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Ford Zetec Engine Repair Manual

Ford Zetec engine - in-car engine repair procedures. This Part of Chapter 2 is devoted to repair procedures possible while the engine is still installed in the vehicle, and includes only the Specifications relevant to those procedures. Similar information concerning the 1.3 litre HCS engine, and the 1.4 and 1.6 litre CVH engines, will be found in Parts A and B of this Chapter respectively. Since these procedures are based on the assumption that the engine is installed in the vehicle, if the engine has been removed from the vehicle and mounted on a stand, some of the preliminary dismantling steps outlined will not apply.

The Zetec engine, (formerly Zeta), is of sixteen-valve, double overhead camshaft (DOHC), four-cylinder, in-line type, mounted transversely at the front of the vehicle, with the (clutch and) transmission on its left-hand end. Apart from the plastic timing belt covers and the cast-iron cylinder block/crankcase, all major engine castings are of aluminium alloy.

Repair operations possible with the engine in the vehicle

The following major repair operations can be accomplished without removing the engine from the vehicle. However, owners should note that any operation involving the removal of the sump requires careful forethought, depending on the level of skill and the tools and facilities available; refer to the relevant text for details:

• a) Compression pressure - testing.
• b) Cylinder head cover - removal and refitting.
• c) Timing belt covers - removal and refitting.
• d) Timing belt - renewal.
• e) Timing belt tensioner and toothed pulleys - removal and refitting.
• f) Camshaft oil seals - renewal.
• g) Camshafts and hydraulic tappets - removal and refitting.
• h) Cylinder head - removal, overhaul and refitting.
• i) Cylinder head and pistons - decarbonising.
• j) Sump - removal and refitting.
• k) Crankshaft oil seals - renewal.
• l) Oil pump - removal and refitting.
• m) Piston/connecting rod assemblies - removal and refitting
• n) Flywheel/driveplate - removal and refitting.
• o) Engine/transmission mountings - removal and refitting.