fuel pump FORD SIERRA 1988 2.G CVH Engines Workshop Manual
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Page 5 of 24
1.8 litre (R6A type) engine
Note: Unless otherwise stated, the Specifications for this later version of the 1.8 litre CVH engine are as given for the earlier R2A type above.
General
Engine code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .R6A
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .5700 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 kW at 5200 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Nm at 3000 rpm
Valve timing
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116º BTDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110º ATDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18º ATDC
1.6 litre engine
The 1.6 litre CVH engine was introduced in
September 1991, to replace the 1.6 litre
SOHC engine used previously in the Sierra
range. The engine is broadly similar to the 1.8
litre (R2A type) CVH engine described below.
The main differences are outlined in the
following paragraphs.
The centre main bearing is fitted with
thrustwashers to control crankshaft endfloat,
instead of a flanged bearing shell.
The hydraulic cam followers operate in a
similar manner to those described for the 1.8
litre (R2A) engine but no rollers are fitted, and
the base of each cam follower is in direct
contact with the cam profile.
A distributorless ignition system is used and
a blanking plate is therefore fitted to the cylinder
head in place of the distributor drive. The
electric fuel pump is mounted in the fuel tank.
A comprehensive emissions control system
is fitted, comprising Central Fuel Injection
(CFI), a sophisticated engine management
system, a crankcase ventilation system, a
catalytic converter, and a pulseair system (to
reduce exhaust gas emissions).
Unless otherwise stated, all procedures are
as described for the 1.8 litre (R2A) engine.
1.8 litre (R2A type) engine
The CVH (Compound Valve angle,
Hemispherical combustion chambers) engine
is of four-cylinder, in-line, single overhead
camshaft type. The engine was introduced to
replace the 1.8 SOHC engine previously used
in the range.
The crankshaft incorporates five main
bearings. The centre main bearing has a
flanged bearing shell (thrust bearing) fitted to
the cylinder block to control crankshaft endfloat
The camshaft is driven by a toothed belt and
operates the compound angled valves via roller
type hydraulic cam followers, which eliminates
the need for valve clearance adjustment. The
cam followers operate in the following way.
When the valve is closed, pressurised engine
oil passes through ports in the body of the cam
follower and the plunger into the cylinder feed
chamber. From this chamber, oil flows through
a ball type non-return valve into the pressurechamber. The tension of the coil spring causes
the plunger to press the rocker arm against the
valve and to eliminate any free play.
As the cam lifts the cam follower, the oil
pressure in the pressure chamber increases
and causes the non-return valve to close the
port to the feed chamber. As oil cannot be
compressed, it forms a rigid link between the
body of the cam follower, the cylinder and the
plunger which then rise as one component to
open the valve.
The clearance between the body of the cam
follower and the cylinder is accurately designed
to meter a specific quantity of oil as it escapes
from the pressure chamber. Oil will only pass
along the cylinder bore when pressure is high
during the moment of valve opening. Once the
valve has closed, the escape of oil will produce
a small amount of free play and no pressure will
exist in the pressure chamber. Oil from the feed
chamber can then flow through the non-return
valve into the pressure chamber so that the
cam follower cylinder can be raised by the
pressure of the coil spring, thus eliminating any
play in the arrangement until the valve is
operated again.
As wear occurs between rocker arm and
valve stem, the quantity of oil which flows into
the pressure chamber will be slightly more
than the quantity lost during the expansion
cycle of the cam follower. Conversely, when
the cam follower is compressed by the
expansion of the valve, a slightly smaller
quantity of oil will flow into the pressure
chamber than was lost.
To reduce valve clatter when the engine is
started, a small plastic stand pipe retains oil
inside the plunger. When the engine is started,
the reservoir in the plunger (and via the non-
return valve, the pressure chamber) are
immediately filled with oil. This reduces the
noise often associated with hydraulic cam
followers as they pressurise with oil after
engine start-up.
The cam follower rollers run in needle
bearings, which greatly reduces friction as the
rollers follow the cam profile.
The distributor and fuel pump are driven
directly from the camshaft and the oil pump is
driven directly from the front of the crankshaft.
The cylinder head is of crossflow design,
with the inlet manifold mounted on the right-
hand side and the exhaust manifold mounted
on the left-hand side.
Lubrication is by means of a bi-rotor pumpwhich draws oil through a strainer located
inside the sump and forces it through a full-
flow filter into the oil galleries where it is
distributed to the crankshaft and camshaft.
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 hydraulic
cam followers are supplied with oil from the
camshaft bearings via short passages in the
cylinder head.
A semi-closed crankcase ventilation system
is employed whereby piston blow-by gases
are drawn from the crankcase, through the
camshaft cover via an external vent hose, out
to an oil separator built into the base of the air
cleaner.
1.8 litre (R6A type) engine
The 1.8 litre (R6A type) CVH engine,
introduced in March 1992, is a further
development of the earlier 1.8 litre (R2A type)
unit described above. Apart from minor
engineering modifications to provide
increased fuel economy, reliability and power
output, the engine is mechanically identical to
the earlier version.
In common with the 1.6 litre unit, a
distributorless ignition system is used,
together with a comprehensive emissions
control system comprising Central Fuel
Injection (CFI), a sophisticated engine
management system, a crankcase ventilation
system, a catalytic converter, and additionally,
an exhaust gas recirculation (EGR) system.
Unless otherwise stated, all procedures are
as described for the 1.8 litre (R2A type)
engine.
Refer to Section 2, Chapter 2, Part A.
Refer to Chapter 1, Section 35.
Refer to Section 5, Chapter 2, Part A.
4Compression test
3Crankcase ventilation system -
inspection and maintenance
2Engine oil and filter - renewal
1General information
CVH engines 2C•5
2C
Page 6 of 24
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)
Page 7 of 24
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)
Page 10 of 24
1.8 litre (R2A type)
Dismantling
1It is best to mount the engine on a
dismantling stand, but if this is not available,
stand the engine on a strong bench at a
comfortable working height. Failing this, it will
have to stripped down on the floor.
2Cleanliness is most important, and if the
engine is dirty, it should be cleaned with
paraffin while keeping it in an upright position.
3Avoid working with the engine directly on a
concrete floor, as grit presents a real source
of trouble.
4As parts are removed, clean them in a
paraffin bath. However, do not immerse parts
with internal oilways in paraffin as it is difficult
to remove, usually requiring a high pressure
hose. Clean oilways with nylon pipe cleaners.
5It is advisable to have suitable containers
available to hold small items according to
their use, as this will help when reassembling
the engine and also prevent possible losses.
6Always obtain a complete set of new
gaskets for use during engine reassembly, but
retain the old gaskets with a view to using
them as a pattern to make a replacement if a
new one is not available.
7Where possible, refit securing nuts, bolts
and washers to their locations after removing
the relevant components. This will help to
protect the threads and will also prevent
possible losses.
8Retain unserviceable components in order
to compare them with the new components
supplied.
9A suitable Torx socket will be required to
remove the oil pump cover securing screws.
10Before dismantling the main engine
components, the following externally mounted
ancillary components can be removed:
Inlet manifold and carburettor
Exhaust manifold
Fuel pump and operating pushrod
Alternator
Spark plugs
Oil pressure warning lamp switch (see
illustration)
Oil filter
Dipstick
Engine mounting brackets
Clutch
Alternator mounting bracket
Crankshaft speed/position sensor
Engine lifting brackets
Examination and renovation
11Refer to Section 18 in Chapter 2, PartA.
Reassembly
12To ensure maximum life with minimum
trouble from a rebuilt engine, not only must
everything be correctly assembled, but it mustalso be spotlessly clean. All oilways must be
clear, and locking washers and spring
washers must be fitted where indicated. Oil all
bearings and other working surfaces
thoroughly with engine oil during assembly.
13Before assembly begins, renew any bolts
or studs with damaged threads.
14Gather together a torque wrench, oil can,
clean rag, and a set of engine gaskets and oil
seals, together with a new oil filter.
15If they have been removed, new cylinder
head bolts, big-end bolts/nuts and new
flywheel bolts will be required.
16After reassembling the main engine
components, refer to paragraph 10 and refit
the ancillary components listed. Delicate
items such as the alternator may be left until
after the engine has been refitted.
1.6 and 1.8 litre (R6A type)
Dismantling
17Refer to paragraphs 1 to 9 inclusive.
18Before dismantling the main engine
components, the following ancillary
components can be removed:
Inlet manifold and CFI unit.
Exhaust manifold .
Alternator.
Spark plugs and HT leads.
Ignition coil and mounting bracket.
Oil pressure warning lamp switch.
Oil filter.
Dipstick and tube.
Engine mounting brackets.
Clutch.
Alternator mounting bracket.Crankshaft speed/position sensor.
Engine lifting brackets.
Crankcase ventilation hose.
Examination and renovation
19Refer to Section 18 in Chapter 2, PartA.
Reassembly
20Refer to paragraphs 12 to 16 but note that
new rocker arm nuts will be required, if they
have been removed.
Note: The belt tension should be checked
using Ford special tool No 21-113 after
refitting. A suitable puller may be required to
remove the sprockets. If the camshaft
sprocket is removed, a new retaining bolt
must be used on refitting, and suitable sealant
(Loctite 74 or 274, or Omnifit 30M blue) will be
required to coat the bolt threads.
1.8 litre (R2A type)
Removal
1If the engine is in the vehicle, carry out the
following operations:
a)Disconnect the battery negative lead
b)Remove the alternator drivebelt
c)Remove the distributor cap, rotor arm and
housing
d)Disconnect the wiring plug from the
crankshaft speed/position sensor
e)Unclip the coolant hoses from the timing
cover, and position them across the top
of the camshaft cover out of the way
f)If desired for improved access, remove
the fan shroud and cooling fan assembly,
although this is not essential
2Slacken the crankshaft pulley bolt. Prevent
the crankshaft from turning by engaging top
gear (manual gearbox only) and having an
assistant apply the brake pedal hard, or by
removing the starter motor and jamming the
ring gear teeth with a lever.
3Remove the bolt and washer and withdraw
the pulley (see illustration). If the pulley will
not come off easily, refit the bolt part way and
use a puller, but take care not to damage the
sensor toothed disc.
18Timing belt and sprockets -
removal and refitting
17Engine dismantling,
examination, renovation and
reassembly - general information
2C•10CVH engines
17.10 Removing the oil pressure warning
lamp switch - 1.8 litre (R2A)
18.5 Withdrawing the timing cover -
1.8 litre (R2A)18.3 Withdrawing the crankshaft pulley -
1.8 litre (R2A)
Page 13 of 24
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)