drain bolt FORD SIERRA 1988 2.G CVH Engines Workshop Manual

Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.910 to 79.920 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.920 to 79.930 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.930 to 79.940 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.940 to 79.950 mm
Standard class 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.950 to 79.960 mm
Standard class 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.960 to 79.970 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.970 to 79.980 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.980 to 79.990 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.990 to 80.000 mm
Camshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 to 0.20 mm (0.006 to 0.008 in)
Thrustplate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.99 to 5.01 mm (0.1966 to 0.1974 in)
Bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.7625 to 45.7375 mm
Valves
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12º ATDC
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.20 mm (1.86 in)
Inlet valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.025 to 8.043 mm
Oversize 0.38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.405 to 8.423 mm
Oversize 0.76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.825 to 8.843 mm
Exhaust valve stem diameter (standard) . . . . . . . . . . . . . . . . . . . . . . . .7.996 to 8.017 mm
Lubrication system
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multigrade engine oil, viscosity range SAE 10W/30 to 20W/50, to API
SG/CD or better
Oil capacity:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres (7.0 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 litres (6.2 pints)
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion C104
Oil pump clearances:
Outer rotor to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.074 to 0.161 mm (0.003 to 0.006 in)
Inner rotor to outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.050 to 0.180 mm (0.002 to 0.007 in)
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.013 to 0.070 mm (0.0005 to 0.0028 in)
Torque wrench settingsNmlbf ft
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 10866 to 80
Big-end bearing caps:
With retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 to 3419 to 25
With retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4126 to 30
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 to 13081 to 96
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 11570 to 85
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 to 9154 to 67
Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 to 168 to 12
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 127 to 9
Sump bolts:
M6 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3015 to 22
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3015 to 22
Rocker arm bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 to 3017 to 22
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 6030 to 44
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slacken bolts by half a turn
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 6030 to 44
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten through a further 90º
Stage 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten through a further 90º
Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Timing cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Timing cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 to 74 to 5
Timing belt tensioner bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 to 3017 to 22
Oil pick-up tube/strainer-to-oil pump bolts . . . . . . . . . . . . . . . . . . . . . .10 to 137 to 9
Camshaft thrustplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 136 to 9
Crankshaft rear oil seal housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3015 to 22
2C•4CVH engines

a)Removal of the cylinder head
b)Removal of the camshaft
c)Removal of the timing belt and sprockets
d)Removal of the engine mountings
e)Removal of the clutch and flywheel
f)Removal of the crankshaft oil seals
a)Removal of the sump
b)Removal of the oil pump
c)Removal of the pistons/connecting rods
d)Removal of the big-end bearings
e)Removal of the crankshaft main bearings
f)Removal of the crankshaft
Refer to Section 8, Chapter 2, Part A.
Note: A suitable hoist and lifting tackle will be
required for this operation.
1.8 litre (R2A type)
1Disconnect the battery negative lead.
2Remove the bonnet.
3Remove the air cleaner.
4Disconnect the cooling fan wiring plug, then
unscrew the retaining nuts and washers and
withdraw the fan shroud and cooling fan
assembly.
5Drain the cooling system.
6Disconnect the coolant hoses from the
coolant pump elbow, and detach the heater
hose from the clip on the front of the timing
cover.
7Disconnect the upper radiator hose and the
expansion tank hose from the thermostat
housing (see illustration).8Disconnect the heater hose from the
automatic choke.
9Disconnect the brake servo vacuum hose
from the inlet manifold (see illustration).
10Disconnect the throttle damper solenoid
vacuum pipes (noting their locations) from the
throttle damper and the carburettor “T”-piece
connector.
11Disconnect the engine management
module vacuum pipe from the inlet manifold.
12Disconnect the fuel hoses from the
carburettor and fuel pump, and plug the ends
of the hoses to minimise petrol spillage. Take
adequate fire precautions.
13Disconnect the throttle cable.
14Disconnect the HT leads from the coil and
spark plugs, unclip the leads from the
camshaft cover, and remove the distributor
cap, rotor arm and housing.
15Disconnect the wiring from the following
components:
Alternator
Starter motor
Oil pressure warning lamp switch
Temperature gauge sender
Engine coolant temperature sensor
Automatic choke
Cooling fan switch
Crankshaft speed/position sensor
Engine earth strap to battery tray16Unscrew and remove the top engine-to-
gearbox bolts which are accessible from the
engine compartment.
17Apply the handbrake (if not already done),
jack up the front of the vehicle and support on
axle stands (see “Jacking and Vehicle
Support”).
18Drain the engine oil into a container.
19Remove the starter motor.
20Remove the exhaust downpipe.
21Unscrew the two nuts securing the engine
mountings to the crossmember. Recover the
washers.
22Unscrew and remove the remaining
engine-to-gearbox bolts, noting the location
of the earth strap (see illustration), and
remove the two bolts from the engine adapter
plate (see illustration).
23Working inside the vehicle, place a
wooden block under the clutch pedal to raise
it fully against its stop which will hold the
automatic adjuster pawl clear of the toothed
quadrant.
24Disconnect the clutch cable from the
release arm, and pass the cable through the
bellhousing. Remove the clip securing the
clutch cable to the right-hand engine
mounting bracket. Note the cable routing for
use when refitting.
25Lower the vehicle to the ground, and
support the gearbox with a trolley jack using a
block of wood between the jack and the
gearbox to spread the load.
26Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate engine removal.
27Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head, and carefully take the weight of
the engine. The engine should be supported
horizontally, ie do not allow it to tilt front to
rear.
28Raise the engine until the engine
mounting studs are clear of the crossmember,
then pull the engine forwards to disconnect it
from the gearbox. Ensure that the gearbox is
adequately supported, and take care not to
strain the gearbox input shaft. It may be
necessary to rock the engine a little to release
it from the gearbox.
8Engine - removal leaving
manual gearbox in vehicle
7Method of engine removal
6Major operations requiring
engine removal
5Major operations possible with
the engine in the vehicle
2C•6CVH engines
8.9 Disconnecting the brake servo vacuum
hose from the inlet manifold -
1.8 litre (R2A)
8.22b Remove the two bolts (arrowed) from
the engine adapter plate - 1.8 litre (R2A)8.22a Earth strap location under engine-to-
gearbox bolt - 1.8 litre (R2A)
8.7 Disconnect the upper radiator hose (1)
and the expansion tank hose (2) from the
thermostat housing - 1.8 litre (R2A)

29Once clear of the gearbox, lift the engine
from the vehicle, taking care not to damage
the radiator fins (see illustration).
1.6 and 1.8 litre (R6A type)
30Proceed as described in paragraphs 1 to 5.
31Disconnect the coolant hoses from the
thermostat housing, noting their locations.
32Disconnect the lower radiator hose from
the coolant pump elbow and, where
applicable, disconnect the heater hose from
the T-piece on the lower radiator hose.
33On 1.6 engines, disconnect the coolant
hose from the central fuel injection (CFI) unit.
34Disconnect the brake servo vacuum hose
from the inlet manifold by carefully pressing
the clip on the inlet manifold connector into
the manifold using a screwdriver, and
withdrawing the hose.
35Disconnect the vacuum hoses from the
inlet manifold, noting their locations.
36On 1.6 litre engines, disconnect the two
hoses from the pulse-air system check valves
(see illustration).
37Gradually loosen the fuel inlet pipe union
on the CFI unit, to relieve the pressure in the
fuel system. Be prepared for fuel spray, and
take adequate fire precautions. Once the
pressure has reduced, disconnect the fuel
inlet and return hoses. Plug the ends of the
hoses to minimise petrol spillage.
38Disconnect the throttle cable, if
necessary.
39Disconnect the wiring from the following
components, as applicable.
Alternator
Starter motor
Oil pressure warning lamp switch
Temperature gauge sender
Engine coolant temperature sensor
Inlet air temperature sensor
Ignition coil
Throttle stepper motor
Throttle position sensor
Fuel injector
Cooling fan switch
Air charge temperature sensor
Engine earth strap to battery tray
40On 1.8 litre engine models with power
steering, slacken the power steering pump
pulley bolts, then remove the alternator/power
steering pump drivebelt. Remove the pulley,
unbolt the power steering pump from its
bracket, and move it clear of the engine.41Unscrew and remove the top engine-to-
gearbox bolts which are accessible from the
engine compartment.
42Apply the handbrake (if not already done),
jack up the front of the vehicle and support it
on axle stands (see “Jacking and Vehicle
Support”).
43Drain the engine oil into a suitable
container.
44Remove the starter motor.
45Disconnect the exhaust gas oxygen
sensor wiring connector, then remove the
exhaust downpipe.
46Disconnect the wiring plug from the
crankshaft speed/position sensor.
47Unscrew the two nuts securing the engine
mountings to the crossmember. Recover the
washers.
48Unscrew and remove the remaining
engine-to-gearbox bolts, noting the location
of the earth strap and any wiring brackets,
and remove the two bolts from the engine
adapter plate (see illustration).
49Unscrew the securing bolt, and remove
the crankshaft speed/position sensor shroud
(where fitted).
50On 1.6 litre engines, working inside the
vehicle, place a wooden block under the
clutch pedal to raise it fully against its stop.
This will hold the automatic adjuster pawl
clear of the toothed quadrant. Disconnect the
clutch cable from the release arm, and pass
the cable through the bellhousing. Note the
cable routing for use when refitting.
51Proceed as shown in paragraphs 25 to 29.Note: A suitable hoist and lifting tackle will be
required for this operation.
1Proceed as described in Section 8,
paragraphs 1 to 15 inclusive. Additionally, if
applicable disconnect the kickdown cable
from the carburettor.
2Unscrew and remove the top engine-to-
transmission bolts which are accessible from
the engine compartment. Note the location of
the vacuum pipe bracket and transmission
dipstick tube bracket.
3Proceed as described in Section 8,
paragraphs 17 to 21 inclusive.
4Working through the starter motor aperture,
unscrew the four torque converter-to-
driveplate nuts. It will be necessary to turn the
crankshaft using a suitable spanner on the
crankshaft pulley bolt in order to gain access
to each nut in turn through the aperture.
5Unscrew and remove the remaining engine-
to-transmission bolts, noting the location of
the earth strap, and remove the two bolts
from the engine adapter plate. Where
applicable pull the blanking plug from the
adapter plate.
6Lower the vehicle to the ground and
support the transmission with a trolley jack,
using a block of wood between the jack and
the transmission to spread the load.
7Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate engine removal.
8Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head, and carefully take the weight of
the engine. The engine should be supported
horizontally, ie do not allow it to tilt front to rear.
9Raise the engine until the engine mounting
studs are clear of the crossmember, then pull
the engine forwards to disconnect it from the
transmission. Ensure that the torque converter
is held firmly in place in the transmission
housing, otherwise it could fall out resulting in
fluid spillage and possible damage. It may be
necessary to rock the engine a little to release
it from the transmission.
10Once clear of the transmission, lift the
engine from the vehicle, taking care not to
damage the radiator fins.
Note: A suitable hoist and lifting tackle will be
required for this operation.
1.8 litre (R2A type)
Removal
1Proceed as described in Section 8,
paragraphs 1 to 15 inclusive.
2Working inside the vehicle, unscrew the
gear lever knob and remove the centre
10Engine/manual gearbox
assembly - removal and
separation
9Engine - removal leaving
automatic transmission in
vehicle
CVH engines 2C•7
2C
8.48 Engine adapter plate bolts (A) and
crankshaft speed/position sensor shroud
(B) - 1.6 litre
8.36 Pulse-air system check valves
(arrowed) - 1.6/1.8 litre (R6A)8.29 Lifting the engine from the vehicle -
1.8 litre (R2A)

console. Where a full-length console is fitted,
it is only necessary to remove the front tray.
3Detach the outer gaiter from the retaining
frame and withdraw it over the gear lever.
4Release the clips and remove the gaiter
retaining frame and inner gaiter.
5Using a suitable Torx key, remove the
screws securing the gear lever to the gearbox
extension housing, and withdraw the gear
lever. Note how the base of the gear lever
locates over the selector shaft.
6Jack up the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
Ensure that there is sufficient working room
beneath the vehicle.
7To improve access, disconnect the exhaust
downpipe from the manifold and remove the
exhaust system.
8Remove the propeller shaft.
9Where applicable bend back the locktabs,
then unscrew the two bolts securing each of
the two anti-roll bar U-clamps to the vehicle
underbody. Lower the anti-roll bar as far as
possible.
10Proceed as described in Section 8,
paragraphs 23 and 24.
11Drain the engine oil into a container.
12Unscrew the two nuts securing the engine
mountings to the crossmember. Recover the
washers.
13Disconnect the wiring from the reversing
lamp switch.
14Remove the retaining circlip, and
withdraw the speedometer cable from the
gearbox extension housing.
15Support the gearbox with a trolley jack,
using a block of wood between the jack and
the gearbox to spread the load.
16Unscrew the four bolts securing the
gearbox crossmember to the vehicle
underbody. Unscrew the central bolt securing
the crossmember to the gearbox and remove
the crossmember. Note the position of the
earth strap, where applicable. Recover the
mounting cup and where applicable the
exhaust mounting bracket and heat shield.
17Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate removal of the
engine/gearbox assembly.
18Attach a hoist to the engine lifting
brackets located at the front and rear of the
cylinder head. Arrange the lifting tackle so that
the engine/gearbox assembly will assume a
steep angle of approximately 40º to 45º as it is
being removed.
19Raise the engine/gearbox so that the
engine mounting studs are clear of the
crossmember, then ease the assembly
forwards, at the same time lowering the trolley
jack which is supporting the gearbox. Lift the
assembly from the vehicle, taking care not to
damage the surrounding components.
20With the engine/gearbox assembly
removed, temporarily reconnect the anti-roll
bar to the underbody if the vehicle is to be
moved.
Separation
21To separate the engine from the gearbox,
proceed as follows. 22Remove the starter motor.
23Support the engine and gearbox
horizontally on blocks of wood.
24Unscrew and remove the engine-to-
gearbox bolts, noting the location of the earth
strap, and remove the two bolts from the
engine adapter plate.
25Pull the engine and gearbox apart, taking
care not to strain the gearbox input shaft. It
may be necessary to rock the units slightly to
separate them.
1.6 and 1.8 litre (R6A type)
26Proceed as described in paragraphs 30 to
40 inclusive of Section 8.
27Proceed as described in paragraphs 2 to
25 inclusive of Section 10, noting the
following points.
28Disconnect the wiring from the vehicle
speed sensor mounted on the gearbox before
removing the engine/gearbox assembly.
29Note that on 1.6 litre engines, the
crankshaft speed/position sensor shroud
(which is secured by a single bolt) must be
removed before separating the engine from
the gearbox.
Note: A suitable hoist and lifting tackle will be
required for this operation. Any suspected
faults in the automatic transmission should be
referred to a Ford dealer or automatic
transmission specialist before removal of the
unit, as the specialist fault diagnosis
equipment is designed to operate with the
transmission in the vehicle.
Removal
1Proceed as described in Section 8,
paragraphs 1 to 15 inclusive, but additionally,
where applicable disconnect the kickdown
cable from the carburettor.
2Jack up the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
Ensure that there is sufficient working room
beneath the vehicle.
3To improve access, disconnect the exhaust
downpipe from the manifold and remove the
exhaust system.
4Remove the propeller shaft.
5Where applicable bend back the locktabs,
then unscrew the two bolts securing each of
the two anti-roll bar U-clamps to the vehicle
underbody. Lower the anti-roll bar as far as
possible.
6Unscrew the unions and disconnect the
fluid cooler pipes from the transmission. Plug
the open ends of the pipes and the
transmission to prevent dirt ingress and fluid
leakage. Remove the fluid cooler pipe bracket
from the engine mounting bracket and place it
to one side.
7Remove the two clips securing the selector
rod, and detach the selector rod from the
manual selector lever, and the selector lever
on the transmission,
8If applicable, disconnect the kickdown cable
from the transmission and withdraw the cable.9Disconnect the wiring from the starter
inhibitor/reversing lamp switch, the lock-up
clutch and where applicable the kickdown
solenoid.
10Remove the securing screw, and
disconnect the speedometer cable from the
transmission extension housing. Plug the
opening in the transmission to prevent dirt
ingress.
11Disconnect the vacuum pipe from the
vacuum diaphragm unit, and unclip the pipe
from its securing bracket on the transmission
housing.
12Drain the engine oil into a container.
13Unscrew the two nuts securing the engine
mountings to the crossmember. Recover the
washers.
14Support the transmission with a trolley
jack using a block of wood between the jack
and the transmission to spread the load.
15Unscrew the four bolts securing the
transmission crossmember to the vehicle
underbody. Note the position of the earth
strap, where applicable. Unscrew the central
bolt securing the crossmember to the
transmission and remove the crossmember.
Recover the mounting cup and the exhaust
mounting bracket.
16Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate removal of the
engine/transmission assembly.
17Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head. Arrange the lifting tackle so that
the engine/transmission assembly will assume
a steep angle of approximately 40º to 45º as it
is being removed.
18Raise the engine/transmission so that the
engine mounting studs are clear of the
crossmember, then ease the assembly
forwards, at the same time lowering the trolley
jack which is supporting the transmission. Lift
the assembly from the vehicle, taking care not
to damage surrounding components.
19With the engine/transmission assembly
removed, temporarily reconnect the anti-roll
bar to the underbody if the vehicle is to be
moved.
Separation
20To separate the engine from the
transmission, proceed as follows.
21Remove the starter motor.
22Support the engine and transmission
horizontally on blocks of wood.
23Working through the starter motor
aperture, unscrew the four torque converter-
to-driveplate nuts. It will be necessary to turn
the crankshaft using a suitable spanner on the
crankshaft pulley bolt in order to gain access
to each nut in turn through the aperture.
24Unscrew and remove the engine-to-
transmission bolts, noting the locations of the
earth strap, vacuum pipe bracket, and
transmission dipstick tube bracket. Remove
the two bolts from the engine adapter plate,
and where applicable pull the blanking plug
from the adapter plate.
25Pull the engine and transmission apart,
ensuring that the torque converter is held
11Engine/automatic
transmission assembly -
removal and separation
2C•8CVH engines

Note: Refer to the note at the beginning of
Section 20 before proceeding.
1.8 litre (R2A type)
Removal
1Disconnect the battery negative lead.
2Drain the cooling system.
3Disconnect the heater coolant hose from
the coolant pump elbow, and the coolant
bypass hose from the left-hand side of the
cylinder head, then unclip the hoses from the
timing cover and move them to one side out
of the way (see illustrations).
4Remove the air cleaner.5Disconnect the HT leads from the spark
plugs and coil, identifying them for position if
necessary, unclip the leads from the camshaft
cover, then remove the distributor cap, rotor
arm and housing. Remove the spark plugs.
6Disconnect the cylinder head earth lead
from the battery tray.
7The cylinder head can be removed either with
or without the manifolds. If desired, the inlet
manifold can be unbolted and moved to one
side, leaving the wires, hoses, pipes and cables
connected, but care must be taken not to strain
any of the wires, hoses, pipes or cables.
8Unscrew the three securing nuts and
disconnect the exhaust downpipe from the
manifoid flange. Recover the gasket.
9If desired, remove the exhaust manifold.
10If the inlet manifold is to be removed with
the cylinder head, disconnect all relevantwires, hoses, pipes and cables, otherwise
unbolt the manifold and move it to one side,
ensuring that it is adequately supported (see
illustration).
11If desired, remove the fuel pump and
operating pushrod.
12Proceed as described in Section 20 to
complete cylinder head removal.
Refitting
13With the cylinder head refitted as
described in Section 20, proceed as follows.
14Where applicable, refit the fuel pump and
operating pushrod.
15Refit the manifolds and/or reconnect all
wires, hoses, pipes and cables, as applicable.
16Reconnect the exhaust downpipe to the
manifold, using a new gasket.
17Reconnect the earth lead to the battery
tray.
18Refit the spark plugs, then refit the
distributor cap, rotor arm and housing, and
reconnect the HT leads.
19Refit the air cleaner.
20Reconnect the coolant hoses to the
coolant pump elbow and the cylinder head,
and locate them in the clip on the timing
cover.
21Fill the cooling system.
22Reconnect the battery negative lead.
1.6 and 1.8 litre (R6A type)
Removal
23Disconnect the battery negative lead.
24Drain the cooling system.
25Disconnect the coolant hoses from the
thermostat housing, and the bypass hose
from the left-hand side of the cylinder head,
then move them to one side out of the way.
26Remove the air cleaner.
27Disconnect the HT leads from the spark
plugs, identifying them for position if
necessary. Unclip them from the camshaft
cover, and move them to one side out of the
way.
28Remove the spark plugs.
29Disconnect the cylinder head earth lead
from the battery tray.
30The cylinder head can be removed either
with or without the manifolds. If desired, the
inlet manifold can be unbolted and moved to
one side (after unbolting the dipstick tube),19Cylinder head - removal and
refitting (engine in vehicle)
CVH engines 2C•13
2C
19.10 Withdraw the inlet manifold -
1.8 litre (R2A)19.3b Coolant bypass hose connection at
cylinder head - 1.8 litre (R2A)19.3a Disconnecting the heater coolant
hose from the coolant pump elbow -
1.8 litre (R2A)
18.33d Oil pump TDC lug (A) and
crankshaft sprocket lug (B) -
1.6/1.8 litre (R6A)18.33c Removing the lower timing cover -
1.6/1.8 litre (R6A)
18.33b Removing the upper timing cover -
1.6/1.8 litre (R6A)18.33a Upper timing cover securing bolts
(arrowed) - 1.6/1.8 litre (R6A)

4Recover the gasket.
5Thoroughly clean the mating faces of the
cylinder block and sump.
Refitting
6Commence refitting by applying sealing
compound (available from a Ford dealer) to
the cylinder block, oil pump housing and
crankshaft rear oil seal housing mating faces
at the points shown (see illustration). Note
that the sump must be fitted within ten
minutes of applying the sealing compound.
7Fit a new gasket, ensuring that it engages
correctly in the grooves in the crankshaft rear
oil seal carrier and the oil pump housing (see
illustration).
8Locate the sump on the gasket and loosely
fit the securing bolts.
9Tighten all the bolts slightly to obtain a light
and even gasket preload.
10Tighten the bolts to the specified torque in
the sequence shown (see illustration). Note
that the ten M8 bolts and the four M6 bolts
are tightened to different torques.
11Refit the engine adapter plate and the
flywheel/driveplate.
1.6 and 1.8 litre (R6A type)
Note: The following procedure applies to the
1.6 litre CVH engine. For the 1.8 litre (R6Atype) engine, proceed as described above for
the 1.8 litre (R2A type).
Removal
12Sump removal and refitting is easier if the
engine is removed from the vehicle. However,
if the engine is in the vehicle, proceed as
follows. If the engine has been removed from
the vehicle, proceed to paragraph 15.
13Remove the clutch.
14Drain the engine oil into a suitable
container.
15Remove the flywheel and the engine
adapter plate.
16Unscrew the eighteen securing bolts and
withdraw the sump. If the sump is stuck,
carefully tap it sideways to free it. Do not prise
between the mating faces. Recover the
gasket.
17Thoroughly clean the mating faces of the
cylinder block and sump.
Refitting
18Apply sealing compound to the joints
between the oil pump and the cylinder block,
and the crankshaft rear oil seal housing and
the cylinder block, as shown (see
illustration).
19Without applying any further sealer, locate
the gasket into the grooves of the oil pump
and the rear oil seal housing. To hold the
gasket in position, studs can be inserted
temporarily in the bolt hole positions circled in
the illustration indicating the bolt tightening
sequence. Make sure that the gasket spacing
pips are seated correctly.20Locate the sump on the gasket, taking
care not to displace the gasket, then loosely
fit the securing bolts. With the sump in
position, where applicable remove the studs
from the bolt holes, and loosely fit the
remaining securing bolts.
21Tighten the bolts to the torque given in the
Specifications at the beginning of this
Chapter, in two stages, and in the sequence
shown (see illustration).
22Refit the engine adapter plate and the
flywheel.
23If the engine is in the vehicle, refit the
clutch. Refill the engine with oil.
Note: New oil pump and oil pick-up tube
gaskets should be used when refitting.
Removal
1With the engine removed, proceed as
follows.
2Remove the timing belt, crankshaft
sprocket and thrustwasher.
3Remove the sump.
4Unscrew and remove the nut securing the
oil strainer/pick-up tube to No 4 main bearing
cap (see illustration).
5Using a suitable Allen key, unscrew the two
bolts securing the oil pick-up tube to the oil
pump, and withdraw the oil strainer/pick-up
tube. Recover the washers and gasket (see
illustration).
28Oil pump - removal and
refitting
2C•20CVH engines
27.6 Apply sealing compound to the areas
shown before fitting the sump gasket -
1.8 litre (R2A)27.10 Sump bolt tightening sequence -
1.8 litre (R2A)
27.21 Sump bolt tightening sequence -
1.6 litre
Arrow indicates front of engine
27.18 Apply sealing compound at the
points arrowed before refitting the sump -
1.6 litre
A Oil pump/cylinder block joint
B Crankshaft rear oil seal
housing/cylinder block joint
27.7 Ensure that the gasket locates
correctly on the oil pump housing -
1.8 litre (R2A)
28.4 Oil strainer/pick-up tube securing nut
(arrowed) on No 4 main bearing cap