Ford Escort Manual

Engine - reassembly
CVH engines / Engine - reassembly


Note: Ensure that all necessary new oil seals and gaskets have been obtained before starting the reassembly procedure.

1 With everything clean and parts renewed where necessary, commence reassembly by inserting the ventilation baffle into the crankcase. Make sure that the spring arms engage securely (see illustration).

15.1 Crankcase ventilation baffle
15.1 Crankcase ventilation baffle

2 Insert the bearing half shells into their seats in the crankcase, making sure that the seats are perfectly clean (see illustration).

15.2 Inserting a main bearing shell into the crankcase
15.2 Inserting a main bearing shell into the crankcase

3 Stick the semi-circular thrustwashers on either side of the centre bearing with thick grease. Make sure that the oil channels face outwards (see illustration).

15.3 Locating the crankshaft thrustwashers on the centre main bearing
15.3 Locating the crankshaft thrustwashers on the centre main bearing

4 Oil the bearing shells and carefully lower the crankshaft into position.

5 Insert the bearings shells into the main bearing caps, making sure that their seats are perfectly clean. Oil the bearings and install the caps in their correct numbered location and with the directional arrow pointing towards the timing belt end of the engine (see illustrations).

15.5a Fit the caps to their correct numbered locations . . .
15.5a Fit the caps to their correct numbered locations . . .

15.5b . . . with the arrows on the caps pointing toward the timing belt end
15.5b . . . with the arrows on the caps pointing toward the timing belt end

6 Tighten the main bearing cap bolts to the specified torque.

7 Check the crankshaft endfloat. Ideally a dial gauge should be used, but feeler blades are an alternative if inserted between the face of the thrustwasher and the machined surface of the crankshaft balance web, having first prised the crankshaft in one direction and then the other (see illustration). Provided the thrustwashers at the centre bearing have been renewed, the endfloat should be within specified tolerance.

If it is not, oversize thrustwashers are available (see Specifications).

15.7 Checking crankshaft endfloat with a feeler blade
15.7 Checking crankshaft endfloat with a feeler blade

8 The pistons/connecting rods should now be installed. Although new pistons may have been fitted to the rods by your dealer or supplier due to the special tools needed, it is worth checking to ensure that with the piston crown arrow or cast nipple in the piston oil cut-out pointing towards the timing belt end of the engine, the F mark on the connecting rod or the oil ejection hole in the rod big-end is as shown (see illustration).

15.8 Piston/connecting rod orientation
15.8 Piston/connecting rod orientation

9 Oil the cylinder bores and install the pistons/connecting rods (Section 9).

10 Fit the oil pressure switch.

11 Before fitting the oil pump, action must be taken to prevent damage to the pump oil seal from the step on the front end of the crankshaft. First remove the Woodruff key and then build up the front end of the crankshaft using adhesive tape to form a smooth inclined surface to permit the pump seal to slide over the step without its lip turning back or the seal spring being displaced during installation (see illustration).

15.11 Using masking tape to eliminate the step on the crankshaft
15.11 Using masking tape to eliminate the step on the crankshaft

12 If the oil pump is new, pour some oil into it before installation in order to prime it and rotate its driving gear a few turns (see illustration).

15.12 Priming the oil pump prior to fitting
15.12 Priming the oil pump prior to fitting

13 Align the pump gear flats with those on the crankshaft and install the oil pump complete with new gasket. Tighten the bolts to the specified torque.

14 Remove the adhesive tape and tap the Woodruff key into its groove.

15 Bolt the oil pump pick-up tube into position (see illustration).

15.15 Fitting the oil pump pick-up tube
15.15 Fitting the oil pump pick-up tube

16 To the front end of the crankshaft, fit the thrustwasher (belt guide) so that its concave side is towards the pump (see illustration).

15.16 Fit the timing belt guide with its concave side towards the pump
15.16 Fit the timing belt guide with its concave side towards the pump

17 Fit the crankshaft belt sprocket. If it is tight, draw it into position using the pulley bolt and a distance piece. Make sure that the belt retaining flange on the sprocket is towards the front of the crankshaft and the nose of the shaft has been smeared with a little grease before fitting (see illustration).

15.17 Fitting the crankshaft sprocket with the flange outward
15.17 Fitting the crankshaft sprocket with the flange outward

18 Install the water pump using a new gasket and tightening the bolts to the specified torque (see illustration).

15.18 Fitting the water pump
15.18 Fitting the water pump

19 Fit the timing belt tensioner and its coil spring (where fitted). Lever the tensioner fully against spring pressure and temporarily tighten the bolts.

20 Using a new gasket, bolt on the rear oil seal retainer, which will have been fitted with a new oil seal and the seal lips greased (see illustration).

15.20 Crankshaft rear oil seal retainer with new seal prior to fitting
15.20 Crankshaft rear oil seal retainer with new seal prior to fitting

21 Engage the engine adapter plate on its locating dowels and then offer up the flywheel. It will only go on in one position as it has offset holes. Insert new bolts and tighten to the specified torque (see illustrations). The bolts should be pre-coated with thread sealant.

15.21a Locate the adapter plate on the dowels . . .
15.21a Locate the adapter plate on the dowels . . .

15.21b . . . fit the flywheel to the crankshaft
15.21b . . . fit the flywheel to the crankshaft

22 Fit the clutch and centralise it (refer to Chapter 6).

23 With the engine resting on its side (not inverted unless you are quite sure that the pistons are not projecting from the block), fit the sump, gaskets and sealing strips as described in Section 8.

24 Fit the cylinder head as described in Section 7, using new bolts. Refit the manifolds (see illustrations).

15.24a Fit the inlet manifold gasket . . .
15.24a Fit the inlet manifold gasket . . .

15.24b . . . and manifold
15.24b . . . and manifold

25 Install and tension the timing belt as described in Section 4.

26 Using a new gasket, fit the rocker cover.

27 Reconnect the crankcase ventilation hoses between the rocker cover and the crankcase (see illustrations).

15.27a Connecting the crankcase rear ventilation hose . . .
15.27a Connecting the crankcase rear ventilation hose . . .

15.27b . . . and the front hose
15.27b . . . and the front hose

28 Screw in a new set of spark plugs, correctly gapped, and tighten to the specified torque - this is important. If the specified torque is exceeded, the plugs may be impossible to remove (see Chapter 1).

29 Fit the timing belt cover.

30 Fit the crankshaft pulley and tighten the bolt to the specified torque while the flywheel ring gear is locked to prevent it turning.

31 Smear the sealing ring of a new oil filter with a little grease, and screw it into position using hand pressure only. Where applicable, refit the oil cooler at the same time.

32 Install the engine mounting brackets, if removed (see illustration).

15.32 Fitting the right-hand engine mounting
15.32 Fitting the right-hand engine mounting

33 Refit the ancillaries. The alternator bracket and alternator (Chapter 5, Part A), the fuel pump, where applicable (Chapter 4, Part A), the thermostat housing (Chapter 3), and the distributor (Chapter 5, Part B) (see illustration).

15.33 Fitting the alternator mounting bracket
15.33 Fitting the alternator mounting bracket

34 Fit the distributor cap and reconnect the HT leads.

35 Check the tightness of the oil drain plug and insert the dipstick.


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