Ford Sierra

1982-1993 of release

Repair and car operation



Ford Siyerra
+ 1.2. Car identification
+ 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. Ignition system
            3.1.4.4.2. Injection system
            3.1.4.4.3. Scheme of EES IV system of the DOHC 2,0 engine of dm3
            3.1.4.4.4. Check and EES IV system adjustment
            3.1.4.4.5. Elimination of malfunctions
            3.1.4.4.6. Check of elements of EES IV system
            3.1.4.4.7. Gazoraspredeleniye system
            3.1.4.4.8. Head of the block of cylinders of the engine
            3.1.4.4.9. Engine dismantling
            3.1.4.4.10. Engine assembly
            3.1.4.4.11. Greasing system
         + 3.1.4.5. Coupling
         3.1.4.6. Mechanical five-speed transmission of type N
         + 3.1.4.7. Mechanical five-speed transmission of MT 75 type
         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 with 1990 till 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. Engine assembly

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 a tightening of carving 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 cooperating elements (should be in the same places in which they were located before engine dismantling).

Designation at the bottom of the DOHC engine piston

The arrow at the bottom of the piston at installation should be directed towards a drive of system of a gazoraspredeleniye (to переду the engine).

Designation of covers of rods of the DOHC engine

Drawing top – complete set designation with a rod.
Drawing bottom – 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 loose leaves 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), follows перешлифовать cylinders for the repair size or to replace the block of cylinders of the engine and to pick up the corresponding pistons.
4. To remove covers of radical bearings.

Gap measurement in radical bearings of a cranked shaft

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

Prevention

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


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

Engine assembly

PERFORMANCE ORDER
1. To establish loose leaves of radical bearings in nests of the block of cylinders of the engine (not to oil an external surface of loose leaves).
2. To oil a surface of sliding of loose leaves of radical bearings for the engine and to establish a cranked shaft in radical bearings.
3. To put on covers of radical bearings (the arrow on a cover is directed to переду the engine) together with their loose leaves (with a surface of sliding also oiled for the engine) and to insert persistent half rings of a cranked shaft into nests of the average radical bearing.
4. To establish the micrometric indicator to an axis of a cranked shaft for measurement axial люфта in bulk.
5. By means of a screw-driver to move it is longitudinal a cranked shaft within axial люфта and to read indicator indications.
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 cranked shaft with half rings of the demanded thickness, for providing the correct axial gap of a cranked 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 a maslosjemny ring in relation to its ekspander (a holding apart spring).
11. To insert pistons together in rods into engine cylinders. The arrow at the bottom of the piston should be directed towards a drive of system of a gazoraspredeleniye (in the direction in front of the engine).
12. To insert into the bottom heads of rods shatunny loose leaves with a surface of sliding oiled for the engine.
13. To put on covers of rods together with loose leaves, to screw up new bolts and to tighten bolts of rods the corresponding moment.
14. To check size of an axial gap of rods on shatunny necks of a shaft.
15. To press into an opening on the end of a cranked shaft the new bearing of primary shaft of a transmission.
16. To take from back covers of the block of cylinders a back sealing ring of a cranked shaft.
17. To screw a back cover on the block of cylinders of the engine.
18. To oil for the engine an edge of a new sealing ring of a cranked shaft 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 should be more than the condensed diameter of a shaft, and external diameter should be equal to external 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 a maslopriyemnik of the oil pump and a grid with new laying.
21. To establish the oil pallet with new laying., tightening bolts of fastening the necessary moment.
22. To screw new bolts a flywheel on a cranked shaft.
23. To center a disk of coupling and to attach a leading part of coupling to a flywheel.
24. To screw the sensor of provision of a cranked shaft and the sensor of pressure of oil.
25. To establish the oil pump (see subsection 3.1.4.4.11).
26. To establish on the block of cylinders the oil filter and the pump of cooling liquid.
27. To establish laying of a head of the block of cylinders.
28. To establish 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 in openings new bolts of fastening of a head 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 for the engine bearings of cam-shafts and to establish on them both shaft.
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 a gazoraspredeleniye (see subsection 3.1.4.4.7).
34. To establish top directing to a chain.
35. To put on a chain and an asterisk of a drive of the oil pump.
36. To establish the tension device of a chain of the oil pump.
37. To establish a shponka in a flute of a cranked shaft.
38. To put on the bottom casing kardanny chains of system of a gazoraspredeleniye.
39. To establish a damper of krutilny fluctuations of a cranked shaft, to center the bottom casing kardanny chains of system of a gazoraspredeleniye and to tighten its bolts the corresponding moment.
40. To put on the top casing kardanny chains of system of a gazoraspredeleniye, 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 plum of system of cooling together with new laying.
43. To screw up spark plugs, to connect wires of a high voltage and to screw them the holder.
44. To establish the pipeline of system of ventilation of a case.
45. To establish the generator, to put on maple a belt of a drive of the generator and the 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.