width FORD SIERRA 1992 2.G CVH Engines Workshop Manual

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

23Check that the crankshaft rotates freely.
Some stiffness is to be expected with new
components, but there must be no tight spots
or binding.
24Check that the crankshaft endfloat is
within the specified limits by inserting a feeler
blade between the centre crankshaft web and
the thrust bearing cap.
25Lubricate the oil seal lip with clean engine
oil, then carefully fit the crankshaft rear oil seal
housing. Using a straight-edge, ensure that
the bottom face of the oil seal housing is
aligned with the bottom face of the cylinder
block before finally tightening the securing
bolts (see illustration).
26Carefully prise the crankshaft front oil seal
from the oil pump housing, then refit the oil
pump, oil strainer/pick-up tube and
crankshaft front oil seal.
27Refit the pistons and connecting rods.
28Refit the thrustwasher, crankshaft
sprocket and timing belt.
1.6 and 1.8 litre (R6A type)
29Proceed as described above, noting the
following point:
On the 1.6 litre engine, note that
thrustwashers are used at the centre main
bearing (one each side of the bearing)
instead of a thrust bearing shell to control
crankshaft endfloat. Oversize
thrustwashers are available to
compensate for wear if necessary. The
thrustwashers should be fitted with the oil
grooves visible
1.8 litre (R2A type)
1Examine the bearing surfaces of the
crankshaft for scratches or scoring and, using
a micrometer, check each journal and
crankpin for ovality. Where this is found to be
in excess of 0.0254 mm (0.001 in) the
crankshaft will have to be reground and
undersize bearings fitted.
2Crankshaft regrinding should be carried out
by a suitable engineering works, who will
normally supply the matching undersize main
and big-end shell bearings.
3Note that undersize bearings may already
have been fitted either in production or by a
previous repairer. Check the markings on the
backs of the old bearing shells, and if in doubt
take them along when buying new ones.
4If the crankshaft endfloat is more than the
maximum specified amount, a new thrust
bearing shell should be fitted to the centre
main bearing.
5An accurate method of determining bearing
wear is by the use of Plastigage. The
crankshaft is located in the main bearings
(and big-end bearings if necessary) and the
Plastigage filament located across the journal
which must be dry. The cap is then fitted and
the bolts/nuts tightened to the specified
torque. On removal of the cap the width of the
filament is checked with a plastic gauge andthe running clearance compared with that
given in the Specifications.
6If the spigot bearing in the rear of the
crankshaft requires renewal extract it with a
suitable puller. Alternatively fill it with heavy
grease and use a close fitting metal dowel
driven into the centre of the bearing. Drive the
new bearing into the crankshaft with a soft
metal drift.
1.6 and 1.8 litre (R6A type)
7Proceed as described above but note that if
the crankshaft endfloat is more than the
maximum specified amount, new
thrustwashers should be fitted to the centre
main bearing.
Refer to Section 36, Chapter 2, Part A but
note that the crankcase ventilation baffle
should be removed from its location at the
rear of the cylinder block and cleaned if
necessary (see illustration).
Refer to Section 37, Chapter 2, Part A.
35Initial start-up after overhaul or
major repair
34Cylinder block and bores -
examination and renovation33Crankshaft and bearings -
examination and renovation
2C•24CVH engines
32.25 Fit the crankshaft rear oil seal
housing and tighten the securing bolts -
1.8 litre (R2A)34.1 Removing the crankcase ventilation
baffle