brake rotor FORD SIERRA 1989 2.G DOHC Engine Workshop Manual

Dismantling
1Refer to Chapter 2, PartA, Section 18,
paragraphs 1 to 8 inclusive.
2A suitable selection of splined and Torx
sockets will be required to remove many of
the bolts when dismantling the engine.
3Before dismantling the main engine
components, the following externally-
mounted ancillary components can be
removed, with reference to the relevant
Chapters of this Manual and the relevant
Sections of this Chapter, where applicable.
Inlet manifold (and carburettor, if applicable)
Exhaust manifold
Alternator.
Coolant pump, and thermostat
Alternator/coolant pump drivebelt tensioner
Distributor cap, HT leads and spark plugs
Oil pressure warning lamp switch
Crankshaft speed/position sensor
Oil filter
Dipstick
Engine mounting brackets (if not already done)
Crankcase ventilation pipe and hoses
Clutch
Alternator mounting bracket.
Air conditioning compressor mounting
bracket (where applicable).
Engine lifting brackets.
Examination and renovation
4Refer to Chapter 2, PartA, Section 18, but
note that the connecting rod bolts should be
renewed on reassembly, and when renewing
the cylinder head bolts, the latest type bolts
with hexagonal heads should always be used.
Reassembly
5Proceed as described in Chapter 2, PartA,
Section 18, noting the following:
6If they have been removed, new cylinder
head bolts (both M11 and M8, of the latest
type with hexagonal heads), flywheel bolts,
and connecting rod bolts must be used.
Note: Refer to the warning at the beginning of
Section 5 before proceeding. A suitable puller
will be required to remove the crankshaft pulley.
A new crankshaft pulley bolt, a new timing chain
tensioner plunger assembly, new upper and
lower timing chain cover gaskets, and a new
camshaft cover gasket and reinforcing sleeve
sealing rings, must be used on refitting.
Removal
1If the engine is in the car, carry out the
following operations:
a)Disconnect the battery negative lead.
b)To improve access, remove the radiator. It
will be difficult to remove the crankshaft
pulley with the radiator in place.c)On carburettor models, remove the air
cleaner.
d)On fuel injection models, remove the air
inlet hose, plenum chamber, and air
cleaner lid as an assembly.
e)Disconnect the breather hose from the
camshaft cover.
f)Remove the distributor cap and HT leads,
and the rotor arm and housing.
2Proceed as described in paragraphs 2 to 11
inclusive of Section 18 (see illustration).
3Remove the alternator drivebelt.
4Slacken the crankshaft pulley bolt. Prevent
the crankshaft from turning by engaging top
gear (manual gearbox only) and having an
assistant press the brake pedal hard, or by
removing the starter motor and jamming the
ring gear teeth with a lever.
5Unscrew the bolt part-way, and use a puller
to remove the crankshaft pulley. The legs ofthe puller must be suitably shaped to enable
them to rest on the metal surfaces of the
pulley. Do not use a puller on the rubber
surface of the pulley (see illustrations).
15Timing chain and sprockets -
removal and refitting
14Engine dismantling,
examination, renovation and
reassembly - general information
2B•8DOHC engine
15.2 Timing chain, oil pump drive chain and associated components
1 Upper timing chain guide
2 Exhaust camshaft sprocket
3 Timing chain
4 Lower timing chain guide
5 Crankshaft sprocket (double)
6 Crankshaft
7 Oil pump chain tensioner
8 Oil pump drive chain
9 Oil pump10 Oil pressure relief valve
11 Oil passage to timing chain tensioner
plunger
12 Plug
13 Timing chain tensioner plunger
14 Timing chain tensioner sprocket
15 Timing chain tensioner arm
16 Inlet camshaft sprocket
17 Copper chain links
15.5a Remove the crankshaft pulley using
a puller (viewed from under vehicle)

should be fitted dry. Drive in the new seal
using a suitable metal tube, making sure that
the seal lip faces into the engine, and taking
care not to damage the timing chain cover
(see illustration).
31Fit the lower timing chain cover using a
new rubber gasket (see illustration).
32Loosely refit the timing chain cover
securing bolts.
33Refit the crankshaft pulley to the end of the
crankshaft, and draw the pulley onto the
crankshaft using the original securing bolt, at the
same time centring the lower timing chain cover.
34With the lower timing chain cover
centralised, and the pulley fully home on the
crankshaft, remove the old securing bolt, then
fit a new bolt.
35Tighten the new crankshaft pulley bolt to
the specified torque, in the two stages given
in the Specifications at the beginning of this
Chapter. Prevent the crankshaft from turning
as during removal.
36Tighten the lower timing chain cover
securing bolts.
37Refit the drivebelt tensioner assembly,
ensuring that the lug on the rear of the
tensioner bracket engages with the
corresponding hole in the cylinder block, and
tighten the securing bolt.
38Swing the alternator into position to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensioner
assembly, then refit the upper mounting bolt,
and tighten the upper bolt and the lower
through-bolt.
39Refit the alternator drivebelt.
40If the engine is in the vehicle, reverse the
operations described in paragraph 1.
41If applicable, refill the cooling system.
1Examine alI the teeth on the camshaft and
crankshaft sprockets. If the teeth are “hooked”
in appearance, renew the sprockets.
2Examine the chain tensioner plastic
sprocket for wear. If excessive wear is
evident, the complete tensioner assembly
must be renewed, as the sprocket cannot be
renewed independently. Note that the
tensioner plunger assembly must be renewed
whenever the timing chain is removed.3Examine the timing chain for wear. If the
chain has been in operation for a considerable
time, or if when held horizontally (rollers
vertical) it takes on a deeply-bowed
appearance, renew it.
Note: Refer to the warning at the beginning of
Section 5 and the note at the beginning of the
following Section before proceeding. The
cylinder head must not be removed when the
engine is warm.
Removal
1Disconnect the battery negative lead.
2On carburettor models, remove the air
cleaner.
3On fuel injection models, remove the air
inlet hose, plenum chamber, and air cleaner
lid as an assembly.
4Drain the cooling system.
5Disconnect the heater coolant hose from
the inlet manifold (see illustration).
6Disconnect the breather hose from the
camshaft cover, and unbolt the hose bracket
from the left-hand side of the cylinder head
(see illustration).
7Unscrew the securing bolt and disconnect
the earth lead from the left-hand rear of the
cylinder head (see illustration).
8Remove the distributor cap and HT leads,
and the rotor arm and housing. If necessary,
mark the HT leads to aid refitting.
9The cylinder head can be removed either
with or without the manifolds and fuel rail,
where applicable (it is easiest to remove thehead complete with the manifolds and fuel
rail). If desired, the inlet manifold and the fuel
rail can be unbolted and moved to one side,
leaving the wires, hoses, pipes and cables
connected, but care must be taken not to
place any strain on them.
10Unscrew the three securing nuts and
disconnect the exhaust downpipe from the
manifold. It may be necessary to jack up the
front of the vehicle to gain access to the nuts
(in which case, apply the handbrake and
support the front of the vehicle securely on
axle stands). Recover the gasket.
11If the inlet manifold and the fuel rail (where
applicable) are to be removed with the
cylinder head, disconnect all relevant wires,
hoses, pipes and cables. Otherwise, unbolt
the manifold and the fuel rail, and move them
to one side, ensuring that they are adequately
supported. If the fuel rail is unbolted, be
prepared for fuel spillage, and take adequate
fire precautions.
12Proceed as shown in paragraphs 2 to 19
of Section 18.
Refitting
13Proceed as shown in paragraphs 20 to 55
of Section 18.
14With the cylinder head refitted, reverse the
procedure described in paragraphs 1 to 11,
noting the following points.
15Use a new gasket when reconnecting the
exhaust downpipe to the manifold.
16Ensure that the HT leads are reconnected
correctly.
17Fill the cooling system.
17Cylinder head - removal and
refitting (engine in vehicle)
16Timing chain, sprockets and
tensioner - examination and
renovation
2B•10DOHC engine
15.30 Fitting a new lower timing chain
cover oil seal
17.5 Disconnecting the heater coolant
hose from the inlet manifold17.7 Disconnect the earth lead (arrowed)
from the cylinder head17.6 Hose bracket bolted to cylinder head
(arrowed)
15.31 Lower timing chain cover rubber
gasket in position. Ensure that lug on
gasket engages with notch in cover
(arrowed)