engine oil FORD SIERRA 1987 2.G Suspension And Steering Workshop Manual

Torque wrench settings (continued)Nmlbf ft
P100 models:
Shock absorber-to-chassis crossmember bolt . . . . . . . . . . . . . . . . . . .60 to 7044 to 52
Leaf spring-to-front bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 to 196116 to 145
Leaf spring-to-spring shackle bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 to 196116 to 145
Spring shackle-to-underbody bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 to 8559 to 63
Axle-to-leaf spring U-bolt nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 to 5829 to 43
Manual steering
Steering gear-to-crossmember bolts:
Stage 1 (“clamping” torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Loosen fully, then Stage 2 (“snug” torque) . . . . . . . . . . . . . . . . . . . . .1511
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten through a further 90º
Steering column adjuster through-bolt . . . . . . . . . . . . . . . . . . . . . . . . . .6 to 84 to 6
Tie-rod end locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 to 6842 to 50
Tie-rod end-to-hub carrier nut* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3215 to 24
Tie-rod-to-steering rack balljoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 to 8853 to 65
Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 to 5533 to 41
Intermediate shaft-to-inner column clamp bolt . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Flexible coupling-to-steering gear clamp nut . . . . . . . . . . . . . . . . . . . . .24 to 2617 to 19
Column mounting pinch-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 to 5533 to 41
Pinion retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 10052 to 74
Slipper plug† . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 to 53 to 4
*Tighten nut to specified torque and then tighten to next available split pin hole
†Tighten nut to specified torque and then loosen off 60º to 70º
Power steering (where different to manual steering)
Tie-rod to steering rack balljoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 7752 to 57
Flexible coupling-to-steering gear clamp bolt . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Intermediate shaft-to-inner column clamp bolt . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Pinion locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 to 4727 to 35
Slipper plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 to 42 to 3
Pump rear support bar nut and bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 to 5130 to 38
Pump mounting bracket-to-engine bolts . . . . . . . . . . . . . . . . . . . . . . . .52 to 6438 to 47
Pump pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 127 to 9
Fluid hose-to-pinion housing bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2615 to 19
Fluid pressure hose-to-pump union . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 to 3119 to 23
Fluid return hose-to-pump union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
The front suspension is of independent
MacPherson strut type incorporating coil
springs and integral telescopic shock
absorbers. The lower end of each strut is
attached to a hub carrier, which carries the
wheel hub and bearings, and the brake
assembly. The lower end of each hub carrier
is attached to a suspension lower arm by a
sealed balljoint. The inboard ends of the lower
arms are attached to the front suspension
crossmember and the lower arms thus
provide lateral location for the strut
assemblies. The upper end of each strut is
bolted to a suspension turret on the vehicle
body. An anti-roll bar is mounted to the rear of
the lower arms, and resists the roll tendency
of the front suspension.
On Saloon, Hatchback and Estate models,
the rear suspension is also of independent
type, incorporating semi-trailing arms, coil
springs and telescopic shock absorbers. The
semi-trailing arms are attached to the
suspension crossmember at their forward
ends, and to the hub carriers at the rear. Thecoil springs are located between the
semi-trailing arms and the vehicle underbody.
On Saloon and Hatchback models, the shock
absorbers are mounted behind the coil
springs, but on Estate models they are
concentric with the coil springs. On some
Estate models the shock absorbers are of the
self-levelling type. The suspension
crossmember is attached to the vehicle
underbody, and to the final drive unit. Certain
models are fitted with an anti-roll bar which is
mounted to the rear of the final drive unit, and
is attached to the semi-trailing arms by
connecting links.
The rear suspension on P100 models
consists of a beam axle located and
supported by a leaf spring on each side, and
utilizing telescopic shock absorbers to control
vertical movement. The hub and brake
assemblies are attached directly to each side
of the axle. The axle is bolted to the leaf
springs using U-bolts and counterplates, and
the shock absorbers are attached to the
counterplates at their lower ends and the
vehicle underbody at their upper ends.
The steering gear is of the conventional
rack and pinion type located ahead of the
front wheels. Movement of the steering wheelis transmitted to the steering gear by means
of a shaft containing a universal joint. The
front hub carriers are connected to the
steering gear by tie-rods, each having an inner
and outer balljoint. Power-assisted steering is
available on some models, assistance being
provided hydraulically by an engine-driven
pump.
Removal
1Remove the steering gear.
2Support the engine with a jack and
interposed block of wood under the sump.
3Unscrew and remove the engine mounting
nuts from the top of the mountings in the
engine bay (see illustration).
4Raise the engine slightly with the jack, and
ensure that it is safely supported, and just
clear of the engine mounting rubbers.
5Unscrew and remove the nuts, washers and
pivot bolts securing the lower arms to the
crossmember, and pull the arms from the
crossmember. Note that the pivot bolt heads
face to the rear of the vehicle.
2Front suspension crossmember
-removalandrefitting
1General information
Suspension and steering 11•3
11

7Working in the engine compartment,
unscrew the strut upper mounting nut, at the
same time supporting the strut from below.
Use a 6 mm Allen key inserted in the end of
the strut piston rod to prevent the rod from
turning as the upper mounting nut is
unscrewed (see illustration). On some
models, the upper mounting nut may be fitted
with a plastic cover. Note the upper mounting
cup under the nut.
8Withdraw the strut from under the wing of
the vehicle.
Overhaul
9To dismantle the strut, proceed as follows.
10Using spring compressors, compress the
coil spring. Do not attempt to compress the
spring without using purpose-made spring
compressors, as the spring is under
considerable tension, and personal injury may
occur if it is suddenly released (see
illustration).
11Hold the piston rod as described in
paragraph 7, unscrew the nut from the pistonrod and remove the lower cup, bearing, spring
seat, gaiter, coil spring and bump stop (see
illustration).
12Working in the engine compartment,
remove the upper cup and nylon spacer, and
if required prise out the rubber insulator.
13Clean all the components and examine
them for wear and damage. Check the action
of the shock absorber by mounting it vertically
in a vice and operating the piston rod several
times through its full stroke. If any uneven
resistance is evident, the shock absorber
must be renewed. Renew any worn or
damaged components as applicable.
Refitting
14Reassembly and refitting is a reversal of
dismantling and removal, bearing in mind the
following points.
15When reassembling, ensure that the gaiter
is fitted over the bump stop, and that the ends
of the coil spring are correctly located on the
spring seats. Also ensure that the bearing is
correctly located on the upper spring seat.
16Fit the nylon spacer over the piston rod
before fitting the strut to the top mounting.
17Tighten all fixings to the specified torque.
18On P100 models align the previously
made marks on the roadwheel and wheel
stud.Note: A balljoint separator tool will be
required for this operation.
Removal
1Loosen the relevant front roadwheel nuts,
apply the handbrake, jack up the front of the
vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
2Remove the roadwheel. On P100 models
mark the position of the roadwheel in relation
to one of the wheel studs before removal.
3Remove the front brake caliper but do not
disconnect the hydraulic hose. Support the
caliper on an axle stand, or suspend it with wire
from the coil spring to avoid straining the hose.
4Mark the position of the brake disc in
relation to the drive flange, and on Saloon,
Hatchback and Estate models, remove the
retaining screw or spire washer(s), as
applicable, and remove the disc. On P100
models, unscrew the five retaining nuts and
remove the wheel adapter plate and disc.
5Where applicable, unbolt the ABS wheel
sensor from the hub carrier and unplug the
wiring connector. Place the sensor to one side.
6Remove the split pin and unscrew the
castellated nut securing the tie-rod end to the
hub carrier. Using a balljoint separator tool,
disconnect the tie-rod end from the hub carrier.
7Repeat the procedure given in the previous
paragraph for the lower arm-to-hub carrier
balljoint.
8Unscrew and remove the pinch-bolt which
secures the hub carrier to the strut (see
illustration). Using a suitable lever, such as a
cold chisel, lever the hub carrier clamp legs
and wedge them apart. Withdraw the hub
carrier from the strut.
Refitting
9Refitting is a reversal of removal, but use
new split pins on the castellated nuts, and
align the previously made marks on the brake
disc and hub. Tighten all fixings to the
specified torque.
10On P100 models align the previously
made marks on the roadwheel and wheel
stud.
5Front hub carrier -removaland
refitting
Suspension and steering 11•5
11
5.8 Unscrewing the hub carrier-to-strut
pinch-bolt
4.11 Cross-section of the front strut upper mounting
A Bearing
B Nylon spacer
C Upper cupD Rubber insulator
E Lower cup
F Spring seatG Bump stop
H Gaiter
4.10 Suspension strut fitted with spring
compressors
4.7 Hold the strut piston rod with a 6 mm
Allen key when unscrewing the upper
mounting nut

Refitting
3When refitting the fluid hoses, use new
O-rings, and take care not to overtighten the
unions. Note that with the unions fully
tightened it is still possible to rotate and move
the hoses.
4On completion of refitting, bleed the power
steering fluid circuit (Section 34).
Note: New power steering fluid hose O-rings
will be required when refitting.
All engines except 1.8 litre (R6A)
CVH and 2.0 litre DOHC
1Place a suitable container under the power
steering pump, unscrew the fluid hose unions,
and drain the fluid. Ensure that fluid is not
allowed to spill onto the alternator.
2Remove the drivebelts and unbolt the
power steering pump pulley if necessary to
ease removal.
3Unbolt the rear support bar from the pump
and the engine block (see illustration).
4Unbolt the pump from its mounting bracket,
and withdraw the pump from the engine.
5Refitting is a reversal of removal, noting the
following points.
6Tension the drivebelts correctly.
7When refitting the fluid hoses, use new
O-rings, and take care not to overtighten the
unions. 8On completion of refitting, bleed the power
steering fluid circuit.
1.8 litre (R6A) CVH engine
9The removal and refitting procedures are
basically the same as described below for the
2.0 litre DOHC engine, except that the pump
is mounted on a bracket above the alternator
on the front left-hand side of the engine.
2.0 litre DOHC engine
10The pump is mounted on a bracket on the
front right-hand side of the cylinder block.
11Place a suitable container under the
pump, unscrew the fluid pipe unions, and
drain the fluid.
12Remove the drivebelt which also drives
the coolant pump and alternator.
13Prevent the pulley from rotating using a
strap wrench (which can be improvised using
an old drivebelt and a large socket and
wrench), and unscrew the three pulley
securing bolts. Withdraw the pulley.
14Unscrew the three pump securing bolts
from the front of the pump bracket, and the
single bolt from the rear of the bracket, and
withdraw the pump (see illustrations).
15Refitting is a reversal of removal, bearing
in mind the following points.
16Reconnect the fluid unions using new O-
rings.
17On completion, bleed the power steering
fluid circuit.
Note: New fluid hose O-rings will be required
when refitting.
Removal
1Clean around the hose unions on the
steering gear. Place a suitable container
beneath the steering gear, then remove the
single bolt securing the hoses to the pinion
housing, unscrew the hose unions and drain
the power steering fluid.
2Clean around the hose unions on the pump.
Place a suitable container beneath the pump,
unscrew the hose unions, and drain any
remaining fluid. Ensure that no fluid is allowed
to spill onto the alternator.3If the hoses are to be left disconnected for a
long period of time, plug the ends of the
hoses and the apertures in the steering gear
and pump, or cover them with masking tape
to prevent dirt ingress.
Refitting
4Refit in reverse order using new O-rings.
5On completion top-up the fluid and bleed
the system.
1Unscrew the filler cap from the power
steering pump reservoir and top-up the fluid
level to the maximum mark using the specified
fluid.
2Disconnect the low tension negative lead
from the ignition coil and crank the engine
several times for two second periods while
slowly turning the steering wheel from
lock-to-lock. Top-up the fluid level if
necessary and continue cranking the engine
until the fluid is free of air bubbles.
3Reconnect the coil lead and start the
engine. Check the system for leaks.
4Switch off the engine and refit the filler cap.
5Drive the vehicle for a few miles to warm up
the fluid and expel any remaining air, then
stop the engine and make a final fluid level
check.
1Remove the tie-rod end.
2Unscrew and remove the tie-rod end
locknut from the tie-rod.
3Remove the clips and slide the gaiter from
the tie-rod and steering gear.
4Slide the new gaiter over the tie-rod and
onto the steering gear. Where applicable,
make sure that the gaiter seats in the cut-outs
in the tie-rod and steering gear.
5Secure the gaiter with new clips.
6Refit the tie-rod end locknut to the tie-rod.
7Refit the tie-rod end.
Note: A balljoint separator tool will be
required for this operation.
Removal
1Loosen the relevant front roadwheel nuts,
apply the handbrake, jack up the front of the
vehicle and support on axle stands.
2Remove the roadwheel. On P100 models
mark the position of the roadwheel in relation
to one of the wheel studs before removal.
3Make alignment marks on the tie-rod and
tie-rod end, then loosen the locknut by a
quarter of a turn.
33Tie-rod end - removal and
refitting
32Steering gear rubber gaiter -
renewal
31Power steering fluid circuit
- bleeding
30Power steering fluid hoses
- removal and refitting
29Power steering pump
- removal and refitting
11•18Suspension and steering
29.3 Power steering pump rear support bar
bolts (arrowed)
29.14b Power steering pump rear securing
bolt29.14a Unbolt the power steering pump
pulley for access to the front pump
securing bolts (arrowed)