compression ratio FORD SIERRA 1988 2.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

1.6 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LCS, LCT, LSD and LSE
LCS and LCTLSD and LSE
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.67 mm81.32 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.00 mm76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1593 cc1597 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2 : 19.5 : 1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . .11 to 13 bar11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .5800 rpm5950 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 kW at 5300 rpm55 kW at 4900 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Nm at 2900 rpm123 Nm at 2900 rpm
Cylinder bore diameterLCS and LCTLSD and LSE
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.650 to 87.660 mm81.300 to 81.310 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.660 to 87.670 mm81.310 to 81.320 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.670 to 87.680 mm81.320 to 81.330 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.680 to 87.690 mm81.330 to 81.340 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.160 to 88.170 mm81.810 to 81.820 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.170 to 88.180 mm81.820 to 81.830 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.180 to 88.190 mm81.830 to 81.840 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.680 to 87.690 mm81.330 to 81.340 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.180 to 88.190 mm81.830 to 81.840 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.680 to 88.690 mm82.330 to 82.340 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:LCS and LCTLSD and LSE
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.615 to 87.625 mm81.265 to 81.275 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.625 to 87.635 mm81.275 to 81.285 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.635 to 87.645 mm81.285 to 81.295 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.645 to 87.655 mm81.295 to 81.305 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.640 to 87.665 mm81.290 to 81.315 mm
Service oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.140 to 88.165 mm81.790 to 81.815 mm
Service oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.640 to 88.665 mm82.290 to 82.315 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.500 mm0.300 to 0.500 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.500 mm0.300 to 0.500 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.400 to 1.400 mm0.400 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
Camshaft
Specifications as for 1.3 litre engine except for the following:
Endfloat:
Engine codes LCS, LCT and LSE . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.104 to 0.204 mm (0.004 to 0.008 in)
Engine code LSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.090 to 0.170 mm (0.003 to 0.007 in)
Valves
Specification as for 1.3 litre engine
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settings
Specification as for 1.3 litre engine
2A¥4SOHC engines

1.8 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four-cylinder, in line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REB and RED
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.20 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1796 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5:1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . .11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .5850 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66kW at 5400 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Nm at 3500 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.180 to 86.190 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.190 to 86.200 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.200 to 86.210 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.210 to 86.220 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.690 to 86.700 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.700 to 86.710 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.710 to 86.720 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.210 to 86.220 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.710 to 86.720 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.210 to 87.220 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.145 to 86.155 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.155 to 86.165 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.165 to 86.175 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.175 to 86.185 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.170 to 86.195 mm
Service oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.670 to 86.695 mm
Service oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.170 to 86.195 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.500 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.500 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 and camshaft
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 ±0.03 mm (0.010 ±0.001 in)
Valve timing:
Inlet opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24¼ BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64¼ ABDC
Exhaust opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70¼ BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18¼ ATDC
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settings
Specifications as for 1.3 litre engine
SOHC engines 2A¥5
2A

2.0 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NES and NET (carburettor, except P100), NRB and N4A (fuel
injection), and NAE (P100)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.82 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1993 cc
Compression ratio:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2:1
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2:1
Compression pressure at starter motor speed:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 to 13 bar
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 12 bar
Maximum continuous engine speed:
Engine code NES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5850 rpm
Engine codes NET and NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5800 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6050 rpm
Maximum engine power (DIN):
Engine codes NES and NET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77kW at 5200 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85kW at 5500 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57kW at 4500 rpm
Maximum engine torque (DIN):
Engine codes NES and NET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 Nm at 4000 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Nm at 4000 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 Nm at 2800 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.800 to 90.810 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.810 to 90.820 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.820 to 90.830 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.830 to 90.840 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.310 to 91.320 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.320 to 91.330 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.330 to 91.340 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.830 to 90.840 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.330 to 91.340 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.830 to 91.840 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness:
All except engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30 to 2.35 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50 to 2.55 mm
Engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.765 to 90.775 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.775 to 90.785 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.785 to 90.795 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.795 to 90.805 mm
Standard service:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.780 to 90.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.790 to 90.815 mm
Service oversize 0.5:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.280 to 91.305 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.290 to 91.315 mm
Service oversize 1.0:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.780 to 91.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.790 to 91.815 mm
2A¥6SOHC engines

4Before fitting the new rings to the pistons,
insert them into the cylinder bore and use a
feelerblade to check that the end gaps are
within the specified limits (see illustration).
5Clean out the piston ring groove using a
piece of old piston ring as a scraper. Be
careful not to scratch the aluminium surface
of the pistons. Protect your fingers - piston
ring edges are sharp.
6Fit the oil control ring sections with the
spreader ends abutted opposite the front of the
piston. The side ring gaps should be 25 mm (1.0
in) either side of the spreader gap. Fit the
tapered lower compression ring with the ÒTOPÓ
mark towards the top of the piston and the gap
150¼ from the spreader gap, then fit the upper
compression ring with the gap 150¼ on the
other side of the spreader gap. Note that the
compression rings are coated with a
molybdenum skin which must not be damaged.
Note also that the compression rings are made
of cast iron, and will snap if expanded too far.
Removal
1With the engine removed from the vehicle,
remove the timing belt, crankshaft sprocket,
auxiliary shaft sprocket and the
flywheel/driveplate.
2Remove the pistons and connecting rods. If
no work is to be done on the pistons and
connecting rods, there is no need to push the
pistons out of the cylinder bores.
3Unbolt the crankshaft front oil seal housing
and the auxiliary shaft front cover and remove
the gasket.4Remove the oil pump and pick-up tube.
5Check the main bearing caps for
identification marks and if necessary use a
centre-punch to identify them (see
illustration).
6Before removing the crankshaft, check that
the endfloat is within the specified limits by
inserting a feeler blade between the centre
crankshaft web and the thrustwashers (see
illustration). This will indicate whether or not
new thrustwashers are required.
7Unscrew the bolts and tap off the main
bearing caps complete with bearing shells. If
the thrustwashers are to be re-used identify
them for location. Recover the sealing wedges
from either side of the rear bearing cap.
8Lift the crankshaft from the crankcase and
remove the rear oil seal. Recover the
remaining thrustwashers (see illustration).
9Extract the bearing shells, keeping them
identified for location (see illustration).
Refitting
10Commence refitting as follows.
11Wipe the bearing shell locations in the
crankcase with a soft, non-fluffy rag.
12Wipe the crankshaft journals with a soft,
non-fluffy rag.
13If the old main bearing shells are to be
renewed (not to do so is a false economy,
unless they are virtually new) fit the five upper
halves of the main bearing shells to their
location in the crankcase.
14Identify each main bearing cap and place
in order. The number is cast on to the cap and
on intermediate caps an arrow is marked
which points towards the front of the engine.
15Wipe each cap bearing shell location with
a soft non-fluffy rag. 16Fit the bearing half shell onto each main
bearing cap.
17Apply a little grease to each side of the
centre main bearing so as to retain the
thrustwashers.
18Fit the upper halves of the thrustwashers
into their grooves either side of the main
bearing. The slots must face outwards.
19Lubricate the crankshaft journals and the
upper and lower main bearing shells with
clean engine oil and locate the rear oil seal
(with lip lubricated) on the rear of the
crankshaft.
20Carefully lower the crankshaft into the
crankcase.
21Lubricate the crankshaft main bearing
journals again, and then fit No 1 bearing cap. Fit
the two securing bolts but do not tighten yet.
22Make sure that the mating faces are
clean, then apply sealant (Loctite 518 or
equivalent) to the areas on the rear main
bearing cap shown (see illustration).
23Fit the rear main bearing cap. Fit the two
securing bolts but as before do not tighten yet.
24Apply a little grease to either side of the
centre main bearing cap so as to retain the
thrustwashers. Fit the thrustwashers with the
tag located in the groove and the slots facing
outwards (see illustration).
25Fit the centre main bearing cap and the
two securing bolts, then refit the intermediate
main bearing caps. Make sure that the arrows
point towards the front of the engine.
26Lightly tighten all main bearing cap
securing bolts and then fully tighten in a
progressive manner to the specified torque
wrench setting.
27Check that the crankshaft rotates freely.
Some stiffness is to be expected with new
34Crankshaft and main bearings
- removal and refitting
SOHC engines 2A¥23
2A
34.6 Checking crankshaft endfloat
34.22 Coat the arrowed areas of the rear
main bearing cap with sealant34.9 Extract each main bearing shell34.8 Removing a thrustwasher from the
centre main bearing
34.5 Main bearing cap identification marks.
The arrow points to the front of the engine
33.4 Checking a piston ring gap at the top
of the cylinder bore