four wheel drive FORD SIERRA 1989 2.G CVH Engines Workshop Manual

Note: New flywheel securing bolts must be
used on refitting.
1.8 litre (R2A type)
1Refer to Section 26, Chapter 2, PartA but
also note the following points.
2The flywheel/driveplate securing bolts must
be renewed when refitting, and the new bolts
are supplied ready-coated with threadlocking
compound (see illustration).
3The ring gear cannot be renewed
independently of the flywheel/driveplate. If the
ring gear is badly worn or has missing teeth, a
new flywheel/driveplate must be fitted.
1.6 and 1.8 litre (R6A type)
4Refer to Section 26, Chapter 2, PartA,
noting the following points.
5If the engine is in the vehicle, refer to
Chapter 6 when removing the clutch.
6The flywheel securing bolts must be
renewed when refitting, and the new bolts are
supplied ready-coated with thread-locking
compound.
7The ring gear cannot be renewed
independently of the flywheel. If the ring gear
is badly worn or has missing teeth, a new
flywheel must be fitted. Similarly, the flywheel
must be renewed if the crankshaft
speed/position sensor toothed disc is
damaged.
1.8 litre (R2A type)
1Remove the timing belt and the crankshaft
sprocket and thrustwasher.
2Withdraw the oil seal using an oil seal
removal tool or by drilling the oil seal outer
face and using self-tapping screws and a pair
of grips.
3Clean the oil seal housing, then smear the
lip of a new oil seal with clean engine oil.
4Fit the oil seal using the crankshaft pulley
bolt and a suitable tool similar to that shown
(see illustration).5As the seal is drawn into position, the inner
edge of the seal may be damaged as it passes
over the end of the shaft. To prevent this, as
soon as the seal begins to locate in the
housing remove the tools being used to fit the
seal, and carefully work the inner edge of the
seal over the end of the crankshaft, using a
small screwdriver or similar blunt tool. The
seal can then be pushed home using the tools
described previously (see illustration).
6Refit the thrustwasher, crankshaft sprocket
and timing belt.
1.6 and 1.8 litre (R6A type)
7Remove the timing belt, and the crankshaft
sprocket and thrustwasher.
8Proceed as described in paragraphs 2 to 4
inclusive.
9Refit the thrustwasher, crankshaft sprocket
and timing belt.
1Remove the flywheel/driveplate.
2Prise out the oil seal. If necessary, drill the
outer face of the oil seal and use self-tappingscrews and a pair of grips to withdraw the
seal (see illustration).
3Clean the oil seal housing, then fit the new
oil seal using two flywheel/driveplate securing
bolts and a tool similar to that shown (see
illustration). A suitable tool can be
improvised using a narrow strip of metal sheet
bent to form a circle of the correct diameter,
and a large metal disc with appropriate holes
drilled to allow the flywheel/driveplate
securing bolts to pass through. Make sure
that the seal lip faces into the engine and
lightly smear the lip with clean engine oil.
4Refit the flywheel/driveplate.
Note: A new gasket and new sump bolts must
be used when refitting, and suitable sealant will
be required (available from a Ford dealer). Note
that it is preferable to keep the engine upright
until the sump has been removed to prevent
sludge from entering the engine internals.
1.8 litre (R2A type)
Removal
1With the engine removed, proceed as
follows.
2Remove the flywheel/driveplate and the
engine adapter plate.
3Unscrew the fourteen securing bolts and
withdraw the two reinforcing strips and the
sump. If the sump is stuck, carefully tap it
sideways to free it. Do not prise between the
mating faces.
27Sump - removal and refitting
26Crankshaft rear oil seal -
renewal
25Crankshaft front oil seal -
renewal
24Flywheel/driveplate - removal,
inspection and refitting
CVH engines 2C•19
2C
25.5 Crankshaft front oil seal (arrowed)
located in oil pump housing - 1.8 litre (R2A)26.3 Using a special tool to fit the
crankshaft rear oil seal - 1.8 litre (R2A)26.2 Crankshaft rear oil seal location
(arrowed)
25.4 Using a special tool to fit the
crankshaft front oil seal - 1.8 litre (R2A)24.2 Using an improvised tool to hold the
flywheel stationary while tightening the
securing bolts - 1.8 litre (R2A)
A tool can be improvised to fit
the crankshaft front oil seal
by using a metal tube of
suitable diameter and a large
washer or metal disc. Do not attempt to
drive the seal home using a tube drift.

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