service FORD SIERRA 1992 2.G DOHC Engine Workshop Manual

Crankshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.090 to 0.300 mm (0.004 to 0.012 in)
Main bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.011 to 0.048 mm
Main bearing journal diameter:
Standard (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.980 to 54.990 mm
Standard (red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.990 to 55.000 mm
Undersize 0.25 (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.730 to 54.750 mm
Main bearing thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.301 to 2.351 mm (0.090 to 0.093 in)
Oversize 0.38 (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.491 to 2.541 mm (0.098 to 0.100 in)
Big-end bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 to 0.060 mm
Big-end bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50.890 to 50.910 mm
Undersize 0.25 (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50.640 to 50.660 mm
Pistons and piston rings
Piston diameter:
Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.970 to 85.980 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.980 to 85.990 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.980 to 85.990 mm
Oversize 0.15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.130 to 86.150 mm
Oversize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.470 to 86.490 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.300 to 0.600 mm (0.012 to 0.024 in)
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.500 to 0.800 mm (0.020 to 0.032 in)
Bottom (oil control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.400 to 1.500 mm (0.016 to 0.059 in)
Cylinder head
Valve guide bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.063 to 7.094 mm
Camshaft bearing parent bore diameter . . . . . . . . . . . . . . . . . . . . . . . .26.000 to 26.030 mm
Camshafts
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020 to 0.260 mm (0.001 to 0.010 in)
Valves
Valve timing:
Carburettor engines:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13º ATDC
Fuel injection engines:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13º ATDC
Valve spring free length:
Inner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48.200 mm (1.899 in)
Outer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46.800 mm (1.844 in)
Inlet valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.025 to 7.043 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.225 to 7.243 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.425 to 7.443 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.625 to 7.643 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.825 to 7.843 mm
Exhaust valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.999 to 7.017 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.199 to 7.217 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.399 to 7.417 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.599 to 7.617 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.799 to 7.817 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres (7.9 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres (7.0 pints)
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion C102
2B•2DOHC engine

6Loosen the alternator lower mounting
through-bolt, then remove the alternator
upper mounting bolt, and swing the alternator
away from the engine.
7Unscrew the central securing bolt, and
withdraw the drivebelt tensioner assembly.
8Unscrew the eleven securing bolts, and
remove the lower timing chain cover. Recover
the rubber gasket.
9Using a suitable Torx socket, unscrew the
securing screw, and carefully withdraw the oil
pump chain tensioner (see illustration).
10Unscrew the Torx type securing bolt, and
withdraw the oil pump sprocket, complete
with the oil pump drive chain.
11Unscrew the two lower timing chain guide
securing bolts, noting their locations, and
withdraw the timing chain guide through the
top of the timing case (see illustration).
12Remove the Woodruff key from the end of
the crankshaft, prising it free with a
screwdriver if necessary, then slide the double
chain sprocket from the end of the crankshaft,
and lift the chain from the sprocket (see
illustration).
13Withdraw the timing chain through the top
of the timing case and, where applicable,
remove the cable-tie from the chain (see
illustration).
Refitting
14Commence refitting as follows. Note that
coppered links are provided in the timing
chain to assist with refitting, but these can be
difficult to see on a chain which has already
been in service. If possible, position thecoppered links as described during the
following procedure. If the coppered links are
not visible, the chain should still be refitted as
described, but ignore the references to the
coppered links.
15Make sure that the slot for the Woodruff
key in the end of the crankshaft is pointing
vertically downwards. If necessary,
temporarily refit the crankshaft pulley bolt in
order to turn the crankshaft to the required
position.
16Lower the timing chain into the timing
case from above, with the single coppered
link at the bottom. If desired, use a cable-tie
to prevent the chain from dropping into the
timing case, as during removal.
17Locate the double chain sprocket loosely
over the end of the crankshaft (larger sprocket
nearest the crankcase), with the timing mark
pointing vertically down.
18Fit the chain over the inner, larger
sprocket, aligning the coppered link in the
chain with the timing mark on the sprocket
(see illustration).
19Coat the threads of the lower timing chain
guide lower securing bolt with a suitable
thread-locking compound.
20Introduce the lower timing chain guide
through the top of the timing case,
manipulating the chain around the guide as
necessary, then fit the chain guide lower
securing bolt and tighten it finger-tight.
21Push the double chain sprocket onto the
crankshaft, engaging the notch in the
sprocket with the groove in the end of the
crankshaft.22Proceed as shown in paragraphs 34 to 42
of Section 18 but when fitting the chain over
the camshaft sprockets, align the timing mark
on each sprocket between the two
corresponding coppered links in the chain.
23Coat the threads of the lower timing chain
guide upper securing bolt with a suitable
thread-locking compound, then fit the bolt
and tighten it finger-tight.
24Proceed as shown in paragraphs 43 to 46
of Section 18.
25Tighten the two chain guide securing
bolts to the specified torque.
26Proceed as shown in paragraphs 47 to 55
of Section 18.
27Fit the oil pump drive chain around the
outer crankshaft sprocket and the oil pump
sprocket, then refit the oil pump sprocket, and
tighten the securing bolt to the specified
torque. If necessary, a screwdriver can be
inserted through one of the holes in the
sprocket to prevent it from turning as the
securing bolt is tightened.
28Refit the oil pump drive chain tensioner,
and tighten the securing bolt to the specified
torque.
29Refit the Woodruff key to the end of the
crankshaft.
30Inspect the oil seal in the lower timing
chain cover. If the oil seal is in good condition,
the cover can be refitted as follows, but if the
seal is damaged, or has been leaking, a new
seal should be fitted to the cover. If
necessary, carefully prise the old oil seal from
the cover using a screwdriver. The new seal
DOHC engine 2B•9
2B
15.11 Withdrawing the lower timing chain
guide
15.18 Coppered link in timing chain aligned
with crankshaft sprocket timing mark
(arrowed)15.13 Withdrawing the timing chain
through the top of the timing case
15.9 Oil pump chain tensioner securing
screw (arrowed)15.5b Position the legs of the puller on the
metal surfaces of the pulley (A), not the
rubber surface (B)
15.12 Sliding the double chain sprocket
from the end of the crankshaft