handbrake FORD SIERRA 1988 2.G CVH Engines Workshop Manual

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)

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 units slightly to
separate them.
1.8 litre (R2A type)
1Reverse the procedure described in
Section 8, noting the following points.
2Before attempting to refit the engine, check
that the clutch friction disc is centralised. This
is necessary to ensure that the gearbox input
shaft splines will pass through the splines in
the centre of the friction disc.
3Check that the clutch release arm and
bearing are correctly fitted, and lightly grease
the input shaft splines.
4Check that the engine adapter plate is
correctly positioned on its locating dowels.
5Reconnect the clutch cable to the release
arm, ensuring that it is routed as noted during
removal.
6Fill the engine with the correct grade and
quantity of oil.
7Fill the cooling system.
8Check and if necessary adjust the tension
of the alternator drivebelt.
9Adjust the throttle cable.
1.6 and 1.8 litre (R6A type)
10Reverse the procedure described in
Section 8, noting the points made above.
1Reverse the procedure described in
Section 9, noting the following points.
2Check that the engine adapter plate is
correctly positioned on its locating dowels.
3As the torque converter is only loosely
engaged in the transmission, care must be
taken to prevent the torque converter from
falling out forwards. When the torque
converter hub is fully engaged with the fluid
pump drivegear in the transmission, distance
“A” in illustration 2.24 of Chapter 7B must be
as specified. Incorrect installation of the
torque converter will result in damage to the
transmission.
4As the engine is installed, guide the torque
converter studs through the holes in the
driveplate. When the engine is positioned
flush with the engine adapter plate and the
transmission housing, check that the torque
converter is free to move axially a small
amount before refitting and tightening the
engine-to-transmission bolts.
5Do not tighten the torque converter-to-
driveplate nuts until the lower engine-to-
transmission bolts have been fitted and
tightened.
6Fill the engine with the correct grade and
quantity of oil. 7Fill the cooling system.
8Check and if necessary adjust the tension
of the alternator drivebelt.
9Adjust the throttle cable.
10If applicable, adjust the kickdown cable.
1.8 litre (R2A type)
1Reverse the procedure described in Section
10, noting the following points.
2Before attempting to reconnect the engine
to the gearbox, check that the clutch friction
disc is centralised. This is necessary to ensure
that the gearbox input shaft splines will pass
through the splines in the centre of the friction
disc.
3Check that the clutch release arm and
bearing are correctly fitted, and lightly grease
the input shaft splines.
4Check that the engine adapter plate is
correctly positioned on its locating dowels.
5Reconnect the clutch cable to the release
arm, ensuring that it is routed as noted during
removal.
6Fill the engine with the correct grade and
quantity of oil.
7Fill the cooling system.
8Check and if necessary top-up the gearbox
oil level.
9Check and if necessary adjust the tension
of the alternator drivebelt.
10Adjust the throttle cable.
1.6 and 1.8 litre (R6A type)
11Reverse the procedure described in
Section 10, noting the points made above.
Ensure that the vehicle speed sensor wiring
plug is reconnected.
1Reverse the procedure described in Section
11, noting the following points.
2Check that the engine adapter plate is
correctly positioned on its locating dowels.
3As the torque converter is only loosely
engaged in the transmission, care must be
taken to prevent the torque converter from
falling out forwards. When the torque
converter hub is fully engaged with the fluid
pump drivegear in the transmission, distance
“A” in illustration 2.24 of Chapter 7B must be
as specified. Incorrect installation of the
torque converter will result in damage to the
transmission.
4As the engine and transmission are
reconnected, guide the torque converter
studs through the holes in the driveplate.
When the engine is positioned flush with the
engine adapter plate and the transmission
housing, check that the torque converter is
free to move axially a small amount beforerefitting and tightening the engine-to-
transmission bolts.
5Do not tighten the torque converter-to-
driveplate nuts until the lower engine-to-
transmission bolts have been fitted and
tightened.
6Reconnect and adjust the selector rod.
7Fill the engine with the correct grade and
quantity of oil.
8Fill the cooling system.
9Check and if necessary top-up the
transmission fluid level.
10Check and if necessary adjust the tension
of the alternator drivebelt.
11Adjust the throttle cable.
12Where applicable, adjust the kickdown
cable.
1The engine mountings incorporate
hydraulic dampers and must be renewed if
excessive engine movement is evident.
2Working in the engine compartment,
unscrew the central nuts securing the engine
mounting brackets to the tops of the
mountings. Recover the washers.
3Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
4Working underneath the vehicle, remove
the central nuts securing the mountings to the
crossmember. Recover the washers.
5Raise the engine using a suitable hoist and
lifting tackle attached to the engine lifting
brackets on the cylinder head, or a jack and
interposed block of wood under the sump,
until the mountings can be withdrawn.
6Fit the new mountings, then lower the
engine onto them. Note that the locating pins
on the mountings must engage with the
corresponding holes in the engine mounting
brackets (see illustration).
7Fit the nuts and washers securing the
mountings to the crossmember and tighten
the nuts.
8Lower the vehicle to the ground and fit the
nuts and washers securing the engine
mounting brackets to the mountings. Tighten
the nuts.
16Engine mountings - renewal
15Engine/automatic
transmission assembly -
reconnection and refitting
14Engine/manual gearbox
assembly - reconnection and
refitting
13Engine - refitting (automatic
transmission in vehicle)
12Engine - refitting (manual
gearbox in vehicle)
CVH engines 2C•9
2C
16.6 Locating pin on mounting must
engage with hole (arrowed) in engine
mounting bracket