air filter FORD SIERRA 1992 2.G SOHC Engines Workshop Manual

1.3 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Engine code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JCT
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.02 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.00 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1294 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0:1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . . 11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5800 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 kW at 5700 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm at 3100 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.000 to 79.010 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.010 to 79.020 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.020 to 79.030 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.030 to 79.040 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.510 to 79.520 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.520 to 79.530 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.530 to 79.540 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.030 to 79.040 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.530 to 79.540 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.030 to 80.040 mm
Chapter 2 Part A:
SOHC engines
Auxiliary shaft - removal, inspection and refitting . . . . . . . . . . . . . . .25
Camshaft and cam followers - removal, inspection and refitting . . . .24
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Crankcase ventilation system - inspection and maintenance . . . . . . .4
Crankshaft and bearings - examination and renovation . . . . . . . . . .35
Crankshaft and main bearings - removal and refitting . . . . . . . . . . . .34
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cylinder block and bores - examination and renovation . . . . . . . . . .36
Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . . .22
Cylinder head - inspection and renovation . . . . . . . . . . . . . . . . . . . . .23
Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . . .20
Cylinder head - removal and refitting (engine removed) . . . . . . . . . . .21
Engine - refitting (automatic transmission in vehicle) . . . . . . . . . . . . .14
Engine - refitting (manual gearbox in vehicle) . . . . . . . . . . . . . . . . . . .13
Engine - removal leaving automatic transmission in vehicle . . . . . . .10
Engine - removal leaving manual gearbox in vehicle . . . . . . . . . . . . . .9
Engine/automatic transmission assembly - reconnection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine/automatic transmission assembly - removal and separation .12Engine dismantling,examination, renovation and reassembly - general
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Engine/manual gearbox - reconnection and refitting . . . . . . . . . . . . .15
Engine/manual gearbox assembly - removal and separation . . . . . .11
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . .26
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Initial start-up after overhaul or major repair . . . . . . . . . . . . . . . . . . .37
Major operations possible with the engine in the vehicle . . . . . . . . . . .6
Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . . .7
Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . .31
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Pistons and connecting rods - examination and renovation . . . . . . .33
Pistons and connecting rods - removal and refitting . . . . . . . . . . . . .32
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Timing belt and sprockets - removal and refitting . . . . . . . . . . . . . . .19
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . . .3
2A¥1
Specifications Contents
2A
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

18Tighten the bolts in the correct sequence
(see illustration)noting the two stages given
in the Specifications. Tighten to the first stage
in a clockwise sequence starting at point ÒAÓ,
then tighten to the second stage in a
clockwise sequence starting at point ÒBÓ.
Tighten to the third stage after the engine has
been running for twenty minutes.
19If the engine is in the vehicle proceed as
follows.
20Carefully lift the crossmember with the
jack, then refit the securing bolts and tighten
to the specified torque.
21Withdraw the jack, then lower the engine
and remove the lifting tackle.
22Where applicable, refit the brake lines to
the crossmember.
23Ensure that the front wheels are pointing
straight ahead and that the steering wheel is
centred, then reconnect the intermediate shaft
to the steering column. Secure the clamp
plate with the bolt.
24Refit the engine mounting bolts andtighten to the specified torque.
25Refit the starter motor.
26Lower the vehicle to the ground.
27Ensure that the sump drain plug is fitted,
then fill the engine with the correct quantity
and grade of oil. If necessary, renew the oil
filter before filling the engine with oil.
28Reconnect the battery negative lead.
29Start the engine and check for leaks
around the sump, and where applicable the oil
filter. When the engine is started, there may
be a delay in the extinguishing of the oil
pressure warning lamp while the system
pressurises.
30Run the engine for twenty minutes then
stop the engine and tighten the sump bolts to
the third stage given in the Specifications,
starting at the point ÒAÓ shown and working
clockwise.
31Check the oil level.
32Dispose of any old engine oil safely. Do
not pour it down a drain - this is illegal and
causes pollution.
Removal
1Remove the sump.
2Unscrew the bolt securing the pick-up tube
and strainer to the cylinder block (see
illustration).
3Using a suitable splined socket, unscrew
the two securing bolts and withdraw the oil
pump and strainer (see illustration).
4If desired, the hexagon-shaped driveshaft
can be withdrawn, but note which way roundit is fitted (see illustration). The driveshaft
engages with the lower end of the distributor
driveshaft.
5Thoroughly clean the mating faces of the oil
pump and cylinder block.
Refitting
6Commence refitting by inserting the oil
pump driveshaft into the cylinder block in its
previously noted position.
7Prime the pump by injecting oil into it and
turning it by hand.
8Fit the pump, insert the securing bolts, and
tighten them to the specified torque.
9Fit the pick-up tube securing bolt and
tighten it.
10Refit the sump.
Note: A new pressure relief valve plug and
pick-up tube gasket will be required for
reassembly.
Dismantling
1If oil pump wear is suspected, check the
cost and availability of new parts and the cost
of a new pump. Examine the pump as
described in this Section and then decide
whether renewal or repair is the best course of
action.
2Unbolt the pick-up tube and strainer.
Recover the gasket.
3Unscrew the three securing bolts and
remove the oil pump cover (see illustration).
31Oil pump - dismantling,
inspection and reassembly
30Oil pump - removal and
refitting
SOHC engines 2A¥21
2A
30.2 Unscrewing the oil pick-up tube
securing bolt
30.4 Withdrawing the oil pump driveshaft30.3 Unscrewing an oil pump securing bolt
29.18 Sump bolt tightening sequence -
refer to text29.16 Locate the sump gasket end tabs
beneath the rubber sealing strips
31.3 Exploded view of the oil pump
A Body
B Outer rotor
C Inner rotor
D Cover
E Strainer
F Pick-up tube
G Gasket
H Pressure relief valve

components, but there must be no tight spots
or binding.
28Check that the crankshaft endfloat is
within the specified limits by inserting a feeler
blade between the centre crankshaft web and
the thrustwashers.
29Make sure that the rear oil seal is fully
located onto its seating. Coat the rear main
bearing cap sealing wedges with sealing
compound, then press them into position
using a blunt screwdriver with the rounded
red face towards the cap (see illustration).
30Refit the oil pump and pick-up tube.
31Refit the crankshaft front oil seal housing
and the auxiliary shaft front cover using a new
gasket, and tighten the securing bolts. Smear
the lip of the oil seal with clean engine oil
before fitting; and using a straight edge, ensure
that the bottom face of the oil seal housing is
aligned with the bottom face of the cylinder
block before finally tightening the bolts.
32Refit the pistons and connecting rods.
33Refit the flywheel/driveplate and the
auxiliary shaft sprocket, crankshaft sprocket,
and timing belt.
1Examine the bearing surfaces of the
crankshaft for scratches or scoring and, using
a micrometer, check each journal and
crankpin for ovality. Where this is found to be
in excess of 0.0254 mm (0.001 in) the
crankshaft will have to be reground and
undersize bearings fitted.
2Crankshaft regrinding should be carried out
by a suitable engineering works, who will
normally supply the matching undersize main
and big-end shell bearings.
3Note that undersize bearings may already
have been fitted, either in production or by a
previous repairer. Check the markings on the
backs of the old bearing shells, and if in doubt
take them along when buying new ones.
Production undersizes are also indicated by
paint marks as follows:
White line on main bearing cap - parent bore
0.40 mm oversize
Green line on crankshaft front counterweight
- main bearing journals 0.25 mm
undersize
Green spot on counterweight - big-end
bearing journals 0.25 mm undersize4If the crankshaft endfloat is more than the
maximum specified amount, new
thrustwashers should be fitted to the centre
main bearings. These are usually supplied
together with the main and big-end bearings
on a reground crankshaft.
5An accurate method of determining bearing
wear is by the use of Plastigage. The
crankshaft is located in the main bearings
(and big-end bearings if necessary) and the
Plastigage filament located across the journal
which must be dry. The cap is then fitted and
the bolts/nuts tightened to the specified
torque. On removal of the cap the width of the
filaments is checked against a scale which
shows the bearing running clearance. This
clearance is then compared with that given in
the Specifications (see illustration).
6If the spigot bearing in the rear of the
crankshaft requires renewal, extract it with a
suitable puller. Alternatively fill it with heavy
grease and use a close fitting metal dowel
driven into the centre of the bearing. Drive the
new bearing into the crankshaft with a soft
metal drift.
1The cylinder bores must be examined for
taper, ovality, scoring and scratches. Start by
examining the top of the bores; if these are
worn, a slight ridge will be found which marks
the top of the piston ring travel. If the wear is
excessive, the engine will have had a high oil
consumption rate accompanied by blue
smoke from the exhaust.
2If available, use an inside dial gauge to
measure the bore diameter just below the
ridge and compare it with the diameter at the
bottom of the bore, which is not subject to
wear. If the difference is more than 0.152 mm
(0.006 in), the cylinders will normally require
reboring with new oversize pistons fitted.
3Proprietary oil control rings can be obtained
for fitting to the existing pistons if it is felt that
the degree of wear does not justify a rebore.
However, any improvement brought about by
such rings may be short-lived.
4If new pistons or piston rings are to be fitted
to old bores, deglaze the bores with abrasive
paper or a Òglaze busterÓ tool. The object is to
produce a light cross-hatch pattern to assistthe new rings to bed in.
5If there is a ridge at the top of the bore and
new piston rings are being fitted, either the
top piston ring must be stepped (Òridge
dodgerÓ pattern) or the ridge must be
removed with a ridge reamer. If the ridge is
left, the piston ring may hit it and break.
6Thoroughly examine the crankcase and
cylinder block for cracks and damage and use
a piece of wire to probe all oilways and
waterways to ensurethatthey are
unobstructed.
1Make a final check to ensure that
everything has been reconnected to the
engine and that no rags or tools have been left
in the engine bay.
2Check that oil and coolant levels are
correct.
3Start the engine. This may take a little
longer than usual as fuel is pumped up to the
engine.
4Check that the oil pressure light goes out
when the engine starts.
5Run the engine at a fast tickover and check
for leaks of oil, fuel or coolant. Also check
power steering and transmission fluid cooler
unions, where applicable. Some smoke and
odd smells may be experienced as assembly
lubricant burns off the exhaust manifold and
other components.
6Bring the engine to normal operating
temperature, then check the ignition timing
and the idle speed (where applicable) and
mixture.
7If splined type cylinder head bolts have
been used, stop the engine after it has been
running for 15 minutes, then remove the
crankshaft cover and tighten the cylinder
head bolts to the fourth stage given in the
Specifications, in the correct order.
8When the engine has completely cooled,
re-check the oil and coolant levels, and
check, and if necessary adjust, the valve
clearances.
9If new bearings, pistons etc have been
fitted, the engine should be run-in at reduced
speeds and loads for the first 500 miles (800
km) or so. It is beneficial to change the engine
oil and filter after this mileage.
37Initial start-up after overhaul or
major repair
36Cylinder block and bores -
examination and renovation35Crankshaft and bearings -
examination and renovation
2A¥24SOHC engines
34.24 Fitting a thrustwasher to the centre
main bearing cap35.5 Checking the width of the filament
against the scale of the packet34.29 Fitting a sealing wedge to the rear
main bearing cap