length FORD SIERRA 1989 2.G CVH Engines Workshop Manual

Crankshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.09 to 0.30 mm (0.004 to 0.012 in)
Main bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.011 to 0.058 mm
Main bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.980 to 58.000 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.730 to 57.750 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.480 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.230 to 57.250 mm
Main bearing thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.301 to 2.351 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.491 to 2.541 mm
Big-end bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 to 0.060 mm
Big-end bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.890 to 47.910 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.640 to 47.660 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.390 to 47.410 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.140 to 47.160 mm
Undersize 1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46.890 to 46.910 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.915 to 79.925 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.925 to 79.935 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.935 to 79.945 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.945 to 79.955 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.205 to 80.215 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.215 to 80.225 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.225 to 80.235 mm
Piston ring end gap:
Top and centre rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.500 mm (0.012 to 0.020 in)
Bottom (oil control) ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.250 to 0.400 mm (0.010 to 0.016 in)
Camshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.050 to 0.150 mm (0.002 to 0.006 in)
Thrustplate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.990 to 5.010 mm (0.1966 to 0.1974 in)
Bearing journal diameter:
Bearing No 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44.750 mm
Bearing No 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.000 mm
Bearing No 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.250 mm
Bearing No 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.500 mm
Bearing No 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.750 mm
Valves
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4º ATDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10º BTDC
Valve spring free length:
Colour code blue/blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.200 mm
Colour code white/blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.400 mm
Inlet valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.025 to 8.043 mm
Oversize 0.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.225 to 8.243 mm
Oversize 0.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.425 to 8.443 mm
Exhaust valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.999 to 8.017 mm
Oversize 0.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.199 to 8.217 mm
Oversize 0.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.399 to 8.417 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 litres (6.2 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25 litres (5.7 pints)
Oil pump clearances:
Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.060 to 0.190 mm (0.002 to 0.007 in)
Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.050 to 0.180 mm (0.002 to 0.007 in)
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.014 to 0.100 mm (0.001 to 0.004 in)
2C•2CVH engines

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

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