maintenance FORD SIERRA 1985 1.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

Piston ring end gap:
Top:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.038 to 0.048 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.400 to 0.600 mm
Centre:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.038 to 0.048 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.400 to 0.600 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.400 to 1.400 mm
Auxiliary shaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.050 to 0.204 mm (0.002 to 0.008 in)
Cylinder head
Specifications as for 1.3 litre engine
Valves
Specifications as for 1.3 litre engine except for the following:
Valve clearance (cold engine):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 ±0.03 mm (0.008 ±0.001 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 ±0.003 mm (0.010 ±0.001 in)
Valve timing:All except code NAEEngine code NAE
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24¼ BTDC18¼ BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64¼ ABDC58¼ ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70¼ BBDC70¼ BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18¼ ATDC6¼ ATDC
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settingsNmlbf ft
Specifications as for 1.3 litre engine except for the following:
Crankshaft pulley bolt:
Fuel injection models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 to 13085 to 96
Fuel injection models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 to 11574 to 85
SOHC engines 2A¥7
2A
The engine is of a four-cylinder, in-line,
single overhead camshaft type, mounted at
the front of the vehicle and available in 1.3,
1.6, 1.8 and 2.0 litre versions.
The crankshaft incorporates five main
bearings. Thrustwashers are fitted to the
centre main bearing in order to control
crankshaft endfloat.
The camshaft is driven by a toothed belt
and operates the slightly angled valves via
cam followers which pivot on ball-pins.
The auxiliary shaft which is also driven by
the toothed belt, drives the distributor, oil
pump and fuel pump.
The cylinder head is of crossflow design
with the inlet manifold mounted on the left-
hand side and the exhaust manifold mounted
on the right-hand side.
Lubrication is by means of a bi-rotor pump
which draws oil through a strainer located
inside the sump, and forces it through a full-
flow filter into the engine oil galleries where it
is distributed to the crankshaft, camshaft and
auxiliary shaft. The big-end bearings are
supplied with oil via internal drillings in the
crankshaft. The undersides of the pistons are
supplied with oil from drillings in the big-ends.
The distributor shaft is intermittently supplied
with oil from the drilled auxiliary shaft. The
camshaft followers are supplied with oil via adrilled spray tube from the centre camshaft
bearing.
A semi-closed crankcase ventilation system
is employed whereby piston blow-by gases
are drawn into the inlet manifold via an oil
separator and control valve.
Refer to Chapter 1, Section 8.
Refer to Chapter 1, Section 23.
Refer to Chapter 1, Section 35.
1When engine performance is poor, or if
misfiring occurs which cannot be attributed to
the ignition or fuel system, a compression test
can provide diagnostic clues. If the test is
performed regularly it can give warning of
trouble before any other symptoms become
apparent.2The engine must be at operating
temperature, the battery must be fully
charged and the spark plugs must be
removed. The services of an assistant will also
be required.
3Disable the ignition system by
disconnecting the coil LT feed. Fit the
compression tester to No 1 spark plug hole.
(The type of tester which screws into the
spark plug hole is to be preferred.)
4Have the assistant hold the throttle wide
open and crank the engine on the starter.
Record the highest reading obtained on the
compression tester.
5Repeat the test on the remaining cylinders,
recording the pressure developed in each.
6Desired pressures are given in the
Specifications. If the pressure in any cylinder
is low, introduce a teaspoonful of clean
engine oil into the spark plug hole and repeat
the test.
7If the addition of oil temporarily improves
the compression pressure, this indicates that
bore, piston or piston ring wear was
responsible for the pressure loss. No
improvement suggests that leaking or burnt
valves, or a blown head gasket, may be to
blame.
8A low reading from the two adjacent
cylinders is almost certainly due to the head
gasket between them having blown.
9On completion of the test, refit the spark
plugs and reconnect the coil LT feed.
5Compression test
4Crankcase ventilation system -
inspection and maintenance
3Valve clearances - checking and
adjustment
2Engine oil and filter - renewal
1General information