radiator cap FORD SIERRA 1989 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)