1982 FORD SIERRA fuel cap

2.0 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NES and NET (carburettor, except P100), NRB and N4A (fuel
injection), and NAE (P100)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.82 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1993 cc
Compression ratio:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2:1
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2:1
Compression pressure at starter motor speed:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 to 13 bar
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 12 bar
Maximum continuous engine speed:
Engine code NES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5850 rpm
Engine codes NET and NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5800 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6050 rpm
Maximum engine power (DIN):
Engine codes NES and NET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77kW at 5200 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85kW at 5500 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57kW at 4500 rpm
Maximum engine torque (DIN):
Engine codes NES and NET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 Nm at 4000 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Nm at 4000 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 Nm at 2800 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.800 to 90.810 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.810 to 90.820 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.820 to 90.830 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.830 to 90.840 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.310 to 91.320 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.320 to 91.330 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.330 to 91.340 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.830 to 90.840 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.330 to 91.340 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.830 to 91.840 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness:
All except engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30 to 2.35 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50 to 2.55 mm
Engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.765 to 90.775 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.775 to 90.785 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.785 to 90.795 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.795 to 90.805 mm
Standard service:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.780 to 90.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90.790 to 90.815 mm
Service oversize 0.5:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.280 to 91.305 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.290 to 91.315 mm
Service oversize 1.0:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.780 to 91.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.790 to 91.815 mm
2A¥6SOHC engines

components, but there must be no tight spots
or binding.
28Check that the crankshaft endfloat is
within the specified limits by inserting a feeler
blade between the centre crankshaft web and
the thrustwashers.
29Make sure that the rear oil seal is fully
located onto its seating. Coat the rear main
bearing cap sealing wedges with sealing
compound, then press them into position
using a blunt screwdriver with the rounded
red face towards the cap (see illustration).
30Refit the oil pump and pick-up tube.
31Refit the crankshaft front oil seal housing
and the auxiliary shaft front cover using a new
gasket, and tighten the securing bolts. Smear
the lip of the oil seal with clean engine oil
before fitting; and 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 bolts.
32Refit the pistons and connecting rods.
33Refit the flywheel/driveplate and the
auxiliary shaft sprocket, crankshaft sprocket,
and timing belt.
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.
Production undersizes are also indicated by
paint marks as follows:
White line on main bearing cap - parent bore
0.40 mm oversize
Green line on crankshaft front counterweight
- main bearing journals 0.25 mm
undersize
Green spot on counterweight - big-end
bearing journals 0.25 mm undersize4If the crankshaft endfloat is more than the
maximum specified amount, new
thrustwashers should be fitted to the centre
main bearings. These are usually supplied
together with the main and big-end bearings
on a reground crankshaft.
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
filaments is checked against a scale which
shows the bearing running clearance. This
clearance is then compared with that given in
the Specifications (see illustration).
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.
1The cylinder bores must be examined for
taper, ovality, scoring and scratches. Start by
examining the top of the bores; if these are
worn, a slight ridge will be found which marks
the top of the piston ring travel. If the wear is
excessive, the engine will have had a high oil
consumption rate accompanied by blue
smoke from the exhaust.
2If available, use an inside dial gauge to
measure the bore diameter just below the
ridge and compare it with the diameter at the
bottom of the bore, which is not subject to
wear. If the difference is more than 0.152 mm
(0.006 in), the cylinders will normally require
reboring with new oversize pistons fitted.
3Proprietary oil control rings can be obtained
for fitting to the existing pistons if it is felt that
the degree of wear does not justify a rebore.
However, any improvement brought about by
such rings may be short-lived.
4If new pistons or piston rings are to be fitted
to old bores, deglaze the bores with abrasive
paper or a Òglaze busterÓ tool. The object is to
produce a light cross-hatch pattern to assistthe new rings to bed in.
5If there is a ridge at the top of the bore and
new piston rings are being fitted, either the
top piston ring must be stepped (Òridge
dodgerÓ pattern) or the ridge must be
removed with a ridge reamer. If the ridge is
left, the piston ring may hit it and break.
6Thoroughly examine the crankcase and
cylinder block for cracks and damage and use
a piece of wire to probe all oilways and
waterways to ensurethatthey are
unobstructed.
1Make a final check to ensure that
everything has been reconnected to the
engine and that no rags or tools have been left
in the engine bay.
2Check that oil and coolant levels are
correct.
3Start the engine. This may take a little
longer than usual as fuel is pumped up to the
engine.
4Check that the oil pressure light goes out
when the engine starts.
5Run the engine at a fast tickover and check
for leaks of oil, fuel or coolant. Also check
power steering and transmission fluid cooler
unions, where applicable. Some smoke and
odd smells may be experienced as assembly
lubricant burns off the exhaust manifold and
other components.
6Bring the engine to normal operating
temperature, then check the ignition timing
and the idle speed (where applicable) and
mixture.
7If splined type cylinder head bolts have
been used, stop the engine after it has been
running for 15 minutes, then remove the
crankshaft cover and tighten the cylinder
head bolts to the fourth stage given in the
Specifications, in the correct order.
8When the engine has completely cooled,
re-check the oil and coolant levels, and
check, and if necessary adjust, the valve
clearances.
9If new bearings, pistons etc have been
fitted, the engine should be run-in at reduced
speeds and loads for the first 500 miles (800
km) or so. It is beneficial to change the engine
oil and filter after this mileage.
37Initial start-up after overhaul or
major repair
36Cylinder block and bores -
examination and renovation35Crankshaft and bearings -
examination and renovation
2A¥24SOHC engines
34.24 Fitting a thrustwasher to the centre
main bearing cap35.5 Checking the width of the filament
against the scale of the packet34.29 Fitting a sealing wedge to the rear
main bearing cap