1985 FORD GRANADA Service Repair Manual

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
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V6 engines 2C•5
2C
Crankshaft
Thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08to 0.32 mm
Permitted undersize for main and big-end bearing journals . . . . . . . . . .0.254 mm
Camshaft
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain
Cam lift (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.72 mm
Cam lobe height (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.08 to 36.25 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.065 to 0.165 mm
Thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.02 to 4.05 mm
Valves
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24°BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64°ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66°BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22°ATDC
Head diameter:
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39.67 to 40.06 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.83 to 34.21 mm
Length:
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.2 to 106.9 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.1 to 107.1 mm
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55.12 mm
Torque wrench settingsNmlbf ft
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 to 6844 to 50
Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Timing chain guide to block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 127 to 9
Timing chain tensioner to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Oil inlet pipe to oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Oil pump to block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 15
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2815to 21
Crankshaft pulley to vibration damper bolts . . . . . . . . . . . . . . . . . . . . . .27 to 3320 to 24
Crankshaft vibration damper bolt:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 5030 to 37
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten further 80°to 90°Tighten further 80°to 90°
2.9 litre engine
Note: Unless otherwise stated, the specifications and torque wrench settings for the 2.9 litre engine are as given for the 2.8 litre engine.
General
Manufacturer’s code:
Models without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . .BRC
Models equipped with type N manual gearbox or automatic
transmission and a catalytic converter . . . . . . . . . . . . . . . . . . . . . .BRD
Models equipped with MT75 manual gearbox and catalytic converter . .BRE
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.0 (2.835)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2936 (179.2)
Compression ratio:
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5:1
BRD and BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.0:1
Maximum power (DIN, kW @ rpm):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 @ 5700
BRD and BRE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 @ 5500
Maximum torque (DIN, Nm @ rpm):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 @ 3000
BRD engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 @ 3000
BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 @ 3000
Cylinder block
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F
Pistons
Clearance in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.028 to 0.048 mm
Piston ring end gaps:
Top and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.30 to 0.50 mm
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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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4Remove the auxiliary drivebelts.
5Remove the fan and viscous clutch if fitted).
6Jam the crankshaft, either by engaging 5th
gear and applying the handbrake, or by
removing the starter motor and having an
assistant jam a screwdriver in the starter ring
gear teeth. Unbolt the crankshaft pulley. When
the pulley is secured to a vibration damper,
also remove the damper central bolt.
7Remove the pulley or damper, using a puller
if necessary.
8Disconnect the coolant hoses from the front
of the engine, including the water pump
bypass hose.
9Disconnect the heater connecting pipe from
the timing cover and unbolt the two clips
which secure the pipe to the cover of the
cylinder block (see illustration).
10If not already done, remove the starter motor.11Remove the sump.
12Remove the nine securing bolts and
remove the timing cover complete with water
pump and thermostat.
13Turn the crankshaft to bring the marks on
the timing gears into alignment as shown (see
illustration). Note that there are two marks on
the crankshaft gear - do not get them
confused.
14Remove the bolt which secures the
camshaft gear. It should now be possible to
remove the camshaft gear by hand.
15Draw off the crankshaft gear using a puller.
Recover the Woodruff keys if they are loose.
16Clean the old gasket off the timing cover
and the cylinder block. Remove the oil seal
from the timing cover.2.4 & 2.9 litre engines
17Using the crankshaft damper centre bolt,
turn the engine until No 1 piston is at its firing
point (12°BTDC). This can be verified by
removing the distributor cap and checking that
the rotor arm is aligned with the No 1 HT lead
contact.
18Disconnect the battery negative terminal.
19Unclip the air cleaner cover and remove it
complete with air flow sensors and air hoses.
Remove the oil filler cap.
20Drain the cooling system, disconnect the
radiator upper hose from the thermostat housing.
21Disconnect the hose which runs between
the water pump and the expansion tank.
22Remove the radiator upper shroud, then
the radiator (see illustrations).
23Remove the fan from the water pump hub
noting that it has a left-hand thread.
24Disconnect the coolant hoses from the
timing cover/water pump hose stubs.
25Remove the alternator and power steering
pump drivebelts (as applicable)
26Unscrew the four bolts and remove the
crankshaft pulley.
27Lock the crankshaft by jamming the starter
ring gear teeth, and unscrew the vibration
damper centre bolt. Withdraw the damper
from the front of the crankshaft. A puller will be
required for this, preferably one which has two
screws for the tapped holes provided (see
illustrations).
28Using an engine support bar or hoist, take
the weight of the engine then unscrew the nuts
2C•10V6 engines
10.9 Heater connecting pipe clip bolts
(arrowed)
10.27a Unscrewing the vibration damper
centre bolt
10.22b Removing radiator upper shroud10.22c Manoeuvre the radiator out from
under the vehicle
10.27b Using a puller to withdraw the
vibration damper10.28a Using an engine support bar to
support the engine
10.13 Camshaft and crankshaft gear marks
in alignment (engine inverted)
Disregard the other mark on the crankshaft gear10.22a Radiator upper shroud plastic clip
and centre pin
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from the top of the engine mounting brackets
(see illustrations).
29Drain the engine oil, retaining it for further
use only if it is not contaminated or due for
renewal.
30Unbolt the coolant distribution pipe bracket
from the timing cover (see illustration).
31Disconnect the leads and remove the
starter motor.
32Ensure that the front roadwheels and the
steering wheels are in the straight-ahead
position, then remove the pinch-bolt from the
steering shaft coupling and slide the coupling
down the shaft (see illustration).
33Unscrew the sump retaining nuts and
bolts. The rear bolts can only be unscrewed
using a box spanner or thin-walled socket.
34Release the brake hydraulic lines from
their support brackets by pulling out their
retaining clips.
35Unscrew the two bolts from each of the
crossmember side brackets. Lower the
crossmember just enough to be able to
remove the sump. In practice, as the car is
standing on its roadwheels, the car body
should be raised by placing two axle stands
under the front jacking points (see
illustration).
36Extract the nine bolts and remove the
timing cover complete with water pump (see
illustration). Removal of the radiator grille will
provide better access to the cover bolts.
37Check that the crankshaft and camshaft
sprocket timing marks are aligned at the
nearest point to each other (see illustration).If not, turn the crankshaft as necessary.
38Unbolt and remove the timing chain
tensioner. Take care not to allow the spring-
loaded tensioner plunger to eject (see
illustration).
39Lock the camshaft sprocket by passing a
rod through one of the holes and unscrew the
sprocket retaining bolt (see illustration).
40Remove the camshaft sprocket then
release the chain from the crankshaft sprocket
and remove the camshaft sprocket and chain
from the engine.
41If required, the crankshaft sprocket, Woodruff
key and chain guide can now be also removed.
42Clean away all old pieces of gasket from
the cylinder block and timing cover flanges.
43Remove and discard the sump gasket.
The gasket rear tabs may break off, so pickthem out of the recesses in the rear main
bearing cap using a sharp, pointed knife.
Refer to Part A, Section 15 of this Chapter.
2.8 litre engine
1Remove the sump.
2Remove the two securing bolts and remove
the oil pump complete with pick-up and
strainer.
12Oil pump - removal
11Flywheel/driveplate and
adapter plate - removal
V6 engines 2C•11
2C
10.28b Engine mounting top nut10.30 Coolant distribution pipe bracket10.32 Steering shaft coupling pinch bolt
10.37 Timing sprocket alignment marks
(arrowed)
10.36 Removing a timing cover retaining
bolt10.35 Unscrewing crossmember side
bracket mounting bolts
10.38 Timing chain tensioner assembly10.39 Slackening camshaft sprocket
retaining bolt
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