alternator belt FORD SIERRA 1991 2.G Cooling And Air Conditioning Systems Workshop Manual

System type
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
thermo-viscous fan, thermostat, and expansion tank
CVH and DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
electric fan, thermostat, and expansion tank
Thermostat
Nominal temperature rating (fully open):
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190º F)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC (212ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102ºC (216ºF)
Opening temperature:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190ºF)
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
Expansion tank cap opening pressure
SOHC models:
Up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.1 bar (12 to 16 lbf/in2)
From 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.4 bar (15 to 20 lbf/in2)
Coolant mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
System capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
Drivebelt tensions
Air conditioning system compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection at the midpoint of the belt’s longest run
under firm thumb pressure
Coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection midway between coolant pump and
alternator (or power steering pump) pulleys under firm thumb pressure
Chapter 3
Cooling, heating and air conditioning systems
Air conditioning system - component renewal . . . . . . . . . . . . . . . . . .21
Coolant pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .9
Coolant pump/alternator drivebelt(s) - checking, renewal and
tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Coolant pump/alternator drivebelt tensioner (DOHC models with
power steering) - removal and refitting . . . . . . . . . . . . . . . . . . . . . .11
Cooling fan switch - removal and refitting . . . . . . . . . . . . . . . . . . . . .14
Cooling system - draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cooling system - filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cooling system - flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electric cooling fan - removal and refitting . . . . . . . . . . . . . . . . . . . . .13
Expansion tank and coolant level sensor - removal and refitting . . . .15General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Heater controls - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .17
Heater motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .20
Heater unit - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Heater unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Radiator - inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Temperature gauge sender - removal and refitting . . . . . . . . . . . . . .16
Thermostat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Thermostat - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Thermo-viscous cooling fan (SOHC models) - removal and refitting .12
3•1
Specifications Contents3
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

Torque wrench settingsNmlbf ft
Radiator upper mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2515 to 18
Radiator lower mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 126 to 9
Coolant pump bolts:
SOHC models:
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 15
M10 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4226 to 31
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2815 to 21
Thermostat housing bolts:
SOHC/DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2013 to 15
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 126 to 9
Cooling fan shroud-to-radiator nuts/bolts . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Coolant pump pulley bolts:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2815 to 21
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Coolant pump/alternator drivebelt tensioner bolt:
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 to 3017 to 22
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 9752 to 72
Cooling fan blades-to-fan hub bolts (SOHC models) . . . . . . . . . . . . . . .8 to 106 to 7
Air conditioning compressor-to-bracket bolts . . . . . . . . . . . . . . . . . . . .65 to 7548 to 55
Air conditioning compressor bracket-to-engine bolts:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 to 9263 to 68
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 to 12081 to 89
Air conditioning condenser fan assembly-to-condenser bolts:
Models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 to 31 to 2
Models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Air conditioning condenser securing bolts (models from 1987) . . . . . . .27 to 3320 to 24
General information
The cooling system is of pressurised type,
and consists of a front mounted radiator,
coolant pump, cooling fan, wax type
thermostat, and an expansion tank.
The radiator matrix is manufactured from
honeycombed metal, and the end tanks are
made of plastic. On automatic transmission
models, the right-hand end tank incorporates
the transmission fluid cooler.
The coolant pump is located on the front
face of the engine block, and is belt-driven.
The pump is of the impeller type.
The cooling fan draws cold air over the
radiator matrix to assist the cooling process
when the forward speed of the vehicle is too
low to provide sufficient cooling airflow, or the
ambient temperature is unusually high. SOHC
models have a thermo-viscous fan, whereas
CVH and DOHC models have an
electrically-operated fan.
The thermo-viscous fan is controlled by the
temperature of the air behind the radiator.
When the air temperature reaches a
predetermined level, a bi-metallic coil
commences to open a valve within the unit,
and silicon fluid is fed through a system of
vanes. Half the vanes are driven directly by
the coolant pump, and the remaining half are
connected to the fan blades. The vanes are
arranged so that drive is transmitted to the fan
blades in relation to the viscosity of the silicon
fluid, and this in turn depends on ambienttemperature and engine speed. The fan is
therefore only operating when required, and
compared with direct-drive type fans
represents a considerable improvement in fuel
economy, drivebelt wear and fan noise.
The electrically-operated fan is switched on
by a temperature sensor mounted in the
thermostat housing when the temperature
reaches a predetermined level. The fan is
therefore only operating when required, and like
the thermo-viscous fan, offers a considerable
advantage over direct-drive type fans.
A thermostat is fitted. Its purpose is to
ensure rapid engine warm-up by restricting
the flow of coolant to the engine when cold
and also to assist in regulating the normal
operating temperature of the engine.
The expansion tank incorporates a pressure
cap which effectively pressurises the cooling
system as the coolant temperature rises,
thereby increasing the boiling point of the
coolant. The tank also has a further degas
function. Any accumulation of air bubbles in the
coolant is returned to the tank and released in
the air space, thus maintaining the efficiency of
the coolant. The pressure cap also incorporates
a vacuum relief valve which prevents a vacuum
forming in the system as it cools.
The system functions as follows. Cold
coolant in the bottom of the radiator circulates
through the bottom hose to the coolant pump
where the pump impeller pushes the coolant
through the passages within the cylinder
block, cylinder head and inlet manifold. After
cooling the cylinder bores, combustion
chambers and valve seats, the coolant
reaches the underside of the thermostat
which is initially closed. A small proportion ofthe coolant passes from the thermostat
housing to the expansion tank, but the main
circulation is through the inlet manifold,
automatic choke (where applicable), and
heater matrix, finally returning to the coolant
pump. When the coolant reaches a
predetermined temperature, the thermostat
opens and hot water passes through the top
hose to the top of the radiator. As the coolant
circulates through the radiator, it is cooled by
the flow of air to the vehicle’s forward motion,
supplemented by the action of the cooling fan
where necessary. By the time it reaches the
bottom of the radiator the coolant is cooled,
and the cycle is repeated. Circulation of
coolant continues through the expansion
tank, inlet manifold, automatic choke (where
applicable) and heater at all times, the heater
temperature being controlled by an air flap.
An air conditioning system is available as
an optional extra on certain models. In
conjunction with the heater, the system
enables any reasonable air temperature to be
achieved inside the vehicle; it also reduces
the humidity of the incoming air, aiding
demisting even when cooling is not required.
The refrigeration side of the air conditioning
system functions in a similar way to a
domestic refrigerator. A compressor, belt-
driven from the crankshaft pulley, draws
refrigerant in its gaseous phase from an
evaporator. The compressed refrigerant
passes through a condenser where it loses
heat and enters its liquid phase. After passing
through the dehydrator, which acts as a
reservoir and filter to extract moisture from
the circuit, the refrigerant returns to the
evaporator where it absorbs heat from the air
1General information and
precautions
3•2Cooling, heating and air conditioning systems

8Unscrew the three retaining bolts and
remove the coolant pump and gasket from the
front of the cylinder block. Note that on
certain models, the alternator adjusting link is
secured by the right-hand retaining bolt (see
illustration).
9If the coolant pump is faulty, it must be
renewed, as it is not possible to obtain
individual components.
10Before refitting, clean the mating faces of
the coolant pump and cylinder block.
11Refitting is a reversal of removal, bearing
in mind the following points.
12Use a new gasket, and tighten the
retaining bolts to the specified torque.
13Before fitting the coolant pump pulley,
ensure that the timing belt cover support bolt
is located in its hole in the pump.14Refill the cooling system.
CVH models
15Unscrew the two securing nuts, and
disconnect the coolant elbow from the
left-hand side of the coolant pump (see
illustration).
16Remove the timing belt.
17Unscrew the camshaft sprocket bolt and
withdraw the distributor drive sleeve.
18Screw the camshaft sprocket bolt part
way back into the end of the camshaft, and
using a suitable puller, pull the sprocket from
the camshaft.
19Remove the plastic rear timing belt cover.
20Unscrew the two retaining bolts, and
remove the timing belt tensioner (see
illustration).
21Unscrew the four securing bolts, and
withdraw the coolant pump (see illustration).
22If the coolant pump is faulty it must be
renewed, as it is not possible to obtain
individual components.
23Before refitting, clean the mating faces of
the coolant pump and cylinder block.
24Refitting is a reversal of removal, bearing
in mind the following points.
25Use a new gasket, and tighten the
securing bolts to the specified torque.
26Before refitting the camshaft sprocket
bolt, the threads must be coated with sealer
(Loctite 74 or 274, or Omnifit 30M blue), as the
bolt acts as an oil seal for the hollow
camshaft. Do not forget to fit the distributor
drive sleeve.
27Correctly tension the timing belt.
28Refill the cooling system.
DOHC models
Note:Before proceeding, take note of the
following modifications: On models up to May
1990, the coolant hoses were connected to the
coolant pump housing as shown (see
illustration). On models from May 1990, the
heater hose (A) and the expansion tank hose (B)
connections were swapped over. If the hoses
are disconnected on earlier models,they should
be reconnected as on later models, ie connect
the heater hose to connection “B”, and connect
the expansion tank hose to connection “A”.
This will prevent the possibility of noises from
the heater matrix due to air in the system.
29On fuel injection models, for access to the
coolant pump, remove the air inlet hose,
plenum chamber, and air cleaner lid as an
assembly.
30Remove the coolant pump/alternator
drivebelt.
31If the pump pulley is to be removed, it is
easiest to do this with the pump in position, as
follows. Prevent the pulley from rotating using
a strap wrench and unscrew the four pulley
securing bolts. Withdraw the pulley.
32Position a suitable container beneath the
coolant pump, to catch the coolant which will
be released as the pump is removed. Unscrew
the five securing bolts, and withdraw the pump
from the housing in the cylinder block (see
illustration). Recover the O-ring seal.
33Before refitting, clean the mating faces of
the coolant pump and the cylinder block.
34Refitting is a reversal of removal, bearing
in mind the following points.
35Use a new O-ring seal (see illustration).
3•6Cooling, heating and air conditioning systems
9.8 Location of the alternator adjusting
link under the right-hand retaining bolt9.20 Remove the timing belt tensioner
9.35 Coolant pump O-ring (arrowed)9.32 Withdrawing the coolant pump from
the cylinder block (engine removed)
9.29 Coolant pump housing hose
connections
A Heater hose connection - up to May 1990
B Expansion tank hose connection - up to
May 1990
C Bottom radiator hose
9.21 Withdraw the coolant pump
9.15 Disconnect the coolant elbow from
the coolant pump

36Tighten the coolant pump securing bolts,
and where applicable the pump pulley
securing bolts, to the specified torque.
37On completion, refill the cooling system.
Refer to Chapter 1, Section 21.
Removal
1Remove the alternator drivebelt.
2Loosen the alternator lower mounting
through-bolt, then remove the alternator
upper mounting bolt and swing the alternator
away from the engine.
3Unscrew the central securing bolt, and
withdraw the drivebelt tensioner assembly
(see illustration).
Refitting
4Commence refitting by positioning the
tensioner on the cylinder block, ensuring that
the lug on the rear of the tensioner bracket
engages with the corresponding hole in the
cylinder block. Tighten the securing bolt.
5Swing the alternator into position, to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensionerassembly. Refit the upper mounting bolt, and
tighten the upper bolt and lower through-bolt.
6Fit the drivebelt by reversing the removal
procedure, and release the tensioner to
tension the drivebelt.
7Observe the tensioner indicator, which
should be central in its slot (see illustration).
Removal
1Disconnect the battery negative lead.
2Remove the four retaining clips and
unscrew the two retaining screws, then
withdraw the upper section of the fan shroud
(see illustrations).
3The cooling fan hub nut must now be
unscrewed from the coolant pump drive
flange. A thin cranked 32.0 mm (1.25 in AF)
spanner with a jaw thickness not exceeding
5.0 mm (0.2 in) will be required (see
illustration). Alternatively, if two of the
coolant pump pulley bolts are removed, a
normal thickness spanner can be used.Note
that the fan hub nut has a left-hand thread, (ie
it is undone in a clockwise direction.) If the
pulley turns as the nut is undone, remove the
drivebelt, and clamp an old drivebelt round
the pulley to restrain it, using self-locking
pliers. Tap the spanner with a mallet if
required to remove the nut.4If required, the fan blades can be separated
from the fan hub by unscrewing the four
securing bolts.
Refitting
5Refitting is a reversal of removal, but where
applicable, take care not to overtighten the
bolts securing the fan blades to the fan hub,
as thread damage may require the whole unit
to be renewed. Where applicable, refit and
tension the drivebelt.
CVH models
1Disconnect the battery negative lead.
Unclip the wiring connector from the fan
motor then unscrew the retaining nuts and
washers. Withdraw the fan shroud and
cooling fan assembly (see illustration).
2To remove the fan blades, prise the
securing clip from the end of the motor shaft
(see illustration).
3The motor can be separated from the fan
shroud by unscrewing the three securing nuts
and bolts.
4Where two cooling fans are fitted, both fans
are secured to the fan shroud in the same
manner.
5Refitting is a reversal of removal, but when
refitting the fan blades, ensure that the
direction of rotation arrow faces away from
the motor, towards the radiator.
13Electric cooling fan -removal
andrefitting
12Thermo-viscous cooling fan
(SOHC models) - removal and
refitting
11Coolant pump/alternator
drivebelt tensioner (DOHC
models with power steering)
- removal and refitting
10Coolant pump/alternator
drivebelt(s) - checking, renewal
and tensioning
Cooling, heating and air conditioning systems 3•7
3
12.2a Remove the retaining clips followed
by the screws . . .
13.1 Withdrawing the fan shroud and
cooling fan assembly
12.3 Modified spanner required for
removing the thermo-viscous cooling fan
X = 25.0 mm (1.0 in)Y = 12.0 mm (0.5 in)12.2b . . . and withdraw the upper section
of the fan shroud
11.7 Alternator/coolant pump drivebelt
tensioner indicator position
Inset shows tensioner at maximum
adjustment11.3 Withdrawing the coolant
pump/alternator drivebelt tensioner
assembly. Note lug (A) on tensioner which
engages with hole (B) in mounting bracket