Ford Sierra

1982-1993 of release

Repair and operation of the car



Ford Siyerra
+ 1.2. Identification of the car
+ 2. Maintenance
- 3. General data
   - 3.1. Cars with petrol engines
      3.1.1. Masses and transfer numbers
      3.1.2. Operational liquids
      + 3.1.3. Changes in a car design from 1984 to 1986.
      - 3.1.4. Changes in a car design from 1987 to 1989.
         3.1.4.1. OHC engine
         + 3.1.4.2. Dm3 CVH 1,8 engine
         + 3.1.4.3. DOHC engine
         - 3.1.4.4. Service and repair
            3.1.4.4.1. System of ignition
            3.1.4.4.2. System of injection
            3.1.4.4.3. Scheme of the EES IV system of the DOHC 2,0 engine of dm3
            3.1.4.4.4. Check and adjustment of the EEC IV system
            3.1.4.4.5. Elimination of malfunctions
            3.1.4.4.6. Check of elements of the EEC IV system
            3.1.4.4.7. System of gas distribution
            3.1.4.4.8. Head of the block of cylinders of the engine
            3.1.4.4.9. Dismantling of the engine
            3.1.4.4.10. Assembly of the engine
            3.1.4.4.11. Lubrication system
         + 3.1.4.5. Coupling
         3.1.4.6. Mechanical five-speed transmission of N type
         + 3.1.4.7. Mechanical MT 75 five-speed transmission
         3.1.4.8. Automatic transmission
         3.1.4.9. Forward suspension bracket
         + 3.1.4.10. Brake system
         + 3.1.4.11. Electric equipment
         3.1.4.12. General data
      + 3.1.5. Changes in a car design from 1990 to February, 1993.
   + 3.2. Cars with diesel engines
+ 4. Engines
+ 5. Coupling
+ 6. Transmissions
+ 7. Driveshaft and back bridge
+ 8. Steering
+ 9. Suspension brackets
+ 10. Brake system
+ 11. Body
+ 12. Electric equipment





3.1.4.4.10. Assembly of the engine

GENERAL INFORMATION

In the course of assembly of the engine it is necessary to pay attention on:

  – careful washing of all details;
  – replacement damaged (or worn out) sealing rings and paper laying;
  – observance of the corresponding moments of tightening of threaded connections;
  – use of new bolts of fastening of a head of the block of cylinders and their tightening in the corresponding sequence;
  – observance of the correct combinations of the interacting elements (have to be in the same places in which they were located before dismantling of the engine).

Designation at the bottom of the DOHC engine piston

The arrow at the bottom of the piston at installation has to be directed towards the drive of system of gas distribution (to an engine pered).

Designation of covers of rods of the DOHC engine

The drawing top – designation of a complete set with a rod.
The drawing lower – designation of the correct provision of a cover concerning a rod.

Measurement of a gap of the piston in the cylinder


PERFORMANCE ORDER
1. To put on covers of radical bearings without inserts and to tighten their bolts of fastening the necessary moment.
2. To turn the engine on 180 ° (openings of cylinders up).
3. To measure diameters of cylinders. If these diameters exceed the corresponding sizes (see subsection 3.1.4.3.1.2), it is necessary to pereshlifovat cylinders on the repair size or to replace the block of cylinders of the engine and to pick up the corresponding pistons.
4. To uncover radical bearings.

Measurement of a gap in radical bearings of a bent shaft

PERFORMANCE ORDER
1. To insert inserts into saddles of radical bearings of the block of cylinders.
2. To install a bent shaft in bearings.
3. To lay along a radical neck in the bearing of which the gap, a measuring core of Plastigage by length to the equal width of an insert has to be measured, put on the corresponding cover of the radical bearing together with its insert and tighten bolts of fastening of a cover the necessary moment.

Prevention

In the course of this operation it is impossible to rotate a bent shaft.


4. To uncover the radical bearing together with its insert.
5. To compare width of the deformed measuring core to the scale delivered together with a core and on this basis to define a neck gap in the bearing. If the gap exceeds admissible limits, then it is necessary to replace radical inserts.

Assembly of the engine

PERFORMANCE ORDER
1. To establish inserts of radical bearings in nests of the block of cylinders of the engine (not to oil an external surface of inserts).
2. To oil the surface of sliding of inserts of radical bearings for the engine and to install a bent shaft in radical bearings.
3. To put on covers of radical bearings (the arrow on a cover is directed to an engine pered) together with their inserts (with the surface of sliding which is also oiled for the engine) and to insert persistent half rings of a bent shaft into nests of the average radical bearing.
4. To install the micrometric indicator to an axis of a bent shaft for measurement of an axial side play of a shaft.
5. By means of the screw-driver to move it is longitudinal a bent shaft within an axial side play and to read indications of the indicator.
6. To compare this value to the correct size (see subsection 3.1.4.3.1.3).
7. In case of need to replace persistent half rings of a bent shaft with half rings of the required thickness, for providing the correct axial gap of a bent shaft and again to check this gap.
8. To check a gap of locks of piston rings after installation them in engine cylinders. In case of need to replace the rings having the wrong gap of the lock.
9. To put on the checked rings pistons.
10. To place locks of rings evenly on perimeter of each piston. It concerns also elements of an oil scraper ring in relation to its expander (the holding apart spring).
11. To insert pistons together in rods into engine cylinders. The arrow at the bottom of the piston has to be directed towards the drive of system of gas distribution (in the direction in front of the engine).
12. To insert into the lower heads of rods connecting rods with the surface of sliding oiled for the engine.
13. To put on covers of rods together with inserts, to screw up new bolts and to tighten bolts of rods the corresponding moment.
14. To check the size of an axial gap of rods on conrod necks of a shaft.
15. To press into an opening on the end of a bent shaft the new bearing of a main shaft of the transmission.
16. To take a back sealing ring of a bent shaft from the back block of cylinders of a cover.
17. To screw a back cover on the block of cylinders of the engine.
18. To oil an edge of a new sealing ring of a bent shaft for the engine and to put on it a back cover of the block of cylinders by means of a plate and two bolts of fastening of a flywheel (internal diameter of a plate has to be more than the condensed diameter of a shaft, and outer diameter has to be equal to the outer diameter of a back sealing ring).
19. To screw on the block of cylinders a forward cover together with new laying.
20. To screw from below on the block of cylinders a partition of the oil pallet (the oil deflector) both an oil receiver of the oil pump and a grid with new laying.
21. To install the oil pallet with new laying., tightening fastening bolts the necessary moment.
22. To screw new bolts a flywheel on a bent shaft.
23. To center a clutch plate and to attach the leading part of coupling to a flywheel.
24. To screw the sensor of provision of a bent shaft and the sensor of pressure of oil.
25. To install the oil pump (see subsection 3.1.4.4.11).
26. To establish an oil filter and the pump of cooling liquid on the block of cylinders.
27. To establish laying of a head of the block of cylinders.
28. To install the piston of the 1st cylinder at distance about 20 mm from VMT.
29. To establish a head of the block of cylinders, to screw up new bolts of fastening of a head in openings and to tighten them in the corresponding way (the description of installation of a head of the block of cylinders see in subsection 3.1.4.4.8).
30. To oil and establish in directing hydraulic pushers.
31. To oil bearings of cam-shafts for the engine and to establish on both of them in bulk.
32. To put on covers of bearings of cam-shafts and to tighten their bolts the corresponding moment.
33. To establish asterisks and a driving chain of system of gas distribution (see subsection 3.1.4.4.7).
34. To establish the top guide of a chain.
35. To put on a chain and an asterisk of the drive of the oil pump.
36. To install the tension device of a chain of the oil pump.
37. To establish a spline in a flute of a bent shaft.
38. To put on the lower casing cardan chains of system of gas distribution.
39. To establish a damper of tortional fluctuations of a bent shaft, to center the lower casing cardan chains of system of gas distribution and to tighten its bolts the corresponding moment.
40. To put on the top casing cardan chains of system of gas distribution, paying attention to laying of its laying and to tighten bolts of its fastening the corresponding moment.
41. To establish a cover of a head of the block of cylinders together with new laying, tightening bolts of its fastening the corresponding moment.
42. To screw up a stopper of discharge of the cooling system together with new laying.
43. To screw up spark plugs, to connect wires of high voltage and to screw them the holder.
44. To install the pipeline systems of ventilation of a case.
45. To install the generator, to put on maple a belt of the drive of the generator and pump of cooling liquid and to adjust its tension.
46. To fill the engine with necessary amount of the corresponding oil and to insert the index of level of oil.