1985 FORD GRANADA fuel pump

together, guide the torque converter studs
through the holes in the driveplate. When the
engine is positioned flush with the engine
adapter plate and the transmission housing,
check that the torque converter is free to move
axially a small amount before refitting and
tightening the engine-to-transmission bolts.
6Do not tighten the torque converter-to-
driveplate nuts until the lower engine-to-
transmission bolts have been fitted and
tightened.
7Ensure that the roadwheels and the steering
wheel are in the straight-ahead position then
align the marks made on removal and
reconnect the intermediate shaft to the
steering gearing. Tighten the clamp bolt to the
specified torque.
8Reconnect the selector rod and adjust as
described in Chapter 7, PartB.
9Refit the propeller shaft.
10Refit the exhaust system.
11Fill the engine with the correct grade and
quantity of oil.
12Check the throttle cable adjustment. Where
necessary, also adjust the speed control cable
in the same way so that there is only a small
amount of slack present in the cable.
13Reconnect the coolant hoses to the water
pump housing.
14Fill the cooling system.
15Check and if necessary top-up the
transmission fluid level.
16Tighten all fixings to the specified torque,
where applicable.
Proceed as described in Part A, Section 23
of this Chapter but note that on certain
models, it may be necessary to unbolt the
engine mounting brackets from the cylinder
block to allow sufficient clearance to remove
the mountings.
1Refer to Part A, Section 8 of this Chapter,
paragraphs 1 to 8 inclusive.
2A selection of splined and Torx sockets will
be required to remove many of the bolts when
dismantling the engine.
3Before dismantling the main engine
components, the following externally mounted
ancillary components can be removed.
a)Inlet manifold (and carburettor, where
applicable).
b)Exhaust manifold.
c)Alternator.
d)Water pump, and thermostat.
e)Water pump/alternator drivebelt tensioner.
f)Distributor cap, HT leads and spark plugs.
g)Oil pressure warning lamp switch.
h)Crankshaft speed/position sensor.
i)Oil filter.
j)Dipstick.
k)Engine mounting brackets (if not already
done).
l)Crankcase ventilation pipe and hoses.m)Clutch.
n)Alternator mounting bracket.
o)Air conditioning compressor mounting
bracket (where applicable).
p)Engine lifting brackets.
Note: A puller will be required to remove the
crankshaft pulley. A new crankshaft pulley bolt,
a new timing chain tensioner plunger
assembly, new upper and lower timing chain
cover gaskets and a new camshaft cover
gasket and reinforcing sleeve sealing rings
must be used on refitting.
1If the engine is in the car, carry out thefollowing operations.
a)Disconnect the battery negative lead.
b)To improve access, remove the radiator. It
will be difficult to remove the crankshaft
pulley with the radiator in place.
c)On carburettor models, remove the air
cleaner.
d)On fuel-injection models, remove the air
inlet hose, plenum chamber and air
cleaner lid as an assembly.
e)Disconnect the breather hose from the
camshaft cover.
f)Remove the distributor cap and HT leads,
and the rotor arm and housing.
2Proceed as described in paragraphs 2 to 11
inclusive of Section 18 (see illustration).
3Remove the water pump/alternator
drivebelt.
15Timing chain and sprockets -
removal and refitting
14Engine dismantling - general
information
13Engine mountings - renewal
2B•8DOHCengine
1 Upper timing chain guide
2 Exhaust camshaft sprocket
3 Timing chain
4 Lower timing chain guide
5 Crankshaft sprocket (double)
6 Crankshaft
7 Oil pump chain tensioner
8 Oil pump drive chain
9 Oil pump10 Oil pressure relief valve
11 Oil passage to timing chain tensioner
plunger
12 Plug
13 Timing chain tensioner plunger
14 Timing chain tensioner sprocket
15 Timing chain tensioner arm
16 Inlet camshaft sprocket
17 Copper chain links
15.2 Timing chain, oil pump drive chain and associated components
procarmanuals.com

prevent the chain from dropping into the
timing case, as during removal.
18Locate the double chain sprocket loosely
over the end of the crankshaft (larger sprocket
nearest the crankcase), with the timing mark
pointing vertically down.
19Fit the chain over the inner, larger
sprocket, aligning the coppered link in the
chain with the timing mark on the sprocket
(see illustration).
20Coat the threads of the lower timing chain
guide lower securing bolt with a suitable
thread-locking compound.
21Introduce 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.
22Push the double chain sprocket onto the
crankshaft, engaging the notch in the sprocket
with the groove in the end of the crankshaft.
23Proceed as described 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.
24Coat 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.
25Proceed as described in paragraphs 43 to 46
of Section 18.
26Tighten the two chain guide securing bolts
to the specified torque.
27Proceed as described in paragraphs 47 to 55
of Section 18.
28Fit 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.
29Refit the oil pump drive chain tensioner,
and tighten the securing bolt to the specified
torque.
30Refit the Woodruff key to the end of the
crankshaft.
31Inspect 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, and drive in the new seal
using a suitable metal tube. Make sure that the
seal lip faces into the engine. Note that the oil
seal should be fitted dry. Take care not to
damage the timing chain cover (see
illustration).
32Fit the lower timing chain cover using a
new rubber gasket (see illustration).
33Loosely refit the timing chain cover
securing bolts.
34Refit the crankshaft pulley to the end of the
crankshaft, and draw the pulley onto the
crankshaft using the original securing bolt, at the
same time centering the lower timing chain cover.
35With the lower timing chain cover
centralised, and the pulley fully home on the
crankshaft, remove the old securing bolt, then
fit a new bolt.
36Tighten the new crankshaft pulley bolt to
the specified torque, in the two stages given in
the Specifications at the beginning of this
Chapter. Prevent the crankshaft from turning
as during removal.
37Tighten the lower timing chain cover
securing bolts to the specified torque.
38Refit the drivebelt tensioner assembly,
ensuring that the lug on the rear of the
tensioner bracket engages with the
corresponding hole in the cylinder block, and
tighten the securing bolt.39Swing the alternator into position to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensioner
assembly, then refit the upper mounting bolt,
and tighten the upper bolt and the lower
through-bolt.
40Refit the water pump/alternator drivebelt.
41If the engine is in the vehicle, reverse the
operations described in paragraph 1 of
Section 15.
42Where applicable, refill the cooling
system.
1Examine all the teeth on the camshaft and
crankshaft sprockets. If the teeth are “hooked”
in appearance, renew the sprockets.
2Examine the chain tensioner plastic
sprocket for wear. If excessive wear is evident,
the complete tensioner assembly must be
renewed as the sprocket cannot be renewed
independently.Note that the tensioner plunger
assembly must be renewed whenever the
timing chain is removed.
3Examine the timing chain for wear. If the
chain has been in operation for a considerable
time, or if when held horizontally (rollers
vertical) it takes on a deeply bowed
appearance, renew it.
Note: The cylinder head must not be removed
when the engine is warm. Refer to the note at
the beginning of the following Section before
proceeding.
1Disconnect the battery negative lead.
2On carburettor models, remove the air
cleaner.
3On fuel-injection models, remove the air
inlet hose, plenum chamber, and air cleaner lid
as an assembly.
4Drain the cooling system.
5Disconnect the heater coolant hose from
the inlet manifold (see illustration).
17Cylinder head - removal and
refitting (engine in vehicle)
16Timing chain, sprockets and
tensioner - examination and
renovation
2B•10DOHCengine
15.19 Coppered link in timing chain aligned
with crankshaft sprocket timing mark
(arrowed)
17.5 Disconnecting the heater coolant hose
from the inlet manifold
15.31 Fitting a new lower timing chain
cover oil seal15.32 Lower timing chain cover gasket in
position. Ensure that lug on gasket
engages with notch in cover (arrowed)
procarmanuals.com

13Apply a sealing compound to the faces of
the cylinder block and sump at the points
indicated(see illustration).
14Apply suitable thread-locking compound
to the sump securing studs and bolts, then
locate the sump on the cylinder block and fit
the securing nuts and bolts, but do not fully
tighten them at this stage.
15Align the sump so that the end faces and
the cylinder block are flush. To do this, use a
straight-edge. If the sump cannot be
positioned so that the faces of the cylinder
block and sump are flush, measure the
difference in height using a feeler blade as
shown (see illustration).
16Tighten the sump securing nuts and bolts
to the specified torque, then repeat the
measurement made in paragraph 15. If the
end faces of the sump and cylinder block are
not flush, suitable shims must be fitted
(available from a Ford dealer) between the
sump and the gearbox/transmission to
eliminate the clearance when mating the
engine to the gearbox/transmission. Note that
shims should be fitted at both sides of the
sump, as required. Select suitable shims from
those listed in the following table.
Clearance measuredShims required
0 to 0.25 mmNo shims required
0.25 to 0.29 mm0.15 mm (silver)
0.30 to 0.44 mm0.30 mm (light blue)
0.45 to 0.59 mm0.45 mm (red)
0.60 to 0.75 mm0.60 mm (black)
17If the engine is in the vehicle, reverse the
procedure described in paragraphs 3 to 8,
noting the following points.
a)Ensure that the roadwheels and the
steering wheel are in the straight-aheadposition then align the marks made on
removal and reconnect the intermediate
shaft to the steering gear. Tighten the
clamp bolt to the specified torque.
b)Fill the engine with the correct grade and
quantity of oil.
c)Refit the engine adapter plate and the
flywheel/driveplate.
d)Refit the gearbox or automatic
transmission, as applicable, ensuring that
the required shims are fitted between the
sump and the gearbox/transmission.
e)Tighten all fixings to the specified torque
where applicable.
Note: A suitable puller will be required to
remove the crankshaft pulley. A new
crankshaft pulley bolt, a new lower timing
chain cover gasket and a new oil pump gasket
must be used on refitting.
1If the engine is in the car, carry out the
following operations.
a)Disconnect the battery negative lead.
b)To Improve access, remove the radiator. It
will be difficult to remove the crankshaft
pulley with the radiator in place.
c)On fuel-injection models, remove the air
inlet hose, plenum chamber and air
cleaner lid as an assembly.
2Proceed as described in paragraphs 3 to 10
of Section 15.3Unscrew the four securing bolts and
withdraw the oil pump from the cylinder block
(see illustration). Recover the gasket and
discard it.
4If desired, the pump can now be dismantled
and inspected.
5Thoroughly clean the mating faces of the
pump and the cylinder block.
6Prime the pump by injecting clean engine oil
into it and turning it by hand.
7Place a new gasket on the oil pump flange,
ensuring that the gasket is correctly located so
that the holes align with the oil passages in the
pump.
8Fit the oil pump, and tighten the securing
bolts to the specified torque.
9Proceed as described in paragraphs 28 to 40
of Section 15.
10If the engine is in the vehicle, reverse the
operations described in paragraph 1.
1The oil pump can be dismantled for
cleaning, but if any of the components are
worn, the pump must be renewed as an
assembly.
2To dismantle the pump, proceed as follows.
3Unscrew the two securing bolts, and
remove the pump cover (see illustration).
4Lift the inner and outer rotors from the
pump casing.
5Unscrew the pressure relief valve plug from
27Oil pump - dismantling,
inspection and reassembly
26Oil pump - removal and
refitting
2B•16DOHCengine
25.13 Apply sealing compound to the
sump/cylinder block mating faces at the
points indicated (2)
Dimensions are for guidance only
27.3 Removing the oil pump cover27.5a Unscrew the pressure relief valve
plug and washer . . .
25.15 Measuring the clearance between the
cylinder block and sump end faces26.3 Oil pump securing bolts (arrowed)
procarmanuals.com

2C•4V6 engines
Torque wrench settings (continued)Nmlbf ft
Timing cover to intermediate plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 to 1710 to 13
Intermediate plate to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 1710 to 13
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Rocker shaft securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 to 7046 to 52
Sump bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 to 73 to 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2816 to 21
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 to 159 to 11
Oil cooler threaded sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 4015 to 30
Cylinder head hexagon bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 4530 to 33
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 to 7041 to 52
Stage 3 (after 10 to 20 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 11570 to 85
Stage 4 (after warm-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 11570 to 85
Cylinder head - Torx bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 7552 to 55
Stage 3 (after 5 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten further 90°Tighten further 90°
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 to 84 to 6
Fuel pump blanking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 1812 to 13
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 to 7047 to 52
Bellhousing-to-engine bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 3020 to 22
2.4 litre engine
Note: Unless otherwise stated, the specifications and torque wrench settings for the 2.4 litre engine are as given for the 2.8 litre engine.
General
Manufacturer’s code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ARC
Bore - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.0 (3.307)
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.0 (2.865)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2394 (146.1)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5:1
Maximum power (DIN, kW @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 @ 5800
Maximum torque (DIN, Nm @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 @ 3000
Cylinder block
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D
Bore diameter:
Standard grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.000 to 84.010 mm
Standard grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.010 to 84.020 mm
Standard grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.020 to 84.030 mm
Standard grade 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.030 to 84.040 mm
Oversize grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.510 to 84.520 mm
Oversize grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.520 to 84.530 mm
Oversize grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.530 to 84.540 mm
Standard service grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.030 to 84.040 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.530 to 84.540 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.030 to 85.040 mm
Pistons
Diameter:
Standard grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.962 to 83.972 mm
Standard grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.972 to 83.982 mm
Standard grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.982 to 83.992 mm
Standard grade 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.992 to 84.002 mm
Standard service grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.978 to 84.002 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.478 to 84.502 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.978 to 85.002 mm
Clearance in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.028 to 0.048 mm
Piston ring end gap:
Top and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.30 to 0.50 mm
Bottom (oil control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.40 to 1.40 mm
Cylinder head
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H
procarmanuals.com

The V6 engine fitted to the Granada is only
available in fuel-injected form. Mechanically,
the design of the engine is well-established,
and it is improved by the latest fuel, ignition and
engine management systems (see illustration).
The combined crankcase and cylinder block
is made of cast iron, and houses the pistons,
crankshaft and camshaft. The sump is
attached to the bottom of the crankcase and
the cylinder heads to the top.
The cylinder heads are of the crossflow
design, the inlet manifold being located
between them and the exhaust manifolds
being on the outboard sides. The overhead
valves are operated by tappets, pushrods and
rockers from the centrally located camshaft.
Camshaft drive is by gears (2.8 litre) or chain
(2.4 & 2.9 litre).
The crankshaft runs in four main bearings.
Endfloat is controlled by thrust flanges on the
No 3 bearing shells. The connecting rods are
selected so that all are in the same weight class.
Aluminium alloy pistons are used. The
gudgeon pins are an interference fit in their
connecting rods.The lubrication system is of the usual wet
sump, pressure fed type, with a full-flow
disposable canister oil filter. The oil pump is
driven by a shaft which engages in the bottom
of the distributor drivegear.
The following operations can be carried out
without removing the engine, although some
work will be easier and quicker with the engine
removed.
a)Removal and refitting of the cylinder
heads
b)Removal and refitting of the sump and oil
pump
c)Removal and refitting of the timing gears
d)Removal and refitting of the pistons,
connecting rods and big-end bearings
e)Renewal of the engine mountings
f)Removal and refitting of the flywheel
g)Renewal of the crankshaft front and rear
oil seals
h)Removal and refitting of the camshaft
(after removal of the cylinder heads,
tappets and timing gears)The engine must be removed for the
following operations:
a)Renewal of the crankshaft main bearings
b)Removal and refitting of the crankshaft
The engine is removed from above, without
the transmission. Removal with the
transmission is not recommended because of
the weight and unwieldiness of the combined
units.
2.8 litre engine
1Disconnect the battery negative lead.
2Remove the bonnet.
3Remove the throttle valve cover, which is
retained by three screws.
4Remove the air cleaner cover, valve airflow
5Engine - removal
4Methods of engine removal
3Major operations requiring
engine removal
2Major operations possible with
the engine in the vehicle
1General information
2C•6V6 engines
Cylinder head
Identification mark:
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F
BRD and BRE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K
Crankshaft
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08 to 0.24 mm
Permitted undersize for main and big-end bearing journals . . . . . . . . . .0.254 mm
Camshaft
Cam lift (inlet and exhaust):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.72mm
BRD and BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.54 mm
Cam lobe height (inlet and exhaust):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.08 to 36.25 mm
BRD and BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.22 to 36.41 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.065 to 0.165 mm
Thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.02 to 4.05 mm
Valves
Valve timing:
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .As 2.4 litre V6
BRD and BRE engines:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30°BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66°ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76°BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20°ATDC
Length:
BRC engine:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.2 to 106.9 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.8 to 107.8 mm
BRD and BRE engine:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104.7 to 105.4 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104.6 to 105.6 mm
Valve spring free length:
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55.12 mm
BRD and BRE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.00 mm
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meters and air inlet trunking. Also remove the
oil filler cap, which is connected to the
trunking by a crankcase ventilation hose.
5Release the securing clips and bolts and
remove the upper half of the fan shroud.
6Drain the cooling system and remove the
radiator.
7Disconnect the heater hoses from the
heater matrix and from the coolant outlet.
Unclip the hoses.
8Remove the fan and viscous clutch (where
fitted).
9Disconnect the following wiring:
a)Alternator
b)Temperature gauge sender
c)Engine management temperature sensor
d)Oil pressure switch
e)Idle speed control valve
f)Throttle position sensor
g)Injector nut-harness
h)Distributor multi-plug
i)Distributor-to-coil HT lead
10Disconnect the throttle cable. When
applicable, also disconnect the downshaft
cable or switch.
11Depressurise the fuel system and
disconnect the fuel supply and return lines
(see Chapter 4).
12Remove the steering pump and air
conditioning compressor drivebelts (as
applicable). Unbolt the steering pump and
compressor, move them aside within the limitsof their flexible hoses and support them by
wiring them to adjacent components.
13Remove the distributor cap and rotor.
14Remove the starter motor.
15Drain the engine oil. Unscrew the oil filter
with a strap or chain wrench and remove it; be
prepared for oil spillage.
16On manual gearbox models, disconnect
the clutch cable from the release lever.
17Unbolt the exhaust pipes from the
manifolds.
18On automatic transmission models, unbolt
the torque converter from the driveplate.
19Attach lifting tackle to the engine. If no
lifting eyes are fitted, pass ropes or chains
round the exhaust manifolds.
20Take the weight of the engine, then
remove the single nut on each side which
holds engine bearer to its mountings.
21From under the vehicle unbolt the engine
adapter plate from the bellhousing.
22Remove the engine-to-bellhousing bolts.
Also disconnect or unclip the battery negative
lead, the starter motor lead and the heat
shield.
23Support the transmission, preferably with
a trolley jack.
24Check that nothing has been overlooked,
then raise the engine and draw it forwards
clear of the transmission input shaft. Do not
allow the weight of the engine to hang on the
shaft, and do not lift the transmission by it.25With automatic transmission, make sure
that the torque converter stays engaged with
the oil pump in the transmission as the engine
is withdrawn.
26Lift the engine out of the engine bay and
take it to the bench.
2.4 & 2.9 litre engines
27The removal operations for these engines
are essentially as described for the 2.8 litre
version. Note the following points.
Coolant hoses
28Remove the hoses which run between the
thermostat housing and the water pump, and
the cooling system expansion tank.
29Remove the heater hoses which run
between the thermostat housing or coolant
distribution pipe and oil cooler (where fitted).
Vacuum hoses
30Disconnect the hose from the fuel
pressure regulator.
31Disconnect the hose from the plenum
chamber.
32Disconnect the hose from the throttle valve.
33Disconnect the hose from the T-piece
connector.
V6 engines 2C•7
2C
1.1 Exploded view of V6 engine
1 Water inlet connection
2 Thermostat
3 Water pump
4 Timing cover
5 By-pass hose flange
7 Camshaft thrust plate
8 Camshaft gear
9 Crankshaft gear
10 Flywheel
11 Crankshaft pilot
bearing
12 Oil seal
13 Oil pump drive shaft
14 Main bearing
15 Oil pump
It may be necessary to rock
the engine a little to release it
from the gearbox.
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Other items
34Disconnect the throttle cable from the
operating lever and bracket.
35Disconnect the right-hand exhaust
downpipe from the manifold then remove the
starter motor, the oil filter, and disconnect the
left-hand exhaust downpipe, in that order.
Refer to Part A, Section 8, paragraphs 1 to 8
of this Chapter.
Cylinder head bolts on the V6 engine may
be conventional (hexagon-headed) or Torx
type. The appropriate Torx key will be needed
to deal with the latter.
Before dismantling the engine into its main
components, the following ancillaries can be
removed. The actual items removed, and the
sequence of removal, will depend on the work
to be done.
Distributor and bracket
Spark plugs
Inlet manifold and associated items
Exhaust manifolds
Clutch
Alternator and bracket
Oil pressure switch(see illustration) Temperature gauge sender
Engine bearer arms
Dipstick
If an oil cooler is fitted between the oil filter
and the block, remove it by disconnecting the
coolant hoses and unscrewing the central
sleeve. The cooler and seal can now be
removed. If the threaded bush is removed
from the block (it may come out with the
sleeve) it must be renewed.
The procedure is described for the engine in
the vehicle. With the engine removed, the
preliminary steps can be ignored.
2.8 litre engine
1Disconnect the battery negative lead.
2Remove the inlet manifold and associated
components.
3Unbolt the power steering pump, remove
the drivebelts and move the pump aside.
Support it by wiring it to adjacent
components.
4Remove the alternator and its bracket.
5Remove the three bolts which secure each
rocker shaft. Remove the shafts and
pushrods, keeping them in order so that they
can be refitted in the same locations.
6Unbolt the exhaust pipes from the
manifolds.
7Remove the spark plugs.8Slacken the cylinder head bolts half a turn at
a time, following the reverse sequence to that
used when tightening (see illustration 38.5).
Remove the bolts.
9Remove the cylinder heads. If they are
stuck, try to rock them free, or tap them with a
soft-faced hammer. Do nothit them directly
with a metal hammer, and do notlever in
between the joint faces.
10Recover the head gaskets.
2.4 & 2.9 litre engines
11Disconnect the battery and drain the
cooling system.
12Disconnect the radiator top hose and the
heater hose from the thermostat housing.
13Disconnect the air hoses from the throttle
valve housing (see illustration).
14Detach the two wiring plugs from the
airflow sensors (see illustrations).
15Pull the breather hose from the oil filler cap
(see illustration).
16Unclip the air cleaner cover and remove it
together with the airflow sensors and air hoses.
17Disconnect the hoses from the coolant
expansion tank.
18Disconnect the wiring from the following
components:
a)Alternator (right-hand cylinder head
removal only).
b)Coolant temperature sensors(see
illustration).
c)Idle speed control valve (see illustration).
d)Throttle valve potentiometer.
e)The fuel-injector wiring loom.8Cylinder heads - removal
7Ancillary components - removal
6Engine dismantling - general
2C•8V6 engines
7.1 The oil pressure switch is on the left-
hand side of the block
8.14b Throttle position sensor wiring plug
Vacuum nozzles arrowed
8.14a Front airflow sensor wiring plug
8.15 Oil filler breather hose (arrowed)8.18a Coolant temperature sensor location
8.13 Disconnecting the air hoses from the
throttle valve housing
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19Disconnect the wiring connectors from the
ignition distributor and the fuel temperature
sensor (see illustrations).
20Release the pressure in the fuel distributor
pipe by depressing the pin in the vent valve.
Cover the valve with a rag during this
operation to prevent fuel being sprayed out
(see illustration).
21Disconnect the fuel lines (see illustration).
22Disconnect the vacuum hoses from the
following components:
a)Fuel pressure regulator.
b)Throttle valve assembly.
c)T-piece connector (see illustration).
23Disconnect the rocker cover breather hose
(see illustration).
24Unbolt the plenum chamber and place it to
one side with the throttle cable attached.25Disconnect the HT leads from the spark
plugs and the ignition coil noting their correct
fitted locations. Undo the two retaining screws
then remove the distributor cap and HT leads
as an assembly.
26Using a 19 mm socket on the crankshaft
damper centre bolt, set No 1 piston to its firing
point (12°BTDC) and remove the distributor.
27If the right-hand cylinder head is to be
removed, remove the drivebelts, unbolt the
alternator and power steering pump and tie
them to one side of the engine compartment.
28Unbolt and remove the rocker cover(s).
29Unbolt and remove the rocker shaft(s) (see
illustration).
30Withdraw the pushrods and keep them in
their originally fitted sequence.
31Disconnect the inlet manifold to timingcover coolant hose from the manifold.
32Unbolt and remove the inlet manifold
complete with fuel rail and injectors. Discard
the gasket.
33Disconnect the exhaust downpipe(s) from
the manifold(s).
34Disconnect the earth straps from the rear
of the left-hand cylinder head and release the
cable retaining clamp.
35Unscrew and remove the spark plugs.
36Unscrew the cylinder head bolts using the
reverse of the tightening sequence (see
illustration 38.5). Obtain new bolts for refitting.
Remove the cylinder head(s) and discard the
gasket(s).
Proceed as described in Part A, Section 16
of this Chapter but note that there are 24 bolts
retaining the sump, not 23.
The procedure is described for the engine in
the vehicle. With the engine removed, the
preliminary steps can be ignored.
2.8 litre engine
1Disconnect the battery negative lead.
2Drain the engine oil.
3Drain the coolant and remove the radiator.
10Timing cover and drive -
removal
9Sump - removal
V6 engines 2C•9
2C
8.18b Disconnecting the idle speed control
valve wiring plug8.19a Disconnecting the distributor wiring
plug8.19b Disconnecting the fuel temperature
sensor wiring plug
8.22 Vacuum hose T-piece connector
8.20 Fuel rail vent (depressurising) valve
and cap8.21 Fuel feed (A) and return (B) hoses
8.23 Rocker cover breather hose (arrowed)8.29 Removing rocker shaft and pedestal
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