Pistons and connecting rods - removal and refitting
Removal
1 Remove the sump and the cylinder head.
2 Check the big-end bearing caps for identification marks and if necessary use a centre-punch to identify the caps and corresponding connecting rods (see illustration).
32.2 Big-end cap and connecting rod identification numbers
3 Turn the crankshaft so that No 1 crankpin is at its lowest point, then unscrew the nuts and tap off the bearing cap. Keep the bearing shells in the cap and connecting rod.
4 Using the handle of a hammer, push the piston and connecting rod up the bore and withdraw from the top of the cylinder block.
Loosely refit the cap to the connecting rod.
5 Repeat the procedure in paragraphs 3 and 4 on No 4 piston and connecting rod, then turn the crankshaft through half a turn and repeat the procedure on Nos 2 and 3 pistons and connecting rods.
Refitting
6 Commence refitting as follows.
7 Clean the backs of the bearing shells and the recesses in the connecting rods and bigend caps.
8 Press the bearing shells into the connecting rods and caps in their correct positions and oil them liberally. Note that the lugs in corresponding shells must be adjacent to each other (see illustration).
32.8 The bearing shell lugs (arrowed) must be adjacent to each other
9 Lubricate the cylinder bores with clean engine oil.
10 Fit a piston ring compressor to No 1 piston, then insert the piston and connecting rod into No 1 cylinder (see illustration).
32.10 Fitting a piston ring compressor
With No 1 crankpin at its lowest point, drive the piston carefully into the cylinder with the wooden handle of a hammer, and at the same time guide the connecting rod onto the crankpin. Make sure that the arrow on the piston crown is facing the front of the engine.
11 Oil the crankpin, then fit the big-end bearing cap in its previously noted position, and tighten the nuts to the specified torque.
12 Check that the crankshaft turns freely.
13 Repeat the procedure given in paragraphs 11 to 13 inclusive on the remaining pistons.
14 Refit the cylinder head and the sump.
See also:
Identifying components in the engine compartment
2.0L DOHC Zetec engine
Transmission fluid dipstick (automatic transaxle)
Battery
Air filter assembly
Engine oil filler cap
Engine oil dipstick
Power steering fluid reservoir
Engine ...
Engine mountings - renewal
1 The engine mountings incorporate
hydraulic dampers and must be renewed if
excessive engine movement is evident.
2 Working in the engine compartment,
unscrew the central nuts securing the engine
...
Battery terminal check (Every 12 000 miles (20 000 km) or 12 months)
Caution: Before carrying out
any work on the vehicle battery,
read through the precautions
given in “Safety first!” at the
beginning of this manual.
1 The battery fitted as original equipment is
...