1993 FORD SIERRA lock

4Mark the rotor faces so that the rotors can
be refitted in their original positions, then lift
the rotors from the pump body.
5Remove the pressure relief valve plug by
piercing it with a punch and levering it out,
then withdraw the spring and plunger.
6Thoroughly clean all parts in petrol or
paraffin and wipe dry using a non-fluffy rag.
Reassembly and inspection
7Commence reassembly by lubricating the
relief valve plunger. Fit the plunger and spring.
8Fit a new relief valve plug, flat side
outwards and seat it with a drift until it is flush
with the pick-up mating face.
9Lubricate the rotors and fit them. Note the
marks made when dismantling, if applicable.
10The necessary clearances may now be
checked using a machined straight edge (a
good steel rule) and a set of feelerblades. The
critical clearances are between the lobes of
the centre rotor and convex faces of the outer
rotor; between the outer and pump body; and
between both rotors and the end cover plate
(endfloat). The desired clearances are given in
the Specifications (see illustrations).
11Endfloat can be measured by placing a
straight edge across the pump body and
measuring the clearance between the two
rotors and the straight edge using feeler
blades (see illustration).
12New rotors are only available as a pair. If
the rotor-to-body clearance is excessive, a
complete new pump should be fitted.
13Refit the pump cover and tighten the
securing bolts.
14Fit the pick-up tube and strainer, using a
new gasket.
15Temporarily insert the driveshaft into the
pump and make sure that the rotors turn freely.16Prime the pump before refitting.
Removal
1Remove the sump and the cylinder head.
2Check the big-end bearing caps for
identification marks and if necessary use a
centre-punch to identify the caps and
corresponding connecting rods (see
illustration).
3Turn the crankshaft so that No 1 crankpin is
at its lowest point, then unscrew the nuts and
tap off the bearing cap. Keep the bearing
shells in the cap and connecting rod.
4Using the handle of a hammer, push the
piston and connecting rod up the bore and
withdraw from the top of the cylinder block.
Loosely refit the cap to the connecting rod.
5Repeat the procedure in paragraphs 3 and
4 on No 4 piston and connecting rod, then
turn the crankshaft through half a turn and
repeat the procedure on Nos 2 and 3 pistons
and connecting rods.
Refitting
6Commence refitting as follows.
7Clean the backs of the bearing shells and
the recesses in the connecting rods and big-
end caps.
8Press the bearing shells into the connecting
rods and caps in their correct positions and oil
them liberally. Note that the lugs in
corresponding shells must be adjacent to
each other (see illustration).
9Lubricate the cylinder bores with clean
engine oil.10Fit a piston ring compressor to No 1
piston, then insert the piston and connecting
rod into No 1 cylinder (see illustration). With
No 1 crankpin at its lowest point, drive the
piston carefully into the cylinder with the
wooden handle of a hammer, and at the same
time guide the connecting rod onto the
crankpin. Make sure that the arrow on the
piston crown is facing the front of the engine.
11Oil the crankpin, then fit the big-end
bearing cap in its previously noted position,
and tighten the nuts to the specified torque.
12Check that the crankshaft turns freely.
13Repeat the procedure given in paragraphs
11 to 13 inclusive on the remaining pistons.
14Refit the cylinder head and the sump.
1Examine the pistons for ovality, scoring,
and scratches. Check the connecting rods for
wear and damage. The connecting rods carry
a letter indicating their weight class; all the
rods fitted must be of the same class.
2The gudgeon pins are an interference fit in
the connecting rods, and if new pistons are to
be fitted to the existing connecting rods, the
work should be carried out by a Ford dealer
who will have the necessary tooling. Note that
the oil splash hole in the connecting rod must
be located on the right-hand side of the piston
(the arrow on the piston crown faces forwards).
3If new rings are to be fitted to the existing
pistons, expand the old rings over the top of
the pistons. The use of two or three old feeler
blades will be helpful in preventing the rings
dropping into empty grooves. Note that the oil
control ring is in three sections.
33Pistons and connecting rods
- examination and renovation
32Pistons and connecting rods
- removal and refitting
2A¥22SOHC engines
31.10a Checking the oil pump outer rotor-
to-body clearance31.11 Checking the oil pump rotor endfloat
32.10 Fitting a piston ring compressor32.8 The bearing shell lugs (arrowed) must
be adjacent to each other32.2 Big-end cap and connecting rod
identification numbers
31.10b Checking the oil pump inner-to-
outer rotor clearance

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