timing belt FORD SIERRA 1992 2.G Cooling And Air Conditioning Systems Workshop Manual

17Note that the thermostat wax capsule
must face into the inlet manifold, with the flow
direction arrow pointing forward, in line with
the pressure relief valve in the housing (see
illustration).
18Refill the cooling system.
DOHC models
19On fuel injection models, for access to the
thermostat housing loosen the clips and
remove the air inlet tube which connects the
plenum chamber to the inlet manifold.
20Disconnect the coolant hoses from the
thermostat housing (see illustrations).
21Disconnect the wiring plug from the
cooling fan switch mounted in the thermostat
housing (see illustration).
22Unscrew the three securing bolts, and
withdraw the thermostat housing (see
illustration).
23Manipulate the thermostat from the inlet
manifold, and recover the O-ring. If it isnecessary to prise the thermostat out, take
care not to damage the surface of the housing
in the inlet manifold.
24Refitting is a reversal of removal, bearing
in mind the following points.
25Ensure that the O-ring seal is correctly
fitted around the edge of the thermostat.
26When fitting the thermostat to the inlet
manifold, ensure that the relief valve is located
in the 12 o’clock position (see illustration).
27Tighten the thermostat housing securing
bolts to the specified torque.
28Refill the cooling system.
1To test the thermostat, suspend it by a
piece of string in a container of water (see
illustration).2Gradually heat the water, and using a
thermometer with a range of at least 100ºC,
note the temperature at which the thermostat
starts to open.
3Remove the thermostat from the water and
check that it is fully closed when cold.
4Renew the thermostat if the opening
temperature is not as given in the
Specifications, or if the unit does not fully
close when cold.
1Disconnect the battery negative lead.
2Drain the cooling system.
3Proceed as follows according to model:
SOHC models
4Disconnect the heater and radiator bottom
hoses from the coolant pump.
5Remove the thermo-viscous fan (Section 12).
6If not already done, remove the coolant
pump drivebelt, then unscrew the four
retaining bolts and remove the coolant pump
pulley. If necessary, the pulley can be
prevented from turning using a strap wrench.
7Unbolt and remove the timing belt cover.
9Coolant pump - removal and
refitting
8Thermostat - testing
Cooling, heating and air conditioning systems 3•5
3
7.20a Disconnect the coolant hoses . . .
8.1 Testing the thermostat opening
temperature7.26 Thermostat relief valve (arrowed)
should be in the 12 o’clock position7.22 Withdrawing the thermostat housing
7.21 Disconnect the cooling fan switch
wiring plug7.20b . . . from the thermostat housing
7.17 Correct orientation of thermostat with
flow direction arrow pointing towards
pressure relief valve7.13 Removing the thermostat housing and
gasket
Holding the pulley can be
improvised using an old
drivebelt, and a suitable
socket and wrench.

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