wheel torque FORD SIERRA 1989 2.G CVH Engines Workshop Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 1989, Model line: SIERRA, Model: FORD SIERRA 1989 2.GPages: 24, PDF Size: 1.09 MB
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1.6 litre engine
Note: Unless otherwise stated, the Specifications for the 1.6 litre CVH engine are as given for the 1.8 litre (R2A type) which follow.
General
Engine code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L6B
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.960 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.520 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1596 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 :1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . . 12.2 to 14.3 bars
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 kW at 5500 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Nm at 3500 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.940 to 79.950 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.950 to 79.960 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.960 to 79.970 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.970 to 79.980 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.230 to 80.240 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.240 to 80.250 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.250 to 80.260 mm
Chapter 2 Part C:
CVH engines
Camshaft and cam followers - removal, inspection and refitting . . . .23
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Crankcase ventilation system - inspection and maintenance . . . . . . .3
Crankshaft and bearings - examination and renovation . . . . . . . . . .33
Crankshaft and main bearings - removal and refitting . . . . . . . . . . . .32
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cylinder block and bores - examination and renovation . . . . . . . . . .34
Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . . .21
Cylinder head - inspection and renovation . . . . . . . . . . . . . . . . . . . . .22
Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . . .19
Cylinder head - removal and refitting (engine removed) . . . . . . . . . . .20
Engine - refitting (automatic transmission in vehicle) . . . . . . . . . . . . .13
Engine - refitting (manual gearbox in vehicle) . . . . . . . . . . . . . . . . . . .12
Engine - removal leaving automatic transmission in vehicle . . . . . . . .9
Engine - removal leaving manual gearbox in vehicle . . . . . . . . . . . . . .8
Engine/automatic transmission assembly - reconnection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine/automatic transmission assembly - removal and separation .11Engine dismantling, examination, renovation and reassembly - general
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine/manual gearbox assembly - reconnection and refitting . . . . .14
Engine/manual gearbox assembly - removal and separation . . . . . .10
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . .24
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Initial start-up after overhaul or major repair . . . . . . . . . . . . . . . . . . .35
Major operations possible with the engine in the vehicle . . . . . . . . . . .5
Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . . .6
Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . .29
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Pistons and connecting rods - examination and renovation . . . . . . .31
Pistons and connecting rods - removal and refitting . . . . . . . . . . . . .30
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Timing belt and sprockets - removal and refitting . . . . . . . . . . . . . . .18
2C•1
Specifications Contents
2C
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
Page 3 of 24
Torque wrench settingsNmlbf ft
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 10066 to 74
Connecting rod (big-end bearing cap) bolts . . . . . . . . . . . . . . . . . . . . . .30 to 3622 to 27
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 to 11574 to 85
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 to 5940 to 44
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 to 9261 to 68
Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 126 to 9
Sump bolts (in two stages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 to 84 to 6
Rocker arm nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 to 2918 to 21
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 4015 to 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 6030 to 44
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle-tighten a further 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle-tighten a further 90º
Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 to 84 to 6
Timing cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Timing belt tensioner bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Oil pick-up tube/strainer-to-oil pump bolts . . . . . . . . . . . . . . . . . . . . . .8 to 126 to 9
Oil pick-up tube/strainer-to-cylinder block bolt . . . . . . . . . . . . . . . . . . .17 to 2313 to 17
Camshaft thrustplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Crankshaft rear oil seal housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
1.8 litre (R2A type) engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Engine code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .R2A
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.00 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.00 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1769 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3:1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . .11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .5850 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 kW at 5250 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 Nm at 3000 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.940 to 79.950 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.950 to 79.960 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.960 to 79.970 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.970 to 79.980 mm
Standard class 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.980 to 79.990 mm
Standard class 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.990 to 80.000 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.000 to 80.010 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.010 to 80.020 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80.020 to 80.030 mm
Crankshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 to 0.20 mm (0.004 to 0.008 in)
Main bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.028 to 0.067 mm
Main bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.980 to 54.000 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.730 to 54.750 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.480 to 53.500 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.230 to 53.250 mm
Centre main thrust bearing shell width:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28.825 to 28.875 mm
Undersize 0.15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28.675 to 28.725 mm
Big-end bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020 to 0.065 mm
Big-end bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.890 to 43.910 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.640 to 43.660 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.390 to 43.410 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.140 to 43.160 mm
Undersize 1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.890 to 42.910 mm
CVH engines 2C•3
2C
Page 4 of 24
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
Page 10 of 24
1.8 litre (R2A type)
Dismantling
1It is best to mount the engine on a
dismantling stand, but if this is not available,
stand the engine on a strong bench at a
comfortable working height. Failing this, it will
have to stripped down on the floor.
2Cleanliness is most important, and if the
engine is dirty, it should be cleaned with
paraffin while keeping it in an upright position.
3Avoid working with the engine directly on a
concrete floor, as grit presents a real source
of trouble.
4As parts are removed, clean them in a
paraffin bath. However, do not immerse parts
with internal oilways in paraffin as it is difficult
to remove, usually requiring a high pressure
hose. Clean oilways with nylon pipe cleaners.
5It is advisable to have suitable containers
available to hold small items according to
their use, as this will help when reassembling
the engine and also prevent possible losses.
6Always obtain a complete set of new
gaskets for use during engine reassembly, but
retain the old gaskets with a view to using
them as a pattern to make a replacement if a
new one is not available.
7Where possible, refit securing nuts, bolts
and washers to their locations after removing
the relevant components. This will help to
protect the threads and will also prevent
possible losses.
8Retain unserviceable components in order
to compare them with the new components
supplied.
9A suitable Torx socket will be required to
remove the oil pump cover securing screws.
10Before dismantling the main engine
components, the following externally mounted
ancillary components can be removed:
Inlet manifold and carburettor
Exhaust manifold
Fuel pump and operating pushrod
Alternator
Spark plugs
Oil pressure warning lamp switch (see
illustration)
Oil filter
Dipstick
Engine mounting brackets
Clutch
Alternator mounting bracket
Crankshaft speed/position sensor
Engine lifting brackets
Examination and renovation
11Refer to Section 18 in Chapter 2, PartA.
Reassembly
12To ensure maximum life with minimum
trouble from a rebuilt engine, not only must
everything be correctly assembled, but it mustalso be spotlessly clean. All oilways must be
clear, and locking washers and spring
washers must be fitted where indicated. Oil all
bearings and other working surfaces
thoroughly with engine oil during assembly.
13Before assembly begins, renew any bolts
or studs with damaged threads.
14Gather together a torque wrench, oil can,
clean rag, and a set of engine gaskets and oil
seals, together with a new oil filter.
15If they have been removed, new cylinder
head bolts, big-end bolts/nuts and new
flywheel bolts will be required.
16After reassembling the main engine
components, refer to paragraph 10 and refit
the ancillary components listed. Delicate
items such as the alternator may be left until
after the engine has been refitted.
1.6 and 1.8 litre (R6A type)
Dismantling
17Refer to paragraphs 1 to 9 inclusive.
18Before dismantling the main engine
components, the following ancillary
components can be removed:
Inlet manifold and CFI unit.
Exhaust manifold .
Alternator.
Spark plugs and HT leads.
Ignition coil and mounting bracket.
Oil pressure warning lamp switch.
Oil filter.
Dipstick and tube.
Engine mounting brackets.
Clutch.
Alternator mounting bracket.Crankshaft speed/position sensor.
Engine lifting brackets.
Crankcase ventilation hose.
Examination and renovation
19Refer to Section 18 in Chapter 2, PartA.
Reassembly
20Refer to paragraphs 12 to 16 but note that
new rocker arm nuts will be required, if they
have been removed.
Note: The belt tension should be checked
using Ford special tool No 21-113 after
refitting. A suitable puller may be required to
remove the sprockets. If the camshaft
sprocket is removed, a new retaining bolt
must be used on refitting, and suitable sealant
(Loctite 74 or 274, or Omnifit 30M blue) will be
required to coat the bolt threads.
1.8 litre (R2A type)
Removal
1If the engine is in the vehicle, carry out the
following operations:
a)Disconnect the battery negative lead
b)Remove the alternator drivebelt
c)Remove the distributor cap, rotor arm and
housing
d)Disconnect the wiring plug from the
crankshaft speed/position sensor
e)Unclip the coolant hoses from the timing
cover, and position them across the top
of the camshaft cover out of the way
f)If desired for improved access, remove
the fan shroud and cooling fan assembly,
although this is not essential
2Slacken the crankshaft pulley bolt. Prevent
the crankshaft from turning by engaging top
gear (manual gearbox only) and having an
assistant apply the brake pedal hard, or by
removing the starter motor and jamming the
ring gear teeth with a lever.
3Remove the bolt and washer and withdraw
the pulley (see illustration). If the pulley will
not come off easily, refit the bolt part way and
use a puller, but take care not to damage the
sensor toothed disc.
18Timing belt and sprockets -
removal and refitting
17Engine dismantling,
examination, renovation and
reassembly - general information
2C•10CVH engines
17.10 Removing the oil pressure warning
lamp switch - 1.8 litre (R2A)
18.5 Withdrawing the timing cover -
1.8 litre (R2A)18.3 Withdrawing the crankshaft pulley -
1.8 litre (R2A)
Page 20 of 24
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