1993 FORD SIERRA fuel

Inspection
3Examine the surfaces of the camshaft
journals and lobes and the contact surfaces of
the cam followers for wear. If wear is
excessive considerable noise would have
been noticed from the top of the engine when
running, and new camshafts and followers
must be fitted. It is unlikely that this level of
wear will occur unless a considerable mileage
has been covered. Note that the cam
followers cannot be dismantled for renewal of
individual components.
4Check the camshaft bearing surfaces in the
cylinder head and the bearing caps for wear. If
excessive wear is evident, the only course of
action available is to renew the cylinder head
and bearing caps.
5Check the cam follower bores in the
cylinder head for wear. If excessive wear is
evident, the cylinder head must be renewed.
6Check the cam follower oil grooves and the
oil ports in the cylinder head for obstructions.
Refitting
7Refit the cam followers and the camshafts
as described in paragraphs 27 to 55 of
Section 18.
8If the engine is in the vehicle, reverse the
operations given in paragraph 1.
Note: New flywheel/driveplate securing bolts
must be used on refitting.
1Refer to Chapter 2, PartA, noting the
following points.
2If the engine is in the car, refer to Chapter 6
when removing and refitting the clutch.
3There is no need to make alignment marks
between the flywheel/driveplate and the end
of the crankshaft, as the securing bolt holes
are offset, so the flywheel/driveplate can only
be fitted to the crankshaft in one position.
4The flywheel/driveplate securing bolts must
be renewed when refitting, and the new bolts
are supplied ready-coated with threadlocking
compound (see illustration).
5Check on the availability of new parts
before contemplating renewal of the ring gear.Note: A suitable puller will be required to
remove the crankshaft pulley. A new
crankshaft pulley bolt, and a new lower timing
chain cover gasket, must be used on refitting.
1The crankshaft front oil seal is located in the
lower timing chain cover.
2If 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.
3Proceed as described in paragraphs 3 to 8
of Section 15.
4With the lower timing chain cover removed,
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. Take care not to
damage the timing chain cover.
5Refit the lower timing chain cover as
described in paragraphs 31 to 39 of Section
15.
6If the engine is in the vehicle, reverse the
operations given in paragraph 2.
Note: New flywheel/driveplate bolts must be
used on refitting.
1Remove the flywheel/driveplate and the
engine adapter plate.
2Extract the seal using an oil seal removal
tool if available. It may also be possible to
remove the oil seal by drilling the outer face
and using self-tapping screws and a pair of
grips.
3Clean the oil seal housing, then carefully
wind a thin layer of tape around the edge of
the crankshaft to protect the oil seal lip as the
seal is installed.4Ideally, the new oil seal should be installed
using a tool similar to that shown (see
illustration).A suitable tool can be
improvised using a metal tube of suitable
diameter, a metal disc or flat bar, and two
flywheel bolts. Draw the seal into position
using the two flywheel bolts. Make sure that
the seal lip faces into the engine.
5With the oil seal installed, carefully pull the
tape from the edge of the crankshaft.
6Refit the engine adapter plate and the
flywheel/driveplate.Removal
1Sump removal and refitting is far easier if
the engine is removed from the vehicle - if so,
proceed to paragraph 9. However, if the
engine is in the vehicle, proceed as follows.
2Remove the gearbox and clutch, or
automatic transmission, as applicable.
3Remove the flywheel/driveplate and the
engine adapter plate.
4Drain the engine oil into a container.
5Ensure 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.
6Attach 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.
7Detach the brake lines from the front
suspension crossmember.
8Support the crossmember with a jack, then
loosen the bolts securing the crossmember to
the underbody. Remove the bolts, and
carefully lower the crossmember sufficiently
to allow the sump to be removed.
9If the engine has been removed, it is
preferable to keep it upright until the sump
has been removed, to prevent sludge in the
sump from entering the engine internals.
10Unscrew the sump securing nuts and
bolts, and withdraw the sump from the
engine. If the sump is stuck, gently tap it
sideways to free it (the sump will not move far
sideways, as it locates on studs in the cylinder
block). Do not prise between the mating faces
of the sump and block. Recover the gasket.
11Thoroughly clean the mating faces of the
cylinder block and sump.
Refitting
12Commence refitting by locating a new
gasket in the grooves in the sump.
25Sump - removal and refitting
24Crankshaft rear oil seal -
renewal
23Crankshaft front oil seal -
renewal
22Flywheel/driveplate - removal
inspection and refitting
DOHC engine 2B•15
2B
24.4 Tool used to fit crankshaft rear oil
seal
A Rear oil seal housing
B Special tool22.4 Improvised tool used to hold flywheel
when tightening securing bolts
Warning: A new sump gasket will
be required on refitting, and
suitable sealing compound will
be required to coat the sump and
cylinder block mating faces.
Shims may be required when mating the
engine and gearbox/transmission - see text.

13Apply a suitable sealing compound to the
faces of the cylinder block and sump, at the
points indicated (see illustration).
14Locate the sump on the cylinder block,
then apply suitable thread-locking compound
to the sump securing studs and bolts. Fit the
securing nuts and bolts, but do not fully
tighten them at this stage.
15Align the sump so that its 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 (available from a Ford
dealer) must be fitted 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, proceed as
follows.
18Reverse the procedure described in
paragraphs 2 to 8, noting the following points.19Ensure that the roadwheels and the
steering wheel are in the straight-ahead
position before reconnecting the lower
steering column to the intermediate shaft.
20Fill the engine with the correct grade and
quantity of oil.
21Refit the engine adapter plate and the
flywheel/driveplate.
22Refit the gearbox or automatic
transmission, ensuring that the required shims
are fitted between the sump and the
gearbox/transmission.
23Tighten 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.
Removal
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 illustrations). Recover the gasket.
Refitting
4Thoroughly clean the mating faces of the
pump and the cylinder block.
5Prime the pump by injecting clean engine
oil into it and turning it by hand.
6Place a new gasket on the oil pump flange,
ensuring that the gasket is correctly located
so that its holes align with the oil passages in
the pump.
7Fit the oil pump, and tighten the securing
bolts to the specified torque.8Proceed as shown in paragraphs 27 to 39
of Section 15.
9If the engine is in the vehicle, reverse the
operations described in paragraph 1.
Dismantling
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.
27Oil pump - dismantling,
inspection and reassembly
26Oil pump - removal and
refitting
2B•16DOHC engine
25.13 Apply sealing compound to the
sump/cylinder block mating faces at the
points indicated (2)
Dimensions are for guidance only
26.3b Withdrawing the oil pump
26.3a Oil pump securing bolts (arrowed)25.15 Measuring the clearance between
the cylinder block and sump end faces
27.3 Removing the oil pump cover