2 75° 75°
Big‐end bearing caps, stage 1 25 18
Big‐end bearing caps, stage 2 60° 60°
Big‐end bearing caps, stage 3 20° 20°
Rear oil seal carrier 20 15
Flywheel, stage 1 18 13
Flywheel, stage 2 45° 45°
Flywheel, stage 3 45° 45°
Clutch pressure plate 30 22
Auxiliary shaft thrust plate 9 7
Auxiliary shaft oil seal carrier 23 17
Crankshaft position sensor (CKP sensor) 5 4
Front plate to cylinder block 24 18
CKP sensor bracket 21 15
Crankshaft vibration damper to flange 35 26
Crankshaft vibration damper hub, stage 1 150 111
Crankshaft vibration damper hub, stage 2 ‐90° ‐667
Crankshaft vibration damper hub, stage 3 120 89
Crankshaft vibration damper hub, stage 4 605 446
Bolt, rear timing belt cover to cylinder block 24 18
TDC setting pin bore blanking plug 24 18
Injection pump bracket to cylinder block 23 17
Generator bracket on cylinder head 48 35
Generator on bracket 25 18
Torques
Coolant circuit Nm lbf.ft
Coolant pump 23 17
Coolant pump pulley 11 8
Thermostat housing 20 15
Coolant pump hose to thermostat housing 3 2
Fuel regulator thermostat to thermostat housing 23 17
Coolant pipe to cylinder block 25 18
Torques
Oil circuit Nm lbf.ft
Oil pump 18 13
Sump 11 8
Oil pressure switch to cylinder head 20 15
Oil drain plug to sump 25 18
Blanking plugs, cylinder block oilways 22 16
Oil intake pipe bracket to cylinder block 22 16
Camshaft oil baffle 20 15
Engine oil dipstick tube 10 7
Oil pump to cylinder block 23 17
Oil feed pipe to turbocharger 18 13
Turbocharger oil feed pipe to oil pump 22 16
Turbocharger oil feed pipe bracket on cylinder block 48 35
Torques
Cylinder head Nm lbf.ft
Cylinder head bolts, stage 1 10 7
Cylinder head bolts, stage 2 100 74
Cylinder head, stage 3, wait three minutes
Cylinder head, stage 3 ‐180° ‐180°
Cylinder head bolts, stage 3 70 52
Cylinder head bolts, stage 3 120° 120°
Glow plug wiring 2 1
Glow plugs 28 21
Fuel filter to bracket 23 17
Injectors 70 52
Vacuum pump to cylinder head 22 16
Injection pump to front plate 24 18
Vacuum pipe bracket to thermostat housing 9 7
Fuel filter bracket to cylinder head/lifting eye 23 17
Vacuum pipe bracket to cylinder head 22 16
Injection pipe to injector/injection pump 25 18
Timing belt idler pulley to cylinder head 45 33
Camshaft timing belt pulley with flange to camshaft 35 26
Auxiliary shaft timing belt pulley 45 33
Locking bolt, camshaft timing belt tensioner 9 7
Injection pump pulley to flange 23 17
Injection pump timing belt tensioner to cylinder block 45 33
Camshaft timing belt tensioner clamp bolt 50 37
Camshaft timing belt pulley to camshaft flange 9 7
Timing belt cover 8 6
Injection pump belt pulley 25 18
Camshaft bearing caps 23 17
Cylinder head cover 5 4
Upper timing belt cover 7 5
Inlet manifold 23 17
Exhaust manifold 24 18
Camshaft timing belt pulley M8 35 26
Camshaft timing belt pulley M10 48 35

Engine ‐ Dismantle and Assemble (Engine

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 134 8)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange‐

holding wrench

16‐067Locator, clutch disc

 21‐031 BMounting bracket,
engine

21‐104Timing peg, crankshaft

TDC

21‐148 AAligner/installer, oil

seal

21‐162ATiming tool, camshaft

TDC alignment

21‐164Socket, cylinder head

bolts

21‐166Angle disk

21‐168Locking tool,
crankshaft

21‐200Remover, crankshaft
timing belt pulley

21‐217Alignment tool,
crankshaft rear oil seal

21‐540Angle gauge

23‐019Alignment pin,
camshaft pulley

23‐03427 mm socket for

injectors

23‐045Socket, injector nozzle

with needle lift sensor

23‐049Timing peg, crankshaft

position sensor (CKP)

Proprietary tools
Description
Dial gauge
Measuring stand
Piston ring compressor
Oil filter strap wrench
New 6 mm drill bit
Two‐legged puller
External micrometer 25 ‐ 50 mm
External micrometer 50 ‐ 75 mm
Internal gauge
Light‐metal drift
Workshop Equipment
Description
Transmission
21‐187
assembly stand
Materials
Description
Obtainable from:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST.
Sealer, cylinder block
mating face SPM‐4G‐9112‐H
intersections
Engine oil 5W‐30 WSS‐112912‐A1
Dismantle
1. General note.
CAUTION:
In '96 MY the camshaft timing belt was
revised. Coolant pumps and timing belt
tensioners with different idler pulleys were
fitted in production. In service there are now
only coolant pumps with two edges on the
idler pulley available. It should be noted that
when renewing the timing belt tensioner, a
tensioner without an edge must not be fitted
in conjunction with a coolant pump without
edges. Converting a mechanical timing belt
tensioner to an automatic timing belt
tensioner is NOT permissible. From '96 MY
PTFE oil seals are fitted at the front and rear
of the crankshaft instead of the familiar Viton
oil seals.
CAUTION:
Since 08.98 (build code WP), a revised oil
pump has been fitted in conjunction with a
revised oil pressure switch (green cover), and
5W 30 engine oil has been used.
CAUTION:
It should be noted that up to and including
07.98 (build code WM) an oil pressure switch
with a black cover was fitted, and 10W‐40
engine oil was used.
 NOTE:
Location of the timing belt tensioner spring
and the fuel injection pump spring. The
springs are NOT interchangeable.

2. Detach the ancillary components from the right‐

hand side of the engine.
1. Front engine mounting
2. Coolant pipe from oil cooler
3. Pipe from oil pump to turbocharger
4. Oil pump with filter and oil cooler
   Remove gasket and oil seal.
5. Fit Special Tool 21‐031B and attach the engine to
the assembly stand.
3. Detach the ancillary components from the right‐
hand side of the engine (continued).
1. Exhaust manifold with turbocharger.
• Remove the gasket.
2. Inlet manifold
• Remove the gasket.

4. Detach the ancillary components from the rear side

of the engine.
1. Clutch pressure plate with clutch disc.
   Slacken the flywheel bolts.
2. Fuel filter with bracket, fuel heater and engine lifting
eye
 3. Vacuum pump
• Remove the seal ring.
• Disconnect the oil return hose.
4. Disconnect the crankcase ventilation hose from the
cylinder headcover and the cylinder block.

5. Detach the ancillary components from the left‐hand

side of the engine.
   Slacken the drive belt and remove it.
1. Detach the drive belt tensioning pulley.
2. Remove the alternator.
3. Detach the alternator bracket.
4. Detach the belt pulley from the power steering
pump.
5. Remove the power steering pump.
6. Detach the power steering pump bracket.
Only for vehicles with air conditioning.
6. Detach the ancillary components from the left‐hand
side of the engine.
   Slacken the power steering pump drive belt and
remove it.
1. Detach the belt pulley from the power steering
pump.
2. Detach the drive belt tensioning pulley (power
steering pump).
3. Remove the power steering pump.
4. Detach the power steering pump bracket.
5. Unscrew and remove the alternator adjustment
strap bolt.
6. Detach the alternator.
7. Detach the brackets for the alternator and air
conditioning compressor.
8. Detach the alternator/air conditioning compressor
intermediate plate bracket.
7. Detach the upper timing belt cover.

8. Disconnect the crankcase ventilation hoses.

1. To the cylinder block.
2. To the turbocharger.
 9. Detach the cylinder head cover.
• Remove the gasket.

Engines with an automatic camshaft timing belt tensioner.

10. Undo the bolt on the adjusting cam.
   Turn the adjusting cam to 6 o'clock.

Engines with an automatic camshaft timing belt tensioner.

11. Loosen the camshaft timing pulley.
NOTE:
Use the special tool to stop the camshaft
timing pulley from turning.
• Undo the camshaft timing pulley bolt three turns.

Engines with an automatic camshaft timing belt tensioner.

NOTE:
The timing belt must not be reused.

12. Remove the camshaft timing pulley.

• Detach the camshaft timing pulley and take it off
with the camshaft timing belt.
• Discard the timing belt.

Engines with a mechanical camshaft timing belt tensioner.

13. Detach the camshaft timing belt.
• Slacken the bolt of the timing belt tensioner and
relax the timing belt.
• Remove the timing belt.
• Tighten the bolt of the timing belt tensioner.
• Discard the timing belt.

Engines with a mechanical camshaft timing belt tensioner.

 CAUTION:
The timing belt tensioner is spring‐loaded.

14. Detach the camshaft timing belt tensioner and the

camshaft timing belt pulley.
1. Timing belt tensioner bolt
NOTE:
Pull off the timing pulley using a two‐legged
puller.
2. Timing pulley bolt.

15. Detach the injection pump timing belt.

• Slacken the bolt of the timing belt tensioner and
relax the timing belt.
• Tighten the bolt of the timing belt tensioner.
• Remove the timing belt.

CAUTION:
The timing belt tensioner is spring‐loaded.

16. Detach the injection pump timing belt tensioner

and the injection pump timing belt pulley.
1. Timing belt tensioner
2. Timing belt pulley

CAUTION:
The timing belt tensioner is spring‐loaded.

17. Detach the camshaft timing belt tensioner and the

camshaft timing belt pulley.
1. Detach the timing belt tensioner.
NOTE:
Pull off the timing pulley using a two‐legged
puller.
2. Detach the timing belt pulley.

NOTE:
Lock the flywheel using Special Tool 21‐
168.
18. Detach the crankshaft vibration damper.
19. Detach the rear timing belt covers.
1. Detach the timing belt pulley.
2. Remove the bolt from the rear cover.

20. Remove the auxiliary shaft timing belt pulley and

oil seal carrier.
1. Remove the auxiliary shaft timing belt pulley.
2. Remove the auxiliary shaft oil seal carrier.

21. Remove the auxiliary shaft.

• Unscrew the thrust plate bolts.
• Withdraw the auxiliary shaft with the thrust plate.

NOTE:
One bolt also holds the bracket of the timing
belt tensioner spring.
22. Detach the coolant pump.

23. Detach the injection pump.

 CAUTION:
Only insert the collet.

24. Remove the rear crankshaft timing pulley.

1. Insert the collet.
2. Pull the collet back as far as its stop.

25. Remove the rear crankshaft timing pulley

(continued).
   Screw in the spindle and pull off the crankshaft
timing pulley.

26. Detach the ancillary components from the left‐hand

side of the engine.
1. Injection pipes from injectors and injection pump.
   Disconnect the leak‐off hoses.
2. Injector pressure pipe from the turbocharger to the
injection pump.
3. Thermostat housing with oil dipstick tube.
   Remove the gasket and oil seal.
4. Injection pump with bracket
5. Coolant distribution pipe
27. Remove the injector and the needle lift sensor.
   Take out the heat shield.

28. Remove the injectors and glow plugs.

1. Remove the injectors.
   Take out the heat shields.
2. Disconnect the glow plug wiring.
3. Remove the glow plugs.

29. Detach the cylinder head cover and oil baffle.

• Detach the cylinder head cover (three bolts).
• Remove the gasket.
• Detach the oil baffle.

30. Detach the cylinder head.

• Slacken the cylinder head bolts in the indicated
sequence and remove them.
• Remove the cylinder head and put it down on a soft
surface.
• Remove the gasket.
31. Detach the crankshaft position sensor (CKP
sensor) with the bracket.
   Remove Special Tool 21‐168.

32. Remove the flywheel.

NOTE:
The oil seal carrier is renewed as a unit with
the oil seal.
33. Detach the crankshaft rear oil seal carrier.

NOTE:
Remove the sump downwards to prevent oil
sludge or abraded particles from entering the
engine.
34. Detach the sump (14 bolts).

35. Detach the front plate.

   Prise out the radial oil seal.
 36. Detach the oil intake pipe and bracket.
   Remove the O‐ring.

CAUTION:
Do not damage the cylinder liner.

37. Remove the connecting rods and pistons.

• Detach the big‐end bearing caps.
• Scrape off the ring of carbon at the top of the
cylinder using a plastic scraper.
NOTE:
Lay the big‐end bearing shells and big‐end
bearing caps in order to one side.
   Press out the pistons with the connecting rods and
big‐end bearing shells, and keep them in order ready
for re‐installation.
NOTE:
Lay the bearing caps and bearing shells in
order to one side.
38. Remove the crankshaft.
• Detach the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half washers,
and keep them in order ready for re‐installation.

Reassemble
39. Thoroughly clean all mating faces and re‐usable
parts and check them for damage.
40. Clean the piston cooling oil splash nozzles and
oilways.
 NOTE:
The main bearing caps must be fitted without
the main bearing shells, and tightened to the
specified torque.
41. Measure the cylinder bores with an internal gauge.
   If the measured diameter of the cylinder liner is too
large for the piston classification, the cylinder block
must be overhauled or exchanged.

NOTE:
Repeat each measurement procedure again,
90 degrees displaced from the previous one.
42. Measure the diameter of the main and big‐end
bearing journals.
• Different sizes of crankshaft are used in production.
The different crankshafts are not marked.
• If the measured values do not correspond to those
given in the General Specifications, either rework or
renew the crankshaft.

43. Preparations for measuring the bearing clearance.

NOTE:
Carry out the following steps to the letter.

• Measure each bearing individually using a length of

Plastigage thread.
• Each time only the bearing cap of the bearing being
measured is fitted and torqued down to specification.
• The bearing shells and bearing journals must be free
of oil and dirt.
• The measurement should be carried out near the
respective dead centre position.
44. Measure the crankshaft main bearing clearance.
• Lay the corresponding bearing shells oil dry in the
cylinder block.
• Lay the crankshaft oil dry in the cylinder block.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
45. Measure the main bearing clearance (continued).
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
• Fit the bearing cap with the associated bearing shell
and secure it.
• Detach the bearing cap.

46. Measure the main bearing clearance (continued).

• The measured value shows the bearing clearance.
• Renew the bearing shells as necessary.

NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point. Do not hit the bearing caps.
47. Install the crankshaft.
• Coat the main bearing journals, bearing shells and
thrust half washers with engine oil.
• Insert the thrust half washers into the second main
bearing with the lubricating groove facing outwards.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
• Tighten the bolts.
NOTE:
If necessary, adjust the end float by fitting
new thrust half washers to the second main
bearing.
48. Check the crankshaft end float.
• Set up the dial gauge.
• Measure the end float by lifting the crankshaft with a
screwdriver.

49. Piston classification.

1. Cylinder bore classification.
2. Piston diameter classification.
3. The weight classes are marked with `+' and `‐'.
 NOTE:
Piston classification, in case a piston must be
replaced.
50. Measure the piston diameters.

CAUTION:
Do not mix up the piston rings. Replace the
rings in the same grooves and at the same
position.
51. Measure the piston ring gaps.
   The values given in the General Specifications apply
to a gauge ring used in production. When measured in
the cylinder, the values may be exceeded by 0,15 mm.

NOTE:
The piston ring axial clearance must be
measured with the ring projecting from its
groove.
52. Measure the piston ring clearance.
• The maximum clearance for the upper compression
ring is 0,2 mm.
• The maximum clearance for the second compression
ring is 0,1 mm.

53. Install the pistons and connecting rods.

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil control ring.
NOTE:
The numbering on the connecting rod starts
at the timing belt end. The arrow on the
crown of the piston points to the timing belt
end.
   Compress the piston rings with a piston ring
compressor.
CAUTION:
Do not damage the cylinder liners or
bearings.
NOTE:
The big‐end bearing journals must be at
bottom dead centre position.
• Press the pistons of cylinder nos. 1 and 4 into the
cylinders using the handle of a hammer, guiding the
connecting rods onto the big‐end bearing journals.
• Place the appropriate bearing shells, clean and dry,
in the connecting rods.
• Fit the pistons of cylinder nos. 2 and 3 as described
above.
 54. Measure the big‐end bearing clearances and fit
the bearing caps.
   Measure the big‐end bearing clearance as described
in steps to
55. Coat the bearing shells and bearing journals with
engine oil.
NOTE:
The numbering of the connecting rods and
big‐end bearing caps must tally.
   Fit the appropriate big‐end bearing caps and
bearing shells and tighten the bolts.
56. Fit the oil intake pipe and bracket.
NOTE:
Correct seating of the O‐ring.

1. Fit the oil intake pipe with a new O‐ring.

2. Fit the bracket.

NOTE:
The front plate mating face must be flush
with the lower edge of the cylinder block
(tolerance± 0,1 mm).
57. Fit the front plate.
   Locate the front plate in position with a new gasket
and new oilway seals.
1. Centre the front plate using the special tool.
2. Secure the front plate (4 bolts).

CAUTION:
Step must be carried out straight after step
to prevent the oil seal from contracting. Only
remove the support ring from the oil seal
immediately before installation.
58. Fit the crankshaft front oil seal.
   Pull on the oil seal using the special tool and the
crankshaft vibration damper bolt.

59. Fit the crankshaft timing belt pulley.

NOTE:
Check the condition of the O‐ring in the
timing belt pulley.
• Lubricate the O‐ring and the end of the crankshaft
with engine oil.
• Slide the pulley on carefully until it reaches the stop.
• The locating pin on the end of the crankshaft and the
hole in the timing belt pulley must line up.
 NOTE:
The sump bolts must be tightened within 20
minutes of applying the sealer.
60. Apply sealer (SPM‐4G‐9112‐H) to the joints in the
cylinder head mating faces.

61. Fit the sump.

• Locate the sump in position with a new gasket and
fit the 14 bolts.
• Align the sump so that it is flush with the cylinder
block.

62. Tighten the sump bolts.

CAUTION:
The sealing lip of the oil seal and the mating
face on the crankshaft must be free of oil.
CAUTION:
The support ring will fall out on its own
when the crankshaft oil seal carrier is fitted.
Do not remove it beforehand.
63. Fit the new crankshaft rear oil seal carrier.
• Locate the new crankshaft oil seal carrier with the
integrated oil seal and the bolts in position.
• Screw in the bolts.
• Fit the special tool and centre the oil seal carrier on
the crankshaft.
 CAUTION:
If the special tool cannot be removed, the
sump must be realigned.
64. Tighten the bolts of the crankshaft oil seal carrier.
   Remove the special tool.

CAUTION:
Renew the bolts.

65. Fit the flywheel (8 bolts).

   Lock the flywheel using Special Tool 21‐168.

66. Fit the coolant pump.

   Locate the coolant pump in position with a new
gasket and the bracket for the timing belt tensioner
spring.

67. Install the auxiliary shaft.

• Lubricate the auxiliary shaft, the bearing bush in the
cylinder block and the thrust plate with engine oil.
NOTE:
The lubricating grooves on the thrust plate
must face outwards.
• Fit the auxiliary shaft with the thrust plate.

CAUTION:
If the plastic fitting bush is removed from the
oil seal carrier before installation, the oil seal
will be unusable.
68. Fit the auxiliary shaft oil seal carrier.
• Lubricate the end of the auxiliary shaft with engine
oil.
• Slide the new oil seal carrier with the integrated oil
seal and plastic fitting bush onto the auxiliary shaft
journal.
• Screw in the bolts of the oil seal carrier.
• After securing the oil seal carrier, detach the plastic
fitting bush and check that the seal is seated correctly.
 NOTE:
Measure the piston protrusion of each
cylinder at TDC.
69. Measure piston protrusion
• Measure the difference in height between the piston
crown and the cylinder block.
NOTE:
Carry out two measurements per cylinder, at
a distance of 5 mm from the edge of the
piston.
• The largest of the measurements determines the
gasket thickness (see General Specifications).
70. Line up the crankshaft and camshaft.
• Turn the crankshaft until the piston of cylinder no. 1
is at TDC.
• Turn the camshaft until the slot in the eccentric on
the camshaft is parallel with the upper edge of the
cylinder head (with the larger semi‐circle at the top).
• The crankshaft and camshaft must not be turned any
more.

NOTE:
The cylinder head gasket is marked
”TOP/OBEN".
71. Fit the new cylinder head gasket.
1. Check that the locating sleeves are seated
correctly.
2. Thickness indicator.

NOTE:
Renew the cylinder head bolts.

72. Tighten the cylinder head bolts.

• Screw in the cylinder head bolts.
• Tighten the cylinder head bolts in the specified order
in two stages.
 NOTE:
The cylinder head bolts must not be
retightened.
73. Tighten the cylinder head bolts (continued).
CAUTION:
In the third stage, undo one cylinder head
bolt, then tighten it applying torque and then
with the angle gauge. Only then move onto
the next bolt.
   Wait three minutes and then tighten the cylinder
head bolts to stage 3 in the specified order.

NOTE:
The heat shield is correctly installed when the
conical side is downwards. Use new heat
shields.
74. Install the injector with the needle lift sensor.

75. Install the injectors and glow plugs.

NOTE:
The heat shield is correctly installed when the
conical side is downwards. Use new heat
shields.
1. Install the injectors with the heat shields.
2. Install the glow plugs.
3. Connect the glow plug wiring.

76. Fit the injection pump.

77. Fit the ancillary components on the left‐hand side
of the engine.
1. Connect the injection pipes to the injectors and the
injection pump.
2. Vacuum pipe from turbocharger to injection pump.
NOTE:
Use a new gasket and oil seal.

3. Thermostat housing with oil dipstick tube.

NOTE:
Fit the injection pump free of stress. If
necessary, detach the injection pump from
the bracket and align it.
4. Injection pump with bracket
5. Coolant distribution pipe
   Slide on the leak‐off hoses.
 78. Fit the rear timing belt covers.
   Locate the covers in position.
1. Timing belt pulley
2. Screw in the bolt.

NOTE:
The auxiliary shaft locating pin and the hole
in the timing belt pulley must line up.
79. Fit the timing belt pulleys and the camshaft
timing belttensioner.
1. Fit the camshaft timing belt pulley.
2. Fit the auxiliary shaft timing belt pulley (one bolt).
3. Secure the timing belt tensioner (2 bolts).
4. Compress the spring on the timing belt tensioner
and use the bolt to lock the tensioner.

NOTE:
Do not tighten the bolts.

80. Fit the injection pump timing belt pulley.

   Centre the bolts in the slots.

81. Fit the injection pump timing belt tensioner.

   Compress the spring on the timing belt tensioner
and use the bolt to lock the tensioner.

NOTE:
Renew the bolt.

82. Fit the crankshaft vibration damper.

   Lock the crankshaft.
NOTE:
The lug and notch must line up.

   Coat the underside of the bolt head of the crankshaft

vibration damper bolt with engine oil and tighten to
the specified torque.
Engines with an automatic camshaft timing belt tensioner.
 83. Insert the special tool in the camshaft groove.

84. Set the crankshaft to TDC.

• Remove the retaining bolt from the cylinder block.
NOTE:
The special tool must be screwed in as far as
it will go.
• Fit Special Tool 21‐104 and carefully turn the
crankshaft in the direction of rotation of the engine
until it comes up against the special tool.
Engines with an automatic camshaft timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the fuel pump timing belt.
CAUTION:
Only carry out work on the timing belt at
workshop temperature.
NOTE:
The crankshaft must be touching Special
Tool 21‐104 and Special Tool 21‐162B must
be inserted in the camshaft.
NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated
correctly.
85. Fit the new camshaft timing belt.
1. Fit the camshaft timing belt tensioner.
2. Attach the adjusting cam.
3. Locate the timing belt in position.
   Slide the camshaft timing pulley onto the taper and
tighten the bolt until the pulley only just turns on the
camshaft.
Engines with an automatic camshaft timing belt tensioner.
86. Pretension the camshaft timing belt.
NOTE:
Coat the bolt contact surface of the adjusting
cam with engine oil.
   Turn the adjusting cam clockwise to 9 o'clock and
tighten the adjusting cam bolt.

Engines with an automatic camshaft timing belt tensioner.

 NOTE:
Use the special tool to stop the camshaft
timing pulley from turning.
87. Tighten the camshaft timing belt pulley bolt.

Engines with an automatic camshaft timing belt tensioner.

CAUTION:
Remove Special Tools 21‐104 and 21‐
162B.
88. Turn the crankshaft six turns in the normal
direction of rotation.
Engines with an automatic camshaft timing belt tensioner.
89. Preparations for tensioning the timing belt.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in as far as
it will go.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Engines with an automatic camshaft timing belt tensioner.
90. Undo the bolt on the adjusting cam half a turn.

Engines with an automatic camshaft timing belt tensioner.

NOTE:
Use the special tool to stop the camshaft
timing pulley from turning.
91. Undo the camshaft timing pulley bolt three turns.

Engines with an automatic camshaft timing belt tensioner.

 NOTE:
Insert a screwdriver between the camshaft
timing pulley and the rear timing belt cover.
92. Loosen the camshaft timing pulley from the taper
by lightly tapping the light‐metal drift.

Engines with an automatic camshaft timing belt tensioner.

NOTE:
If necessary, turn the camshaft until the
adjusting tool can be inserted.
93. Insert the special tool.

Engines with an automatic camshaft timing belt tensioner.

NOTE:
Check that the camshaft timing pulley is still
free to turn on the camshaft.
94. Tighten the camshaft timing belt pulley bolt finger
tight and loosen by half a turn.

Engines with an automatic camshaft timing belt tensioner.

95. Tension the camshaft timing belt.
NOTE:
The adjustment range of the adjusting cam
lies between 6 o'clock (MIN) and 12 o'clock
(MAX).
   Tension the camshaft timing belt by turning the
adjusting cam clockwise so that the arrow of the
automatic camshaft timing belt tensioner is located in
the right‐hand corner of the adjustment range.

Engines with an automatic camshaft timing belt tensioner.

 NOTE:
Hold the adjusting cam in position.

96. Tighten the adjusting cam bolt evenly.

Engines with an automatic camshaft timing belt tensioner.

97. Checking the position of the automatic camshaft
timing belttensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: tension the
camshaft timing belt again as described.
CAUTION:
To avoid damage to the engine, make sure
that the pointer is within range ”A".

Engines with an automatic camshaft timing belt tensioner.

NOTE:
Use the special tool to stop the camshaft
timing pulley from turning.
98. Tighten the camshaft timing pulley bolt.
• Tightening torque for M8 bolt: 35 Nm
• Tightening torque for M10 bolt: 48 Nm

Engines with an automatic camshaft timing belt tensioner.

99. Detach Special Tools 21‐104 and 21‐162B.
Engines with an automatic camshaft timing belt tensioner.
100. Checking the valve timing.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in as far as
it will go.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Engines with an automatic camshaft timing belt tensioner.
101. Install the Special Tool. If the special tool cannot
be inserted, tension the camshaft timing belt again as
described.

Engines with an automatic camshaft timing belt tensioner.

 102. Checking the position of the automatic timing belt
tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: tension the
camshaft timingbelt again as described.
CAUTION:
To avoid damage to the engine, make sure
that the pointer is within range ”A".

Engines with an automatic camshaft timing belt tensioner.

103. Remove Special Tools 21‐162B and 21‐104.
Engines with a mechanical camshaft timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the injection pump timing belt.
NOTE:
The timing belt tensioner springs are not
interchangeable.
104. Fit the new camshaft timing belt.
• Insert the Special Tool 23‐019.
NOTE:
Make sure the timing belt is seated correctly
and positioned inthe correct direction of
rotation.
NOTE:
Slots The bolts of the camshaft timing belt
pulley must be central in the slots.
• Fit a new camshaft timing belt anti‐clockwise
starting from the crankshaft.
• Undo the mechanical belt tensioner clamp bolt and
allow the tensioner to snap against the belt.
1. Tighten the mechanical belt tensioner clamp bolt.
2. Tighten the bolts of the camshaft timing belt
pulley.
Engines with a mechanical camshaft timing belt tensioner.
105. Preparations for tensioning the timing belt.
CAUTION:
Remove Special Tools 21‐104 and 23‐
019.
• Carefully turn the crankshaft six revolutions in the
normal direction of rotation.
1. Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
2. The special tool must go into the camshaft timing
belt pulley.
3. Undo the bolts of the camshaft timing belt pulley.
Engines with a mechanical camshaft timing belt tensioner.
CAUTION:
Retensioning a used timing belt is not
permissible.
106. Tension the timing belt.
• Undo the bolts of the mechanical timing belt
tensioner a quarter of a turn so that the tensioner
presses against the belt.
NOTE:
Make sure the special tools are correctly
seated.
1. Tighten the bolts of the mechanical timing belt
tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
3. Remove the special tool.
4. Unscrew the special tool and tighten the retaining
bolt to 24 Nm.

107. Align the injection pump timing belt pulley.

1. Using the special tool or a new 6 mm drill bit, align
the injection pump timing belt pulley through the
timing pulley recess and the hole in the injection
pump housing.
   Unscrew the blanking plug from the hole for TDC
adjustment in the cylinder block.
2. Screw the special tool into the cylinder block.
NOTE:
The special tool must be screwed in as far as
it will go. The crankshaft must be touching
the special tool.
   Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
CAUTION:
Use a new toothed belt.

NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated
correctly.
108. Fit the injection pump timing belt.
• Fit a new camshaft timing belt anti‐clockwise
starting from the crankshaft.
• Undo the timing belt tensioner bolt and let the
tensioner snap against the timing belt.
1. Tighten the bolt of the timing belt tensioner.
NOTE:
The bolts must not be at the ends of the
slots.
2. Tighten the bolts of the injection pump pulley.
• Remove the special tool.
 CAUTION:
The following operating steps are important
for the injection timing adjustment of the
injection pump. The setting to 10 degrees
must be exact. Special Tools 21‐166 or 21‐
540 can be used.
109. Set the crankshaft to 10 degrees after TDC on
the first cylinder.
• Turn the crankshaft onto the timing pin.
• Locate the CKP sensor bracket in position without
the CKP sensor and attach it loosely.
NOTE:
When using Special Tool 21‐540 take care
not to move the disc during tightening.
Pressure must be applied to the tool during
measuring. If the 10 degree mark is not
reached exactly, unscrew and remove the
angle disc from the measuring area and
reset it from the start.
• Put the Special Tool on the crankshaft vibration
damper and set the disc to 10 degrees.
• Remove the timing pin.
NOTE:
If the mark is exceeded, set the crankshaft
to 10 degrees before TDC on the first
cylinder and repeat the adjustment
procedure starting from the previous step.
110. Set the crankshaft to 10 degrees after TDC on
the first cylinder (cont.).
   Turn the crankshaft vibration damper until the
arrows on the special tools line up.

111. Align the bracket of the CKP sensor.

• Insert the timing peg through the CKP sensor
bracket and ensure it engages in the hole on the
flywheel.
• Tighten the bolts on the CKP sensor bracket and
remove the timing peg.

112. Check the alignment of the CKP sensor.

• Set the crankshaft to 10 degrees after TDC on the
first cylinder as described in steps to
NOTE:
If the timing peg cannot be inserted into the
hole on the flywheel, repeat the adjustment
procedure from step to Then check the
alignment again.
• The timing pin must be able to be inserted in the
flywheel.
113. Check the valve clearances and adjust them as
necessary as described in Operation No. 21 213 0.
114. Fit the oil baffle.

NOTE:
Clean the gasket, check it for damage and
coat it with engine oil. Renew it if necessary
(it can be used several times).
115. Install the cylinder head cover.

116. Install the toothed belt upper cover.

 117. Install the components on the left‐hand side of
the engine.
1. Attach the power steering pump bracket.
2. Fit the power steering pump.
3. Install the power steering pump pulley.
4. Fit the alternator bracket.
5. Fit the alternator.
6. Install the drive belt tensioning pulley.
   Fit the drive belt and tension it.
Only for vehicles with air conditioning.
118. Install the components on the left‐hand side of
the engine.
1. Install the alternator/air conditioning compressor
intermediate plate bracket.
2. Attach the brackets for the alternator and air
conditioning compressor.
3. Fit the alternator.
4. Insert and tighten the alternator adjusting strap
bolt.
5. Attach the power steering pump bracket.
6. Fit the power steering pump.
7. Install the drive belt tensioning pulley (power
steering pump).
8. Install the power steering pump pulley.
   Put on the power steering pump drive belt and
tension it.
119. Fit the ancillary components to the rear side of
the engine.
NOTE:
Use a new oil seal.

1. Vacuum pump
   Push on the oil return hose.
2. Crankcase ventilation hose to cylinder head cover
and cylinder block.
3. Fuel filter with bracket, fuel heater and engine lifting
eye
120. Centre the clutch disc on the clutch pressure
plate.

121. Secure the clutch.

1. Locate the clutch pressure plate and the centred
clutch disc in place.
2. Tighten the bolts (6 x) uniformly, working
diagonally.
3. Remove the special tool.

NOTE:
Use new gaskets and self‐locking nuts.

122. Attach the ancillary components on the right‐hand

side of the engine.
1. Inlet manifold
2. Exhaust manifold with turbocharger
   Connect the oil return pipe to the cylinder block.
 123. Attach the ancillary components on the right‐hand
side of the engine (continued).
NOTE:
Fill the oil pump manually and lubricate the
oil pump drive gear with engine oil.
NOTE:
Use a new gasket.

1. Front engine mounting

2. Coolant pipe to oil cooler
3. Pipe from oil pump to turbocharger
4. Oil pump with new filter and oil cooler.

General Specifications Escort/Orion 1991 (08/1990-09/2001)

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Specifications
Engine data
Description 1,8 Endura‐DE
(TCI) Engine
Emissions standard 93EEC/96EEC
Engine code RFK / RKD
Firing order 1‐3‐4‐2
Bore mm 82,5
Stroke mm 82,0
Cubic capacity (effective) cm3 1753
Compression ratio 21,5 : 1
Compression pressure at starter motor speed bar 28 ‐ 34
rev/
Idle speed 850 ± 50
min
rev/
Maximum engine speed ‐ continuous 4500
min
rev/
Maximum engine speed ‐ intermittent 5250 ± 50
min
Power output (DIN) kW 66
Power output (DIN) (PS) 90
rev/
Power output (DIN) at 4500
min
Torque (DIN) Nm 180
rev/
Torque (DIN) at 2000
min
Dimensions
Cylinder block 1,8 Endura‐DE
(TCI) Engine
Cast mark 91FF‐6015‐BB
Main bearing bore diameter mm 57,683 ‐ 57,696
Cylinder bore diameter ‐ class A mm 82,500 ‐ 82,515
Cylinder bore diameter ‐ class B mm 82,515 ‐ 82,530
Cylinder bore diameter ‐ class C mm 82,660 ‐ 82,675
Cylinder bore diameter ‐ class D mm 82,675 ‐ 82,690
Cylinder bore diameter ‐ class E, service oversize 0,5 mm 83,000 ‐ 83,015
Cylinder bore diameter ‐ class F, service oversize 1,0 mm 83,500 ‐ 83,515
Dimensions
Crankshaft 1,8 Endura‐DE
(TCI) Engine
Main bearing journal diameter, standard mm 53,970 ‐ 53,990
Main bearing journal diameter, undersize 0,25 mm 53,720 ‐ 53,740
Main bearing journal diameter, undersize 0,5 mm 53,470 ‐ 53,490
Main bearing clearance mm 0,015 ‐ 0,062
Big‐end bearing journal diameter, standard mm 48,970 ‐ 48,990
Big‐end bearing journal diameter, undersize 0,25 mm 48,720 ‐ 48,740
Big‐end bearing journal diameter, undersize 0,50 mm 48,470 ‐ 48,490
Big‐end bearing clearance mm 0,016 ‐ 0,074
Crankshaft end float mm 0,09 ‐ 0,37
End float between connecting rod and crank web mm 0,125 ‐ 0,375
Maximum turning torque without connecting rods and pistons Nm 10
Dimensions
Connecting rods 1,8 Endura‐DE
(TCI) Engine
Bore diameter, big‐end mm 52,000 ‐ 52,020
Bore diameter, small end with bush mm 26,012 ‐ 26,020
Connecting rod length (distance between connecting rod
mm 129,880 ‐ 129,94
bores), class A
Connecting rod length (distance between connecting rod
mm 129,941 ‐ 130,00
bores), class B
Connecting rod length (distance between connecting rod
mm 130,001 ‐ 130,06
bores), class C
Connecting rod length (distance between connecting rod
mm 130,061 ‐ 130,12
bores), class D
Dimensions
Pistons 1,8 Endura‐DE (TCI)
Engine
Piston diameter, class A mm 82,461 ‐ 82,479
Piston diameter, class B mm 82,476 ‐ 82,494
Piston diameter, class C mm 82,621 ‐ 82,639
Piston diameter, class D mm 82,636 ‐ 82,654
Piston diameter, class E, oversize 0,5 mm mm 82,961 ‐ 82,979
Piston diameter, class F, oversize 1,0 mm mm 83,461 ‐ 83,479
Piston clearance in bore (initial installation), classes A to D mm 0,021 ‐ 0,054
Piston clearance in bore (initial installation), classes E to F mm 0,021 ‐ 0,054
Piston protrusion at TDC mm 0,500 ‐ 0,840
”Floating" in piston
Piston pin type
and connecting rod
Piston pin diameter mm 25,996 ‐ 26,000
Piston pin retention Circlip
Piston ring clearance in groove ‐ upper compression ring mm 0,09 ‐ 0,122
Piston ring clearance in piston groove,lower compression ring mm 0,05 ‐ 0,082
Piston ring clearance in piston groove ‐ oil scraper ring mm 0,03 ‐ 0,065
Ring gap (fitted), upper compression ring mm 0,35 ‐ 0,500
Ring gap (fitted), lower compression ring mm 0,35 ‐ 0,500
Ring gap (fitted), oil scraper ring mm 0,25 ‐ 0,580
Dimensions
Cylinder head 1,8 Endura‐DE
(TCI) Engine
Camshaft bearing bore diameter, standard mm 30,500 ‐ 30,525
Camshaft bearing bore diameter, oversize mm 30,575 ‐ 30,600
Valve tappet bore diameter, standard mm 35,000 ‐ 35,030
Valve tappet bore diameter, oversize mm 35,500 ‐ 35,530
Valve guide bore diameter, standard mm 8,000 ‐ 8,025
Valve guide bore diameter, 1st oversize mm 8,263 ‐ 8,288
Valve guide bore diameter, 2nd oversize mm 8,463 ‐ 8,488
Thickness of cylinder head gasket (number of tooth marks)
mm 1,36 (2)
with piston protrusion of 0,500 ‐ 0,680 mm
Thickness of cylinder head gasket (number of tooth marks)
mm 1,42 (3)
with piston protrusion of 0,681 ‐ 0,740 mm
Thickness of cylinder head gasket (number of tooth marks)
mm 1,52 (4)
with piston protrusion of 0,741 ‐ 0,840 mm
Maximum permissible unevenness over entire head area mm 0,08
Swirl chamber seat, standard, diameter A mm 31,250 ‐ 31,280
Swirl chamber seat, standard, diameter B mm 27,530 ‐ 27,660
Swirl chamber seat, standard, size C mm 4,983 ‐ 5,034
Swirl chamber seat, class A, diameter A mm 31,550 ‐ 31,580
Swirl chamber seat, class A, diameter B mm 27,830 ‐ 27,960
Swirl chamber seat, class A, size C mm 5,233 ‐ 5,284
Swirl chamber protrusion at cylinder head mating face mm 0,000 ‐ 0,061
Dimensions
Camshaft 1,8 Endura‐DE
(TCI) Engine
Valve timings, inlet valve opens before TDC °CS 6 degrees
Valve timings, inlet valve closes after BDC °CS 32 degrees
Valve timings, exhaust valve opens before TDC °CS 57 degrees
Valve timings, exhaust valve closes after BDC °CS 7 degrees
Camshaft cam lift, inlet mm 9,0
Camshaft cam lift, exhaust mm 10,0
End float mm 0,100 ‐ 0,240
Bearing journal diameter mm 27,960 ‐ 27,980
Bearing clearance mm 0,016 ‐ 0,075
Valve clearances (cold), inlet mm 0,35 ± 0,05
Valve clearances (cold), exhaust mm 0,50 ± 0,05
Dimensions
Valves Inlet Exhaust
Distance between valve spring retainer and cylinder
mm 0,85 ‐ 1,15 1,05 ‐ 1,35
head mating face
38,000 ‐ 33,000 ‐
Valve seats, standard A mm
38,003 33,030
Valve seats, standard size B mm 8,300 ‐ 8,500 8,800 ‐ 9,000
38,200 ‐ 33,200 ‐
Valve seats, class A ‐ A mm
38,230 33,230
Valve seats, class A ‐ size B mm 8,600 ‐ 8,800 9,100 ‐ 9,300
38,400 ‐ 33,400 ‐
Valve seats, service oversize A mm
38,430 33,430
Valve seats, service oversize B mm 8,900 ‐ 9,100 9,400 ‐ 9,600
107,05 ‐ 109,15 ‐
Valve length mm
107,15 109,25
Valve spring retainer, diameter mm 36,40 ‐ 36,60 31,90 ‐ 32,10
Valve stem diameter, standard mm 7,97 ± 0,015 7,96 ± 0,015
Valve stem diameter, 1st oversize mm 8,223 ± 0,015 8,223 ± 0,015
Valve stem diameter, 2nd oversize mm 8,433 ± 0,015 8,423 ± 0,015
34,950 ‐ 34,950 ‐
Valve tappet diameter, standard mm
34,975 34,975
35,450 ‐ 35,450 ‐
Valve tappet diameter, oversize mm
35,475 35,475
Thickness of valve adjustment shims mm 3,00 ‐ 4,75 3,00 ‐ 4,75
Valve adjustment shims available in steps of mm 0,05 0,05
Valve spring free length mm approx. 43 approx. 43
Motor oil to model year 1999
Description Viscosity / Ambient Specification
temperature
Recommended engine oil:
Ford XR+ High‐performance High‐ SAE 10W40 /‐20 °C to over
ACEA A3/B3
lubricity Motor Oil 40 °C
Alternative engine oils:
SAE 5W40 / under‐20 °C to
Ford Formula S Synthetic Motor Oil ACEA A3/B3
over 40 °C
Motor oil from model year 1999
Description Viscosity / Ambient Specification
temperature
Recommended engine oil:
SAE 5W 30 /‐20 °C to over WSS‐M2C912‐A1 or WSS‐
Ford Formula E Motor Oil
40 °C M2C913‐A
Alternative engine oils:
SAE 5W40 /‐20 °C to over
Ford Formula S Synthetic Motor Oil ACEA A3/B3
40 °C
Ford XR+ High‐performance High‐ SAE 10W40 /‐20 °C to over
ACEA A3/B3
lubricity Motor Oil 40 °C
Engine Lubrication
Description 1,8 Endura‐DE
 (TCI) Engine
Oil pressure at idle speed bar 0,75
Oil pressure at 2000 rev/min bar 1,50
Pressure relief valve opens at bar 2,0 ‐ 4,0
Oil pump, max. inner/outer rotor clearance mm 0,174
Lubricants, Adhesives and Sealers
Description Ford
Specification
Coolant (Ford antifreeze concentrate ”Motorcraft Super Plus 4") ESD‐M97B‐49A
Transmission fluid SQM‐2C‐9008‐A
Power steering hydraulic fluid ESPM‐2C‐166‐H
Lubricant for transmission input shaft splines and release bearing guide
ESD‐M1C‐220‐A
sleeve
Mating face ‐ sump/cylinder block, bearing cap no. 1 (camshaft), oil
SPM‐4G‐9112‐F/G
pressure switch
Oil passage blanking plugs SM‐4G‐4644‐AA/AB
Hose connections, coolant pump SM‐1C‐1022‐A
Capacities
Description Litres
Coolant 9,3
Engine oil, initial fill with filter 5,4
Engine oil, oil change with filter change 5,1
Engine oil ‐ oil change without filter change 4,5
Drive Belt Tension
1,8 Endura‐DE (TCI) Engine
Alternator (new) 400 ‐ 500 N
Alternator (used) 300 ‐ 400 N
Alternator with power steering pump or air conditioning
550 ‐ 650 N
compressor (new)
Alternator with power steering pump or air conditioning
400 ‐ 500 N
compressor (used)
Torques
Cylinder block Nm lbf.ft
Main bearing caps, stage 1 27 20
75
Main bearing caps, stage 2 75 degrees
degrees
Big‐end bearing caps, 1st stage 25 18
60
Big‐end bearing caps, 2nd stage 60 degrees
degrees
20
Big‐end bearing caps, 3rd stage 20 degrees
degrees
Auxiliary shaft thrust plate 9 7
Auxiliary shaft oil seal carrier 23 17
Blanking plug for hole for TDC pin 24 18
Alternator bracket to cylinder block 23 17
Flywheel, stage 1 18 13
45
Flywheel, stage 2 45 degrees
degrees
45
Flywheel, stage 3 45 degrees
degrees
Crankshaft rear oil seal carrier 20 15
Front plate to cylinder block 24 18
Crankshaft position sensor (CKP sensor) 21 15
Clutch pressure plate to flywheel 30 22
Crankshaft pulley/vibration damper, 1st stage 150 111
‐90 ‐90
Crankshaft pulley/vibration damper, 2nd stage
degrees degrees
Crankshaft pulley/vibration damper, 3rd stage 120 88
60
Crankshaft pulley/vibration damper, 4th stage 60 degrees
degrees
Torques
Oil circuit Nm lbf.ft
Sump 11 8
Oil intake pipe bracket to cylinder block 22 16
Oil pump to cylinder block 24 18
Oil drain plug 11 8
Oil pressure switch to cylinder head 20 15
Oil filter 15 11
Oil cooler to connecting housing, stage 1 11 8
Oil cooler to connecting housing, stage 2 65 48
Turbocharger lubrication oil pipe to turbocharger 8,5 6
Turbocharger oil return pipe to turbocharger 22 16
Oil pipe to turbocharger 22 16
Oil pipe to cylinder block 48 35
Blanking plug for cylinder block oil passages 45 33
Blanking plugs for cylinder head oil passages 18 13
Oil pipe/turbocharger bracket to cylinder block 48 35
Oil dipstick tube to thermostat housing 10 7
Transmission fluid drain plug 45 33
Torques
Cooling system Nm lbf.ft
Coolant pump to cylinder block 23 17
Coolant drain plug 22 16
Coolant pipe to cylinder block 20 15
Thermostat housing to cylinder head 23 17
Coolant pump hose connections 3 2
Auxiliary shaft timing belt pulley 45 33
Timing belt idler pulley to cylinder block 45 33
Timing belt cover plate 10 7
Alternator adjustment bracket to cylinder block 25 18
Crankshaft pulley 35 26
Timing belt cover 9 7
Injection pump timing belt pulley (M8) 23 17
Injection pump timing belt tensioner (M10) 45 33
Camshaft timing belt pulley (M6) 9 7
Camshaft timing belt pulley (M8) 35 26
Camshaft timing belt pulley (M10) 48 35
Camshaft timing belt tensioner 50 37
Rear timing belt cover 24 18
Alternator clamp bolt to adjustment bracket 25 18
Torques
Fuel system Nm lbf.ft
Injection pump to front plate 24 18
Injection pump bracket to cylinder block 23 17
Injector to cylinder head 70 52
Injection pipe union nuts 20 15
Fuel filter bracket to cylinder head/lifting eye 23 17
Banjo bolts for pump/filter fuel pipe 40 30
Union nuts to injection pump 26 19
Injection pump to bracket 23 17
Fuel filter retaining plate 23 17
Torques
Cylinder head Nm lbf.ft
Cylinder head bolts, stage 1 10 7
Cylinder head bolts, stage 2 100 74
Cylinder head bolts, stage 3 (wait 3 minutes) (undo by 180 degrees)
70 52
(tighten to 120 degrees)
Camshaft bearing caps 20 15
Cylinder head cover 5 4
Oil baffle 20 15
Inlet/exhaust manifold studs to cylinder head 12 9
Inlet/exhaust manifold to cylinder head 22 16
Glow plug to cylinder head 28 21
Glow plug wiring 2 1
Vacuum pump to cylinder head 22 16
Lifting eyes to cylinder head 20 15
Exhaust gas recirculation valve (EGR valve) to inlet/exhaust manifold 23 17
Exhaust gas recirculation pipe to EGR valve 23 17
Exhaust pipe to turbocharger 38 28
Turbocharger to exhaust manifold 46 34
Turbocharger bracket to cylinder block 23 17
Torques
General Nm lbf.ft
Starter motor 40 30
Front exhaust pipe/catalytic converter to exhaust manifold nuts 47 35
Engine/transmission adapter plate to clutch housing 40 30
Transmission ground cable 40 30
Engine/transmission flange bolts 40 30
Engine mounting bracket to cylinder block 69 51
Engine mounting to fender apron panel 84 62
Engine mounting to cylinder block bracket 120 89
Brace to engine mounting 69 51
Brace to front crossmember 69 51
Suspension arm to spindle carrier 52 38
Track rod to steering arm 26 19
Shift rod to transmission 16 12
Gearshift stabiliser bar to transmission 55 41
Gearshift linkage clamp bolt 16 12
Transmission brace to front left‐hand transmission bracket 50 37
Transmission bracket to rear left‐hand rubber insulator 69 51
Rear left‐hand bracket to transmission 50 37
Rear exhaust pipe to flexible pipe 40 30
Rear exhaust pipe to catalytic converter 40 30
Air conditioning dehydrator to bracket 7 5
Air conditioning compressor to bracket 24 18
Power steering high‐pressure pipe to power steering pump 29 21
Left‐hand engine mounting to side member 69 51
Vibration damper cover 10 7
Radiator crossmember 24 18
Engine mounting nut, rear right‐hand side 83 61
Engine mounting, rear right‐hand side 69 51
Engine roll restrictor 120 89
Brake servo vacuum line 16 12
Alternator bolts 22 16
Intermediate shaft bearing 26 19
Bracket, exhaust system 40 30
Upper timing belt cover 7 5

Description and Operation Escort/Orion 1991 (08/1990-09/2001)

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Description and Operation

Engine code
1.
Locatio
n of
engine
code
and
serial
numbe
r.
1.
Engine
code.
2.
Serial
numbe
r.

CAUTION:
The camshaft timing belt has been modified from '96 MY. The timing belt pulleys, idler
pulleys and the belt itself are not interchangeable with designs from previous model
years. In addition, from '96 MY onwards, the crankshaft front and rear oil seals are
made of PTFE instead of Viton. Refer to the repair instructions for further information.
 CAUTION:
A modified oil pump has been fitted in conjunction with a revised oil pressure switch
(green cover) in production since 08.98 (build code WP), and 5W 30 engine oil has
been used since this date. On vehicles built up to 07.98 inclusive (build code WM) an
oil pressure switch with a black cover should be fitted, and 10W40 engine oil should be
used.

Item Description
1 Front right‐hand engine mounting
Brace for front right‐hand engine
2
mounting
3 Engine roll restrictor, right‐hand side
4 Rear right‐hand engine mounting
5 Rear left‐hand engine mounting
6 Transmission
7 Engine

Engine ‐ Dismantle and Assemble (Engine

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 134 8)
 Print

Removal and Installation

Special Tools

15‐030AUniversal flange
holding wrench

16‐067Aligner, clutch disc

21‐011FCrankshaft rear oil

seal installer
 21‐031BMounting bracket

21‐104Setting pin, crankshaft

TDC position

21‐148AAligner/installer, oil
seal

21‐162BTiming tool, camshaft

alignment

21‐164Socket, cylinder head

bolts

21‐166Angle gauge

21‐168Locking tool,
crankshaft

21‐200Remover, crankshaft
pulley

21‐217Alignment tool,
crankshaft rear oil seal

21‐540Angle gauge

23‐019Timing pin, camshaft

timing pulley

23‐03427 mm socket for

injectors

23‐045Socket, injectors

Proprietary tools
Description
Dial gauge
Dial gauge stand
Piston ring compressor
Oil filter strap wrench
New 6 mm drill bit
Two‐legged puller
Micrometer screw 25 ‐ 50 mm
Micrometer screw 50 ‐ 75 mm
Internal gauge
Plastic scraper
Workshop Equipment
Description
Mounting stand with
21‐187
geared drive
Materials
Description
from: Replacement
Services Ltd., 30,
Euston Street,
Plastigage
Freemans Industrial
Estate, Leicester, LE2
7ST
Motor oil SAE 5W‐30 WSS‐M2C912‐A1
Sealer for cylinder
block mating face
SPM‐4G‐9112‐F/G
intersections and oil
pressure switch
Dismantle
1. General Note.
CAUTION:
In '96 MY the camshaft timing belt was
revised. Coolant pumps and timing belt
tensioners with different idler pulleys were
fitted in production. In service there are now
only coolant pumps with two edges on the
idler pulley available. When renewing the
timing belt tensioner make sure that if the
timing belt tensioner does not have an edge
on the idler pulley it is not matched with a
coolant pump without edges on the idler
pulley. It is NOT permissible to convert from
a mechanical to an automatic timing belt
tensioner. From '96 MY PTFE oil seals
superseded the use of the familiar Viton oil
seals fitted at the front and rear of the
crankshaft.
CAUTION:
A modified oil pump has been fitted in
conjunction with a revised oil pressure switch
(green cover) in production since 08.98 build
code WP), and 5W 30 engine oil has been
used since this date. It should be noted that
up to and including 07.98 (build code WM) an
oil pressure switch with a black cover was
fitted and 10W‐40 engine oil was used up to
this date.
NOTE:
Location of the timing belt tensioner spring
and the injection pump spring. Do NOT mix
 up the springs.

2. Detach the ancillary components from the right‐

hand side of the engine.
1. Front engine mounting
2. Pipe from the oil cooler.
NOTE:
Detach the oil filter.

3. Oil pipe from oil pump to turbocharger

4. Oil pump and oil cooler
   Remove the gasket and oil seal.
5. Attach Special Tool 21‐031B and fit the engine to
the assembly stand.
6. Exhaust manifold with turbocharger and exhaust
gas recirculation valve (EGR valve)
• Disconnect the breather hose and oil return pipe.
• Remove the gasket.
7. Inlet manifold
   Remove the gasket.
3. Detach the ancillary components from the rear side
of the engine.
1. Clutch pressure plate with clutch disc.
   Loosen the flywheel bolts.
2. Fuel filter with bracket, fuel heater and engine lifting
eye
3. Vacuum pump
• Remove the seal ring.
• Disconnect the oil return hose.
4. Crankcase ventilation hose from the cylinder head
cover and cylinder block.

4. Detach the ancillary components from the left‐hand

side of the engine.
   Slacken the drive belt and remove it.
 1. Detach the drive belt tensioning pulley.
2. Remove the alternator.
3. Detach the alternator bracket.
4. Detach the belt pulley from the power steering
pump.
5. Remove the power steering pump.
6. Detach the bracket for the power steering pump.
Only vehicles equipped with air conditioning.
5. Detach the ancillary components from the left‐hand
side of the engine.
   Slacken the drive belt for the power steering pump
and remove it.
1. Detach the belt pulley from the power steering
pump.
2. Detach the drive belt tensioning pulley (power
steering pump).
3. Remove the power steering pump.
4. Detach the power steering pump bracket.
5. Remove the bolt of the alternator adjustment
bracket.
6. Detach the alternator.
7. Detach the bracket for the alternator and air
conditioning compressor.
8. Detach the adapter plate for the alternator and air
conditioning compressor bracket.
 6. Detach the timing belt upper cover.
7. Remove the cylinder head cover.

Vehicles with an automatic timing belt tensioner

8. Undo the adjusting cam bolt.
   Turn the adjusting cam to 6 o'clock.

Vehicles with an automatic timing belt tensioner

9. Free the camshaft timing pulley.
NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
• Undo the camshaft timing pulley bolt three turns.

Vehicles with an automatic timing belt tensioner

 NOTE:
The timing belt must not be reused.

10. Remove the camshaft timing pulley.

• Detach the camshaft timing pulley and take it off
with the camshaft timing belt.
• Discard the timing belt.

Vehicles with a mechanical belt tensioner.

11. Detach the camshaft timing belt.
• Release the bolt of the timing belt tensioner and
loosen the timing belt.
• Remove the timing belt.
• Tighten the bolt of the timing belt tensioner.
• Discard the timing belt.

Vehicles with a mechanical belt tensioner.

CAUTION:
The timing belt tensioner is spring‐loaded.

12. Detach the timing belt tensioner and the camshaft

timing belt pulley.
1. Timing belt tensioner bolt
NOTE:
Remove the timing pulley using a two‐legged
puller.
2. Timing pulley bolt.

13. Detach the injection pump timing belt.

• Release the bolt of the timing belt tensioner and
loosen the timing belt.
• Tighten the bolt of the timing belt tensioner.
• Discard the timing belt.

CAUTION:
The timing belt tensioner is spring‐loaded.

14. Detach the timing belt tensioner and the injection

pump timing belt pulley.
1. Timing belt tensioner bolt
2. Timing pulley bolt.
 NOTE:
Immobilise the flywheel using Special Tool
21‐168.
15. Detach the crankshaft pulley.

16. Detach the timing belt rear covers.

1. Detach the timing belt pulley.
2. Rear cover bolt

17. Detach the auxiliary shaft pulley and auxiliary

shaft oil seal.
1. Remove the auxiliary shaft timing belt pulley
2. Remove the auxiliary shaft oil seal carrier.

18. Remove the auxiliary shaft.

• Unscrew the thrust plate bolts.
• Withdraw the auxiliary shaft with the thrust plate.

NOTE:
One bolt holds the bracket for the timing belt
tensioner spring.
19. Detach the coolant pump.
20. Detach the injection pump.

CAUTION:
Only insert the special tool.

21. Remove the rear timing pulley from the

crankshaft.
1. Insert the special tool.
2. Withdraw the special tool up to the shoulder.

22. Remove the rear timing pulley from the crankshaft

(cont.).
   Screw the special tool onto the spindle and remove
the crankshaft timing pulley.
23. Detach the ancillary components from the left‐hand
side of the engine.
1. Injection pipes from injectors and injection pump
   Disconnect the leak‐off hoses.
2. Charge air pipe from the turbocharger to the
injection pump
3. Thermostat housing complete with oil dipstick tube
   Remove the gasket and oil seal.
4. Injection pump with bracket
5. Coolant distribution pipe
24. Remove the injectors and the needle lift sensor.
   Take out the heat shield.
25. Remove the injectors and glow plugs.
1. Remove the injectors.
   Take out the heat shields.
2. Disconnect the power supply to the glow plugs.
3. Remove the glow plugs.

26. Detach the oil baffle.

• Remove the gasket.
• Detach the oil baffle.

27. Detach the cylinder head.

• Slacken the cylinder head bolts in the indicated order
and remove them.
• Remove the cylinder head and place it on a soft
surface.
• Remove the gasket.

28. Detach the crankshaft position sensor (CKP

sensor) and the bracket.
 29. Remove the flywheel.

Viton oil seal only

30. Remove the crankshaft rear oil seal carrier.
   Press out the oil seal on a flat surface.

PTFE oil seal only

NOTE:
The oil seal and oil seal carrier are renewed
as a unit.
31. Remove the crankshaft rear oil seal carrier.

NOTE:
Remove the sump downwards so that no oil
sludge or debris enter the engine.
32. Remove the sump (14 bolts).

33. Detach the front plate.

   Prise out the radial oil seal.
 34. Detach the oil intake pipe and bracket.
   Remove the O‐ring.

CAUTION:
Do not damage the cylinder liners.

35. Remove the pistons and connecting rods.

• Detach the big‐end bearing caps.
• Remove the carbon ring around the top of the
cylinder using a plastic scraper.
NOTE:
Keep the big‐end bearing shells and caps in
order for re‐use.
   Press out the pistons with the connecting rods and
the big‐end bearing shells and put them down in order.
NOTE:
Keep the bearing shells and caps in order for
re‐use.
36. Remove the crankshaft.
• Detach the main bearing caps.
• Remove the crankshaft.
• Keep the bearing shells and thrust rings in order for
re‐use.

Reassemble
37. Thoroughly clean all mating faces and re‐usable
parts and check them for damage.
38. Clean the piston cooling oil splash nozzles and
oilways.
 NOTE:
The main bearing caps must be fitted without
the main bearing shells, and tightened to the
specified torque.
39. Measure the cylinder bore diameters using an
internal gauge.
   If the measured diameter of the cylinder liner is too
large for the piston classification, the cylinder block
must be overhauled or renewed.

NOTE:
Repeat each measurement procedure again,
90 degrees displaced from the previous one.
40. Measure the diameter of the main and big‐end
bearing journals.
• Different sizes of crankshaft are used in production.
The different crankshafts are not marked.
• If the measurements are outside the range given in
General Specifications, the crankshaft must be re‐
worked or renewed.

NOTE:
Carry out the following steps to the letter.

41. Preparations for measuring the bearing clearance.

• Measure each bearing individually using a length of
Plastigage thread.
• Each time only the bearing cap of the bearing being
measured is fitted and torqued down to specification.
• The bearing shells and journals must be free of oil
and dirt.
• The measurement should be carried out near the
respective dead centre position.
42. Measure the main bearing clearance.
• Insert the corresponding bearing shells dry in the
cylinder block.
• Insert the crankshaft dry in the cylinder block.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
43. Measure the bearing clearance (continued).
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
• Fit each bearing cap with its associated bearing shell
and tighten it.
• Remove the bearing cap.

44. Measure the bearing clearance (continued).

• The measured value shows the bearing clearance.
• If necessary renew the bearing shells.

45. Install the crankshaft.

• Coat the main bearing journals, the bearing shells
and the thrust rings with engine oil.
• Insert the thrust half rings at the second main
bearing with the lubrication grooves outwards.
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point. Do not strike the bearing caps.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
• Tighten the bolts.
NOTE:
If necessary, correct the end float with the
thrust half rings on the second main bearing.
46. Check the crankshaft end float.
• Set up the dial gauge.
• Measure the end float by lifting the crankshaft using
a screwdriver.

47. Piston classification.

1. Cylinder bore classification.
2. Piston diameter classification.
3. The weight classes are marked with `+' and `‐'.
 NOTE:
Piston classification, in case a piston must be
replaced.
48. Measure the piston diameters.

CAUTION:
Do not mix up the piston rings. Replace the
rings in the same grooves and at the same
position.
49. Measure the piston ring gaps.
   The values given in the General Specifications were
obtained inproduction using a gauge ring. When
measured in the cylinder, the values may be exceeded
by 0,15 mm.

NOTE:
The piston ring clearance must be measured
with the ring projecting from its groove.
50. Measure the piston ring clearance.
• The maximum clearance for the top compression ring
is 0,2 mm.
• The maximum clearance for the second compression
ring is 0,1 mm.

51. Install the pistons with connecting rods.

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil scraper ring.
NOTE:
The numbering on the connecting rods begins
at the timing belt end. The arrow on the
piston crown points to the timing belt end.
   Compress the piston rings using a piston ring
compressor.
CAUTION:
Do not damage the cylinder liners and
bearings.
NOTE:
The crank pin must be at TDC.

• Press the pistons of cylinder nos. 1 and 4 into the

cylinders,guiding the connecting rods onto the big‐end
bearing journal.
• Place the corresponding bearing shells dry into the
big‐end bearings.
• Fit the pistons of cylinder nos. 2 and 3 as described
above.
 52. Measure the big‐end bearing clearances and fit
the bearing caps.
   Measure the big‐end bearing clearances as
described in the previous operating steps.
53. Coat the bearing shells and journals with engine
oil.
NOTE:
The numbering of the connecting rods and
big‐end bearing caps must tally.
   Fit the appropriate big‐end bearing caps and
bearing shells and tighten the bolts.
54. Fit the oil intake pipe and bracket.
NOTE:
Pay attention that the O‐ring is correctly
seated.
1. Fit the oil intake pipe and with the new O‐ring.
2. Fit the bracket.

55. Fit the front plate.

NOTE:
The front plate mating face must be flush
with the lower edge of the cylinder block
(tolerance± 0,1 mm).
   Locate the front plate in position with a new gasket
and new rubber seals for the oil passages.
1. Centre the front plate using the special tool.
2. Attach the front plate (four bolts).

CAUTION:
If a PTFE oil seal (Teflon ring) is used, step
58 must be carried out immediately after
step to prevent the oil seal from contracting.
Only remove the support ring from the oil
seal immediately before installation.
56. Fit the crankshaft front oil seal.
   Fit the oil seal using the special tool and the bolt of
the vibration damper.

NOTE:
Condition of the O‐ring in the crankshaft
timing pulley.
57. Fit the crankshaft timing belt pulley.
• Lubricate the O‐ring and the end of the crankshaft
with engine oil.
• Carefully slide the timing belt pulley on as far as the
shoulder.
• The guide pin in the crankshaft journal and the hole
in the crankshaft timing pulley must line up.
 NOTE:
The sump bolts must be tightened within 20
minutes of applying the sealer.
58. Apply sealer (SPM‐4G‐9112‐F/G) to the mating face
intersections of the cylinder block.

NOTE:
Renew the gasket.

59. Fit the sump.

• Put on the sump and gasket and screw in the bolts
finger tight (14 off).
• Align the sump so that it is flush with the cylinder
block.

60. Tighten the sump bolts.

Viton oil seal only

NOTE:
It is centred by means of the guide lugs in
the locating bore of the oil seal carrier.
61. Fit the crankshaft rear oil seal carrier.
• Locate the oil seal carrier in position with the bolts.
• Tighten the bolts, working diagonally.

Viton oil seal only

62. Draw the oil seal in the crankshaft oil seal carrier.
   Press the oil seal home using the special tool and
two used flywheel bolts.

PTFE oil seal only

 CAUTION:
The sealing lip of the oil seal and the mating
face on the crankshaft must be free of oil.
CAUTION:
The support ring falls out by itself when the
crankshaft oil seal carrier is fitted. Do not
remove it beforehand.
63. Fit the new crankshaft rear oil seal carrier.
• Locate the new crankshaft oil seal carrier with the
integrated seal and bolts in position.
• Insert the bolts.
• Fit the special tool and centre the oil seal carrier on
the crankshaft.
PTFE oil seal only
CAUTION:
If the special tool cannot be removed, the
sump must be realigned.
64. Tighten the bolts of the crankshaft oil seal carrier.
   Remove the special tool.

CAUTION:
Use new bolts.

65. Fit the flywheel (8 bolts).

   Immobilise the flywheel using
Special Tool 21‐168.

66. Fit the CKP sensor and bracket.

67. Fit the coolant pump.

   Locate the coolant pump with its new gasket and
the bracket for the spring of the timing belt tensioner
in position.
 68. Fit the auxiliary shaft.
• Lubricate the auxiliary shaft, the bearing bush in the
cylinder block and the thrust plate with engine oil.
NOTE:
The lubricating grooves on the thrust plate
must face outwards.
• Fit the auxiliary shaft with the thrust plate

CAUTION:
If the plastic fitting bush is removed from the
oil seal carrier before installation, the oil seal
is unusable.
69. Fit the auxiliary shaft oil seal carrier.
• Lubricate the end of the auxiliary shaft with engine
oil.
• Slide the new auxiliary shaft oil seal carrier with
integral oil seal and plastic fitting sleeve onto the
auxiliary shaft journal.
• Screw in the bolts of the auxiliary shaft oil seal
carrier.
• After securing the oil seal housing, detach the plastic
fitting bush and check that the seal is seated correctly.
NOTE:
Carry out two measurements per cylinder at
a distance of 5 mm from the edge of the
piston.
NOTE:
Measure the piston protrusion of each
cylinder at TDC.
70. Measure the piston protrusion.
• Measure the difference in height between the piston
crown and the cylinder block.
• The largest measurement determines the choice of
cylinder head gasket (see General Specifications).
71. Line up the crankshaft and camshaft.
• Turn the crankshaft until the piston of cylinder no. 1
is at TDC.
• Turn the camshaft until the slot in the cam on the
camshaft is parallel with the upper edge of the cylinder
head (with the larger semi‐circle at the top).
• The crankshaft and camshaft must not be turned any
more.

72. Lay a new cylinder head gasket in place.

NOTE:
The cylinder head gasket is marked
”TOP/OBEN".
1. Check that the locating sleeves are seated
correctly.
2. Thickness markings.
 CAUTION:
Renew the cylinder head bolts.

73. Tighten the cylinder head bolts.

• Insert the cylinder head bolts.
• Tighten the cylinder head bolts in two stages in the
specified sequence.

CAUTION:
For the third stage, slacken one single
cylinder head bolt at a time, then tighten it to
the specified torque and angle. Only then go
on to tighten the next cylinder head bolt.
74. Tighten the cylinder head bolts (cont.).
NOTE:
The cylinder head bolts must not be
retorqued.
   Wait three minutes and then tighten the cylinder
head bolts to stage 3 in the specified order.

NOTE:
Make sure that the heat shields are fitted
correctly with the conical side downwards.
Use new heat shields.
75. Install the fuel injector with the needle lift sensor.
 NOTE:
Make sure that the heat shields are fitted
correctly with the conical side downwards.
Use new heat shields.
76. Fit the injectors and glow plugs.
1. Fit the injectors with the heat shields.
2. Fit the glow plugs.
3. Install the glow plug power supply.

77. Fit the injection pump.

78. Attach the ancillary components to the left‐hand

side of the engine.
1. Coolant distribution pipe
 NOTE:
Install the fuel injection pump free of stress.
If necessary, release the bracket and align
the injection pump.
2. Injection pump with bracket
NOTE:
Use a new gasket and new oil seal.

3. Thermostat housing with oil dipstick tube

4. Charge air pipe from the turbocharger to the
injection pump
5. Injection pipes to injectors and injection pump
   Connect the leak‐off hoses.
79. Fit the rear timing belt covers.
   Fit the covers in position.
1. Timing belt pulley.
2. Screw in the bolt.

Vehicles with a mechanical belt tensioner.

NOTE:
The auxiliary shaft locating pin and the hole
in the timing belt pulley must line up.
80. Fit the timing belt pulleys and camshaft timing
belt tensioner.
1. Fit the camshaft timing belt pulley.
2. Fit the auxiliary shaft timing belt pulley (one bolt).
3. Secure the timing belt tensioner (two bolts).
4. Compress the timing belt tensioner spring and lock
it using a bolt.

NOTE:
Do not tighten the
bolts.
81. Fit the injection pump
timing belt pulley.
   Centre the bolts in the
slots.

82. Fit the injection pump timing belt tensioner.

   Compress the injection pump timing belt tensioner
spring and lock it in place with a bolt.
 NOTE:
Renew the bolt.

83. Install the crankshaft pulley.

• Stop the crankshaft from turning using Special Tool
21‐168.
NOTE:
The lug and the notch must line up.

• Coat the bolt contact surface of the crankshaft

vibration damper bolt with engine oil and tighten to
the specified torque.
Vehicles with an automatic timing belt tensioner.
84. Fit the special tool in the camshaft groove.

85. Set the crankshaft to TDC.

• Remove the retaining bolt from the cylinder block.
NOTE:
Screw to special tool in to the shoulder.

• Fit special tool 21‐104 and carefully turn the

crankshaft in the normal direction of rotation until it
comes up against the special tool.
Vehicles with an automatic timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the fuel pump timing belt.
CAUTION:
Only perform work on the timing belt when
the engine has reached the ambient
temperature of the workshop.
NOTE:
The crankshaft must touch special tool 21‐
104 and special tool 21‐162B must be
inserted in the camshaft.
NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated
correctly.
86. Fit the new camshaft timing belt.
1. Install the camshaft timing belt tensioner.
2. Install the adjusting cam.
3. Put on the timing belt.
   Slide the camshaft timing pulley onto the taper and
tighten the bolt until the pulley only just turns on the
camshaft.
Vehicles with an automatic timing belt tensioner.
 87. Pre‐tighten the camshaft timing belt.
NOTE:
Coat the bolt contact surface of the adjusting
cam with engine oil.
   Turn the adjusting cam clockwise to 9 o'clock and
tighten the adjusting cam bolt.

Engines with an automatic timing belt tensioner from the camshafttiming belt.
NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
88. Tighten the camshaft timing pulley bolt.

Vehicles with an automatic timing belt tensioner.

CAUTION:
Remove special tools 21‐104 and 21‐
162B.
89. Turn the crankshaft six complete revolutions in the
normal operating direction.
Vehicles with an automatic timing belt tensioner.
90. Preparations for tensioning the timing belt.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in to the
shoulder.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Vehicles with an automatic timing belt tensioner.
91. Undo the bolt on the adjusting cam half a turn.

Vehicles with an automatic timing belt tensioner.

 NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
92. Undo the camshaft timing pulley bolt three turns.

Vehicles with an automatic timing belt tensioner.

NOTE:
Position a screwdriver between the camshaft
timing belt pulley and the timing belt rear
cover.
93. Free the camshaft timing pulley from the taper by
striking it lightly with a soft metal drift.

Vehicles with an automatic timing belt tensioner.

NOTE:
If necessary, turn the camshaft until the
timing tool can be inserted.
94. Install the Special Tool.

Vehicles with an automatic timing belt tensioner.

NOTE:
Check that the camshaft timing pulley is still
free to turn on the camshaft.
95. Tighten the camshaft timing pulley bolt finger tight
and then loosen it half a turn.

Vehicles with an automatic timing belt tensioner.

 96. Tension the camshaft timing belt.
NOTE:
The adjustment range of the adjusting cam is
between 6 o'clock (MIN) and 12 o'clock
(MAX).
   Tension the camshaft timing belt clockwise via the
adjusting cam until the pointer on the camshaft timing
belt tensioner appears in the right‐hand corner of the
adjustment range.

Vehicles with an automatic timing belt tensioner.

NOTE:
Stop the adjusting cam from turning.

97. Evenly tighten the bolt on the adjusting cam.

Vehicles with an automatic timing belt tensioner.

98. Checking the position of the automatic camshaft
timing belt tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: renew and tension
the camshaft timing belt as described.
CAUTION:
To avoid engine damage make sure that the
pointer is within range `A'.

Vehicles with an automatic timing belt tensioner.

NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
99. Tighten the camshaft timing pulley bolt.
• Tightening torque for M8 bolt: 35 Nm
• Tightening torque for M10 bolt: 48 Nm

Vehicles with an automatic timing belt tensioner.

100. Detach special tools 21‐104 and 21‐162B.
Vehicles with an automatic timing belt tensioner.
101. Turn the crankshaft six complete revolutions in
 the normal operating direction.
Vehicles with an automatic timing belt tensioner.
102. Checking the valve timing.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in to the
shoulder.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Vehicles with an automatic timing belt tensioner.
103. Insert the special tool. If the special tool cannot
be inserted, renew and tension the camshaft timing
belt as described.

Vehicles with an automatic timing belt tensioner.

104. Checking the position of the automatic timing belt
tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: renew and tension
the camshaft timing belt as described.
CAUTION:
To avoid engine damage make sure that the
pointer is within range `A'.

Vehicles with an automatic timing belt tensioner.

105. Remove special tools 21‐162B and 21‐104.
Vehicles with a mechanical timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the injection pump timing belt.
NOTE:
Do not mix up the springs of the timing belt
tensioner.
106. Fit the new camshaft timing belt.
• Put the special tool 23‐019 in place.
NOTE:
Check the timing belt is properly positioned
and correctly seated.
NOTE:
Slots. Centre the bolts of the camshaft
timing pulley in the slots.
• Fit a new camshaft timing pulley anti‐clockwise
starting from the crankshaft.
• Undo the mechanical belt tensioner clamp bolt and
allow the tensioner to snap against the belt.
1. Tighten the mechanical belt tensioner clamp bolt.
2. Tighten the bolts of the camshaft timing belt
pulley.
Vehicles with a mechanical timing belt tensioner.
107. Preparations for tensioning the timing belt.
CAUTION:
Remove special tools 21‐104 and 23‐
019.
• Carefully turn the crankshaft six revolutions in the
normal direction of rotation of the engine.
1. Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
2. The special tool must go into the camshaft timing
belt pulley.
3. Undo the camshaft timing pulley bolts.

Vehicles with a mechanical timing belt tensioner.

CAUTION:
Retensioning a used timing belt is not
permissible.
108. Tension the timing belt.
• Slacken the bolts of mechanical timing belt
tensioner a quarter of a turn so that the tensioner
presses against the belt.
NOTE:
Check the special tools are correctly seated.

1. Tighten the bolts of the mechanical timing belt

tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
3. Remove the special tool.
4. Remove the special tool and tighten the retaining
bolt to 24 Nm.
109. Align the injection pump timing pulley.
1. Align the injection pump timing pulley with the
special tool or the shaft of a new 6 mm drill bit via
the timing pulley recess and injection pump housing
hole.
   Unscrew the blanking plug from the hole for TDC
adjustment in thecylinder block.
2. Screw the special tool into the cylinder block.
NOTE:
The special tool must be screwed in to the
shoulder. The crankshaft must touch the
special tool.
   Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
CAUTION:
Use a new timing belt.

NOTE:
The direction of rotation is marked.

NOTE:
Make sure the timing belt is seated
correctly.
110. Fit the injection pump timing belt.
• Fit a new camshaft timing pulley anti‐clockwise
starting from the crankshaft.
• Loosen the timing belt tensioner bolt and allow the
tensioner to snap against the timing belt.
1. Tighten the bolt of the timing belt tensioner.
NOTE:
The bolts must not be at the ends of the
slots.
2. Tighten the bolts of the injection pump timing belt
pulley.
• Remove the special tool.
CAUTION:
Make sure the settings and tension
adjustments are adjusted correctly The
setting to 10 degrees must be exact. Special
Tools 21‐166 or 21‐540 can be used.
111. Set the crankshaft to 10 degrees after TDC on
the first cylinder.
• Locate the CKP sensor bracket in position without
the CKP sensor and attach it loosely.
NOTE:
When using Special Tool 21‐540 take care
not to move the disc during tightening.
Pressure must be applied to the tool during
measuring. If the 10 degree mark is not
reached exactly, unscrew and remove the
angle disc from the measuring area and
reset it from the start.
• Put special tool 21‐540 on the crankshaft vibration
damper and set the disc to 10 degrees.
• Remove the timing pin from special tool 21‐166.
 NOTE:
If the mark is exceeded, set the crankshaft
to 10 degrees before TDC on the first
cylinder and repeat the adjustment
procedure starting from the previous step.
112. Set the crankshaft to 10 degrees after TDC on
the first cylinder(cont.).
   Turn the crankshaft vibration damper until the
arrows on the special tools line up.

113. Align the bracket of the CKP sensor.

• Insert the timing peg through the CKP sensor
bracket and ensure it engages in the hole on the
flywheel.
• Tighten the bolts on the CKP sensor bracket and
remove the timing peg.

114. Check the alignment of the CKP sensor.

• Set the crankshaft to 10 degrees after TDC on the
first cylinder as described in the previous steps.
NOTE:
If the timing peg cannot be inserted into the
hole on the flywheel, repeat the adjustment
procedure as described.
NOTE:
Then check the alignment again.

• The timing peg must be able to be inserted in the

flywheel.
115. Check the valve clearances and adjust them if
necessary as described in Operation Number 21 213 0.
116. Fit the oil baffle.

NOTE:
Clean the gasket, inspect it for damage and
lubricate with engine oil. Renew it if
necessary (it can be re‐used several times).
117. Install the cylinder head cover.
 118. Install the timing belt upper cover.

119. Attach the ancillary components to the left‐hand

side of the engine.
1. Attach the power steering pump bracket.
2. Fit the power steering pump.
3. Fit the power steering pump belt pulley.
4. Fit the alternator bracket.
5. Fit the alternator.
6. Fit the drive belt tensioning pulley.
   Put the drive belt in place and tension it.
Only vehicles equipped with air conditioning.
120. Fit the ancillary components on the left‐hand side
of the engine.
1. Fit the adapter plate for the alternator and air
conditioning compressor bracket.
2. Fit the alternator and air conditioning compressor
bracket.
3. Fit the alternator.
4. Screw in the bolt of the alternator adjustment
bracket.
5. Attach the power steering pump bracket.
6. Fit the power steering pump.
7. Fit the drive belt tensioning pulley (power steering
pump).
8. Fit the power steering pump belt pulley.
   Fit the power steering pump drive belt and tension
it.

121. Attach the ancillary components to the rear side

of the engine.
 NOTE:
Use a new oil seal.

1. Vacuum pump
   Connect the oil return hose.
2. Crankcase ventilation hose on the cylinder head and
cylinder block.
3. Fuel filter with bracket, fuel heater and engine lifting
eye
122. Centre the clutch disc on the clutch pressure
plate.

123. Fit the clutch.

1. Install the clutch pressure plate and centred clutch
disc.
2. Tighten the bolts (x6) uniformly, working
diagonally.
3. Remove the special tool.
 124. Attach the ancillary components to the right side
of the engine.
NOTE:
Use a new gasket.

1. Inlet manifold
NOTE:
Use a new gasket.

2. Exhaust manifold with turbocharger and EGR valve

   Connect the breather hose to the cylinder head and
the oil return pipe to the cylinder block.
3. Detach the engine from the assembly stand and
remove the special tool from the engine.
NOTE:
Prime the oil pump by hand and coat the oil
pump sprocket with oil.
NOTE:
Use a new gasket.

4. Oil pump with new oil filter and oil cooler.

5. Oil pipe from oil pump to turbocharger
6. Pipe to the oil cooler.
7. Front engine mounting

Cylinder Head ‐ Remove and Install (21

Escort/Orion 1991 (08/1990-09/2001)
163 0)
  Print

Removal and Installation

Special Tools

15‐030AUniversal flange
holding wrench

21‐068AEngine lifting tackle

21‐104Setting pin, crankshaft

TDC position

21‐162AAlignment tool,
camshaft TDC setting

21‐164Wrench, cylinder head

bolts

21‐540Angle gauge

23‐019Timing pin, camshaft

timing pulley

23‐03427 mm socket for

injectors

23‐045Socket, fuel injectors

24‐003Remover and installer,

radiator hose clip

Proprietary tools
New 6 mm drill bit
Two‐legged puller
Workshop Equipment
Workshop crane
Materials
Coolant ESD‐M97B‐49A
Motor oil SAE 5W‐30 WSS‐M2C912‐A1
Cable ties
Remove
1. Standard preparatory measures.
• Make a note of the radio keycode.
• Make a note of the pre‐set radio stations.
• Remove the battery cover.
CAUTION:
Disconnect the battery negative lead.

• Raise the vehicle.

WARNING:
Before opening the cooling system, cover
the cap with a thick cloth to avoid scalding.
NOTE:
Screw the drain plug back on when the
coolant has been drained.
2. Drain the coolant.

3. Remove the lower cover of the multi‐groove belt.

4. Detach the alternator drive belt.

   Slacken the drive belt via the adjusting tab on the
alternator and take it off.

5. Remove the drive belt tensioner pulley (3 bolts,

upper boltshown).

6. Detach the alternator and tie it to one side.

• Unscrew one bolt at the top and two at the bottom.
7. Detach the belt pulley and the lower belt pulley
cover.
   Lower the vehicle.

8. Remove the air cleaner housing intake pipe.

1. Undo the hose clamp.
2. Undo the two clamps.
3. Detach the MAF multiplug.

9. Remove the intercooler.

1. Remove the nut.
2. Release the hose clips.

10. Pull out the power steering fluid reservoir.

   Detach the return hose and tie the power steering
reservoir to one side.

11. Detach the fuel filter and the bracket for the
vacuum lines.
1. Disconnect the fuel lines.
2. Unscrew the nuts.
3. Unclip the bracket for the vacuum lines.
12. Detach the fuel heater.
• Press in the locking pins on the clips.
• Detach the clips.

13. Separate the connectors and detach the cables.

1. Needle lift sensor.
2. Power supply to glow plugs
3. Disconnect the fuel return lines.

14. Detach the two vacuum lines from the vacuum

pump.

15. Detach the thermostat housing and push it to one

side.

NOTE:
Plug the openings in the injectors and
injection pump.
16. Disconnect the fuel pipes.
1. Disconnect the leak‐off pipes.
2. Disconnect the injection pipes from the injectors
and the injection pump.
17. Disconnect the coolant expansion tank coolant
hose using Special Tool 24‐003.

18. Detach the coolant hose and disconnect the

vacuum hose from the exhaust gas recirculation
valve (EGR valve).
1. EGR valve
2. Coolant hose

19. Remove the turbocharger oil line.

20. Remove the turbocharger.

1. Turbocharger bracket
2. Turbocharger
3. Oil line for lubrication of the turbocharger

21. Detach the timing belt cover (engine shown

removed from vehicle).
 22. Detach the crankcase ventilation hoses.
1. To the cylinder block.
2. To the turbocharger.

23. Remove the cylinder head cover.

   Remove the gasket.

24. Detach the oil baffle.

NOTE:
Turn the crankshaft until the slot on the
injection pump pulley is at 11 o'clock.
25. Turn the crankshaft to TDC.

Vehicles with an automatic timing belt tensioner.

 26. Detach the camshaft timing belt.
1. Remove the adjusting cam bolt and take off the
adjusting cam and the camshaft timing belt.
2. Detach the camshaft timing belt.
NOTE:
Hold the camshaft timing pulley with Special
Tool 15‐030A.
3. Remove the camshaft pulley bolt.
   Discard the timing belt.

Vehicles with an automatic timing belt tensioner.

NOTE:
Position a screwdriver between the camshaft
timing belt pulley and the timing belt rear
cover.
27. Free the camshaft timing pulley from the taper by
striking it lightly with a soft metal drift.

Vehicles with a mechanical timing belt tensioner.

28. Detach the camshaft timing belt.
• Release the bolt of the timing belt tensioner and
loosen the timing belt.
• Discard the timing belt.

Vehicles with a mechanical timing belt tensioner.

WARNING:
The timing belt tensioner is spring‐loaded.

NOTE:
Use a two legged puller if necessary.

29. Detach the timing belt tensioner and the

camshaft timing belt pulley.
1. Timing belt pulley.
2. Timing belt tensioner
30. Remove the timing belt
idler pulley.

31. Remove the right‐hand rear timing belt cover.

32. Remove the fuel injectors and the needle lift

sensor.
   Take out the heat shield.

33. Remove the injectors.

   Remove the heat shields.
 34. Slacken and remove the cylinder head bolts in the
indicated sequence using the special tool.

35. Attach the special tool to the lifting eyes and lift off
the cylinder head.
   Remove the cylinder head gasket.

Install
36. Preparations.
CAUTION:
Clean the mating face thoroughly with a
scraper. Do not use abrasive paper under
any circumstances.
   Lay a new cylinder head gasket in place.
1. Check that the guide sleeve is seated correctly.
2. The thickness is indicated by the number of teeth.

NOTE:
The larger semi‐circle must be uppermost.

37. Align the camshaft.

   Set the slot parallel to the top edge of the cylinder
head.
 NOTE:
Set the crankshaft so that piston number 1 is
at about 25 mm before TDC.
38. Put the cylinder head on the cylinder block.

NOTE:
Renew the cylinder head bolts.

39. Tighten the cylinder head bolts.

• Install the cylinder head bolts.
• Tighten the cylinder head bolts in the specified
sequence in two stages.

CAUTION:
For stage 3, slacken one cylinder head bolt at
a time, then tighten it to the specified torque
and angle. Only then move on to the next
cylinder head bolt.
NOTE:
The cylinder head bolts must not be
retorqued.
40. Tighten the cylinder head bolts (cont.).
   Wait three minutes and then tighten the cylinder
head bolts to stage 3 in the specified order.
 NOTE:
Make sure the heat shields are fitted correctly
with the conical side downwards. Use new
heat shields.
41. Install the fuel injectors and the needle lift sensor.

NOTE:
Make sure the heat shields are fitted correctly
with the conical side downwards. Use new
heat shields.
42. Install the fuel injectors.

43. Install the right‐hand rear timing belt cover.

44. Install the timing belt idler pulley.

NOTE:
The special tool must be screwed in up to
the shoulder.
45. Turn the crankshaft to TDC for cylinder no. 1.
• Remove the blanking plugs and screw in the special
tool.
   Carefully turn the crankshaft against the special
tool.

Vehicles with a mechanical timing belt tensioner.

 46. Fit the camshaft timing belt tensioner and timing
belt pulley.
1. Camshaft timing belt pulley
2. Camshaft timing belt tensioner

Vehicles with a mechanical timing belt tensioner.

47. Align the camshaft timing pulley.
1. Align the camshaft timing pulley with the shaft of a
new 6 mm twist drill bit or a special tool via the
timing pulley recess and cylinder head hole.
2. Slacken the four pulley bolts on the timing belt
pulley.

NOTE:
If the drill or the special tool cannot be
inserted, reset the injection pump.
48. Check the setting of the injection pump.
• Make sure that the crankshaft touches special tool
21‐104.
   Insert the shaft of a new 6 mm drill bit or special
tool in the timing pulley and the injection pump.

Vehicles with an automatic timing belt tensioner.

CAUTION:
Always renew the camshaft timing belt and
the injection pump timing belt.
CAUTION:
Only perform work on the timing belt when
the engine has reached the ambient
temperature of the workshop.
NOTE:
The direction of rotation is marked.

NOTE:
Correct seating of timing belt.

49. Fit the new camshaft timing belt.

1. Fit the camshaft timing belt.
NOTE:
Coat the bolt contact surface with engine oil.

2. Move the camshaft timing pulley and the installed

timing belt into position. Screw the camshaft timing
pulley bolt in so that the camshaft timing pulley is still
free to turn on the camshaft.
Vehicles with an automatic timing belt tensioner.
 50. Pre‐tighten the camshaft timing belt.
NOTE:
Coat the bolt contact surface of the adjusting
cam with engine oil.
   Turn the adjusting cam clockwise to 9 o'clock and
tighten the adjusting cam bolt.

Vehicles with an automatic timing belt tensioner.

NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
51. Tighten the camshaft timing pulley bolt.

52. Remove special tools 21‐104 and 21‐162B.

Vehicles with an automatic timing belt tensioner.

53. Turn the crankshaft six complete revolutions in the
normal operating direction.
Vehicles with an automatic timing belt tensioner.
54. Preparations for tensioning the timing belt.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
Screw in the special tool up to the shoulder.

• Screw in the special tool.

• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Vehicles with an automatic timing belt tensioner.
55. Undo the bolt on the adjusting cam half a turn.

Vehicles with an automatic timing belt tensioner.

 NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
56. Undo the camshaft timing pulley bolt three turns.

Vehicles with an automatic timing belt tensioner.

NOTE:
Position a screwdriver between the camshaft
timing belt pulley and the timing belt rear
cover.
57. Free the camshaft timing pulley from the taper by
striking it lightly with a soft metal drift.

Vehicles with an automatic timing belt tensioner.

NOTE:
If necessary, turn the camshaft until the
alignment tool can be inserted.
58. Insert the alignment tool into the slot on the
camshaft.

Vehicles with an automatic timing belt tensioner.

NOTE:
Check that the camshaft timing pulley is still
free to turn on the camshaft.
59. Tighten the camshaft timing pulley bolt finger tight
and then loosen it half a turn.

Vehicles with an automatic timing belt tensioner.

 60. Tension the camshaft timing belt.
NOTE:
The adjustment range of the adjusting cam is
between 6 o'clock (MIN) and 12 o'clock
(MAX).
   Tension the camshaft timing belt clockwise via the
Allen screw on the adjusting cam until the pointer on
the camshaft timing belt tensioner appears in the
right‐hand corner of the adjustment range.

Vehicles with an automatic timing belt tensioner.

NOTE:
Hold the adjusting cam in position.

61. Tighten the adjusting cam bolt.

Vehicles with an automatic timing belt tensioner.

62. Checking the position of the automatic camshaft
timing belt tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: renew and tension
the camshaft timing belt as described.
CAUTION:
To avoid engine damage make sure that the
pointer is within range 'A'.

Vehicles with an automatic timing belt tensioner.

NOTE:
Stop the camshaft timing pulley from turning
by using the special tool.
63. Tighten the camshaft timing pulley bolt.
• Tightening torque for M8 bolt: 35 Nm
• Tightening torque for M10 bolt: 48 Nm

Vehicles with an automatic timing belt tensioner.

64. Remove the special tools 21‐104 and 21‐162B.
Vehicles with an automatic timing belt tensioner.
65. Turn the crankshaft six complete revolutions in the
 normal operating direction.
Vehicles with an automatic timing belt tensioner.
66. Checking the valve timing.
• Turn the crankshaft in the normal direction of
rotation until the slot on the injection pump timing
pulley is at 11 o'clock.
NOTE:
The special tool must be screwed in up to
the shoulder.
• Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
Vehicles with an automatic timing belt tensioner.
67. Fit the special tool in the camshaft groove. If the
special tool cannot be inserted in the camshaft groove,
renew and tension the camshaft timing belt as
described.

Vehicles with an automatic timing belt tensioner.

68. Checking the position of the automatic timing belt
tensioner.
• If the pointer is in range A: proceed to the next step.
• If the pointer is outside range A: renew and tension
the camshaft timing belt as described.
CAUTION:
To avoid engine damage make sure that the
pointer is within range 'A'.

Vehicles with an automatic timing belt tensioner.

69. Remove the special tools and tighten the blanking
plug to 24 Nm.
Vehicles with a mechanical timing belt tensioner.
CAUTION:
Always renew the camshaft timing belt and
the injection pump timing belt.
NOTE:
Position of timing belt tensioner spring and
the injection pump spring. Do NOT mix up
the springs.
CAUTION:
The crankshaft must touch special tool 21‐
014 and special tool 23‐019 must be
inserted in the camshaft timing pulley.
70. Fit the new camshaft timing belt.
NOTE:
Check the timing belt is properly positioned
and correctly seated.
NOTE:
Slots. The bolts of the camshaft timing belt
must be central in the slots.
• Fit a new camshaft timing pulley anti‐clockwise
starting from the crankshaft.
 • Undo the timing belt tensioner bolt and press the
tensioner against the belt.
1. Tighten the bolt of the timing belt tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
Vehicles with a mechanical timing belt tensioner.
71. Remove special tools 21‐104 and 23‐019.
Vehicles with a mechanical timing belt tensioner.
72. Preparations for tensioning the timing belt.
• Turn the crankshaft six complete revolutions in the
normal operating direction.
1. Screw in the special tool.
• Carefully turn the crankshaft in the normal direction
of rotation of the engine until it comes up against the
special tool.
2. The special tool must go into the camshaft timing
belt pulley.
3. Undo the camshaft timing pulley bolts.

Vehicles with a mechanical timing belt tensioner.

CAUTION:
Retensioning a used timing belt is not
permissible.
73. Tension the timing belt.
• Slacken the bolts of mechanical timing belt
tensioner a quarter of a turn so that the tensioner
presses against the belt.
NOTE:
Correct seating of the special tools.

1. Tighten the bolts of the camshaft timing belt

tensioner.
2. Tighten the bolts of the camshaft timing belt
pulley.
3. Remove the special tool.
4. Remove the special tool and tighten the retaining
bolt to 24 Nm.
 74. Fit the oil baffle.

NOTE:
Clean the gasket, inspect it for damage and
lubricate with engine oil. Renew it if
necessary (it can be re‐used several times).
75. Fit the cylinder head cover.

76. Install the timing belt cover (engine shown

removed from the vehicle).

77. Install the crankcase ventilation hoses.

1. To the cylinder block.
2. To the turbocharger.

78. Fit the turbocharger.

1. Turbocharger to exhaust manifold
2. Turbocharger bracket
3. Oil line for lubrication of the turbocharger
79. Install the turbocharger oil line.

80. Install the coolant hose and push on the EGR

valve vacuum hose.
1. EGR valve
2. Coolant hose

81. Connect the coolant hose to the coolant expansion

tank using Special Tool 24‐003.

82. Connect the fuel pipes.

1. Connect the injection pipes to the injectors and
injection pump.
2. Connect the leak‐off pipes.

83. Attach the oil dipstick tube.

1. Bolts for thermostat housing
2. Oil dipstick bracket bolt.
84. Attach the two vacuum lines to the vacuum pump.

85. Push on the multiplugs and install the cables.

1. Needle lift sensor.
2. Power supply to glow plugs
3. Connect the fuel return pipe.

86. Install the fuel pre‐heater.

• Position the fuel pre‐heater and clips.
• Press the pins into the clips.

87. Attach the fuel filter and the bracket for the
vacuum lines.
1. Connect the fuel lines.
2. Tighten the nut.
3. Clip the bracket for the vacuum lines in place.

88. Insert the power steering reservoir.

   Connect the return hose.
89. Fit the intercooler.
1. Tighten the nut.
2. Tighten the hose clips.

90. Install the air cleaner housing intake pipe.

1. Attach the hose clamp.
2. Attach the two clamps.
3. Connect the mass air flow (MAF) plug.

91. Raise the vehicle.

92. Fit the pulley.
93. Fit the lower pulley cover.

94. Fit the alternator.

95. Install the drive belt tensioner pulley.

 96. Put the alternator drive belt in place and tension
it.
• Tension the drive belt using the adjustment bracket
as described in Operation Number 31 414 0.
• Tighten the alternator bolts.

97. Install the lower drive belt cover.

98. Lower the vehicle.

99. Standard finishing operations.
• Make sure that all the coolant hoses and hose clips
have been fitted.
• Fill up with coolant (ESD‐M97B‐49A).
• Change the engine oil.
• Check the fluid levels and correct as necessary.
• Bleed the fuel system.
• Bleed the cooling system.
• Secure the wiring and hoses with cable ties.
• Check the cooling system for leaks.
• Connect the battery negative lead.
• Enter the radio keycode.
• Reprogram the pre‐set radio stations.
• Reset the clock.
• Carry out a road test to allow the PCM to re‐learn
values.
• Check the fluid levels and correct as necessary.

Valve Stem Seals ‐ Renew (21 238 0) Escort/Orion 1991 (08/1990-09/2001)

 Print

Removal and Installation

Special Tools

21‐007 AInstaller, valve stem

oil seals

21‐024Valve spring
compressor

21‐024‐05Adapter for 21‐024

 21‐156Installer, valve collets

21‐165Pliers, valve stem seals

Materials
Motor oil SAE 5W‐30 WSS‐M2C912‐A1
Renew
1. Remove the camshaft as described in Operation No.
21 283 0.
NOTE:
Keep the tappets in order ready for re‐use.

2. Remove the valve tappets with the adjusting shims.

3. Turn the crankshaft to bring the pistons of cylinder

nos. 1 and 4 roughly to TDC.
• Turn the crankshaft until the slot in the injection
pump timing belt pulley is at 12 o'clock.
• Mark the position on the crankshaft.

NOTE:
Only to be done on the first and fourth
cylinders.
4. Remove the valve springs.
• Press the valve spring down using the special tools
and remove the valve collets using Special Tool 21‐
156.
• Remove the valve spring retainer and the valve
spring.

5. Remove the valve stem oil seals using the special

tool.
 NOTE:
Cover the grooves in the valve stems with
adhesive tape while fitting the seals.
NOTE:
Renew the valve stem oil seals and coat them
with engine oil.
6. Install the valve stem oil seals using the special
tool.

7. Fit the valve spring.

• Fit the valve spring and the valve spring retainer.
• Compress the valve spring using the special tools
and insert the collets using Special Tool 21‐156.

8. Turn cylinder nos. 2 and 3 to TDC and repeat the

previous operating steps.
   Turn the crankshaft a further 180 degrees until the
slot of the injection pump timing pulley is at 3 o'clock.

NOTE:
Lubricate the tappets with engine oil.

9. Fit the tappets with the shims in the correct order.

10. Install the camshaft as described in Operation No.

21 283 0.

General Specifications Escort/Orion 1991 (08/1990-09/2001)

 Print

Specifications
General
Engine management EEC IV / EFI
Emissions standard 93 EEC
Identification code N7A
Firing order 1‐3‐4‐2
Bore mm 86,0
Stroke mm 86,0
Cubic capacity Effective cc 1998
Compression ratio 10,3:1
Power output (EEC) kW 110
Power output (EEC) (PS) (150)
Power output (EEC) at rev/min 6000
Torque (EEC) Nm 190
Torque (EEC) at rev/min 4500
Idle speed rev/min 950
Max. permissible engine speed, continuous rev/min 5950
Max. permissible engine speed, short‐term rev/min 6175
Spark plugs AGPR 22 C1
Electrode gap mm 1,0
Dimensions
Cylinder block
Cast mark 20
Cylinder bore diameter, standard class 1 mm mm 86,000 ‐ 86,010
Cylinder bore diameter, standard class 2 mm mm 86,010 ‐ 86,020
Cylinder bore diameter, oversize 0,15 mm, class A mm 86,150 ‐ 86,160
Cylinder bore diameter, oversize 0,15 mm, class B mm 86,160 ‐ 86,170
Cylinder bore diameter, oversize 0,5 mm mm 86,500 ‐ 86,510
Number of main bearings 5
Centre main bearing width (without thrust half rings),
mm 21,12 ‐ 21,23
standard
Vertical inside diameter ‐ main bearing shells, service
mm 54,261 ‐ 55,038
standard
Vertical inside diameter ‐ main bearing shells, standard mm 54,983 ‐ 55,020
Vertical inside diameter ‐ main bearing shells ‐ 1st
mm 54,961 ‐ 54,988
undersize 0,05 mm
Vertical inside diameter ‐ main bearing shells ‐ 2nd
mm 54,761 ‐ 54,788
under size 0,25 mm
Vertical inside diameter ‐ main bearing shells ‐ 3rd
mm 54,511 ‐ 54,538
undersize 0,50 mm
Vertical inside diameter ‐ main bearing shells ‐ 4th
mm 54,261 ‐ 54,288
undersize 0,75 mm
Main bearing parent bore diameter, standard mm 59,287 ‐ 59,300
Main bearing parent bore diameter, oversize 0,40 mm,
mm 59,687 ‐ 59,700
black
Dimensions
Crankshaft
End float mm 0,093 ‐ 0,303
Main bearing journal diameter, standard (yellow) mm 54,98 ‐ 54,99
Main bearing journal diameter, (red) mm 54,99 ‐ 55,00
Main bearing journal diameter, undersize (green) mm 54,73 ‐ 54,75
Clearance ‐ main bearing journal/bearing shell mm 0,011 ‐ 0,048
Big‐end bearing journal diameter, standard mm 50,89 ‐ 50,91
Big‐end bearing journal diameter, undersize 0,25 mm
mm 50,64 ‐ 50,66
(green)
Thrust half washer thickness, standard mm 2,301 ‐ 2,351
Thickness of thrust half rings, oversize 0,38 mm
mm 2,491 ‐ 2,541
(yellow)
Centre main bearing journal width, standard mm 26,025 ‐ 26,075
Centre main bearing journal width, oversize 0,38 mm
mm 26,405 ‐ 26,455
(yellow)
Dimensions
Connecting rods
Bore diameter, big end mm 53,890 ‐ 53,910
Bore diameter, small end mm 20,589 ‐ 20,609
Vertical insider diameter ‐ big‐end bearing journal,
mm 49,916 ‐ 50,950
service, standard
Vertical inside diameter ‐ big‐end bearing journal,
mm 50,916 ‐ 50,950
standard
Vertical inside diameter ‐ big‐end bearing journal, 1st
mm 50,892 ‐ 50,926
undersize 0,025 mm
Vertical inside diameter ‐ big‐end bearing journal, 2nd
mm 50,652 ‐ 50,686
undersize 0,25 mm
Vertical inside diameter ‐ big‐end bearing journal, 3rd
mm 50,416 ‐ 50,450
undersize 0,50 mm
Vertical inside diameter ‐ big‐end bearing journal, 4th
mm 50,166 ‐ 50,200
undersize 0.75 mm
Vertical inside diameter ‐ big‐end bearing journal, 5th
mm 49,916 ‐ 49,950
undersize 1,00 mm
Clearance ‐ big‐end bearing journal/bearing shell mm 0,006 ‐ 0,060
Big‐end bearing end float mm 0,090 ‐ 0,310
Dimensions
Pistons
Piston diameter, service, standard mm 85,980 ‐ 86,000
Piston diameter, standard 1 mm 85,970 ‐ 85,980
Piston diameter, standard 2 mm 85,980 ‐ 85,990
Piston diameter, oversize 0,15 mm mm 86,130 ‐ 86,150
Piston diameter, oversize 0,50 mm mm 86,470 ‐ 86,490
Piston installation clearance, production mm 0,02 ‐ 0,04
Piston installation clearance, service mm 0,01 ‐ 0,04
Piston pin length mm 63,4
Piston pin diameter (white) mm 20,622 ‐ 20,625
Piston pin diameter (red) mm 20,625 ‐ 20,628
Piston pin diameter (blue) mm 20,628 ‐ 20,631
Piston pin diameter (yellow) mm 20,631 ‐ 20,634
Clearance in piston (colour match) mm 0,008 ‐ 0,014
Interference fit in connecting rod mm 0,018 ‐ 0,039
Piston ring gap (fitted), upper compression ring mm 0,30 ‐ 0,60
Piston ring gap (fitted), lower compression ring mm 0,50 ‐ 0,80
Piston ring gap (fitted), oil scraper ring (three parts) mm 0,40 ‐ 1,50
Stagger the piston ring gaps at 120°
to one another around the piston
circumference. This also applies to
Ring gap position
the intermediate ring gaps of the oil
scraper ring in relation to the
expander gap.
Dimensions
Cylinder head and valve seats
Cast mark 20
Upper correction angle (prod.), inlet/exhaust 70°
Valve seat angle 44°30"
Lower correction angle (prod.), inlet/exhaust 30°
Valve seat width, inlet mm 1,33 ‐ 2,19
Valve seat width, exhaust mm 1,68 ‐ 2,54
Stem bore diameter (inlet/exhaust) mm 7,063 ‐ 7,094
Camshaft bearing parent bore diameter mm 26,00 ‐ 26,03
Dimensions
Camshafts
Number of camshaft bearings 2x5
Single roller chain, hydraulic chain
Drive
tensioner
Camshaft end float mm 0,02 ‐ 0,26
Cam lift, inlet mm 9,99
Cam lift, exhaust mm 9,16
Cam length (between heel and tip), inlet mm 51,87 ‐ 52,10
Cam length (between heel and tip), exhaust mm 51,04 ‐ 51,27
Valve timing, inlet opens before TDC 9°
Valve timing, inlet closes after BDC 59°
Valve timing, exhaust opens before BDC 57°
Valve timing, exhaust closes after TDC 11°
Camshaft bearing journal diameter mm 25,96 ‐ 25,98
Inside diameter of bearing mm 26,00 ‐ 26,03
Dimensions
Valves
Valve control DOHC
Valve Clearances Hydraulic tappets
Hydraulic tappet diameter mm 30
Hydraulic tappet clearance in housing mm 0,025 ‐ 0,071
Valve length, inlet mm 111,67 ‐ 112,13
Valve length, exhaust mm 111,37 ‐ 111,83
Valve head diameter, inlet mm 33,5
Valve head diameter, exhaust mm 30
Valve stem diameter, standard inlet mm 7,025 ‐ 7,043
Valve stem diameter, standard exhaust mm 6,999 ‐ 7,017
Valve stem diameter, oversize 0,2, exhaust mm 7,199 ‐ 7,217
Valve stem diameter, oversize 0,4, inlet mm 7,425 ‐ 7,443
Valve stem diameter, oversize 0,4, exhaust mm 7,399 ‐ 7,417
Valve stem guide clearance, inlet mm 0,020 ‐ 0,069
Valve stem guide clearance, exhaust mm 0,046 ‐ 0,095
Valve spring free length mm 44,8
Spring force ‐ inlet and exhaust are identical
Spring force, valve open N 635
Spring force, valve closed N 210
Spring length (compressed)
Spring length, valve open mm 28,0
Spring length, valve closed mm 38,0
Valve spring inside diameter mm 17,2
Valve spring wire diameter mm 3,7
Number of turns 7,4
Dimensions
Engine Lubrication/Cooling
Oil pressure at 750 rev/min (SAE 10W/30 and 80°C oil
bar 1,60
temp.)
Oil pressure at 2000 rev/min (SAE 10W/30 and 80°C
bar 3,10
oil temp.)
Pressure relief valve opens at bar 3,70 ‐ 4,60
Oil pressure warning light comes on at bar 0,30 ‐ 0,50
Oil pump rotor/housing clearance mm 0,154 ‐ 0,304
Inner/outer rotor gap mm 0,05 ‐ 0,20
Rotor mating face end float mm 0,039 ‐ 0,104
Coolant temperature switch comes on at °C 99
Coolant temperature switch goes off at °C 94
Thermostat opening temperature °C 88
Dimensions
Steering
Power steering pressure switch closes at bar 38 ‐ 48
Power steering pressure switch opens at bar 14 ‐ 30
* The location of the angle on the valve seat is explained in the section Description and
Operation.

Spacer plates for the sump

Equalisation range Available spacer plates Colour coding
0,00 ‐ 0,25 mm No spacer required
0,26 ‐ 0,29 mm 0,15 mm silver
0,30 ‐ 0,44 mm 0,30 mm light blue
0,45 ‐ 0,59 mm 0,45 mm red
0,60 ‐ 0,75 mm 0,60 mm black
Lubricants, Adhesives and Sealers
Description Ford
Specification
Super Plus 4 coolant (blue/green) (do not mix coolants of different
ESD‐M97B49‐A
colour/specification with each other)
Super Plus 2000 coolant (orange) (do not mix coolants of different
WSS‐M97B44‐D
colour/specification with each other)
Transmission fluid (MTX 75) ESD‐M2C186A
Transmission fluid for transfer box (4x4) SQM‐2C9008‐A
Transmission fluid for rear differential (4x4) SQM‐2C9002‐A
Sealer for crankshaft front oil seal carrier (Loctite 518) WSK‐M2G348‐A5
Sealer for sump (Hylosil 502) WSK‐M4G320‐A
Adhesive sealer for coolant pump angle connector (Loctite 243) WSK‐M2G349‐A7
Adhesive sealer for coolant temperature sensor (Loctite 243) WSK‐M2G349‐A7
Adhesive for oil dipstick tube SPM‐2G9123‐A
Lubricant for O‐ring of engine speed/crankshaft position sensor (CKP
SM1C‐115‐A
sensor)
Lubricant for release bearing guide sleeve ESD‐M1C‐220‐A
Lubricant for transmission input shaft splines ESD‐M1C‐220‐A
Power steering hydraulic fluid SQM‐2C‐9010‐A
Thread‐locking compound (Loctite 270) SDM‐M4G9107‐A
Spark plug threads (Never Seeze) ESE‐M1244‐A
Heated oxygen sensors (Never Seeze) ESE‐M1244‐A‐A
Thread locking compound ‐ power steering pump to bracket SDM‐M4G9107‐A
Fill Capacity
Description Litres
Engine oil, initial fill capacity incl. filter 4,75
Engine oil, oil change incl. filter change (every 10.000km) 4,5
Engine oil, oil change excl. filter change 4,0
Coolant 7,5
Engine oil
Viscosity/Ambient Designation Specification
temperature
Recommended engine oil:
SAE 5W30 / less than ‐20 °C Ford Formula E Economy ACEA A1‐96/B1‐96 and WSS‐
to over 40 °C Engine Oil M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 °C to over Ford Super Multigrade Engine ACEA A1‐96/B1‐96 or A2‐
40 °C Oil 96/B2‐96 or API/SH/CD EC
SAE 10W40 / ‐20 °C to over Ford XR+ High‐performance ACEA A3‐96/B3‐96 or
40 °C High‐lubricity Engine Oil API/SH/CD EC
SAE 5W40 / less than ‐20 °C Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
to over 40 °C Motor Oil API/SH/CD EC
If engine oils with these specifications are not available, only engine oils which at least meet
the API/SH/CD EC specification may be used.

Torques
General Nm lbf.ft
Hose clamps 4 3
Fuel feed pipe to cylinder head 25 18
Ground cable to engine lifting eye 9 7
Torques
Intake system Nm lbf.ft
Studs in cylinder head 16 12
Inlet manifold to cylinder head 22 16
Intake air temperature sensor in intake pipe (IAT sensor) 15 11
Bracket for pulse air system air cleaner/air conditioning dehydrator to
9 7
radiator crossmember
Air cleaner to body 9 7
Pulse air system air cleaner to bracket 9 7
Torques
Exhaust Nm lbf.ft
Exhaust manifold to catalytic converter 44 32
Studs in cylinder head 14 10
Exhaust manifold to cylinder head 23 17
Torques
Alternator Nm lbf.ft
Alternator to bracket (M8) 25 18
Alternator to bracket (M10) 44 32
Positive lead 23 17
Lead for ignition warning light 11 8
Alternator heat shield 6 4
Torques
Transmission Nm lbf.ft
Ground cable to flange bolt 44 32
Negative lead to transmission 26 19
Starter motor to transmission 35 26
Starter motor to engine 32 24
Engine/transmission flange bolts 40 30
Driveshaft to rear axle extension 38 28
Driveshaft centre bearing to body 19 14
Clutch pressure plate 29 21
Oil drain and oil check plug ‐ manual transmission 45 33
Oil check plug ‐ transfer box 45 33
Gearshift stabiliser bar to transmission 55 41
Shift rod to transmission 23 17
Shift rod clamp bolt to selector shaft 16 12
Torques
Air Conditioning Nm lbf.ft
Air conditioning compressor to bracket 26 19
Air conditioning compressor bracket to cylinder block 47 35
Air conditioning compressor pipes to radiator crossmember and
9 7
bracket
Dehydrator to bracket 9 7
Torques
Coolant circuit Nm lbf.ft
Expansion tank to body 9 7
Radiator crossmember to right‐ and left‐hand body side member 23 17
Cooling fan shroud to radiator 9 7
Coolant pump 23 17
Coolant pipe bracket to cylinder block 9 7
Temperature gauge sender unit 6 4
Thermostat housing 20 15
Coolant temperature switch (CTS) 29 21
Engine coolant temperature sensor (ECT sensor) 12 9
Coolant pump angle connector 14 10
Coolant pump blanking plug 16 12
Coolant outlet blanking cover to cylinder head 20 15
Torques
Steering Nm lbf.ft
Power steering pump to bracket 23 17
Lower power steering pump bracket to cylinder block 25 18
Upper power steering pump bracket to cylinder block 25 18
Upper to lower power steering pump bracket 25 18
Power steering pipe to cylinder block 44 32
Power steering pipe to cylinder head cover/engine lifting eye 9 7
Torques
Engine mounting Nm lbf.ft
Rear right‐hand engine mounting to body 69 51
Rear left‐hand engine mounting to side member 69 51
Front right‐hand engine mounting to cylinder block 69 51
Front right‐hand engine mounting to body 78 58
Engine roll restrictor to body 69 51
Bracket to transmission 44 32
Engine support bracket to engine mounting/axle beam 69 51
Torques
Oil circuit Nm lbf.ft
Oil drain plug 25 18
Oil pressure switch to cylinder block 14 10
Oil filter mounting to cylinder block 37 27
Oil filter to oil filter mounting 15 11
Oil baffle to cylinder block 19 14
Oil pump to cylinder block 10 7
Oil intake pipe to cylinder block 11 8
Oil intake pipe to main bearing bracket 19 14
Sump to cylinder block (studs) 7 5
Sump to cylinder block (nuts) 9 7
Torques
Belt drive Nm lbf.ft
Coolant pump pulley 23 17
Belt pulley to power steering pump 25 18
Vibration damper belt pulley to vibration damper hub 34 25
Belt pulley cover to power steering pump 9 7
Multi‐groove belt cover to body 11 8
Multi‐groove belt idler pulley to bracket 49 36
Torques
Cylinder block Nm lbf.ft
Lower timing chain cover 10 7
Alternator/power steering pump bracket to cylinder block 47 35
Rear oil seal carrier 10 7
Front support bracket to cylinder block 26 19
Timing chain guide, M8 26 19
Positive crankcase ventilation 9 7
Main bearing cap 97 72
Big‐end bearing cap
Stage 1 7 5
Stage 2 16 12
Stage 3 90° 90°
Vibration damper hub to crankshaft
Stage 1 52 38
Stage 2 85° 85°
Flywheel 87 64
Crankshaft position sensor (CKP sensor) 4 3
Oil pump chain tensioning arm 12 9
Oil pump sprocket 18 13
Engine oil dipstick tube 10 7
Torques
Cylinder head Nm lbf.ft
Timing chain guide, upper 12 9
Timing chain guide, lower 26 19
MAP sensor bracket 9 7
Cover to cylinder head cover 5 4
Cylinder head cover
Stage 1 3 2
Stage 2 6 4
Cylinder head
Stage 1 40 30
Stage 2 55 41
Stage 3 90° 90°
Stage 4 90° 90°
Auxiliary cylinder head bolts (x 3) 38 28
Upper timing chain cover to cylinder head 11 8
Lower timing chain cover to cylinder block 10 7
Camshaft bearing cap to cylinder head 24 18
Camshaft sprockets to camshafts 59 44
Engine lifting eyes to cylinder head 25 18
Camshaft bearing studs in cylinder head (x 20) 20 15
Cylinder head cover studs in cylinder head (x 4) 6 4
Oil circuit blanking plugs in cylinder head 52 38
Coolant blanking cover in cylinder head 20 15
Spark plugs 18 13
Ignition coils to cylinder head cover 11 8
Torques
Front axle Nm lbf.ft
Wheel bolts 85 63
Driveshaft nut to wheel hub 235 173
Brake caliper to spindle carrier 58 43
Track rod end to spindle carrier 26 19
Stabiliser link rod to suspension strut 50 37
Lower suspension arm ball joint to spindle carrier 70 52

Description and Operation Escort/Orion 1991 (08/1990-09/2001)

 Print

Description and Operation

The 2,0 DOHC 16V engine in the Escort RS 2000 is largely based on the familiar 2,0 DOHC
engine from the Sierra and Scorpio model ranges.

This powerful drive assembly with an output of 110 kW (150 PS) is also a 2,0 DOHC engine,
but is equipped with 16 valves and an electronic ignition (EI) system.

The 22 KW (30 PS) power increase was achieved primarily by means of the following
technical modifications:

 New light metal cylinder head with 16 valves and new camshafts with revised valve
timings.
 Revised pistons.
 New intake assembly (air plenum chamber and manifold).
 New exhaust manifold (sectional manifold).
 Revised calibration of EEC IV engine management.
 Optimised electronic fuel injection.
 Electronic ignition (EI) system with two separate ignition coils.
Other changes, which do not have a direct effect on the engine power output, have been
made to the following components:

 Two heated oxygen sensors for cylinders nos. 1‐4 and 2‐3
 Power steering pressure switch (PSP switch) for stabilisation at idle speed
  Cylinder block
 Transversely mounted sump
 Cylinder head gasket
 Flywheel
 Lubricant circuit
 Coolant circuit

Electrical connections ‐ engine wiring loom

Item Description
1 EI ignition coils
Engine coolant temperature sensor
2
(ECT sensor)
3 Throttle position sensor (TP sensor)
4 Injectors
Intake air temperature sensor (IAT
5
sensor)
Crankshaft position sensor (CKP
6
sensor)
7 Oil pressure switch
Power steering pressure switch (PSP
8
switch)
Engine management overview

Item Description
1 Powertrain control module (PCM)
2 Fuel pump
3 Inertia switch
4 Fuel pump relay
Manifold absolute pressure sensor
5
(MAP sensor)
6 Fuel filter
7 Idle air control valve (IAC valve)
8 Air cleaner
9 Pressure regulator
10 Fuel rail
11 Throttle position sensor (TP sensor)
Intake air temperature sensor (IAT
12
sensor)
13 EI ignition coil
14 Injector
15 Carbon canister
16 EVAP canister purge valve
17 EI 4 module
Crankshaft position sensor (CKP
18
sensor)
19 Oil pressure switch
20 Heated oxygen sensor 1 (HO2S)
21 Heated oxygen sensor 2 (HO2S)
22 Battery
23 Catalytic converter
24 Power supply relay
25 Ignition switch
Engine coolant temperature sensor
26
(ECT sensor)
27 Diagnostic plug
Wide‐open throttle air conditioning
28
cut‐off
29 Fuel octane adjustment plug
30 Idle adjust plug
Power steering pressure switch (PSP
31
switch)

Pin configuration ‐ fully electronic ignition system

Item Description
1 PIP signal ‐ ICM to PCM
2 Tachometer
3 SAW signal ‐ PCM to ICM
4 Not used
5 CKP (‐)
6 CKP (+)
7 Shield
8 Battery (15)
9 Module to earth
10 EI ignition coil (cylinder nos. 1‐4)
11 Not used
12 EI ignition coil (cylinder nos. 2‐3)

Diagram of vacuum hoses and connections

Item Description
1 Carbon canister
2 EVAP canister purge valve
3 To fuel tank
4 To brake servo
5 Flow restrictor
6 Pulse air solenoid
7 Inlet manifold
8 Pulse air valve (pulse air system)
9 Pressure regulator
10 MAP sensor
Operating principle of the injectors

Item Description
1 Fuel rail
2 Fuel supply
3 Return to fuel tank
4 Fuel pressure regulator
5 Injector
6 Lateral slots for fuel supply
7 Valve chamber, filled with fuel
8 O‐rings
9 Inlet manifold
10 Intermediate flange
11 Cylinder head intake port
12 Inlet valve
The injectors are fitted in a fuel rail and are supplied via a central fuel feed. As a result, the
injectors are constantly immersed in and cooled with fresh fuel. Vapour bubbles which form
after the engine is switched off are flushed with the flow of fuel via the pressure regulator
into the fuel tank when the engine is switched on again. Problems with starting the engine
when warm due to bubble formation are therefore largely eliminated. In addition, the intake
pipe and the fuel rail are separated from the cylinder head by a heat‐insulating plate (see
diagram on next page). This reduces the amount of engine heat which is transferred.

The injectors seal the fuel‐filled valve chamber towards the outside by means of two O‐rings.
Lateral slots on the injector form the fuel supply.

The injectors are actuated in pairs in a parallel process. In other words, cylinders 1 and 4
and cylinders 2 and 3 are in each case regulated together.
Cylinder head ancillary components

Item Description
1 Cover to cylinder head cover
2 Cylinder head cover
3 Upper timing chain cover
4 Heat‐insulating plate
Intermediate flange and fuel rail with
5 integrated injectors and pressure
regulator
6 Inlet manifold gasket
7 Intake pipe with air plenum chamber
8 Exhaust manifold
9 Thermostat housing
10 Engine lifting eye
The cylinder head of the 2,0 DOHC 16V engine has been completely redeveloped and has a
number of special design features.

 The camshaft cams trail eccentrically onto the hydraulic valve tappets, thereby
ensuring that the tappets are constantly rotated.
 The single valve springs have a larger coil diameter in the middle and, as a result,
are virtually free of resonance across the entire engine speed range.
  The arrangement of the inlet and exhaust valves inclined at 20° to the vertical
enables the combustion chamber to have a compact, roof‐shaped design.

Modifications to the crankshaft position sensor (CKP sensor)

Item Description
Position of CKP sensor in 8‐valve
1
engine
Position of CKP sensor in 16‐valve
2
engine
3 Missing tooth
4 Identification notch
Because the engine is mounted transversely, the bore for the crankshaft position sensor
(CKP sensor) and the missing tooth on the toothed wheel have been moved by 15° in the
TDC direction.

The new crankshaft for the 16V engine is now also used in the 8V engine. The attachment
holes for the toothed wheel are therefore the same for both engines. To avoid mixing up the
wheels, the wheel for the 16V engine has a notch next to the missing tooth and is also
marked "16V".

NOTE:
If the wrong toothed wheel is fitted, this can cause serious damage both to the 16V
engine and the 8V engine.
Belt routing with and without air conditioning

Item Description
1 Vibration damper belt pulley
2 Coolant pump
3 Automatic belt tensioner
4 Alternator
5 Power steering pump
6 Idler pulley
7 Air conditioning compressor

Engine ‐ Dismantle and Assemble (engine

Escort/Orion 1991 (08/1990-09/2001)
removed) (21 134 8)
 Print

Removal and Installation

Special Tools

15‐030 A Universal flange

holding wrench

16‐067 Locator, clutch disc

17‐055‐02 Depth gauge,

combustion chamber

21‐031 B Mounting bracket

 21‐036 A Remover, pilot
bearing

21‐044 A Installer/aligner,
pilot bearing/clutch disc

21‐051 Remover, oil seal

21‐094 Installer, oil seal

21‐135 Locking tool, flywheel

21‐141 Installer, oil seal

21‐146 C Mounting plate

21‐153B Remover, vibration

damper

21‐153‐01 Guide bolts and

remover bolts, vibration
damper
21‐202 Socket wrench, spark
plugs

21‐226 Pliers, spark plug

connectors

21‐540 Angle gauge

Proprietary tools
Description
Dial gauge
Micrometer gauge
Magnetic fixture
Piston ring compressor
Steel rule (500 mm)
Feeler gauges
Oil filter strap wrench
Workshop Equipment
Description
Assembly stand
Materials
Description Specification
obtainable from:
Replacement Service
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST.
Welding rod Ø 2,5
mm, length approx.
220 mm
Spark plug lubricant
ESE‐M1244‐A
'Never‐Seeze'
Sealer (Loctite 518) WSK‐M2G348‐A5
Sealer (Hylosil 502) WSK‐M4G320‐A
Adhesive SPM‐2G9123‐A
Refer to General
Engine oil
Specifications
Silicone grease A960‐M1C171‐AA
Dismantle 09‐70">
NOTE:
The position of the engine mounting is
described looking from the transmission
towards the engine.
1. Standard preparatory measures.
   Drain the engine oil.
2. Detach the exhaust manifold and remove the oil
dipstick tube.

3. Mount the engine on an assembly stand.

1. Mounting plate
2. Mounting bracket

Only vehicles with air conditioning. 09‐71">

 4. Detach the bracket and the alternator.
1. Detach the alternator from the bracket at the top.
2. Release the lower alternator bolt.
3. Detach the lower bracket of the power steering
pump/alternator from the cylinder block.

Only vehicles with air conditioning.

5. Detach the upper bracket for the power steering
pump from the cylinder head.

6. Detach the belt pulley and the alternator.

1. Remove the coolant pump belt pulley.
2. Unscrew the upper alternator bolt.
   Swing the alternator down.

7. Detach the bracket and the hoses.

1. Detach the bracket for the alternator/power
steering pump together with the alternator.
2. Disconnect the coolant hose to the heater.
3. Remove the positive crankcase ventilation (PCV)
hose.
4. Detach the coolant pump.
8. Remove the thermostat housing.
1. Disconnect the plug of the throttle position sensor
(TP sensor).
2. Disconnect the plug of the engine coolant
temperature sensor (ECT sensor).
3. Remove the thermostat housing.
4. Detach the bracket for the coolant pipe.

9. Disconnect the plugs.

1. Disconnect the injector plugs (x 4).
2. Disconnect the plug of the intake air temperature
sensor.

10. Detach the air intake pipe.

1. Disconnect the plug from the crankshaft position
sensor (CKP sensor) and detach the CKP sensor.
2. Disconnect the plug of the oil pressure switch and
remove the oil pressure switch.
3. Remove the oil filter.
4. Detach the PCV pipe from the air intake pipe.
NOTE:
One bolt also holds a fuel pipe bracket.

5. Detach the air intake pipe.

CAUTION:
Do not pull on the cable when unplugging the
spark plug connectors. If necessary
disconnect the ignition cables from the
ignition coil to prevent kinking of the cables.
Slightly twist the spark plug connectors
before pulling them off in order to release
the seals.
CAUTION:
Pull off the spark plug connectors in a
straight line with the axis of the spark plug
(use Special Tool 21‐226 for angled spark
plug connectors).
11. Remove the cylinder head cover.
• Detach the cover from the cylinder head cover.
• Disconnect the plugs of the ignition coils and remove
the engine wiring loom.
• Remove the ignition coils and spark plug connectors.
• Remove the spark plugs using special tool 21‐202.
• Disconnect the positive crankcase ventilation.
• Detach the cylinder head cover (11 bolts and 4
nuts).
 12. Detach the front right‐hand engine mounting
from the cylinder block.

Detach the crankshaft pulley/vibration damper.

13. Detach the crankshaft pulley/vibration damper.
   Immobilise the flywheel with locking tool 21‐135.
1. Unscrew the bolts.
2. Unscrew the hub bolt.

14. Detach the crankshaft pulley/vibration damper

(cont.).
   Pull the crankshaft pulley/vibration damper off the
hub using two M6 bolts.

15. Detach the crankshaft pulley/vibration damper

hub.
   Detach the locking tool from the flywheel.

16. Remove the clutch.

 17. Remove the flywheel (six bolts).

18. Detach the upper timing chain cover (seven bolts).

Only vehicles with an aluminium cover. 09‐77">

19. Detach the lower timing chain cover.
• Remove the front oil seal.
• Detach the lower timing chain cover.

Only vehicles with a sheet steel cover.

NOTE:
The sheet steel cover must be renewed for
installation.
20. Detach the lower timing chain cover.

21. Detach the oil pump

sprocket and chain.
1. Remove the chain
tensioner.
2. Remove the sprocket and
chain.
22. Set the camshaft sprockets to the mark.

23. Detach the upper chain guide rail.

NOTE:
Counterhold with the special tool.

24. Detach the camshaft sprockets.

25. Remove the chain tensioning arm.

1. Pull off the circlip with pliers.
2. Draw out the chain tensioner pivot pin with a bolt
(M6).
3. Remove the chain tensioning arm from the
housing.
26. Unscrew the chain guide bolts.

27. Remove the timing chain.

• Remove the crankshaft Woodruff key.
• Remove the crankshaft sprocket.

NOTE:
Renew the chain tensioner hydraulic
plunger.
28. Remove the chain tensioner hydraulic plunger
and the timing chain together with the chain guide.
 NOTE:
Slackening sequence: uniformly from
camshaft cap five to one.
29. Remove the camshafts.
• Detach the bracket of the chain guide rail with the
front bearing caps.
• Remove the hydraulic tappets and put them down
in order.

CAUTION:
The cylinder head must be cooled to room
temperature before the bolts are removed.
CAUTION:
Only reuse cylinder head bolts with
integrated washers (see following step).
NOTE:
First remove the auxiliary bolts (x 3).

NOTE:
Do not put the cylinder head down on its
mating face.
30. Detach the cylinder head.

31. Identification of cylinder head bolts.

1. New cylinder head bolt with integrated washer.
2. Old cylinder head bolt with separate washer.
 32. Detach the oil pump (four bolts).

NOTE:
Remove the oil sump downwards to prevent
oil sludge and abraded particles from
getting into the engine.
33. Detach the sump, oil baffle and oil intake pipe.

34. Detach the front support bracket from the

cylinder block.

35. Detach the crankshaft rear oil seal carrier.

Remove the crankshaft pilot bearing

 36. Remove the crankshaft pilot bearing.

37. Remove the pistons, together with the connecting

rods.
• Detach the big‐end bearing caps.
• Detach the bearing shells from the big‐end bearing
caps and connecting rods and mark them.
• Push out the pistons with the connecting rods.

38. Remove the crankshaft.

• Detach the main bearing caps.
• Remove the crankshaft.
• Take out the bearing shells and thrust half rings and
put them down in order or mark them for reuse.

Assemble
39. Preparations.
NOTE:
No material must be worn away from the
ancillary parts during cleaning.
   All mating faces and reusable parts must be cleaned
thoroughly with a spatula, checked for damage and
renewed if necessary.
CAUTION:
Do not damage the cylinder liner.

40. Remove the carbon around the upper edge of the

cylinder.
Check the cylinder head evenness. 09‐84">
41. Check the cylinder head mating face for distortion.
• Lay the steel rule (at least 500 mm long and 5 mm
wide) laterally across all the combustion chamber
steps and in each case take measurements at three
points.
• Permissible distortion at the combustion chamber
steps: lateral 0,05 mm, longitudinal and diagonal 0,10
mm.
• Lay the steel rule lengthways across the cylinder
head in the area of the combustion chambers at three
points and check the measurements at all the
combustion chamber steps.
 • Lay the steel rule diagonally across the cylinder head
and check the measurements at all the combustion
chamber steps.
• If necessary rework the cylinder head as described in
the next step.
42. Note on reworking the cylinder head.
   Maintain a peak‐to‐valley height (Rz) of 0,0135
micrometers when reworking. The cylinder head must
not be reworked by more than 0,20 mm (milling or
surface grinding). Dimensions ”a" and ”b" must not be
less than 13,80 mm (see next step) and 147,25 mm
respectively.

NOTE:
Remove any carbon deposits from the
measuring area.
43. Position of the measuring point for dimension ”a"
in the combustion chamber.

44. Measure the diameter of the main and big‐end

bearing journals using the micrometer gauge.
• Repeat the measuring operation at intervals of 90°.
• If the measured values do not correspond with
those given in the General Specifications, rework or
renew the crankshaft.

Measure the main bearing clearance

CAUTION:
Do not damage the bearings when laying
the crankshaft in place.
45. Lay the crankshaft in place.
• Lay the grooved bearing shells in the cylinder block.
• Place the crankshaft in the cylinder block unoiled.
 NOTE:
The measuring point must be free of oil.

CAUTION:
Do not turn the crankshaft during the
measuring procedure.
46. Measure the crankshaft main bearing clearance.
• Lay a length of Plastigage thread across the bearing
on the bearing journal.
• Attach the bearing caps (see next step).

NOTE:
Measure the bearing clearances in turn in
numerical order (one to five).
47. Measure the crankshaft main bearing clearance
(continued).
NOTE:
The bearing cap numbering starts at the
timing chain end.
• Fit the bearing cap with its associated bearing shell
with the arrow pointing towards the timing chain end,
and tighten it.
• Detach the bearing cap.
48. Measure the crankshaft main bearing clearance
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
• If the specified bearing clearance of 0,011 ‐ 0,048
mm is not obtained, change the bearing shells and
repeat the measurement from the previous step
onwards.
• If the specified bearing clearance is still not obtained,
then the next size up bearing shells can be fitted on
standard cylinder blocks and crankshafts up to 0,02
mm undersize, provided the bearing clearance was not
greater than 0,098 mm.
49. Install the crankshaft.
• Lubricate the main bearing journals and bearing
shells, the threads and contact faces of all the bolts
with engine oil.
• Install the crankshaft.
• Install the thrust washers with the copper‐coloured
side facing the crankshaft.
• Coat the contact faces and the sides of the rear
bearing cap with sealer.
NOTE:
The bearing cap numbering starts at the
timing chain end, to which the arrows also
point.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
NOTE:
Fit the bolts with the stud extension at
bearings 3 and 5.
• Tighten the bolts.
50. Check the crankshaft end float.
• Set up the dial gauge.
• Measure the end float by lifting the crankshaft with a
screwdriver.
• If necessary, correct the end float with thrust half
rings at main bearing no. 3.

NOTE:
The piston ring must be positioned in the
upper part of the cylinder.
51. Check the piston ring gaps.
   The values given in the General Specifications are
based on a gauge ring used in production. Measured
in the cylinder, these values may be exceeded by
0,15 mm.

CAUTION:
The upper piston rings are coated with
molybdenum. This coating must not be
damaged.
52. Arrangement of the piston rings.
   The maximum width to which the piston rings may
be expanded is equal to the cylinder diameter + 1,7
mm.

53. Install the pistons, together with the connecting

rods.
• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil control ring.
NOTE:
The numbering on the connecting rods starts
at the timing chain end. The arrow on the
piston crown points towards the timing chain.
• Compress the piston rings using a piston ring
compressor.
• Press piston nos. 1 and 4 into the cylinders using the
handle of a hammer. The crank pin must be at BDC.
• Lubricate the bearing shells with engine oil.
• Lay the associated bearing shells in their connecting
rods and bearing caps.
• Fit the bearing caps.
• Turn the crankshaft through 180° and install piston
nos. 2 and 3.
54. Measure the big end bearing clearances.
   Measure the big end bearing clearance as described
in the previous steps.
 55. Attach the bearing caps.
• Lubricate the bearing shells and bearing journals
with engine oil.
NOTE:
The numbers on the connecting rods and
big‐end bearing caps must correspond.
• Fit the appropriate big‐end bearing caps and
bearing shells and tighten the bolts.

Install the crankshaft pilot bearing

56. Install the crankshaft pilot bearing.

57. Remove the crankshaft rear oil seal from the oil
seal carrier.

Align the rear oil seal carrier

58. Align the rear oil seal carrier
   Fit the oil seal carrier with a new gasket and screw
in the bolts.
1. The mating face of the oil seal carrier must be
below the mating face of the cylinder block. The
height difference must not be more than 0,46 mm.
2. Tighten the bolts.
 CAUTION:
The oil seal must be inserted in the tool as
far as it will go.
59. Insert the oil seal in the special tool with the
guide sleeve.
   Place the special tool in a vice and press the oil seal
in with the handle of a hammer.
1. Incorrect way.
2. Correct way.

60. Attach the oil seal carrier.

61. Install the crankshaft rear oil seal.
   Draw in the oil seal with two flywheel bolts.

NOTE:
Sealer (WSK‐M2G348‐A5) must protrude
sufficiently at the front and side after the
front support bracket has been fitted.
62. Fit the front support bracket to the cylinder block.
NOTE:
Do not remove the excess sealer before
fitting the sump.
• Apply four beads of sealer 3‐5 mm in diameter and
10 mm in length.

63. Apply sealer (WSK‐M4G320‐A) to the flywheel

side of the cylinder block.
NOTE:
The bead of sealer must cover the mating
face intersections.
• Apply a bead of sealer 3‐5 mm thick and 10 mm
wide on both sides.

Align the sump.

64. Align the sump.
• Align the sump so that it is offset by no more than
0,25 mm inwards or 0,1 mm outwards.
• Measure the height difference with a steel straight
edge and feeler gauges. Make a note of the
measurement.
• When installing the engine, eliminate the difference
using spacer plates (refer to General Specifications).

CAUTION:
Before fitting the new oil pump, fill it with oil
and turn it manually.
NOTE:
In the event of wear install a complete new
oil pump.
NOTE:
The dots must face outwards.

65. Dismantle and clean the oil pump.

66. Assemble the oil pump.
NOTE:
The oil pump passages must not be covered
by the gasket.
67. Fit the oil pump using a new gasket.

68. Set the piston of no. 1 cylinder to 25 mm before

TDC.
 69. Fit the cylinder head.
1. Insert the guide bushes.
2. Fit the cylinder head gasket.
3. Fit the cylinder head.

CAUTION:
Do not reuse old style cylinder head bolts
with separate washers.
70. Only reuse new bolts with integrated washers if
the dimension of 174,3 mm is not exceeded and the
cylinder head bolts show no signs of damage.
1. New cylinder head bolts
2. Old cylinder head bolts

CAUTION:
Renew the bolts.

NOTE:
Tightening order.

71. Tighten the cylinder head bolts.

 CAUTION:
The cylinder head bolts must not be
retorqued.
72. Tighten the cylinder head bolts (continued).

73. Tighten the cylinder head auxiliary bolts.

74. Tightening sequence for camshaft bearing caps.

CAUTION:
When installing the camshafts the piston of
no. 1 cylinder must be approx. 25 mm
before TDC.
75. Install the camshafts.
CAUTION:
After the camshafts are installed, wait 15
minutes before cranking the engine.
• Oil the bearings.
1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side and L is the exhaust side.

3. Fit the camshaft bearing caps so that the position

marks can be seen from behind.
• Fit the chain guide bracket with the front bearing
caps.
 76. Set the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released chain tensioner
hydraulic plungers (new or used) must not
be installed.
77. Check the new chain tensioner hydraulic plunger.
1. Chain tensioner hydraulic plunger latched.
2. Chain tensioner hydraulic plunger partially
released.
3. Chain tensioner hydraulic plunger fully released
(the detent ring is visible).

CAUTION:
Only use a new, latched chain tensioner
hydraulic plunger.
78. Install the chain tensioner hydraulic plunger.
79. Insert the timing chain with the chain guide.
   Do not tighten the chain guide yet.

Fit the timing chain

80. Fit the timing chain at the bottom.
• Slide the sprocket on approx. 10 mm.
• Lay the timing chain over the inner chain wheel.
• Insert the crankshaft Woodruff key.
81. Tighten the chain guide
bolts.

82. Install the chain tensioner.

1. Locate the chain tensioner in the installation
position.
2. Insert the pivot pin.
3. Fit the circlip.

NOTE:
The timing chain must be taut on the long
side. If necessary, turn the camshaft
slightly.
83. Fit the timing chain at the top.

NOTE:
The timing chain may hang down slightly
between the camshaft sprockets.
84. Fit the timing chain at the top (continued)
   Screw in the bolts of the camshaft sprockets (do
not tighten the bolts).
 85. Attach the new upper chain guide rail to the
bracket.

86. Release the chain tensioner tappet.

• Press down the chain tensioning arm manually and
release the tappet.
• If the chain tensioner mounting does not reach the
tappet, the tappet must be relaxed using an auxiliary
tool.

87. Make the auxiliary tool.

   Use a piece of 2,5 mm welding rod approx. 220 mm
in length.

NOTE:
Counterhold with the special tool.

88. Tighten the bolts on the camshaft sprockets.

89. Check the valve timings.

• Crank the engine in the normal direction of rotation
and set it to the mark.
• If it is necessary to correct the valve timings, i.e.
the chain tensioner has to be released, a new chain
tensioner hydraulic plunger must be fitted.
 90. Check the valve timings (continued).
• Crank the engine in the normal direction of rotation
to the next TDC.
• The marks on the camshaft sprockets must line up
level with the top edge of the cylinder head.

91. Install the oil pump drive.

1. Lay the timing chain over the crankshaft drive
pinion.
2. Fit the oil pump sprocket with the timing chain to
the oil pump.
3. Install the chain tensioner.

Only vehicles with an aluminium cover.

92. Install the front oil seal.
• Fit the lower timing chain cover with the centring
cap.
• Install the front oil seal.

Only vehicles with a sheet steel cover.

93. Attach the lower timing chain cover at the
bottom.
NOTE:
Fit the cover with a new gasket and new oil
seal.
• Fit the new lower timing chain cover with the
centring cap.
• Tighten the bolts.
• Remove the centring cap.

94. Attach the upper timing

belt cover.
 CAUTION:
Renew the bolts.

NOTE:
There is only one installation position.

95. Fit the flywheel (6 bolts).

Centralise the clutch disc.

96. Centre the clutch disc on the pressure plate.

97. Fit the clutch.

1. Locate the clutch pressure plate, with
the centred clutch disc in position for
installation.
2. Tighten the bolts (x 6) uniformly,
working diagonally.
3. Remove the special tool.

98. Attach the crankshaft pulley/vibration damper

hub.
   Immobilise the flywheel using locking tool 21‐135.
99. Attach the crankshaft pulley/vibration damper.
1. Screw the bolt into the crankshaft pulley/vibration
damper hub.
2. Screw the bolts into the crankshaft pulley/vibration
damper.
   Detach locking tool 21‐135.

100. Attach the front right‐hand engine mounting to

the cylinder block.
 NOTE:
Tightening order.

101. Install the cylinder head cover.

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) to avoid
damaging the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line with the axis of the spark plug.
NOTE:
Coat the inside of the spark plug connectors
to a depth of 5‐10 mm with silicone grease
(A960‐M1C171‐AA).
NOTE:
Apply lubricant 'Never Seeze' (ESE‐M1244‐A)
to the spark plug thread.
102. Fit the cover to the cylinder head cover.
• Connect the PCV.
• Install the spark plugs using special tool 21‐202.
• Install the ignition coils and spark plug connectors.
• Lay the engine wiring loom in the cylinder head
cover and connect the ignition coil plugs.
• Attach the cover to the cylinder head cover.

103. Fit the air intake pipe.

NOTE:
One bolt also holds a fuel pipe bracket.

1. Fit the CKP sensor and connect the plug.

2. Connect the PCV pipe to the intake pipe.
3. Fit the oil filter.
4. Install the oil pressure switch and connect the oil
pressure switch plug.
5. Fit the air intake pipe.

104. Connect the injector plugs and the IAT sensor

plug.
1. Injector plugs
2. IAT sensor plug
 105. Fit the thermostat housing.
1. Connect the TP sensor plug.
2. Connect the ECT sensor plug.
3. Fit the thermostat housing.
4. Attach the coolant pipe bracket.

106. Attach the bracket and hoses.

1. Fit the coolant pump.
2. Install the PCV valve.
3. Attach the coolant hose for the heater.
4. Attach the alternator/power steering pump
bracket.

107. Attach the alternator to the bracket and fit the

belt pulley.
1. Screw in the upper alternator bolt.
2. Install the coolant pump belt pulley.

Only vehicles with air conditioning. 09‐108">

108. Attach the power steering pump bracket to the
cylinder block.

Only vehicles with air conditioning.

 109. Attach the alternator and bracket.
1. Attach the alternator to the bracket at the top.
2. Attach the alternator to the bracket at the bottom.
3. Attach the power steering pump bracket.

Fit the dipstick tube.

110. Prepare the oil dipstick tube for installation.
• Remove residues of oil and grease from the contact
face of the oil dipstick tube.
• Apply adhesive SP‐M2G‐9123‐A to the contact face.

111. Install the oil dipstick tube and attach the

exhaust manifold.

Cylinder Head ‐ Remove And Install (21

Escort/Orion 1991 (08/1990-09/2001)
163 0)
 Print

Removal and Installation

Special Tools

15‐030 A Universal flange

holding wrench
 17‐055‐02 Depth gauge,
combustion chamber height

21‐202 Socket wrench, spark

plugs

21‐226 Pliers, spark plug

connectors

21‐540 Angle gauge

Workshop Equipment
Description
Steel rule (500 mm)
Materials
Description Specification
Welding rod Ø 2,5
mm, length approx.
220 mm
Spark plug lubricant
ESE‐M1244‐A
`Never‐Seeze'
Refer to General
Engine oil
Specifications
Super Plus 4 coolant
ESD‐M97B49‐A
(blue/green)
Super Plus 2000
WSS‐M97B44‐D
coolant (orange)
Cable ties
Silicone grease A960‐M1C171‐AA
Remove
1. Standard preparatory measures.
WARNING:
Before opening the cooling system on a hot
engine, cover the cap of the coolant
expansion tank with a thick cloth to prevent
the risk of scalding.
• Open the coolant expansion tank.
• Drain off the coolant at the radiator drain plug and
refit and tighten the plug.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
CAUTION:
Disconnect the battery negative lead.

• Cut the cable ties where necessary and renew them

on installation.
• Lay protective coverings on the fenders.
2. Remove the air cleaner.
1. Remove the intake hose.
2. Disconnect the plug of the idle air control valve
(IAC valve).
3. Unscrew the nut.

3. Detach the intake pipe from the lock panel.

4. Remove the air cleaner (continued).

1. Detach the positive crankcase ventilation (PCV)
hose.
2. Disconnect the air hose from the IAC valve.
3. Detach the accelerator cable.
4. Lift out the air cleaner.

5. Disconnect the plugs and the vacuum hose.

1. Disconnect the plug of the coolant temperature
switch (ECT switch).
2. Disconnect the plug of the engine coolant
temperature sensor (ECT sensor).
3. Disconnect the vacuum hose from the throttle
body.

WARNING:
Fuel will escape. Observe the Safety
Regulations for handling fuel.
6. Disconnect the plugs, detach the fuel pipe and
disconnect the vacuum hoses.
1. Detach and disconnect the engine wiring loom
plugs (x 2).
2. Detach the fuel feed pipe.
3. Disconnect the vacuum hose of the pulse air
system.
4. Disconnect the vacuum hose of the manifold
absolute pressure sensor (MAP sensor).
5. Disconnect the vacuum pipe for the brake servo.
 WARNING:
Fuel will escape. Observe the Safety
Regulations for handling fuel.
7. Disconnect the fuel return pipe and detach the fuel
pipes from the intake pipe.

8. Detach the coolant hoses at the thermostat

housing.
1. From the radiator.
2. From the vent.
3. From the heater.

Only vehicles with air conditioning.

9. Detach the upper bracket of the power steering
pump.

Only vehicles with air conditioning.

10. Detach the power steering pipe.

Only vehicles with air conditioning.

11. Detach the bracket of the power steering pipe.
12. Detach the power steering reservoir.
1. Detach the upper hose from the power steering
reservoir.
2. Detach the upper hose from the coolant expansion
tank.
3. Lift out the power steering reservoir and place to
one side.
4. Detach the ground cable from the engine lifting
eye.

13. Remove the coolant expansion tank.

1. Detach the lower coolant hose from the expansion
tank.
2. Detach the bracket for the MAP sensor.
3. Remove the expansion tank.
   Raise the vehicle.

14. Detach the PCV pipe and disconnect the plug.

1. Detach the PCV pipe.
2. Disconnect the plug of the crankshaft position
sensor (CKP sensor).
3. Disconnect the oil pressure switch plug.

15. Detach the exhaust manifold from the catalytic

converter.

NOTE:
The exhaust manifold cannot be removed.

16. Detach the exhaust manifold from the cylinder

head.
   Pull the exhaust manifold off the studs and lay it to
one side.
 CAUTION:
Do not pull on the cable when unplugging the
spark plug connectors. If necessary
disconnect the ignition cables from the
ignition coil to prevent kinking of the cables.
Slightly twist the spark plug connectors
before pulling them off in order to release
the seals.
CAUTION:
Pull off the spark plug connectors in a
straight line with the axis of the spark plug
(use Special Tool 21‐226 for angled spark
plug connectors).
17. Detach the cylinder head cover.
• Detach the cover from the cylinder head cover.
• Disconnect the plugs of the ignition coils and remove
the engine wiring loom.
• Remove the ignition coils and the spark plug
connectors.
• Remove the spark plugs using special tool 21‐202.
• Disconnect the positive crankcase ventilation.
• Detach the cylinder head cover (11 bolts and 4
nuts).

18. Detach the upper timing chain cover (7 bolts).

19. Turn the camshaft sprockets to the mark.

20. Detach the camshaft sprockets.

21. Remove the chain tensioning arm.
1. Pull off the circlip with pliers.
2. Draw out the chain tensioner pivot pin using a bolt
(M6).
3. Remove the chain tensioning arm from the
housing.

22. Detach the upper chain guide.

NOTE:
Bolt slackening sequence: uniformly from
camshaft cap five to one.
23. Remove the camshafts.
• Detach the chain guide bracket with the front
bearing caps.
• Remove the hydraulic tappets and put them down
in order.
 CAUTION:
The cylinder head must be cooled to room
temperature before the bolts are removed.
CAUTION:
Only reuse cylinder head bolts with
integrated washers (see following step).
NOTE:
Remove the auxiliary bolts first (x 3).

NOTE:
Do not put the cylinder head down on its
mating face.
24. Detach the cylinder head.
   Renew the cylinder head bolts.

25. Identification of cylinder head bolts.

1. New cylinder head bolt with integrated washer.
2. Old cylinder head bolt with separate washer.

Install
CAUTION:
Do not damage the cylinder liner.

26. Remove the carbon around the upper edge of the

cylinder.
NOTE:
No material must be worn away during
cleaning.
27. Clean the mating faces with a spatula.
Check the cylinder head evenness.
28. Check the cylinder head mating face for distortion.
• Lay the steel rule (at least 500 mm long and 5 mm
wide) laterally across all the combustion chamber
steps and in each case take measurements at three
points.
• Permissible distortion at the combustion chamber
steps: lateral 0,05 mm, longitudinal and diagonal 0,10
mm.
• Lay the steel rule lengthways across the cylinder
head in the area of the combustion chambers at three
points and check the measurements at all the
combustion chamber steps.
• Lay the steel rule diagonally across the cylinder head
and check the measurements at all the combustion
chamber steps.
• If necessary rework the cylinder head as described in
the next step.
29. Note on reworking the cylinder head.
   Maintain a peak‐to‐valley height (Rz) of 0,0135
micrometers when reworking. The cylinder head must
not be reworked by more than 0,20 mm (milling or
surface grinding). Dimensions ”a" and ”b" must not be
less than 13,80 mm (see next step) and 147,25 mm
respectively.

NOTE:
Remove any carbon deposits from the
measuring point.
30. Location of the measuring point for dimension 'a'
in the combustion chamber.

31. Set the piston of cylinder no. 1 to 25 mm before

TDC.

32. Fit the cylinder head.

1. Fit the guide bushes.
2. Fit the cylinder head gasket.
3. Fit the cylinder head.
 CAUTION:
Do not reuse old style cylinder head bolts
with separate washers.
33. Only reuse new bolts with integrated washers if
the dimension of 174,3 mm is not exceeded and the
cylinder head bolts show no signs of damage.
1. New cylinder head bolts
2. Old cylinder head bolts

NOTE:
Tightening order.

34. Tighten the cylinder head bolts.

CAUTION:
The cylinder head bolts must not be
retorqued.
35. Tighten the cylinder head bolts (continued).

36. Tighten the cylinder head auxiliary bolts.

 37. Tightening sequence for camshaft bearing caps.

38. Install the camshafts.

CAUTION:
When installing the camshafts, the piston of
cylinder no. 1 must be approx. 25 mm
before TDC.
CAUTION:
After the camshafts are installed, wait 15
minutes before cranking the engine.
• Oil the bearings.
1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side and L is the exhaust side.

NOTE:
Follow the tightening sequence from the
previous step.
3. Fit the camshaft bearing caps so that the position
marks can be seen from behind.
• Fit the chain guide bracket with the front bearing
caps.

39. Turn the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released chain tensioner
hydraulic plungers (new or used) must not
be fitted.
40. Check the new chain tensioner hydraulic plunger.
1. Chain tensioner hydraulic plunger latched.
2. Chain tensioner hydraulic plunger partially
released.
3. Chain tensioner hydraulic plunger fully released
(the detent ring is visible).
 CAUTION:
Only use a new, latched chain tensioner
hydraulic plunger.
41. Install the chain tensioner hydraulic plunger.
42. Fit the timing chain with the chain guide.
   Do not tighten the chain guide yet.

43. Attach the upper timing chain guide.

44. Install the chain tensioner.

1. Fit the chain tensioner.
2. Fit the pivot pin.
3. Fit the circlip.

NOTE:
The timing chain must be taut on the long
side. If necessary, turn the camshaft
slightly.
45. Fit the timing chain at the top.

NOTE:
The timing chain may hang down slightly
between the camshaft sprockets.
46. Fit the timing chain at the top (continued).
   Screw in the bolts of the camshaft sprockets (do
not tighten the bolts).
 47. Attach the new upper chain guide rail to the
bracket.

48. Release the tappet of the chain tensioner.

• Press down the chain tensioning arm manually and
release the tappet.
• If the chain tensioner mounting does not reach the
tappet, the tappet must be relaxed using an auxiliary
tool.

49. Make the auxiliary tool.

   Use a piece of 2,5 mm welding rod approx. 220 mm
in length.

NOTE:
Counterhold with the special tool.

50. Tighten the camshaft sprockets.

51. Check the valve timings.

• Crank the engine in the normal direction of rotation
and set it to the mark.
• When the timing chain is released again, renew the
chain tensioner hydraulic plunger.
 52. Check the valve timings (continued).
• Turn the engine in the normal direction of rotation
to the next TDC.
• The marks on the camshaft sprockets must line up
level with the top edge of the cylinder head.

53. Attach the upper timing chain cover.

NOTE:
Tighten the bolts in the specified order.

54. Install the cylinder head cover.

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) to avoid
damaging the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line with the axis of the spark plug.
NOTE:
Coat the inside of the spark plug connectors
to a depth of 5‐10 mm with silicone grease
(A960‐M1C171‐AA).
NOTE:
Apply lubricant `Never Seeze' (ESE‐M1244‐
A) to the spark plug thread.
55. Fit the cover to the cylinder head cover.
• Connect the positive crankcase ventilation.
• Install the spark plugs using special tool 21‐202.
• Install the ignition coils and spark plug connectors.
• Lay the engine wiring loom in the cylinder head
cover and connect the ignition coil plugs.
• Attach the cover to the cylinder head cover.
 56. Attach the exhaust manifold to the cylinder head.

57. Attach the exhaust manifold to the catalytic

converter.

58. Attach the PCV pipe and connect the plugs.

1. Attach the PCV pipe.
2. Connect the plug to the CKP sensor.
3. Connect the plug to the oil pressure switch.

59. Install the coolant expansion tank.

1. Install the expansion tank.
2. Attach the bracket of the MAP sensor.
3. Connect the lower coolant hose to the expansion
tank.

Only vehicles with air conditioning. 09‐129">

60. Attach the bracket for the power steering pipe.

Only vehicles with air conditioning.

 61. Connect the power steering pipe.

Only vehicles with air conditioning.

62. Attach the upper bracket for the power steering
pump.

63. Fit the power steering reservoir.

1. Attach the ground cable to the engine lifting eye.
2. Slide the power steering reservoir onto the coolant
expansion tank.
3. Connect the upper coolant hose to the coolant
expansion tank.
4. Connect the upper hydraulic hose to the power
steering reservoir.

64. Connect the coolant hoses at the thermostat

housing.
1. To the radiator.
2. To the vent.
3. To the heater.

65. Connect the plugs, attach the fuel pipe and

connect the vacuum hoses.
1. Connect the vacuum pipe for the brake servo.
2. Connect the vacuum hose of the pulse air system.
3. Connect the vacuum hose to the MAP sensor.
4. Connect the fuel feed pipe.
5. Connect the plugs of the engine wiring loom and
attach them to the body (x 2).
 66. Connect the fuel return pipe and attach the fuel
pipes to the intake pipe.

67. Connect the plugs and the vacuum hose.

1. Connect the plug to the CTS.
2. Connect the ECT sensor plug.
3. Connect the vacuum hose to the throttle body.

68. Install the air cleaner.

1. Insert the air cleaner.
2. Connect the throttle cable.
3. Connect the air hose to the IAC valve.
4. Connect the air hose for the PCV.

69. Attach the intake pipe to the lock panel.

70. Install the air cleaner (continued).

1. Screw on the nut.
2. Connect the plug to the IAC valve.
3. Fit the intake hose.

71. Standard finishing operations.

• Change the engine oil.
 CAUTION:
Do not mix Super Plus 4 coolant (blue/green)
and Super Plus 2000 coolant (orange).
• Fill up with coolant and close the coolant expansion
tank.
• Connect the battery negative lead.
• Check the fluid levels and rectify as necessary.
• Check the routing of vacuum hoses and wiring and
secure with cable ties.
• Remove the protective coverings.
• Enter the radio keycode.
• Adjust the clock.
• Reprogram the radio stations.
• Carry out a road test to enable the PCM to collect
data.

Valve Seat ‐ Cut (One) (Valve(s)

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 231 9)
 Print

Removal and Installation

Proprietary Tools
Valve seat cutter (fixed in the valve guide)
30°, 45° and 70° cutters
Rework
1. Location of the angle on the valve seat.
1. Upper correction angle (70°).
2. Valve seat angle (45°).
3. Lower correction angle (30°).
4. Valve seat width.

NOTE:
Only use tools which can be firmly fixed in
the valve guide.
NOTE:
The procedure is shown using a proprietary
tool. Follow the tool manufacturer's
instructions.
2. Insert a locating pin in the valve guide and tighten
it.
3. Attach the turning handle to the valve seat cutter.

NOTE:
Avoid making chatter marks.

NOTE:
Do not cut away more than 0,1 mm of
material, otherwise the cylinder head must
be renewed.
4. Cutting process.
• Attach the 45° cutter with the turning handle to the
guide pin and turn it smoothly in the clockwise
direction, applying light pressure of approx. 2 kg.
• Repeat this process until an even seat face is
 obtained.
5. Check the valve seat width and check for good valve
contact.
• Make four evenly spaced pencil lines on the valve
seat ring.
• Insert the valves and turn them through 90°.
• The valve seat width, the area of contact of the valve
seat face on the valve, and the evenness of the contact
face can be determined according to how the pencil
lines have blurred.
• If necessary, repeat the cutting process.
6. Correct the position and width of the valve seat
face.
NOTE:
The seat face of the valve should rest
centrally on the seat face of the valve seat
ring.
• The seat width and the position of the contact
surface can be changed by reworking the correction
angle (see previous step).
• If the lower correction angle (30°), is recut, the
valve seat face is narrowed and displaced in the
direction of the valve stem.
• If the upper correction angle (70°) is recut, the
valve seat face is narrowed and displaced in the
direction of the valve head.

Valve Guide ‐ Ream (One) (Valve

Escort/Orion 1991 (08/1990-09/2001)
Removed) (21 233 4)
 Print

Removal and Installation

Special Tools

21‐212 Mounting plate

Proprietary Tools
Adjustable reamer, diameter 7 ‐ 7,5 mm
Workshop Equipment
Dial indicator gauge
with magnetic fixture
Rework
1. Fit mounting plate 21‐212 and the dial indicator
gauge.
2. Insert a 7 mm drill bit between the valve seat ring
and the valve head.
3. Check the valve stem/valve guide clearance.
• Permitted valve stem/valve guide clearance
measured at the valve head: Inlet 0,06 ‐ 0,21 mm,
Exhaust 0,12 ‐ 0,29 mm.
NOTE:
The dial indicator gauge must be at 90° to
the valve stem.
• Position the plunger of the dial indicator gauge on
the edge of the valve head.
• Measure the valve stem clearance by moving the
valve sideways back and forth.
• If necessary install a new valve and/or rework the
 valve guide as described in the next step.
4. Detach the dial indicator gauge and the mounting
plate and remove the drill bit.
CAUTION:
After reaming the valve guide, recut the
valve seat ring as described in Operation
No. 21 231 9 and renew the valve.
NOTE:
Use drilling oil for lubrication.

5. Ream the valve guide.

NOTE:
The specified clearance must be achieved to
prevent the valve from sticking.
• Ream the valve guide to the appropriate oversize in
several stages using the adjustable reamer (see
General Specifications).

Camshaft ‐ Remove and Install (21 283

Escort/Orion 1991 (08/1990-09/2001)
0)
 Print

Removal and Installation

Special Tools
Description

15‐030 A Universal flange

holding wrench

21‐202 Socket wrench, spark

plugs

21‐226 Pliers, spark plug

connectors

Materials
Spark plug lubricant
ESE‐M1244‐A
`Never‐Seeze'
Super Plus 4 coolant
ESD‐M97B49‐A
(blue/green)
Coolant Super Plus
WSS‐M97B44‐D
2000 (orange)
Refer to General
Engine oil
Specifications
Cable ties
Silicone grease A960‐M1C171‐AA
Remove
1. Standard preparatory measures.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
CAUTION:
Disconnect the battery negative lead.

• Cut the cable ties where necessary and renew them

on installation.
 • Lay protective coverings on the fenders.
• Open the coolant expansion tank.
• Raise the vehicle.
• Drain off the coolant via the radiator drain plug and
refit the drain plug.
• Lower the vehicle.
Only vehicles with air conditioning.
2. Detach the power steering pipe.

3. Detach the power steering reservoir.

1. Disconnect the upper hydraulic hose from the
power steering reservoir.
2. Disconnect the coolant hose from the coolant
expansion tank.
3. Lift out the power steering reservoir and place to
one side.
4. Detach the ground cable.

4. Remove the coolant expansion tank.

1. Detach the lower coolant hose from the expansion
tank.
2. Detach the bracket for the manifold absolute
pressure sensor (MAP sensor).
3. Detach the expansion tank.
   Remove the expansion tank.
 CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plugs slightly before removing them in order
to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 to remove angled
spark plug connectors).
5. Remove the cylinder head cover.
• Detach the cover from the cylinder head cover.
• Disconnect the plugs from the ignition coils and
remove the engine wiring loom.
• Remove the ignition coils and the spark plug
connectors.
• Remove the spark plugs using special tool 21‐202.
• Disconnect the positive crankcase ventilation.
• Detach the cylinder head cover (11 bolts and 4
nuts).

6. Detach the upper timing chain cover (7 bolts).

7. Set the camshaft sprockets to the mark.

1. Position ‐ camshaft sprockets
2. Timing Chain
3. Position ‐ crankshaft

NOTE:
The chain guide must be renewed on
installation.
8. Detach the chain guide rail.
 NOTE:
Counterhold with the special tool.

9. Detach the camshaft sprockets.

10. Remove the chain tensioning arm.

1. Pull off the circlip using pliers.
2. Pull out the chain tensioner pivot pin using a bolt
(M6).
3. Remove the chain tensioning arm from the
housing.

11. Unscrew the upper bolt of the chain guide.

 12. Remove the camshafts.
   Detach the bracket for the chain guide rail with
the front bearing caps.

Install
13. Tightening sequence for camshaft bearing caps.
 14. Install the camshafts.
CAUTION:
Before installing the camshafts, the piston
of cylinder no. 1 must be set to approx. 25
mm before TDC.
CAUTION:
After the camshafts have been installed,
wait 15 minutes before cranking the engine.
• Oil the bearings.
1. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side and L is the exhaust side.

NOTE:
Follow the tightening sequence from the
previous step.
2. Fit the camshaft bearing caps so that the position
marks can be seen from behind.
• Attach the chain guide bracket with the front
bearing caps.

15. Turn the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released chain tensioner
hydraulic plungers (new or used) must not
be installed.
16. Check the new chain tensioner hydraulic plunger.
1. Chain tensioner hydraulic plunger latched.
2. Chain tensioner hydraulic plunger partially
released.
3. Chain tensioner hydraulic plunger fully released
(the detent ring is visible).

CAUTION:
Only use a new, latched chain tensioner
hydraulic plunger.
17. Install the chain tensioner hydraulic plunger.
NOTE:
Do not tighten the chain guide.

18. Fit the timing chain with the chain guide.

19. Screw in the upper chain guide bolt.

20. Install the chain tensioner.

1. Fit the chain tensioner.
2. Fit the pivot pin.
3. Fit the circlip.

NOTE:
The timing chain must be taut on the long
side. If necessary, turn the camshaft
slightly.
21. Fit the timing chain at the top.

NOTE:
The timing chain may hang down slightly
between the camshaft sprockets.
22. Fit the timing chain at the top (continued).
   Screw in the bolts of the camshaft sprockets (do
not tighten the bolts).

23. Attach the new chain guide rail to the bracket.

 24. Relax the tappet of the chain tensioner.
NOTE:
If the chain tensioner mounting does not
reach the tappet, the tappet must be
relaxed using an auxiliary tool.
   Press down the chain tensioning arm manually and
release the tappet.

25. Make the auxiliary tool.

   Use a piece of 2,5 mm welding rod approx. 220 mm
in length.

NOTE:
Counterhold with the special tool.

26. Tighten the camshaft sprockets.

NOTE:
If it is necessary to correct the valve
timings, i.e. the timing chain has to be
released, a new chain tensioner hydraulic
plunger must be fitted.
27. Check the valve timings.
   Crank the engine in the normal direction of rotation
and set it to the mark.

NOTE:
The marks on the camshaft sprockets must
line up level with the top edge of the
cylinder head.
28. Check the valve timings (continued).
   Turn the engine in the normal direction of rotation
to the next TDC.
 29. Attach the upper timing chain cover (7 bolts).

NOTE:
Tighten the bolts in the specified order.

30. Install the cylinder head cover.

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) to avoid
damaging the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line with the axis of the spark plug.
NOTE:
Coat the inside of the spark plug connectors
to a depth of 5‐10 mm with silicone grease
(A960‐M1C171‐AA).
NOTE:
Apply lubricant 'Never Seeze' (ESE‐M1244‐A)
to the spark plug thread.
31. Fit the cover to the cylinder head cover.
• Connect the positive crankcase ventilation.
• Install the spark plugs using special tool 21‐202.
• Install the ignition coils and spark plug connectors.
• Lay the engine wiring loom in the cylinder head
cover and connect the ignition coil plugs.
• Attach the cover to the cylinder head cover.

32. Install the coolant expansion tank.

1. Attach the expansion tank.
2. Attach the bracket of the MAP sensor.
3. Attach the lower coolant hose to the coolant
expansion tank.

Only vehicles with air conditioning. 09‐154">

 33. Attach the power steering pipes.

34. Fit the power steering reservoir.

1. Attach the ground cable.
2. Slide the power steering reservoir onto the coolant
expansion tank.
3. Attach the coolant hose to the coolant expansion
tank.
4. Connect the upper hose to the power steering
reservoir.

35. Standard finishing operations.

CAUTION:
Do not mix Super Plus 4 coolant (blue/green)
and Super Plus 2000 coolant (orange).
• Top up the coolant.
• Connect the battery negative lead.
• Check the fluid levels and rectify as necessary.
• Check the routing of vacuum hoses and wiring and
secure with cable ties.
• Remove the protective coverings.
• Enter the radio keycode.
• Reprogram the radio stations.
• Adjust the clock.
• Carry out a road test to enable the PCM to collect
data.