1991 FORD SIERRA vacuum

Note:A hoist and lifting tackle will be
required.
1Disconnect the battery negative lead.
2Remove the bonnet.
3On carburettor models, remove the air
cleaner.
4On fuel injection models, remove the air
inlet hose, plenum chamber, and air cleaner
lid as an assembly.
5Disconnect the breather hose from the
camshaft cover, and unscrew the bolt securing
the hose support bracket to the left-hand side
of the cylinder head (see illustration).
6Drain the cooling system.
7To provide additional working space,
remove the radiator.
8Disconnect the coolant hoses from the
coolant pump housing on the left-hand side of
the engine.
9Disconnect the coolant hoses from the
thermostat housing.
10Disconnect the heater coolant hose from
the inlet manifold.
11Where applicable, release the coolant
hose from the bracket under the carburettor
automatic choke housing.
12On carburettor models, disconnect the
vacuum pipe from the engine management
module.
13Disconnect the brake servo vacuum hose
from the inlet manifold.14On fuel injection models, disconnect the
vacuum pipes from the MAP sensor (located
at the rear right-hand side of the engine
compartment) and, where applicable, from the
air conditioning system.
15On carburettor models, disconnect the
fuel supply and return hoses at the
carburettor, and plug the ends of the hoses to
minimise petrol spillage. Take adequate fire
precautions.
16On fuel injection models, slowly loosen
the fuel feed union at the fuel rail, to relieve
the pressure in the fuel system before
disconnecting the union. Be prepared for
petrol spillage, and take adequate fire
precautions. Disconnect the fuel feed hose,
and disconnect the fuel return hose from the
fuel pressure regulator. Plug the ends of the
hoses to minimise petrol spillage.
17Disconnect the throttle cable and move it
to one side.
18Disconnect the HT lead from the ignition
coil, and unclip it from the timing chain cover.
19Disconnect the wiring from the following
components as applicable, depending on
model:
Alternator.
Starter motor.
Oil pressure warning lamp switch.
Temperature gauge sender.
Cooling fan switch.
Anti-dieselling valve (carburettor models).
Automatic choke heater (carburettor models).
Engine coolant temperature sensor.
Crankshaft speed/position sensor.
Air charge temperature sensor.
Throttle position sensor.
Fuel temperature sensor.
Fuel injectors.
20On models fitted with power steering,
unbolt the power steering pump from its
mounting bracket and move it clear of the
engine. Note that there is no need to
disconnect the fluid hoses, but make sure that
the pump is adequately supported to avoid
straining them.
21On models fitted with air conditioning,
unbolt the air conditioning compressor from
its mounting bracket, and move it clear of the
engine. Do not disconnect the hoses; make
sure that the compressor is adequately
supported to avoid straining them.
22Unscrew and remove the top engine-to-
gearbox bolts which are accessible from theengine compartment. Note the location of the
bolts, and note the positions of the earth strap
and any wiring clips attached to the bolts (see
illustration).
23Unscrew the securing bolt, and
disconnect the earth lead from the rear left-
hand side of the cylinder head.
24Unscrew the nuts securing the engine
mountings to the engine mounting brackets.
25Apply the handbrake, jack up the front of
the vehicle and support it securely on axle
stands (see “Jacking and Vehicle Support”).
26Drain the engine oil into a suitable
container.
27Remove the starter motor.
28Remove the exhaust downpipe.
29Ensure that the steering wheel is
positioned in the straight-ahead position, then
remove the clamp bolt from the lower steering
column clamp, swivel the plate to one side, and
disconnect the lower steering column from the
lower flexible coupling (see illustration).
30Working inside the vehicle, place a wooden
block under the clutch pedal to raise it fully
against its stop, so holding the automatic
adjuster pawl clear of the toothed quadrant.
31Disconnect the clutch cable from the
clutch release arm, and pass the cable
through the bellhousing.
32Support the gearbox with a trolley jack,
using a block of wood between the jack and
the gearbox to spread the load.
33Unscrew and remove the remaining
engine-to-gearbox bolts, and remove the bolt
from the engine adapter plate (see
illustration). Recover any shims fitted
between the sump and the gearbox when
removing the lower engine-to-gearbox bolts.
5Engine - removal leaving
manual gearbox in vehicle
2B•4DOHC engine
5.5 Removing the hose support bracket
bolt from the cylinder head5.29 Removing the lower steering column
clamp bolt
5.33 Engine adapter plate bolt (arrowed)
5.22 Earth strap position on top engine-to-
gearbox (arrowed)
Warning: Vehicles equipped
with air conditioning:
Components of the air
conditioning system may
obstruct work being undertaken
on the engine and it is not always possible
to unbolt and move them aside
sufficiently, within the limits of their
flexible connecting pipes. In such a case,
the system should be discharged by a
Ford dealer or air conditioning specialist.
The refrigerant is harmless under normal
conditions but in the presence of a naked
flame (or a lighted cigarette) it forms a
highly toxic gas. Liquid refrigerant spilled
on the skin will cause frostbite. If
refrigerant enters the eyes, rinse them
with a diluted solution of boric acid and
seek medical advice immediately.

34Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate engine removal.
35Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head, and carefully take the weight of
the engine.
36To improve clearance in the engine
compartment when lifting the engine, unbolt
the engine mounting brackets from the
cylinder block, and remove them (see
illustration).
37Detach the brake lines from the front
suspension crossmember (see illustration).
38Support the crossmember with a jack (do
not remove the jack from under the gearbox),
then loosen the bolts securing the
crossmember to the underbody. Remove the
bolts from one side (see illustration), and
carefully lower the crossmember sufficiently
to allow the sump to clear the steering rack
and crossmember when pulling the engine
forwards from the gearbox.
39Gently raise the engine, then pull it
forwards to disconnect it from the gearbox.
Ensure that the gearbox is adequately
supported, and take care not to strain the
gearbox input shaft. It may be necessary to
rock the engine a little to release it from the
gearbox.
40Once clear of the gearbox, lift the engine
from the vehicle, taking care not to damage
the components in the engine compartment
(see illustration).Note: Refer to the warning at the beginning of
Section 5 before proceeding. A suitable hoist
and lifting tackle will be required for this
operation.
1Proceed as described in paragraphs 1 to 21
of Section 5.
2Unscrew and remove the top engine-to-
transmission bolts which are accessible from
the engine compartment. Note the location of
the earth strap, vacuum pipe bracket, and
transmission dipstick tube bracket, as
applicable.
3Proceed as described in paragraphs 23 to 29
of Section 5.
4Where applicable, remove the bolt securing
the transmission fluid dipstick tube to the left-
hand side of the cylinder block.
5Working through the starter motor aperture,
unscrew the four torque converter-to-
driveplate nuts. It will be necessary to turn the
crankshaft, using a suitable spanner on the
crankshaft pulley bolt, in order to gain access
to each bolt in turn through the aperture.
6Support the transmission with a trolley jack,
using a block of wood between the jack and
the transmission to spread the load.
7Unscrew and remove the remaining engine-
to-transmission bolts, and remove the bolt
from the engine adapter plate. Recover any
shims fitted between the sump and the
transmission when removing the lower engine-
to-transmission bolts. Where applicable, pull
the blanking plug from the adapter plate.
8Proceed as described in paragraphs 34 to 38
of Section 5.
9Gently raise the engine, then pull the engine
forwards to disconnect it from the
transmission. Ensure that the torque converter
is held firmly in place in the transmission
housing, otherwise it could fall out, resulting in
fluid spillage and possible damage. It may be
necessary to rock the engine a little to release
it from the transmission.
10Once clear of the transmission, lift the
engine from the vehicle, taking care not to
damage the components in the engine
compartment.Note: Refer to the warning at the beginning of
Section 5 before proceeding. A suitable hoist
and lifting tackle will be required for this
operation.
Removal
1Proceed as described in paragraphs 1 to 21
of Section 5.
2Unscrew the securing bolt, and disconnect
the earth lead from the rear left-hand side of
the cylinder head.
3Unscrew the nuts securing the engine
mountings to the engine mounting brackets.
4Jack up the vehicle and support it securely
on axle stands (see “Jacking and Vehicle
Support”).
Ensure that there is enough working room
beneath the vehicle.
5To improve access, disconnect the exhaust
downpipe from the manifold, and remove the
exhaust system.
6Drain the engine oil into a suitable
container.
7On models fitted with a catalytic converter,
release the securing clips, and withdraw the
exhaust heat shield from under the vehicle for
access to the propeller shaft.
8Remove the propeller shaft.
9Where applicable, bend back the locktabs,
then unscrew the two bolts in each case
securing the two anti-roll bar U-clamps to the
vehicle underbody. Lower the anti-roll bar as
far as possible.
10Working inside the vehicle, place a
wooden block under the clutch pedal to raise
it fully against its stop, so holding the
automatic adjuster pawl clear of the toothed
quadrant.
11Disconnect the clutch cable from the
clutch release arm, and pass the cable
through the bellhousing.
12Support the gearbox with a trolley jack,
using a block of wood between the jack and
the gearbox to spread the load.
13Unscrew the four nuts securing the
gearbox crossmember to the vehicle
underbody. Unscrew the central bolt securing
7Engine/manual gearbox
assembly - removal and
separation6Engine - removal leaving
automatic transmission in
vehicle
DOHC engine 2B•5
2B
5.38 Removing a suspension crossmember
securing bolt
5.40 Lifting the engine from the vehicle
5.37 Removing a brake line securing clip
from the suspension crossmember5.36 Remove the engine mounting
brackets to improve clearance