Ford Sierra 1983 1990 User Manual

Engine
Oil filter type:
SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C102
CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104
Valve clearances (cold):
SOHC:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.03 mm (0.008 ± 0.001 in)
DOHC and CVH:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)
Chapter 1
Routine maintenance and servicing
Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Air cleaner inlet air temperature control check . . . . . . . . . . . . . . . . . .36
Air conditioner refrigerant charge check . . . . . . . . . . . . . . . . . . . . . .26
Automatic transmission brake band adjustment . . . . . . . . . . . . . . . .40
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . .17
Automatic transmission selector lubrication . . . . . . . . . . . . . . . . . . .28
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Battery electrolyte level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Battery terminal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Brake system seal and hose renewal . . . . . . . . . . . . . . . . . . . . . . . . .43
Brake pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Camshaft drivebelt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Crankcase ventilation system check . . . . . . . . . . . . . . . . . . . . . . . . .35
Crankcase ventilation vent valve renewal . . . . . . . . . . . . . . . . . . . . . .42
Driveshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Engine idle speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine valve clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Final drive oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Ford Sierra maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Front and rear brake pad/shoe check . . . . . . . . . . . . . . . . . . . . . . . . .9
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Handbrake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . . .19
Idle speed linkage clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Ignition system component check . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Manual gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Mixture adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Oil filler cap check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pulse air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Radiator matrix and air conditioner condenser clean . . . . . . . . . . . . .25
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Roadwheel security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Steering and suspension security check . . . . . . . . . . . . . . . . . . . . . .29
Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Underbody inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1•1
Easy, suitable for novice with little experience
Fairly easy, suitable for beginner with some experience
Fairly difficult,
suitable for competent DIY mechanic
Difficult, suitable for experienced DIY mechanic
Very difficult,
suitable for expert DIY or professional
Degrees of difficulty
Specifications
Contents
1
Cooling system
Drivebelt tensions:
Air conditioning system compressor . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection at the midpoint of the belt’s longest run
under firm thumb pressure
Coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection midway between coolant pump and
alternator (or power steering pump) pulleys under firm thumb pressure
Fuel system
Air filter element:
Carburettor type:
1.3 and 1.6 litre (SOHC - Ford carburettor) . . . . . . . . . . . . . . . . . . Champion W110
1.6 litre (SOHC - Weber carburettor) and 1.8 litre SOHC . . . . . . . . Champion W118
1.6 litre (SOHC - 1984-on) and 2.0 litre SOHC . . . . . . . . . . . . . . . . Champion W152
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W219
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W152
Fuel injection type:
2.0 litre SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U507
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W219
Fuel filter:
All fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L204
Ignition system
Spark plugs: Make and type:
All except 1.8 CVH, CVH (R6A), 2.0 DOHC and P100 . . . . . . . . . . . . Champion RF7YCC or RF7YC
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RF7YC or F7YC
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC
Electrode gap*:
Champion F7YCC or RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.032 in)
Champion RF7YC, F7YC or RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.028 in)
Ignition HT leads
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 k ohms maximum per lead
Type:
All SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-09 or LS-10 boxed set
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-10 boxed set
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-30 boxed set
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-29 boxed set
*The spark plug gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other type are to be fitted, refer to their manufacturer’s recommendations.
Brakes
Brake pad friction material minimum thickness . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in)
Brake shoe friction material minimum thickness . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in)
Torque wrench settings Nm lbf ft
Engine oil drain plug:
SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 28 16 to 21
CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 30 15 to 22
Engine block coolant drain plug (where fitted) . . . . . . . . . . . . . . . . . . . . 21 to 25 16 to 18
Manual gearbox:
Oil filler/level plug:
A,B,C and N types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 to 41 24 to 30
MT75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 41 21 to 30
Oil drain plug:
MT75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 41 21 to 30
Final drive oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 45 26 to 33
Roadwheel nuts:
Saloon, Hatchback and Estate models (steel and alloy wheels) . . . . 70 to 100 52 to 74
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 90 63 to 66
Spark plugs:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 28 15 to 21
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 33 13 to 24
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 21 11 to 15
Brake caliper guide bolts:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 to 35 23 to 26
1•2 Servicing specifications
The maintenance intervals in this manual are provided with the assumption that you will be carrying out the work yourself. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may
wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle.
If the vehicle is driven in dusty areas, used
to tow a trailer, or driven frequently at slow
speeds (idling in traffic) or on short journeys, more frequent maintenance intervals are recommended.
When the vehicle is new, it should be serviced by a factory-authorised dealer service department, in order to preserve the factory warranty.
Capacities
Engine oil
SOHC engines:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 litres (6.6 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 pints)
DOHC engine:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres (7.9 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres (7.0 pints)
1.6 litre CVH engine:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres (6.2 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 pints)
1.8 CVH engines:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres (7.0 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres (6.2 pints)
Cooling system (including heater)
SOHC engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 litres (14.1 pints)
DOHC engine:
Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres (12.3 pints)
Fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 litres (12.8 pints)
CVH engines:
1.6 and 1.8 litre (R2A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 litres (16.7 pints)
1.8 litre (R6A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 litres (13.9 pints)
Fuel tank
All models except P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 litres (13.2 gals)
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.0 litres (14.5 gals)
Manual gearbox
A1 and A2 types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 litre (1.72 pints)
B type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46 litres (2.57 pints)
C type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 litres (2.20 pints)
N type up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.90 litres (3.34 pints)
N type from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 litres (2.20 pints)
MT75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 litres (2.1 pints)
Automatic transmission
C3 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 litres (11.1 pints)
A4LD type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 litres (15.0 pints)
Final drive (from dry)
All models except 1.3 and 1.6 litre Hatchback and P100 . . . . . . . . . . . 0.9 litre (1.6 pints)
1.3 and 1.6 litre Hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 litre (1.4 pints)
P100 models (rear axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 litres (2.0 pints)
Power steering
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.65 litre (1.14 pints)
Servicing specifications 1•3
1
1 Ford Sierra maintenance schedule
1•4 Maintenance schedule
Every 250 miles (400 km) or weekly
mm Check the engine oil level (Section 3) mm Check the engine coolant level (Section 3) mm Check the brake fluid level (Section 3) mm Check the power steering fluid level (Section 3) mm Check the screen washer fluid level (Section 3) mm Visually examine the tyres for tread depth, and wear
or damage (Section 4)
mm Check and if necessary adjust the tyre pressures
(Section 4)
mm Check and if necessary top-up the battery electrolyte
level - where applicable (Section 6)
mm Check the operation of the horn, all lights, and the
wipers and washers (Sections 5 and 7)
Every 6000 miles (10 000 km) or 6 months - whichever comes sooner
mm Renew engine oil and filter (Section 8) mm Check brake pads or shoes for wear (front and rear)
(Section 9)
mm Check operation of brake fluid level warning indicator
(Section 9)
mm Inspect engine bay and underside of vehicle for fluid
leaks or other signs of damage (Section 10)
mm Check function and condition of seat belts
(Section 11)
mm Check condition and security of exhaust system
(Section 12)
mm Check tightness of wheel nuts (Section 13) mm Clean oil filler cap (Section 14) mm Check idle speed (where applicable) (Section 15) mm Check mixture adjustment (where applicable)
(Section 16)
Every 12 000 miles (20 000 km) or 12 months - whichever comes sooner
mm Check automatic transmission fluid level (engine hot)
(Section 17)
mm Check manual gearbox oil level (Section 18) mm Check operation of latches, check straps and locks;
lubricate if necessary (Section 19)
mm Renew spark plugs (Section 20) mm Check condition and tension of auxiliary drivebelt(s);
adjust or renew as necessary (Section 21)
mm Check tightness of battery terminals, clean and
neutralise corrosion if necessary (Section 22)
mm Check engine valve clearances - SOHC only
(Section 23)
mm Check handbrake mechanism (Section 24)
Every 24 000 miles (40 000 km) or 2 years - whichever comes sooner
mm Check air cleaner inlet air temperature control
operation (carburettor models) (Section 36)
mm Renew pulse air filter element (1.6 litre CVH)
(Section 37)
mm Renew air cleaner element (Section 38) mm Clean and inspect distributor cap and HT leads
(Section 39)
mm Check automatic transmission brake band
adjustment (Section 40)
mm Renew fuel filter (fuel-injection models only)
(Section 41)
mm Renew crankcase ventilation vent valve (SOHC and
DOHC) (Section 42)
mm Clean radiator matrix and air conditioning condenser
fins (where applicable) (Section 25)
mm Check air conditioning refrigerant charge (where
applicable) (Section 26)
mm Check final drive oil level (Section 27) mm Lubricate automatic transmission selector/kickdown
linkage (Section 28)
mm Check security and condition of steering and
suspension components, gaiters and boots (Section 29)
mm Check condition and security of driveshaft joints and
gaiters (Section 30)
mm Inspect underbody and panels for corrosion or other
damage (Section 31)
mm Inspect brake pipes and hoses (Section 32) mm Clean idle speed control linkage at throttle (where
applicable) (Section 33)
mm Road test and check operation of ABS (Section 34) mm Check crankcase ventilation system (Section 35)
Every 36 000 miles (60 000 km) or 3 years - whichever comes sooner
mm Renew brake hydraulic system seals and hoses if
necessary (Section 43)
mm Renew brake hydraulic fluid (Section 44) mm Renew camshaft drivebelt (optional on SOHC
models - compulsory on CVH) (Section 45)
mm Renew coolant (Section 46)
Every 12 000 miles (20 000 km) or 12 months - whichever comes sooner (continued)
Maintenance - component location 1•5
1
Underbonnet view of a 1985 2.0 litre SOHC
fuel injection model
1 Battery 2 Brake servo non-return valve 3 Ignition coil 4 Suspension strut top 5 Fuel filter 6 Air cleaner 7 Airflow meter 8 Fuel pressure regulator 9 Air inlet hose 10 Throttle body 11 Alternator 12 VIN plate 13 Windscreen washer reservoir 14 Coolant expansion tank 15 Oil filler cap 16 Idle speed control valve 17 Inlet manifold 18 Brake fluid reservoir 19 Fusebox 20 Windscreen wiper motor 21 Engine oil level dipstick
Underbonnet view of a 1983 2.0 litre SOHC
carburettor model (air cleaner removed)
1 Brake fluid reservoir 2 Windscreen wiper motor 3 Battery 4 Ignition coil 5 Carburettor 6 Distributor 7 Fuel pressure regulator 8 Thermostat housing 9 Radiator top hose 10 Upper fan shroud 11 Alternator 12 Windscreen washer reservoir 13 Oil filler cap 14 Cooler expansion tank 15 Suspension strut top 16 VIN plate 17 Fusebox
1•6 Maintenance - component location
Underbonnet view of a 1990 2.0 litre DOHC
fuel injection model
1 Battery 2 Braking system deceleration-sensitive valve 3 Ignition coil 4 Suspension strut top 5 Air cleaner 6 Plenum chamber 7 Idle speed control valve 8 Distributor 9 Oil filler cap 10 VIN plate 11 Windscreen washer reservoir filler neck 12 Power steering fluid reservoir 13 Coolant expansion tank 14 Manifold absolute pressure (MAP) sensor 15 Brake fluid reservoir 16 Inlet manifold 17 Fuel pressure regulator 18 Fusebox 19 Windscreen wiper motor
Underbonnet view of a 1989 1.8 litre (R2A)
CVH model (air cleaner removed)
1 Battery 2 Suspension strut top 3 Ignition coil 4 Coolant expansion tank 5 Alternator 6 Distributor cap shroud 7 VIN plate 8 Electric cooling fan 9 Radiator top hose 10 Windscreen washer reservoir 11 Fuel vapour separator 12 Thermostat housing 13 Oil filler cap 14 Carburettor 15 Brake fluid reservoir 16 Engine oil level dipstick 17 Windscreen wiper motor 18 Fusebox
Maintenance - component location 1•7
1
Front underside view of a 1990
2.0 GLS model
1 Horns 2 Tie-rod end 3 Tie-rod 4 Gaiter 5 Coolant pump 6 Suspension lower arm 7 Anti-roll bar 8 Starter motor 9 Exhaust downpipes 10 Crossmember 11 Engine sump 12 Oil filter 13 Power steering fluid pump 14 Windscreen washer reservoir 15 Cooling fans
Underbonnet view of a 1992 1.6 litre
CVH model (air cleaner removed)
1 Battery 2 Braking system deceleration-sensitive
valve 3 Suspension strut top 4 Coolant expansion tank 5 Pulse-air filter 6 Vacuum-operated air valve 7 Alternator 8 Cooling fans 9 Oil filler cap 10 Thermostat housing 11 VIN plate 12 Windscreen washer reservoir filler neck 13 Ignition module 14 Pulse-air control solenoid 15 CFI unit 16 Brake fluid reservoir 17 Engine oil level dipstick 18 Manifold absolute pressure (MAP)
Sensor 19 Fusebox 20 Windscreen wiper motor
1•8 Maintenance - component location
Rear underside view of a Hatchback
models
1 Fuel tank 2 Suspension lower arm 3 Lower shock absorber mounting 4 Suspension crossmember 5 Suspension guide plate 6 Final drive unit 7 Exhaust system 8 Propeller shaft 9 Driveshaft
Rear underside view of a P100 model
1 Suspension leaf spring 2 Rear axle 3 Shock absorber 4 Propeller shaft 5 Exhaust system 6 Handbrake cable adjuster 7 Brake load apportioning valve
General information
This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance.
The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components.
Servicing your vehicle in accordance with the mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service intervals, will not produce the same results.
As you service your vehicle, you will discover that many of the procedures can - and should ­be grouped together, because of the particular procedure being performed, or because of the close proximity of two otherwise-unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the
suspension and steering components.
The first step in this maintenance programme is to prepare yourself before the actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather together all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.
Intensive maintenance
If, from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised.
It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out, outside of the regular maintenance intervals.
If engine wear is suspected, a compression test will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to be carried out. If, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this Chapter will not greatly
improve the performance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first.
The following series of operations are those most often required to improve the performance of a generally poor-running engine:
Primary operations
a) Clean, inspect and test the battery b) Check all the engine-related fluids c) Check the condition and tension of the
auxiliary drivebelt d) Renew the spark plugs e) Inspect the distributor cap and HT leads -
as applicable f) Check the condition of the air cleaner
filter element, and renew if necessary g) Renew the fuel filter h) Check the condition of all hoses, and
check for fluid leaks i) Check the idle speed and mixture settings
- as applicable
If the above operations do not prove fully effective, carry out the following secondary operations:
Secondary operations
a) Check the charging system b) Check the ignition system c) Check the fuel system d) Renew the distributor cap and rotor arm -
as applicable
f) Renew the ignition HT leads - as
applicable
2 Introduction
See “Weekly checks”.
See “Weekly checks”.
See “Weekly checks”.
See “Weekly checks”.
See “Weekly checks”.
7 Wiper blade check
6 Battery electrolyte level check
5 Electrical system check
4 Tyre checks
3 Fluid level checks
1 Frequent oil and filter changes are the most
important preventative maintenance procedures which can be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear. 2 Before starting this procedure, gather together all the necessary tools and materials. Also make sure that you have plenty of clean rags and newspapers handy, to mop up any spills. Ideally, the engine oil should be warm, as it will drain better, and more built-up
sludge will be removed with it. Take care, however, not to touch the exhaust or any other hot parts of the engine when working under the vehicle. To avoid any possibility of scalding, and to protect yourself from possible skin irritants and other harmful contaminants in used engine oils, it is advisable to wear gloves when carrying out this work. Access to the underside of the vehicle will be greatly improved if it can be raised on a lift, driven onto ramps, or jacked up and supported on axle stands (see “Jacking and vehicle support”). Whichever method is chosen, make sure that the vehicle remains level, or if it is at an angle, so that the drain plug is at the lowest point (see
illustration).
8 Engine oil and filter renewal
Maintenance procedures 1•9
1
8.2 Sump drain plug location
Every 250 miles (400 km) or weekly
Every 6000 miles (10 000 km) or 6 months
3 Slacken the drain plug about half a turn.
Position the draining container under the drain plug, then remove the plug completely. If possible, try to keep the plug pressed into the sump while unscrewing it by hand the last couple of turns. As the plug releases from the threads, move it away sharply so the stream of oil issuing from the sump runs into the container, not up your sleeve! Recover the sealing washer from the drain plug. 4 Allow some time for the old oil to drain, noting that it may be necessary to reposition the container as the oil flow slows to a trickle. 5 After all the oil has drained, wipe off the drain plug with a clean rag. Check the sealing washer for condition, and renew it if necessary. Clean the area around the drain plug opening, and refit the plug. Tighten the plug to the specified torque. 6 Move the container into position under the oil filter. 7 Using an oil filter removal tool if necessary, slacken the filter initially, then unscrew it by hand the rest of the way (see illustration). Empty the oil from the old filter into the container, and discard the filter. 8 Use a clean rag to remove all oil, dirt and sludge from the filter sealing area on the engine. Check the old filter to make sure that the rubber sealing ring hasn’t stuck to the engine. If it has, carefully remove it. 9 Apply a light coating of clean engine oil to the sealing ring on the new filter, then screw it into position on the engine. Tighten the filter firmly by hand only - do not use any tools. Wipe clean the filter and sump drain plug.
10 Remove the old oil and all tools from under the car, then lower the car to the ground (if applicable). 11 Remove the oil filler cap and withdraw the dipstick. Fill the engine, using the correct grade and type of oil (see “Lubricants and fluids”). An oil can spout or funnel may help to reduce spillage. Pour in half the specified quantity of oil first, then wait a few minutes for the oil to fall to the sump. Continue adding oil a small quantity at a time until the level is up to the lower mark on the dipstick. Finally, bring the level up to the upper mark on the dipstick. Insert the dipstick, and refit the filler cap. 12 Start the engine and run it for a few minutes; check for leaks around the oil filter seal and the sump drain plug. Note that there may be a delay of a few seconds before the oil pressure warning light goes out when the engine is first started, as the oil circulates through the engine oil galleries and the new oil filter, before the pressure builds up. 13 Switch off the engine, and wait a few minutes for the oil to settle in the sump once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary. 14 Dispose of the used engine oil safely, with reference to “General repair procedures” in the Reference section of this manual.
1 Firmly apply the handbrake, then jack up the front and rear of the car and support it securely on axle stands (see “Jacking and vehicle support”). 2 For a quick check, the front brake disc pads can be inspected without removing the front wheels by inserting a mirror between each caliper and roadwheel (see illustration). If any one pad is worn down to the minimum specified thickness, all four pads (on both front wheels) must be renewed. 3 It is necessary to remove the rear wheels in order to inspect the rear disc pads. The pads can be viewed through the top of the caliper after removing the blanking spring clip (see illustration). If any one pad is worn down to the minimum specified, all four pads (on both rear wheels) must be renewed.
4 For a comprehensive check, the brake disc pads should be removed and cleaned. The operation of the caliper can then also be checked, and the condition of the brake discs can be fully examined on both sides. Refer to Chapter 10 for further information. 5 On rear drum brake models, the brake shoe friction material can be inspected for wear without removing the roadwheels. Working beneath the vehicle, prise the plug from the brake backplate, and using an inspection lamp or torch, check that the friction material thickness is not less than the minimum given in the Specifications (see illustration). If any one of the shoes has worn below the specified limit, the shoes must be renewed as an axle set (4 shoes). 6 At the same interval, check the function of the brake fluid level warning light. Chock the wheels, release the handbrake and switch on the ignition. Unscrew and raise the brake fluid reservoir cap whilst an assistant observes the warning light: it should come on as the level sensor is withdrawn from the fluid. Refit the cap. 7 On completion, refit the wheels and lower the car to the ground.
1 Visually inspect the engine joint faces, gaskets and seals for any signs of water or oil leaks. Pay particular attention to the areas around the rocker cover, cylinder head, oil filter and sump joint faces. Bear in mind that over a period of time some very slight seepage from these areas is to be expected but what you are really looking for is any indication of a serious leak. Should a leak be found, renew the offending gasket or oil seal by referring to the appropriate Chapter(s) in this manual. 2 Similarly, check the transmission for oil leaks, and investigate and rectify and problems found. 3 Check the security and condition of all the engine related pipes and hoses. Ensure that all cable-ties or securing clips are in place and in good condition. Clips which are broken or missing can lead to chafing of the hoses, pipes or wiring which could cause more serious problems in the future.
10 Fluid leak check
9 Front and rear brake pad/shoe
check
1•10 Every 6000 miles or 6 months
8.7 Unscrewing the oil filter
9.3 Disc pads viewed through caliper inspection hole (roadwheel removed)
9.5 Brake shoe inspection hole plug (arrowed)
9.2 Using a mirror to inspect the disc pad friction material for wear
A Brake disc B Brake disc pads
4 Carefully check the condition of all coolant, fuel, power steering and brake hoses. Renew any hose which is cracked, swollen or deteriorated. Cracks will show up better if the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the system components. Hose clips can pinch and puncture hoses, resulting in leaks. If wire type hose clips are used, it may be a good idea to replace them with screw-type clips. 5 With the vehicle raised, inspect the fuel tank and filler neck for punctures, cracks and other damage. The connection between the filler neck and tank is especially critical. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deteriorated rubber. 6 Similarly, inspect all brake hoses and metal pipes. If any damage or deterioration is discovered, do not drive the vehicle until the necessary repair work has been carried out. Renew any damaged sections of hose or pipe. 7 Carefully check all rubber hoses and metal fuel lines leading away from the petrol tank. Check for loose connections, deteriorated hoses, crimped lines and other damage. Pay particular attention to the vent pipes and hoses which often loop up around the filler neck and can become blocked or crimped. Follow the lines to the front of the vehicle carefully inspecting them all the way. Renew damaged sections as necessary. 8 From within the engine compartment, check the security of all fuel hose attachments and pipe unions, and inspect the fuel hoses and vacuum hoses for kinks, chafing and deterioration. 9 Where applicable, check the condition of the oil cooler hoses and pipes. 10 Check the condition of all exposed wiring harnesses.
1 Periodically check the belts for fraying or other damage. If evident, renew the belt. 2 If the belts become dirty, wipe them with a damp cloth using a little detergent only. 3 Check the tightness of the anchor bolts and if they are ever disconnected, make quite sure that the original sequence of fitting of washers, bushes and anchor plates is retained.
With the vehicle raised on a hoist or supported on axle stands, check the exhaust system for signs of leaks, corrosion or damage and check the rubber mountings for condition and security. Where damage or corrosion are evident, renew the system complete or in sections, as applicable, using the information given in Chapter 4.
With the wheels on the ground, slacken each wheel nut by a quarter turn, then retighten it immediately to the specified torque.
Remove and clean the oil filler cap of any sludge build-up using paraffin.
Inspect the vent hose for blockage or damage. A blocked hose can cause a build­up of crankcase pressure, which in turn can cause oil leaks.
Ford VV carburettor
1 Ensure that the air cleaner is correctly fitted, and that all vacuum hoses and pipes are securely connected and free from restrictions, then run the engine until it is at normal operating temperature. 2 Stop the engine, and connect a tachometer and an exhaust gas analyser in accordance with the manufacturer’s instructions. 3 Start the engine and run it at 3000 rpm for 30 seconds, ensuring that all electrical loads are switched off (headlamps, heater blower etc), then allow the engine to idle and check the idle speed and CO content. Note that the CO reading will initially rise, then fall and finally stabilise after between 5 and 25 seconds.
4 If necessary, adjust the idle speed screw to give the specified idle speed (see
illustration). 5 Checking and adjustment should be
completed within 30 seconds of the meter readings stabilising. If this has not been possible, repeat paragraphs 3 and 4, ignoring the reference to starting the engine.
Weber 2V carburettor
Models without stepper motor
6 Proceed as described for the Ford VV
carburettor but note the following: 7 It is permissible to loosen the air cleaner securing screws to allow easier access to the carburettor adjustment screws but ensure that all vacuum hoses and pipes are securely connected. For adjustment screw location
(see illustrations).
Models with stepper motor (ESC II system)
8 The idle speed is controlled by the ESC II
module via the stepper motor. The only idle speed adjustment possible is provided by the “idle speed adjustment” wire, which can be earthed to raise the idle speed by 75 rpm. No other method of idle speed adjustment should be attempted. If the idle speed is incorrect, the problem should be referred to a Ford dealer, as the problem probably lies in the ESC II module for which special diagnostic equipment is required.
15 Engine idle speed check
14 Oil filler cap check
13 Roadwheel security check
12 Exhaust system check
11 Seat belt check
Every 6000 miles or 6 months 1•11
1
15.7b Weber 2V carburettor adjustment screw locations - 1.6 litre models
A Idle mixture screw B Idle speed screw
15.7a Weber 2V carburettor adjustment
screw locations - 2.0 litre models up to 1985
A Idle speed screw B Idle mixture screw
15.4 Ford VV carburettor adjustment screw locations
A Idle speed screw B Idle mixture screw
Caution: Refer to the precautions in Section 1, Chapter 4, Part A or B (as
applicable), before proceeding. Before carrying out any carburettor adjustments, ensure that the ignition timing and spark plug gaps are set as specified. To carry out the adjustments an accurate tachometer and an exhaust gas analyser (CO meter) will be required.
Pierburg 2V carburettor
9 Proceed as described for the Ford VV carburettor. For adjustment screw location
(see illustration).
Weber 2V TLD carburettor
10 Proceed as described for the Ford VV carburettor, noting the following points: 11 Ensure that the vacuum pipe and the camshaft cover breather hose are securely connected to the air cleaner and are free from restrictions. 12 When warming-up the engine, run the engine until the cooling fan cuts in.
13 For adjustment screw location (see illustration).
Fuel injection
2.0 litre SOHC models
14 Idle speed is controlled by the EEC IV
module and the only means of adjustment provided is by the yellow “idle speed adjustment” wire (Chapter 5, Section 17) which allows the idle speed to be raised by 75 rpm.
2.0 litre DOHC models
15 Idle speed is controlled by the EEC IV
module, and manual adjustment is not possible. 16 The “base” idle speed can be adjusted, but only by a Ford dealer, using special equipment.
Ford VV carburettor
1 Ensure that the air cleaner is correctly fitted and that all vacuum hoses and pipes are securely connected and free from restrictions, then run the engine until it is at normal operating temperature. 2 Stop the engine, and connect a tachometer and an exhaust gas analyser in accordance with the manufacturer’s instructions. 3 Start the engine and run it at 3000 rpm for 30 seconds, ensuring that all electrical loads are switched off (headlamps, heater blower etc), then allow the engine to idle and check the idle speed and CO content. Note that the CO reading will initially rise, then fall and finally stabilise after between 5 and 25 seconds. 4 If the reading noted in paragraph 3 is not as specified, proceed as follows. 5 Using a thin screwdriver, remove the tamperproof seal from the mixture screw.
6 Run the engine at 3000 rpm for 30 seconds, then allow the engine to idle, and using a small screwdriver or a 4.0 mm Allen key, as applicable, adjust the mixture screw to give the specified CO content. 7 Checking and adjustment should be completed within 30 seconds of the meter readings stabilising. If this has not been possible, then repeat paragraph 6. 8 If necessary adjust the idle speed, then recheck the CO content. 9 On completion of the adjustments, stop the engine and disconnect the tachometer and exhaust gas analyser. Fit a new tamperproof seal to the mixture screw.
Weber 2V carburettor
Models without stepper motor
10 Proceed as described for the Ford VV
carburettor but note the following: 11 To remove the mixture screw tamperproof seal, it will be necessary to drill the seal in order to prise it from the mixture screw housing. Alternatively a self-tapping screw can be used to draw out the seal. If the tamperproof seal is to be renewed, ensure that a blue-coloured replacement seal is fitted. 12 It is permissible to loosen the air cleaner securing screws to allow easier access to the carburettor adjustment screws, but ensure that all vacuum hoses and pipes are securely connected.
Models with stepper motor (ESC II system)
13 If necessary, the mixture can be adjusted
as described for the Ford VV carburettor with reference to paragraphs 11 and 12 of this Section. Do not attempt to adjust the idle speed on completion of mixture adjustment. For adjustment screw location (see illustration).
Pierburg 2V carburettor
14 Proceed as described for the Ford VV carburettor.
Weber 2V TLD carburettor
15 Proceed as described for the Ford VV carburettor, noting the following points: 16 Ensure that the vacuum pipe and the camshaft cover breather hose are securely connected to the air cleaner and are free from restrictions. 17 When warming-up the engine, run the engine until the cooling fan cuts in. 18 If adjustment of the mixture (CO content) is required, the air cleaner must be removed for access to the adjustment screw, as follows. 19 Remove the air cleaner, and prise the tamperproof seal from the mixture screw. 20 Loosely refit the air cleaner, ensuring that the vacuum pipe and the camshaft cover breather hose are securely connected and free from restrictions (there is no need to secure the air cleaner in position). 21 On completion, fit a new tamperproof seal to the mixture screw (the service replacement plug is coloured blue), and refit the air cleaner assembly.
Fuel injection
2.0 litre SOHC models
22 The idle mixture can be checked and if
necessary adjusted as follows: 23 Run the engine until it is at normal operating temperature. 24 Stop the engine and connect a tachometer and an exhaust gas analyser in accordance with the manufacturer’s instructions.
16 Mixture adjustment check
1•12 Every 6000 miles or 6 months
15.9 Pierburg 2V carburettor adjustment screw locations
A Idle speed screw B Idle mixture screw
A Idle mixture screw B Idle speed screw
16.13 Weber 2V carburettor idle mixture adjustment screw location (arrowed) -
2.0 litre models from 1985
15.13 Weber 2V TLD carburettor adjustment screw locations
Caution: Refer to the precautions in Section 1, Chapter 4, Part A or B (as
applicable), before proceeding. Before carrying out any carburettor adjustments, ensure that the ignition timing and spark plug gaps are set as specified. To carry out the adjustments an accurate tachometer and an exhaust gas analyser (CO meter) will be required.
25 Start the engine and run it at 3000 rpm for 15 seconds, ensuring that all electrical loads (headlamps, heater blower etc) are switched off, then allow the engine to idle and check the CO content. Note that the CO reading will initially rise, then fall and finally stabilise. 26 If adjustment is necessary, remove the tamperproof cap from the base of the airflow meter, and turn the mixture screw using a suitable Allen key to give the specified CO content (see illustration). 27 Checking and adjustment should be completed within 30 seconds of the meter readings stabilising. If this has not been possible, run the engine at 3000 rpm, for 15 seconds, then allow the engine to idle. Re­check the CO content and carry out further adjustment if necessary. 28 On completion of adjustment, stop the engine and disconnect the tachometer and exhaust gas analyser. Fit a new tamperproof cap to the mixture screw.
2.0 litre DOHC models
29 On models with a catalytic converter, the
mixture is controlled by the EEC IV module. No manual adjustment is possible. 30 On models without a catalytic converter, the idle mixture can be adjusted as follows: 31 Run the engine until it is at normal operating temperature. 32 Stop the engine, and connect a tachometer and an exhaust gas analyser in accordance with the equipment manufacturer’s instructions. 33 Start the engine and run it at 3000 rpm for 15 seconds, ensuring that all electrical loads (headlamps, heater blower, etc) are switched off. Allow the engine to idle, and check the CO content. Note that the reading will initially rise, then fall and finally stabilise. 34 If adjustment is necessary, remove the cover from the mixture adjustment potentiometer (located at the rear right-hand
side of the engine compartment, behind the MAP sensor), and turn the screw to give the specified CO content (see illustrations). 35 If adjustment does not produce a change in reading, the potentiometer may be at the extreme of its adjustment range. To centralise the potentiometer, turn the adjustment screw 20 turns clockwise followed by 10 turns anti­clockwise, then repeat the adjustment proce­dure. 36 Checking and adjustment should be completed within 30 seconds of the meter readings stabilising. If this has not been possible, run the engine at 3000 rpm for 15 seconds, then allow the engine to idle. Re­check the CO content, and carry out further adjustments if necessary. 37 On completion of adjustment, stop the engine, and disconnect the tachometer and the exhaust gas analyser. Refit the cover to the adjustment screw.
1 Fluid level should be checked with the transmission at operating temperature (after a run) and with the vehicle parked on level ground. 2 Open and prop the bonnet. With the engine idling and the handbrake and footbrake applied, move the gear selector through all positions three times, finishing up in position “P”, 3 Wait one minute. With the engine still idling, withdraw the transmission dipstick (see illustration). Wipe the dipstick with a clean lint-free rag, re-insert it fully and withdraw it again. Read the fluid level at the end of the dipstick: it should be between the two notches. 4 If topping-up is necessary, do so via the dipstick tube, using clean transmission fluid of the specified type (see illustration). Do not overfill. 5 Stop the engine, refit the dipstick and close the bonnet.
6 Note that if the fluid level was below the minimum mark when checked or is in constant need of topping-up, check around the transmission for any signs of excessive fluid leaks.If present, leaks must be rectified without delay. 7 If the colour of the fluid is dark brown or black this denotes the sign of a worn brake band or transmission clutches, in which case have your Ford dealer check the transmission at the earliest opportunity.
1 Place the vehicle over a pit, or raise and support it at front and rear. The vehicle must be level for an accurate check. 2 If the gearbox is hot after a run, allow it to cool for a few minutes. This is necessary because the oil can foam when hot and give a false level reading.
18 Manual gearbox oil level
check
17 Automatic transmission fluid
level check
Every 12 000 miles or 12 months 1•13
1
16.34b . . . to enable mixture adjustment ­DOHC models
17.4 Topping-up the transmission fluid17.3 Automatic transmission dipstick
location and markings
16.34a Remove the cover from the mixture adjustment potentiometer . . .
16.26 Adjusting the idle mixture ­SOHC models
Every 12 000 miles (20 000 km) or 12 months
3 Wipe clean around the filler/level plug. Unscrew the plug and remove it (see illustration). 4 Using a suitably marked piece of bent wire
as a dipstick, check that the oil level is as shown in the table at the top of this page, according to gearbox type. 5 Top-up the level if necessary, using clean oil of the specified type. Do not overfill, as this can lead to leakage and difficult gear changing. Allow excess oil to drip out of the filler/level hole if necessary. Refit and tighten the filler/level plug on completion. 6 The frequent need for topping-up can only be due to leaks, which should be rectified. The most likely sources of leaks are the rear extension housing and input shaft oil seals. 7 No periodic oil changing is specified, and no drain plug is fitted.
1 Work around the vehicle, and lubricate the bonnet, door and tailgate hinges with a light machine oil. 2 Lightly lubricate the bonnet release mechanism and exposed sections of inner cable with a smear of grease. 3 Check the security and operation of all hinges, latches and locks, adjusting them where required. Where applicable, check the operation of the central locking system. 4 Check the condition and operation of the tailgate struts, renewing them if either is leaking or is no longer able to support the tailgate securely when raised.
1 The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropriate for the engine. 2 Make sure that the ignition is switched off before inspecting the HT leads to see if they carry their cylinder numbers. Note that the position of No 1 cylinder HT lead in the distributor cap is marked with either a pip, or a number “1 “.
3 Where necessary, for improved access remove the air cleaner and/or the inlet hose. 4 Disconnect the leads from the plugs by pulling on the connectors, not the leads. 5 On 2.0 litre DOHC carburettor models, the location of the spark plugs and the close proximity of the carburettor makes spark plug access difficult, particularly when removing the plugs from cylinders 2 and 3. It is suggested that a 3/8 inch ratchet drive spark plug socket with rubber insert and long extension bar is used, possibly in conjunction with a universal joint adapter. It is also advisable to disconnect No 3 cylinder HT lead from the distributor first, to allow some slack for disconnection at the spark plug. 6 Clean the area around each spark plug using a small brush, then using a plug spanner (preferably with a rubber insert), unscrew and remove the plugs (see illustration). Cover the spark plug holes with a clean rag to prevent the ingress of any foreign matter. 7 Before fitting new spark plugs, check that the threaded connector sleeves are tight. As the plugs incorporate taper seats, make sure that the threads and seats are clean.
8 On DOHC models before refitting the spark plugs, coat their threads with suitable anti­seize compound, taking care not to contaminate the electrodes. 9 Screw in the spark plugs by hand, then tighten them to the specified torque. Do not
exceed the torque figure.
10 Push the HT leads firmly onto the spark plugs, and where applicable refit the air cleaner and/or inlet hose.
1 Refer to the Specifications at the beginning of this Chapter and check the tension of each drivebelt at the point stated. Check the full length of each drivebelt for cracks and deterioration. It will be necessary to turn the engine in order to check that portion of the drivebelt in contact with the pulleys. Renew or tension each belt as necessary as follows, according to model type:
SOHC models
2 Note that two drivebelts are fitted to models equipped with power steering and both should be renewed if either one is unserviceable. Where fitted, the air conditioning compressor is driven by a separate belt.
3 Disconnect the battery negative lead. 4 Where applicable, remove the air
conditioning compressor drivebelt. 5 Loosen the alternator mounting and adjustment nuts and bolts, and pivot the alternator towards the cylinder block. 6 Slip the drivebelt(s) from the alternator, water pump, crankshaft and (where applicable) the power steering pump pulleys. 7 Fit the new drivebelt(s) over the pulleys, then lever the alternator away from the cylinder block until the specified belt tension is achieved. Lever the alternator using a wooden or plastic lever at the pulley end to prevent damage and straining the brackets. It is helpful to partially tighten the adjustment link bolt before tensioning the drivebelt(s).
21 Auxiliary drivebelt check
20 Spark plug renewal
19 Hinge and lock check and
lubrication
1•14 Every 12 000 miles or 12 months
18.3 Gearbox filler/level plug location (arrowed) - N type gearbox
20.6 Removing a spark plug - CVH engine
Note: The vehicle build code appears as the twelfth and thirteenth characters of the VIN number on the plate in the engine compartment.
Gearbox type
All four-speed gearboxes
All five-speed gearboxes up to April 1984 (build code E6) except those subsequently fitted with a modified extension housing
All five-speed gearboxes from May 1984 (build code EC) to end of April 1985 (build code FP) and all vehicles built up to April 1984 (build code E6) subsequently fitted with a modified gearbox extension housing
All five-speed gearboxes from May 1985
Oil level
0 to 5.0 mm (0 to 0.2 in) below lower edge of filler/level hole
Level with bottom edge of filler/level hole
20.0 to 25.0 mm (0.79 to 0.99 in) below lower edge of filler/level hole
0 to 5.0 mm (0 to 0.2 in)below lower edge of filler/level hole
Number each HT lead using sticky tape or paint before removal so as to avoid confusion when refitting.
8 Tighten the alternator mounting and adjustment nuts and bolts in the order shown
(see illustration). 9 Where applicable, refit and tension the air
conditioning compressor drivebelt.
10 Reconnect the battery negative lead. 11 Drivebelt tension should be rechecked
and if necessary adjusted after the engine has been run for a minimum of ten minutes.
DOHC models
12 Three different types of drivebelt arrangement are used, depending on model (see illustrations). On models without power
steering, the drivebelt is tensioned by moving the alternator. On models with power steering, the power steering pump is also driven by the coolant pump/alternator drivebelt and an automatic belt tensioner is fitted (see illustration). On models with air conditioning, the drivebelt drives the alternator, coolant pump, power steering pump and air conditioning compressor, and an automatic belt tensioner is fitted. 13 On models without power steering, loosen the alternator mounting and adjustment bolts, and pivot the alternator towards the cylinder block. Slip the drivebelt from the pulleys. 14 On models with power steering, the automatic tensioner can be released using a 17 mm socket and a wrench on the boss in the centre of the pulley. Lever the tensioner assembly clockwise, slide the belt from the pulleys, then slowly release the tensioner. 15 To fit a new belt on models without power steering, slide the belt over the pulleys, then lever the alternator away from the cylinder block until the correct belt tension is achieved. Lever the alternator using a plastic or wooden lever at the pulley end to prevent damage. It is helpful to partially tighten the adjustment link bolt before tensioning the drivebelt. When the correct tension is achieved, tighten all the bolts. 16 To fit a new belt on models with power steering, lever the tensioner clockwise as during removal, then slide the belt over the pulleys, and slowly release the tensioner.
1 The battery fitted as original equipment is “maintenance-free”, and requires no
maintenance apart from having the case kept clean, and the terminals clean and tight. 2 To clean the battery terminals disconnect them, after having first removed the cover (later models) - negative earth first. Use a wire brush or abrasive paper to clean the terminals. Bad corrosion should be treated with a solution of bicarbonate of soda, applied with an old toothbrush. Do not let this solution get inside the battery. 3 Coat the battery terminals with petroleum jelly or a proprietary anti-corrosive compound before reconnecting them. Reconnect and tighten the positive (live) lead first, followed by the negative (earth) lead. Do not overtighten. 4 Keep the top of the battery clean and dry. Inspect the battery tray for corrosion, and make good as necessary.
SOHC engines
1 The valve clearances must be checked with the engine cold. On carburettor models remove the air cleaner. 2 Disconnect the HT leads from the spark plugs and release them from the clips on the camshaft cover. 3 On fuel injection models, unbolt and remove the bracing strut securing the inlet manifold to the right-hand side of the cylinder head. 4 Where applicable, unclip any hoses and wires from the camshaft cover, then unscrew the securing bolts and remove the camshaft cover and gaskets. Take care not to lose the spacer plates which fit under the bolt heads, where applicable.
23 Engine valve clearance
check
22 Battery terminal check
Every 12 000 miles or 12 months 1•15
1
21.12b Coolant pump/alternator drivebelt arrangement - 2.0 litre DOHC engine with
power steering
1 Alternator 2 Automatic belt
tension
3 Coolant pump
4 Crankshaft pulley 5 Power steering
pump
21.12d Alternator/coolant pump drivebelt tensioner indicator position -
2.0 litre DOHC engine
Inset shows tensioner at maximum
adjustment
1 Alternator 2 Automatic belt
tensioner
3 Coolant pump
4 Air conditioning
compressor 5 Crankshaft pulley 6 Power steering
pump
21.12c Coolant pump/alternator drivebelt arrangement - 2.0 litre DOHC engine with
power steering and air conditioning
21.12a Coolant pump/alternator drivebelt arrangement - 2.0 litre DOHC engine
without power steering
1 Alternator 2 Coolant pump
3 Crankshaft
pulley
21.8 Alternator mounting tightening sequence - SOHC engines
Caution: Before carrying out any work on the vehicle battery, read through the precautions given in “Safety first!” at the beginning of this manual.
It will be easier to turn the engine by hand if the spark plugs are removed but take care not to allow dirt to enter
the spark plug holes.
5 Numbering from the front (camshaft sprocket) end of the engine, the exhaust valves are 1, 3, 5 and 7, and the inlet valves are 2, 4, 6 and 8. 6 Turn the engine clockwise using a suitable socket on the crankshaft pulley bolt, until the exhaust valve of No 1 cylinder (valve No 1) is fully closed; ie the cam lobe is pointing vertically upwards (see illustration). 7 Insert a feeler blade of the correct thickness (see Specifications) between the cam follower and the heel of the No 1 valve cam lobe. The feeler blade should be a firm sliding fit. If not, loosen the locknut and adjust the ball-pin position accordingly by turning the adjuster
nut, then tighten the locknut (see illustrations). Allowance must be made for tightening the locknut, as this tends to decrease the valve clearance. Recheck the adjustment after tightening the locknut. 8 Repeat the procedure given in paragraphs 6 and 7 for the remaining valves. With the carburettor/inlet manifold fitted, some diffi­culty may be experienced when adjusting the exhaust valve clearances, and a suitable open-ended spanner bent to 90º will be found helpful. 9 Check the condition of the camshaft cover gasket, and renew if necessary. Fit the gasket to the camshaft cover ensuring that the locating tabs and dovetails are correctly located (see illustration), then refit the camshaft cover and tighten the securing bolts in the order shown (see illustration), ensuring that the spacer plates are in position under the bolt heads, where applicable. 10 On fuel injection models, refit the inlet manifold bracing strut. 11 Where applicable refit the spark plugs. Reconnect the HT leads and locate them in the clips on the camshaft cover. 12 Where applicable, refit any wires and hoses to the clips on the camshaft cover and on carburettor models, refit the air cleaner.
DOHC and CVH engines
13 These engines are fitted with hydraulic cam followers therefore no adjustment is necessary.
Chock the front roadwheels and jack the rear wheels clear of the ground, supporting the vehicle with axlestands.
Check that with the handbrake released, the rear wheels are free to rotate and no brake “bind” is evident. The handbrake lever travel should be between two and four clicks of the ratchet. If brake “bind” or excessive lever travel is evident, check the handbrake cable routing and check the self-adjuster mechanism for wear or damage. Refer to Chapter 10 for full service information.
Gain access to the radiator matrix by removing the surrounding body panels, fan shrouds, etc. Clean dirt and debris from the matrix using an air jet or water and a soft brush. Be careful not to damage the fins or cut your fingers.
Remove the protecting grille and clean any leaves, insects etc. from the air conditioner condenser coil and fins. Be very careful not to damage the condenser fins: use a soft brush, or a compressed air jet, along (not across) the fins.
1 If applicable, remove the radiator grille being careful not to damage the condenser fins. 2 Check the refrigerant charge as follows. The engine should be cold and the ambient temperature should be between 64° and 77°F (18° and 25°C). 3 Start the engine and allow it to idle. Observe the refrigerant sight glass (see illustration) and have an assistant switch on the air conditioning to fan speed III. A few bubbles should be seen in the sight glass as the system starts up, but all bubbles should disappear within 10 seconds. Persistent bubbles, or no bubbles at all, mean that the refrigerant charge is low. Switch off the
26 Air conditioner refridgerant
charge check
25 Radiator matrix and air
conditioner condenser clean
24 Handbrake check
1•16 Every 12 000 miles or 12 months
23.6 Cam lobe correctly positioned for
checking valve clearance. Insert feeler
gauge as shown by arrow
23.7b Adjusting a valve clearance
26.3 Air conditioning system refrigerant sight glass (arrowed)
23.9b Camshaft cover bolts (A) and spacer plates (B)
Tighten bolts in following stages:
Stage 1 Bolts 1 to 6 Stage 2 Bolts 7 and 8 Stage 3 Bolts 9 and 10 Stage 4 Bolts 7 and 8 (again)
23.9a Camshaft cover gasket dovetails
23.7a Using a feeler gauge to check a valve clearance
system immediately if the charge is low and do not use it again until it has been recharged. 4 Inspect the refrigerant pipes, hoses and unions for security and good condition. Refit the radiator grille. 5 The air conditioning system will lose a proportion of its charge through normal seepage typically up to 100 g (4 oz) per year ­so it is as well to regard periodic recharging as a maintenance operation.
1 Check the final drive oil level as follows. 2 Position the vehicle over a pit, or raise it at
front and rear on ramps or axle stands. The vehicle must be level. 3 Wipe clean around the final drive filler/level plug (see illustrations) and unscrew the plug. Using a piece of bent wire as a dipstick, check that the oil is no more than 10 mm (0.4 in) below the plug hole. 4 If topping-up is necessary, use clean gear oil of the specified type. Do not overfill. Frequent need for topping-up can only be due to leaks, which should be rectified. 5 When the level is correct, refit the filler/level plug and tighten it to the specified torque loading. 6 There is no requirement for periodic oil changing, and no drain plug is provided.
Lubricate the transmission selector and kickdown linkages with engine oil or aerosol lubricant.
1 Check the shock absorbers by bouncing the vehicle up and down at each corner in turn. When released, it should come to rest within one complete oscillation. Continued movement, or squeaking and groaning noises from the shock absorber suggests that renewal is required . 2 Raise and support the vehicle. Examine all steering and suspension components for wear and damage. Pay particular attention to dust covers and gaiters, which if renewed promptly when damaged can save further damage to the component protected. 3 At the same intervals, check the front suspension lower arm balljoints for wear by levering up the arms (see illustration). Balljoint free movement must not exceed 0.5 mm (0.02 in). The track rod end balljoints can be checked in a similar manner, or by observing them whilst an assistant rocks the steering wheel back and forth. If the lower arm balljoint is worn, the complete lower arm must be renewed .
4 Wheel bearings can be checked for wear by spinning the relevant roadwheel. Any roughness or excessive noise indicates worn bearings, which must be renewed, as no adjustment is possible. It is unlikely that any wear will be evident unless the vehicle has covered a very high mileage. It should be noted that it is normal for the bearings to exhibit slight endfloat, which is perceptible as wheel rock at the wheel rim.
1 Position the vehicle over a pit, or raise it at front and rear on ramps or axle stands (see “Jacking and vehicle support”). 2 Examine the driveshaft joint rubber gaiters. Flex the gaiters by hand and inspect the folds and clips. Damaged or leaking gaiters must be renewed without delay to avoid damage occurring to the joint itself 3 Check the tightness of the final drive mounting bolts and the driveshaft flange screws.
1 Except on vehicles with a wax-based underbody protective coating, have the whole of the underframe of the vehicle steam­cleaned, engine compartment included, so that a thorough inspection can be carried out to see what minor repairs and renovations are necessary.
2 Steam-cleaning is available at many garages and is necessary for the removal of the accumulation of oily grime which sometimes is allowed to become thick in certain areas. If steam-cleaning facilities are not available, there are some excellent grease solvents available which can be brush­applied; the dirt can then be simply hosed off. 3 After cleaning, position the vehicle over a pit, or raise it at front and rear on ramps or axle stands (see “Jacking and vehicle support”). 4 Using a strong light, work around the underside of the vehicle, inspecting it for corrosion or damage. If either is found, refer to Chapter 12 for details of repair.
Periodically inspect the rigid brake pipes for rust and other damage, and the flexible hoses for cracks, splits or “ballooning”. Have an assistant depress the brake pedal (ignition on) and inspect the hose and pipe unions for leaks. Renew any defective item without delay.
On carburettor models which incorporate a stepper motor (ie. Weber 2V from 1985), good electrical contact between the motor plunger and the adjusting screw is essential to maintain a regular idle speed.
Clean the plunger and adjusting screw contact faces with abrasive paper followed by switch cleaning fluid. Switch cleaning fluid is available from electronic component shops.
Instruments and electrical equipment
1 Check the operation of all instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment in turn to check that it functions properly.
34 Road test
33 Idle speed linkage clean
32 Brake pipe and hose check
31 Underbody inspection
30 Driveshaft check
29 Steering and suspension
security check
28 Automatic transmission
selector linkage lubrication
27 Final drive oil level check
Every 12 000 miles or 12 months 1•17
1
29.3 Levering up lower arm to check balljoint for wear
27.3b Rear axle filler plug location ­P100 models
27.3a Final drive unit filler plug location (arrowed) -
Saloon, Hatchback and Estate models
Steering and suspension
3 Check for any abnormalities in the steering, suspension, handling or road “feel”. 4 Drive the vehicle, and check that there are no unusual vibrations or noises. 5 Check that the steering feels positive, with no excessive “sloppiness”, or roughness, and check for any suspension noises when cornering, or when driving over bumps.
Drivetrain
6 Check the performance of the engine, clutch, transmission and driveshafts. 7 Listen for any unusual noises from the engine, clutch and transmission. 8 Make sure that the engine runs smoothly when idling, and that there is no hesitation when accelerating.
9 Where applicable, check that the clutch action is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 Check that all gears can be engaged smoothly, without noise, and that the gear lever action is not abnormally vague or “notchy”.
Check the operation and performance of the braking system
11 Make sure that the vehicle does not pull to one side when braking, and that the wheels do not lock prematurely when braking hard. 12 Check that there is no vibration through the steering when braking. 13 Check that the handbrake operates correctly, without excessive movement of the
lever, and that it holds the vehicle stationary on a slope. 14 Test the operation of the brake servo unit as follows. With the engine off, depress the footbrake four or five times to exhaust the vacuum. Start the engine, holding the brake pedal depressed. As the engine starts, there should be a noticeable “give” in the brake pedal as vacuum builds up. Allow the engine to run for at least two minutes, and then switch it off. If the brake pedal is depressed now, it should be possible to detect a hiss from the servo as the pedal is depressed. After about four or five applications, no further hissing should be heard, and the pedal should feel considerably firmer.
1 Inspect the crankcase ventilation system for blockage or damage. A blocked hose can cause a build-up of crankcase pressure, which in turn can cause oil leaks (see
illustration). 2 On carburettor model SOHC engines, clean
the oil filler cap with paraffin and check that the vent valve is not blocked by pulling it from the oil separator and loosening the hose clip (Section 42). 3 On CVH engines, check that the oil separator and mushroom valve are not blocked, and clean if necessary (see
illustration).
35 Crankcase ventilation system
check
SOHC and DOHC carburettor models
1 A vacuum pump will be required to test the control components.
2 To check the operation of the air temperature control, the engine must be cold. First observe the position of the flap valve which should be fully closed prior to starting the engine (see illustration). The position of the flap can be observed by disconnecting the cold air inlet hose from the air cleaner spout and looking into the spout. 3 Start the engine and allow it to idle. Check that the flap is now fully open to admit hot air from the exhaust manifold shroud. If the flap does not fully open, stop the engine and check the vacuum diaphragm unit and heat sensor as follows (see illustrations).
4 Working under the base of the air cleaner body, disconnect the diaphragm unit-to-heat sensor vacuum pipe at the sensor end, and connect a vacuum pump to the diaphragm unit. Apply a vacuum of 100.0 mm (4.0 in) of mercury. 5 If the flap opens, then the heat sensor is faulty and should be renewed. If the flap remains closed, then the diaphragm unit is faulty, and a new air cleaner body will have to be obtained, as the diaphragm unit is not available separately. 6 On completion of the checks, disconnect the vacuum pump, and reconnect the vacuum pipe and cold air inlet hose.
36 Air cleaner inlet air
temperature control check
1•18 Every 24 000 miles or 2 years
35.1 Loosening the crankcase ventilation hose clip - CVH models
36.3b Air cleaner heat sensor viewed from inside air cleaner - OHC models
36.3a Air cleaner vacuum diaphragm unit ­OHC models
36.2 Air cleaner flap valve operation ­OHC models
A Flap fully open to admit hot air
B Flap fully closed to admit cold air
35.3 Oil separator (1) and mushroom valve (2) locations in air cleaner - CVH models
Every 24 000 miles (40 000 km) or 2 years
CVH carburettor models
7 To test the unit the engine must initially be cold. Disconnect the hot air inlet hose from the air cleaner spout and observe the position of the flap which should be fully open to allow only hot air to enter (see illustration). 8 Refit the hose and warm up the engine to normal operating temperature. 9 Disconnect the hot air inlet hose again, and observe the position of the flap which should be fully closed to admit only cold air. 10 If the flap positions are not as described, the waxstat is defective and the complete air cleaner must be renewed as the waxstat is not available separately. 11 On completion of the checks, stop the engine and reconnect the hot air inlet hose.
1 The pulse-air filter is located at the front left-hand side of the engine compartment. 2 To renew the element, simply unclip the filter cover, then lift out the metal gauze, and withdraw the filter element (see illustration). 3 Refitting is a reversal of removal. Ensure that the holes in the gauze and the filter element are positioned on the engine side of the filter housing.
Carburettor models
1 Remove the screws from the top of the air cleaner cover (see illustration). 2 Where applicable release the spring clips around the edge of the cover, then lift or prise off the cover (see illustration). 3 Lift out the air cleaner element. Wipe the inside of the air cleaner body clean, taking care not to allow dirt to enter the carburettor throat. Also clean the inside of the cover. 4 Place a new element in position, then refit the air cleaner cover.
Fuel-injection models
All models except 2.0 litre DOHC
5 Disconnect the battery negative lead. 6 Depress the locking clip on the airflow
meter wiring plug and disconnect the plug. Pull on the plug, not the wiring (see
illustration). 7 Loosen the securing clip and disconnect
the air inlet hose from the airflow meter. 8 Release the four securing clips and lift off the air cleaner lid with the airflow meter.
9 Lift out the old air cleaner element (see illustration), then wipe the inside of the air
cleaner casing and lid clean. 10 Fit the new element with the sealing lip uppermost. 11 Refit the air cleaner lid and secure with the four clips. 12 Reconnect the air inlet hose to the airflow meter, ensuring that the securing clip is correctly aligned (see illustration). Reconnect the wiring plug.
38 Air cleaner element renewal
37 Pulse air filter element
renewal (1.6 litre CVH)
Every 24 000 miles or 2 years 1•19
1
37.2 Withdrawing the pulse-air filter
element and gauze - 1.6 litre CVH models
38.12 Air intake hose clip correctly aligned38.9 Unclip the lid and remove the air
cleaner element
38.6 Disconnecting the airflow meter wiring plug
38.2 . . . release the spring clips, and lift off the cover for access to the element
38.1 Remove the air cleaner cover screws . . .
36.7 Air cleaner flap valve operation - CVH models
A Flap fully open to admit hot air B Flap fully closed to admit cold air 1 Air inlet spout 2 Hot air inlet hose
3 Flap valve 4 Link arm 5 Waxstat 6 Air cleaner body
13 Reconnect the battery negative lead.
2.0 litre DOHC models
14 Disconnect the battery negative lead. 15 Disconnect the wiring plug from the idle
speed control valve at the front of the plenum chamber. 16 Loosen the clamp, and detach the air inlet hose from the air inlet tubing. 17 Unscrew the securing nut, and release the air inlet tube from the bracket on the engine compartment front panel (see illustration). 18 Release the air cleaner lid securing clips, then lift away the air inlet tube, plenum chamber and air cleaner lid as an assembly, disconnecting the breather hose from the air inlet tube.
19 Lift out the air cleaner element (see illustration), then wipe the inside of the air
cleaner lid and casing clean. 20 Fit the new element with the sealing lip uppermost.
21 Further refitting is a reversal of removal.
1 Before disturbing any part of the ignition
system, disconnect the battery negative lead. 2 Identify and clearly mark all HT leads before disconnecting them from the spark plugs. 3 Refer to the appropriate Section in Chapter 5 and, where applicable, remove the distributor cap and rotor arm. 4 Clean the HT leads and distributor cap with a dry cloth. Scrape any corrosion or other
deposits from the connectors and terminals. Also clean the coil tower. 5 Renew the HT leads if they are cracked, burnt or otherwise damaged. If a multi-meter is available, measure the resistance of the leads. The desired value is given in the Specifications of Chapter 5. 6 Renew the distributor cap if it is cracked or badly burnt inside, or if there is evidence of “tracking” (black lines marking the path of HT leakage). If there is a carbon brush at the centre of the cap, make sure that it moves freely, and is not excessively worn (see
illustration). 7 Clean the metal track of the rotor arm with
fine abrasive paper. Renew the arm if it is cracked or badly burnt.
8 Refit the rotor arm and distributor cap. 9 Reconnect the HT leads to the spark plugs
and coil.
10 Reconnect the battery and run the engine.
Note: A brake band torque wrench - Ford tool
No 17-005, or a conventional torque wrench and a splined socket of suitable size to fit the square section head of the adjuster screw(s) will be required for this operation.
1 For improved access, apply the handbrake, then jack up the front of the vehicle and support on axle stands (see “Jacking and vehicle support”).
2 The brake band adjuster screw(s) is/are situated on the left-hand side of the transmission housing, forward of the kickdown lever. Note that the C3 type transmission has a single adjuster screw for adjustment of the front brake band, whereas the A4LD type transmission has two adjuster screws for adjustment of the front and intermediate brake bands (see illustration). 3 Disconnect the kickdown cable from the kickdown lever on the transmission housing. 4 Loosen the locknut on the front brake band adjuster screw, and back off the adjuster screw several turns. 5 Using the Ford special tool or a suitable equivalent, tighten the adjuster screw to the specified torque, then back off the screw two complete turns, and tighten the locknut. Ensure that the adjuster screw does not turn as the locknut is tightened. 6 Repeat the procedure given in paragraphs 4 and 5 for the remaining adjuster screw on A4LD type transmissions, but on all models where the part number on the transmission identification tag starts with “88” (see illustration) and additionally on all 1.8 CVH engine models, the adjuster screw should be backed off two and a half turns after tightening to the specified torque. On all other models, the adjuster screw should be backed off two turns. 7 Reconnect the kickdown cable, and lower the vehicle to the ground on completion.
2.0 litre SOHC fuel injection models
1 The fuel filter is located on the left-hand side of the engine compartment (see
illustration). 2 Disconnect the battery negative lead. 3 Position a suitable container beneath the
filter, then slowly loosen the fuel inlet union to relieve the pressure in the fuel lines. 4 Disconnect the fuel inlet and outlet unions. Be prepared for petrol spillage. If necessary, identify the fuel line unions for use when refitting. 5 Loosen the filter clamp screw, and withdraw the filter from the clamp. Drain the petrol from the filter into the container. Dispose of the filter carefully.
41 Fuel filter renewal
40 Automatic transmission
brake band adjustment
39 Ignition system component
check
1•20 Every 24 000 miles or 2 years
38.17 Air intake tube securing nut (arrowed)
39.6 Bosch distributor cap showing HT segments (A) and carbon brush (B)
40.6 Transmission identification tag with part number starting with “88”
40.2 Brake band adjustment - A4LD type transmission
A Adjuster screws B Locknuts
C Kickdown lever
38.19 Lifting out the air cleaner element
Caution: Refer to the precautions in Chapter 4, Part B, Section 1 before proceeding.
6 Fit the new filter, ensuring that the arrows on the filter body point in the direction of fuel flow. 7 Tighten the clamp screw, and reconnect the fuel inlet and outlet unions. Ensure that the unions are correctly connected. 8 Reconnect the battery negative lead, and check the fuel line unions for leaks, pressurising the system by switching the ignition on and off several times.
All models except 2.0 litre SOHC
9 Proceed as described for the 2.0 litre SOHC
models, noting the following points. 10 The fuel filter is located under the rear of the vehicle, above the driveshaft (see illustration). For access to the filter, chock the front wheels, then jack up the rear of the vehicle and support it on axle stands. 11 To remove the filter, the mounting bracket must first be removed from the floor, after unscrewing the securing bolt. The filter can then be removed from the bracket after unscrewing the clamp bolt.
On carburettor model SOHC engines, renew the crankcase ventilation vent valve by pulling it from the oil separator and loosening the hose clip (see illustration). Fit the new valve, tighten the clip, and insert it into the oil separator grommet.
42 Crankcase ventilation vent
valve renewal
If in doubt as to the condition of any of the brake system seals and hoses, then renew defective items whilst referring to the relevant Sections of Chapter 10.
1 An assistant and bleeding equipment will be needed. A considerable quantity of hydraulic fluid will be required - probably about 2 litres (nearly half a gallon). 2 Slacken the front wheel nuts. Raise and support the front of the vehicle and remove the front wheels.
3 Remove the hydraulic fluid reservoir cap. 4 Open both front bleed screws one full turn.
Attach one bleed tube to each screw, placing the free end of each tube in a jar. 5 Pump the brake pedal to expel fluid from the bleed screws. Pause after each upstroke to allow the master cylinder to refill. 6 When air emerges from both bleed screws, stop pumping. Detach the left-hand caliper without disconnecting it and remove the inboard brake pad. 7 Depress the caliper piston, using a purpose-made tool or a blunt item such as a tyre lever, to force more fluid out of the caliper. Hold the piston depressed and have the assistant pump the pedal until air emerges from the bleed screw again.
8 Tighten the bleed screw on the left-hand caliper. Loosely refit the caliper and pad so that the piston is not accidentally ejected. 9 Repeat the purging operation on the right­hand caliper, but do not refit it or tighten the bleed screw yet. 10 Fill the reservoir with fresh hydraulic fluid. Position the bleed jar for the right-hand caliper at least 300 mm (1 foot) above the level of the bleed screw. 11 Have the assistant pump the brake pedal until fluid free of bubbles emerges from the bleed screw. Tighten the bleed screw at the end of a downstroke. 12 Place a piece of wood in the caliper jaws to limit piston travel. Keep your fingers clear of the piston. Have the assistant depress the brake pedal gently in order to move the caliper piston out. 13 With the pedal held depressed, slacken the bleed screw on the right-hand caliper and again depress the piston. Tighten the bleed screw when the piston is retracted. The pedal can now be released. 14 Disconnect the bleed tube. Refit the right­hand brake pad and caliper. 15 Remove the left-hand caliper and inboard pad again. Carry out the operations described in paragraphs 10 to 14 on the left-hand caliper.
16 Bleed the rear brakes (Chapter 10). 17 Refit the front wheels, lower the vehicle
and tighten the wheel nuts. 18 Pump the brake pedal to bring the pads up to the discs, then make a final check of the hydraulic fluid level. Top-up and refit the reservoir cap.
Camshaft drivebelt renewal is recommended as a precautionary measure for SOHC engines but is compulsory for CVH engines. Refer to Chapter 2 for the appropriate renewal procedure.
1 Disconnect the battery negative lead. 2 It is preferable to drain the cooling system
with the engine cold. If this is not possible, take precautions against scalding when removing the expansion tank cap. Place a thick rag over the cap and slacken the cap a little to release any pressure. When all pressure has been released, carry on unscrewing the cap and remove it. 3 Early models have no radiator drain plug, so the radiator must be drained by detaching the bottom coolant hose from the outlet on the right-hand side of the radiator. Later SOHC models have a drain plug located in the base of the left-hand radiator end tank, whilst all CVH models have a drain plug in the right-hand radiator end tank and DOHC models have a plug to the bottom right-hand side of the radiator.
46 Engine coolant renewal
45 Camshaft drivebelt renewal
44 Brake hydraulic fluid renewal
43 Brake hydraulic system seal
and hose renewal
Every 36 000 miles or 3 years 1•21
1
42.1 Removing the crankcase vent valve from the oil separator
41.10 Fuel filter location (arrowed) under rear of vehicle
41.1 Fuel filter location - outlet union arrowed
Caution: Before proceeding, note the precautions given in Chapter 3, Section 1.
Every 36 000 miles (60 000 km) or 3 years
4 Certain SOHC models have a bleed spigot
on the thermostat housing, which is covered by a rubber cap. The cap should be removed from the spigot before commencing draining
(see illustration). 5 With the expansion tank cap removed,
place a suitable container beneath the radiator bottom hose or drain plug as applicable. 6 On early models, loosen the clip and ease the bottom hose away from the radiator outlet. On later models, unscrew the drain plug (see illustrations). Allow the coolant to drain into the container. 7 On SOHC models, place a second container beneath the drain plug on the right-hand side of the cylinder block (see illustration). Unscrew the drain plug and allow the coolant to drain into the container. No cylinder block drain plug is fitted on CVH and DOHC models.
8 Dispose of the drained coolant safely. 9 After some time the radiator and engine
waterways may become restricted or even blocked with scale or sediment, which reduces the efficiency of the cooling system. When this occurs, the coolant will appear rusty and dark in colour and the system should then be flushed. 10 Disconnect the top hose from the radiator, then insert a garden hose and allow water to circulate through the radiator until it runs clear from the outlet. 11 Insert the hose in the expansion tank filler neck and allow water to run out of the bottom hose (and cylinder block on SOHC models) until clear. If, after a reasonable period the water still does not run clear, the radiator can be flushed with a good proprietary cleaning agent. 12 Disconnect the inlet hose from the inlet manifold, connect the garden hose and allow water to circulate through the manifold, automatic choke (where applicable), heater and out through the bottom hose until clear. 13 In severe cases of contamination the system should be reverse flushed. To do this, remove the radiator, invert it and insert a hose in the outlet. Continue flushing until clear water runs from the inlet. 14 The engine should also be reverse flushed. To do this, remove the thermostat
and insert the hose into the cylinder head on SOHC models, or into the inlet manifold on CVH and DOHC models. Continue flushing until clear water runs from the bottom hose (and cylinder block on SOHC models). 15 Where applicable, refit the radiator and the thermostat. 16 Reconnect any disturbed hoses and refit and tighten the cylinder block drain plug and/or radiator drain plug, as applicable. 17 On SOHC models fitted with a bleed spigot on the thermostat housing, ensure that the rubber cap is removed before refilling the system. 18 Pour coolant in through the expansion tank filler hole until the level is up to the “MAX” mark. 19 Where applicable, refit the rubber cap to the bleed spigot when coolant starts to emerge from the spigot. Tighten the clip. 20 Squeeze the coolant hoses to help disperse air locks. Top-up the coolant further if necessary, then refit and tighten the expansion tank cap. 21 Run the engine up to operating temperature, checking for coolant leaks. Stop the engine and allow it to cool, then re-check the coolant level. Top-up the level as necessary, taking care to avoid scalding as the expansion tank cap is removed.
1•22 Every 36 000 miles or 3 years
46.4 Unscrew the clip and remove the rubber cap from the bleed spigot -
SOHC models
46.6b Radiator drain plug (arrowed) - later CVH models
46.7 Cylinder block drain plug (arrowed) ­SOHC models (engine removed)
46.6a Disconnect the bottom hose from the radiator - early OHC models
1.3 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Engine code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JCT
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.02 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.00 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1294 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0:1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . . 11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5800 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 kW at 5700 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm at 3100 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.000 to 79.010 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.010 to 79.020 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.020 to 79.030 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.030 to 79.040 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.510 to 79.520 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.520 to 79.530 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.530 to 79.540 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.030 to 79.040 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.530 to 79.540 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.030 to 80.040 mm
Chapter 2 Part A:
SOHC engines
Auxiliary shaft - removal, inspection and refitting . . . . . . . . . . . . . . .25
Camshaft and cam followers - removal, inspection and refitting . . . .24
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Crankcase ventilation system - inspection and maintenance . . . . . . .4
Crankshaft and bearings - examination and renovation . . . . . . . . . .35
Crankshaft and main bearings - removal and refitting . . . . . . . . . . . .34
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cylinder block and bores - examination and renovation . . . . . . . . . .36
Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . . .22
Cylinder head - inspection and renovation . . . . . . . . . . . . . . . . . . . . .23
Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . . .20
Cylinder head - removal and refitting (engine removed) . . . . . . . . . . .21
Engine - refitting (automatic transmission in vehicle) . . . . . . . . . . . . .14
Engine - refitting (manual gearbox in vehicle) . . . . . . . . . . . . . . . . . . .13
Engine - removal leaving automatic transmission in vehicle . . . . . . .10
Engine - removal leaving manual gearbox in vehicle . . . . . . . . . . . . . .9
Engine/automatic transmission assembly - reconnection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine/automatic transmission assembly - removal and separation .12
Engine dismantling,examination, renovation and reassembly - general
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Engine/manual gearbox - reconnection and refitting . . . . . . . . . . . . .15
Engine/manual gearbox assembly - removal and separation . . . . . .11
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . .26
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Initial start-up after overhaul or major repair . . . . . . . . . . . . . . . . . . .37
Major operations possible with the engine in the vehicle . . . . . . . . . . .6
Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . . .7
Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . .31
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Pistons and connecting rods - examination and renovation . . . . . . .33
Pistons and connecting rods - removal and refitting . . . . . . . . . . . . .32
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Timing belt and sprockets - removal and refitting . . . . . . . . . . . . . . .19
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . . .3
2A•1
Specifications
Contents
2A
Easy, suitable for novice with little experience
Fairly easy, suitable for beginner with some experience
Fairly difficult,
suitable for competent DIY mechanic
Difficult, suitable for experienced DIY mechanic
Very difficult,
suitable for expert DIY or professional
Degrees of difficulty
Crankshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 to 0.28 mm (0.003 to 0.011 in)
Main bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.064 mm
Main bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.970 to 56.990 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.720 to 56.740 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.470 to 56.490 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.220 to 56.240 mm
Undersize 1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.970 to 55.990 mm
Main bearing thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 to 2.35 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 to 2.55 mm
Big-end bearing running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 to 0.060 mm
Big-end bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.980 to 52.000 mm
Undersize 0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.730 to 51.750 mm
Undersize 0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.480 to 51.500 mm
Undersize 0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.230 to 51.250 mm
Undersize 1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.980 to 51.000 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.965 to 78.975 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.975 to 78.985 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.985 to 78.995 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.995 to 79.005 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.990 to 79.015 mm
Service oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.490 to 79.515 mm
Service oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.990 to 80.015 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 1.400 mm
Auxiliary shaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.204 mm (0.002 to 0.008 in)
Cylinder head
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 30’ to 45º 00’
Service correction cutter*:
Upper correction angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30º
Lower correction angle:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75º
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.5º
Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.0 mm
Valve guide bore:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.063 to 8.088 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.263 to 8.288 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.463 to 8.488 mm
*Not for use with hardened valve seats
Camshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.104 to 0.204 mm (0.004 to 0.008 in)
Thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98 to 4.01 mm (0.156 to 0.158 in)
Bearing journal diameter:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.987 to 42.013 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.607 to 44.633 mm
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.987 to 45.013 mm
Valves
Valve clearance (cold engine):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.03 mm (0.008 ± 0.001 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.03 mm (0.010 ± 0.001 in)
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12º ATDC
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.00 mm (1.85 in)
2A•2 SOHC engines
Inlet valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.025 to 8.043 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.225 to 8.243 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.425 to 8.443 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.625 to 8.643 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.825 to 8.843 mm
Exhaust valve stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.999 to 8.017 mm
Oversize 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.199 to 8.217 mm
Oversize 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.399 to 8.417 mm
Oversize 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.599 to 8.617 mm
Oversize 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.799 to 8.817 mm
Lubrication system
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity range SAE 10W/30 to 20W/50 to API
SG/CD or better
Oil capacity:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 litres (6.6 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 pints)
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C102
Oil pump clearances:
Outer rotor to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.153 to 0.304 mm (0.006 to 0.012 in)
Inner rotor to outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.200 mm (0.002 to 0.008 in)
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 to 0.104 mm (0.002 to 0.004 in)
Torque wrench settings Nm lbf ft
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 to 102 65 to 75
Big-end bearing cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 47 30 to 35
Crankshaft pulley bolt:
Strength class 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 to 60 41 to 44
Strength class 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 to 115 74 to 85
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 50 33 to 37
Auxiliary shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 50 33 to 37
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 to 70 47 to 52
Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 21 13 to 15
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 13 7 to 10
Sump bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 2 0.7 to 1.5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Stage 3 (after running engine for 20 minutes) . . . . . . . . . . . . . . . . . . . 8 to 10 6 to 7
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 28 15 to 21
Oil pressure warning lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 to 15 9 to 11
Valve adjustment ball-pin locknuts:
7 mm thick nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 50 33 to 37
8 mm thick nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 55 37 to 41
Cylinder head bolts:
Splined type bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 55 30 to 41
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 70 37 to 52
Stage 3 (after 20 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 to 83 54 to 61
Stage 4 (after running engine for 15 minutes at 1000 rpm) . . . . . . 95 to 115 70 to 85
Torx type bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 40 26 to 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 75 52 to 55
Stage 3 (after 5 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten through a further 90º
Camshaft cover bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 3 1.5 to 2
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Timing cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 17 10 to 13
Timing belt tensioner bolts:
Models with tensioner spring:
Spring bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 21 13 to 15
Pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18
Models without tensioner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18
Oil pick-up tube/strainer-to-oil pump bolts . . . . . . . . . . . . . . . . . . . . . . 11 to 14 8 to 10
Oil pick-up tube/strainer-to-cylinder block bolts . . . . . . . . . . . . . . . . . . 17 to 21 13 to 15
SOHC engines 2A•3
2A
1.6 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCS, LCT, LSD and LSE
LCS and LCT LSD and LSE
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.67 mm 81.32 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.00 mm 76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1593 cc 1597 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 : 1 9.5 : 1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . . 11 to 13 bar 11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5800 rpm 5950 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kW at 5300 rpm 55 kW at 4900 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm at 2900 rpm 123 Nm at 2900 rpm
Cylinder bore diameter LCS and LCT LSD and LSE
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.650 to 87.660 mm 81.300 to 81.310 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.660 to 87.670 mm 81.310 to 81.320 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.670 to 87.680 mm 81.320 to 81.330 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.680 to 87.690 mm 81.330 to 81.340 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.160 to 88.170 mm 81.810 to 81.820 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.170 to 88.180 mm 81.820 to 81.830 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.180 to 88.190 mm 81.830 to 81.840 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.680 to 87.690 mm 81.330 to 81.340 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.180 to 88.190 mm 81.830 to 81.840 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.680 to 88.690 mm 82.330 to 82.340 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 to 2.53 mm
Pistons and piston rings
Piston diameter: LCS and LCT LSD and LSE
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.615 to 87.625 mm 81.265 to 81.275 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.625 to 87.635 mm 81.275 to 81.285 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.635 to 87.645 mm 81.285 to 81.295 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.645 to 87.655 mm 81.295 to 81.305 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.640 to 87.665 mm 81.290 to 81.315 mm
Service oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.140 to 88.165 mm 81.790 to 81.815 mm
Service oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.640 to 88.665 mm 82.290 to 82.315 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm 0.300 to 0.500 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm 0.300 to 0.500 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 1.400 mm 0.400 to 1.400 mm
Auxiliary shaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.204 mm (0.002 to 0.008 in)
Cylinder head
Specifications as for 1.3 litre engine
Camshaft
Specifications as for 1.3 litre engine except for the following:
Endfloat:
Engine codes LCS, LCT and LSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.104 to 0.204 mm (0.004 to 0.008 in)
Engine code LSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 to 0.170 mm (0.003 to 0.007 in)
Valves
Specification as for 1.3 litre engine
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settings
Specification as for 1.3 litre engine
2A•4 SOHC engines
1.8 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REB and RED
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.20 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1
Compression pressure at starter motor speed . . . . . . . . . . . . . . . . . . . . 11 to 13 bar
Maximum continuous engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5850 rpm
Maximum engine power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66kW at 5400 rpm
Maximum engine torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm at 3500 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.180 to 86.190 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.190 to 86.200 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.200 to 86.210 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.210 to 86.220 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.690 to 86.700 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.700 to 86.710 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.710 to 86.720 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.210 to 86.220 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.710 to 86.720 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.210 to 87.220 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.145 to 86.155 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.155 to 86.165 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.165 to 86.175 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.175 to 86.185 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.170 to 86.195 mm
Service oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.670 to 86.695 mm
Service oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.170 to 86.195 mm
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.300 to 0.500 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 1.400 mm
Auxiliary shaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.204 mm (0.002 to 0.008 in)
Cylinder head and camshaft
Specifications as for 1.3 litre engine
Valves
Specifications as for 1.3 litre engine except for the following:
Valve clearance (cold engine):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.03 mm (0.008 ± 0.001 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.03 mm (0.010 ± 0.001 in)
Valve timing:
Inlet opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64º ABDC
Exhaust opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18º ATDC
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settings
Specifications as for 1.3 litre engine
SOHC engines 2A•5
2A
2.0 litre engine
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Four-cylinder, in-line, single overhead camshaft
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NES and NET (carburettor, except P100), NRB and N4A (fuel
injection), and NAE (P100)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.82 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.95 mm
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1993 cc
Compression ratio:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2:1
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2:1
Compression pressure at starter motor speed:
All except engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 to 13 bar
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 12 bar
Maximum continuous engine speed:
Engine code NES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5850 rpm
Engine codes NET and NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5800 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6050 rpm
Maximum engine power (DIN):
Engine codes NES and NET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77kW at 5200 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85kW at 5500 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57kW at 4500 rpm
Maximum engine torque (DIN):
Engine codes NES and NET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Nm at 4000 rpm
Engine codes NRB and N4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm at 4000 rpm
Engine code NAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Nm at 2800 rpm
Cylinder bore diameter
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.800 to 90.810 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.810 to 90.820 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.820 to 90.830 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.830 to 90.840 mm
Oversize class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.310 to 91.320 mm
Oversize class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.320 to 91.330 mm
Oversize class C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.330 to 91.340 mm
Standard service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.830 to 90.840 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.330 to 91.340 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.830 to 91.840 mm
Crankshaft
Specifications as for 1.3 litre engine except for the following:
Main bearing thrustwasher thickness:
All except engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 to 2.35 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 to 2.55 mm
Engine codes NES, NET, NRB and N4A from 1987:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 to 2.53 mm
Pistons and piston rings
Piston diameter:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.765 to 90.775 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.775 to 90.785 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.785 to 90.795 mm
Standard class 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.795 to 90.805 mm
Standard service:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.780 to 90.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.790 to 90.815 mm
Service oversize 0.5:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.280 to 91.305 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.290 to 91.315 mm
Service oversize 1.0:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.780 to 91.805 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.790 to 91.815 mm
2A•6 SOHC engines
Piston ring end gap:
Top:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 to 0.048 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 0.600 mm
Centre:
Up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 to 0.048 mm
From 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 0.600 mm
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.400 to 1.400 mm
Auxiliary shaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.204 mm (0.002 to 0.008 in)
Cylinder head
Specifications as for 1.3 litre engine
Valves
Specifications as for 1.3 litre engine except for the following:
Valve clearance (cold engine):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.03 mm (0.008 ± 0.001 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.003 mm (0.010 ± 0.001 in)
Valve timing: All except code NAE Engine code NAE
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24º BTDC 18º BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64º ABDC 58º ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70º BBDC 70º BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18º ATDC 6º ATDC
Lubrication system
Specifications as for 1.3 litre engine
Torque wrench settings Nm lbf ft
Specifications as for 1.3 litre engine except for the following:
Crankshaft pulley bolt:
Fuel injection models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 to 130 85 to 96
Fuel injection models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 to 115 74 to 85
SOHC engines 2A•7
2A
The engine is of a four-cylinder, in-line, single overhead camshaft type, mounted at the front of the vehicle and available in 1.3,
1.6, 1.8 and 2.0 litre versions.
The crankshaft incorporates five main bearings. Thrustwashers are fitted to the centre main bearing in order to control crankshaft endfloat.
The camshaft is driven by a toothed belt and operates the slightly angled valves via cam followers which pivot on ball-pins.
The auxiliary shaft which is also driven by the toothed belt, drives the distributor, oil pump and fuel pump.
The cylinder head is of crossflow design with the inlet manifold mounted on the left­hand side and the exhaust manifold mounted on the right-hand side.
Lubrication is by means of a bi-rotor pump which draws oil through a strainer located inside the sump, and forces it through a full­flow filter into the engine oil galleries where it is distributed to the crankshaft, camshaft and auxiliary shaft. The big-end bearings are supplied with oil via internal drillings in the crankshaft. The undersides of the pistons are supplied with oil from drillings in the big-ends. The distributor shaft is intermittently supplied with oil from the drilled auxiliary shaft. The camshaft followers are supplied with oil via a
drilled spray tube from the centre camshaft bearing.
A semi-closed crankcase ventilation system is employed whereby piston blow-by gases are drawn into the inlet manifold via an oil separator and control valve.
Refer to Chapter 1, Section 8.
Refer to Chapter 1, Section 23.
Refer to Chapter 1, Section 35.
1 When engine performance is poor, or if misfiring occurs which cannot be attributed to the ignition or fuel system, a compression test can provide diagnostic clues. If the test is performed regularly it can give warning of trouble before any other symptoms become apparent.
2 The engine must be at operating temperature, the battery must be fully charged and the spark plugs must be removed. The services of an assistant will also be required. 3 Disable the ignition system by disconnecting the coil LT feed. Fit the compression tester to No 1 spark plug hole. (The type of tester which screws into the spark plug hole is to be preferred.) 4 Have the assistant hold the throttle wide open and crank the engine on the starter. Record the highest reading obtained on the compression tester. 5 Repeat the test on the remaining cylinders, recording the pressure developed in each. 6 Desired pressures are given in the Specifications. If the pressure in any cylinder is low, introduce a teaspoonful of clean engine oil into the spark plug hole and repeat the test. 7 If the addition of oil temporarily improves the compression pressure, this indicates that bore, piston or piston ring wear was responsible for the pressure loss. No improvement suggests that leaking or burnt valves, or a blown head gasket, may be to blame. 8 A low reading from the two adjacent cylinders is almost certainly due to the head gasket between them having blown. 9 On completion of the test, refit the spark plugs and reconnect the coil LT feed.
5 Compression test
4 Crankcase ventilation system -
inspection and maintenance
3 Valve clearances - checking and
adjustment
2 Engine oil and filter - renewal
1 General information
The following operations can be carried out without removing the engine from the vehicle:
a) Removal and servicing of the cylinder
head
b) Removal of the camshaft after removal of
the cylinder head c) Removal of the timing belt and sprockets d) Removal of the sump e) Removal of the oil pump f) Removal of the pistons and connecting
rods g) Removal of the big-end bearings h) Removal of the engine mountings i) Removal of the clutch and flywheel j) Removal of crankshaft front and rear oil
seals k) Removal of the auxiliary shaft
The following operations can only be carried out after removing the engine from the vehicle:
a) Removal of the crankshaft main bearings b) Removal of the crankshaft
The engine may be lifted out either on its own, or together with the manual gearbox/automatic transmission. Unless work is to be carried out on the manual gearbox/automatic transmission, it is recommended that the engine is removed on its own. Where automatic transmission is fitted, the engine should where possible be removed on its own due to the additional weight of the transmission.
Note: The air conditioning system should always be discharged by a Ford dealer or air conditioning specialist. Note: Refer to the warning in Section 8 before proceeding. A suitable hoist and lifting tackle will be required for this operation.
1 Disconnect the battery negative lead. 2 Remove the bonnet. 3 On carburettor models remove the air cleaner. 4 On fuel injection models, disconnect the
crankcase ventilation hose from the air inlet hose, then disconnect the air inlet hose from the throttle body. Depress the locking clip on the airflow meter wiring plug and disconnect the plug (pulling on the plug, not the wiring) then release the four securing clips and lift off the air cleaner lid with the airflow meter and air inlet hose. 5 Remove the four retaining clips and unscrew the two retaining screws, then withdraw the upper section of the cooling fan shroud from the radiator. Unclip and remove the lower section of the shroud. 6 Remove the thermo-viscous cooling fan as described in Chapter 3.
7 Drain the cooling system. 8 Disconnect the upper radiator hose and
where applicable, the expansion tank hose from the thermostat housing. 9 Disconnect the coolant hoses from the coolant pump, and where applicable from the inlet manifold and automatic choke. Unclip the coolant hose from the bracket on the exhaust manifold hot air shroud/heat shield, or the camshaft cover, as applicable. 10 On carburettor models, where applicable disconnect the vacuum pipe from the engine management module. 11 Disconnect the brake servo vacuum pipe from the inlet manifold. 12 On carburettor models, disconnect the fuel hoses from the carburettor and where applicable the mechanical fuel pump and plug the ends of the hoses to minimise petrol spillage. Remember to take adequate fire precautions. 13 On fuel injection models, disconnect the fuel feed line from the fuel pressure regulator, then disconnect the fuel supply hose from the
fuel rail. Position a suitable container beneath the pressure regulator, then slowly loosen the fuel feed union to relieve the pressure in the fuel lines before disconnecting the union. Take adequate fire precautions. Plug the ends of the hoses to minimise petrol spillage. 14 Disconnect the throttle cable, and where applicable remove its bracket. 15 Disconnect the HT lead from the ignition coil. 16 Disconnect the wiring from the following components as applicable depending on model:
Alternator Starter motor Distributor Oil pressure warning lamp switch Temperature gauge sender Engine coolant temperature sensor Automatic choke Automatic choke pull-down solenoid Carburettor anti-dieselling valve Inlet manifold heater Carburettor stepper motor Fuel injection harness Dipstick
17 Where applicable, detach the power steering pump from the cylinder block and move it to one side. 18 Unscrew and remove the top engine-to­gearbox bolts which are accessible from the engine compartment. Note the location of the earth strap on one of the bolts. 19 Note the location of the earth strap on the rear inlet manifold stud, then remove the nut and disconnect the strap. 20 Apply the handbrake (if not already done), jack up the front of the vehicle and support on axle stands (see “Jacking and Vehicle Support”). 21 Drain the engine oil into a suitable container.
22 Remove the starter motor. 23 Remove the exhaust downpipe. 24 Unscrew the nuts or bolts, as applicable,
securing the engine mountings to the crossmember. Recover the washers. 25 Unscrew and remove the remaining engine-to-gearbox bolts, and remove the bolt from the engine adapter plate (see
illustration). 26 Remove the two securing bolts and
disconnect the engine-to-gearbox brace from the engine and gearbox. 27 Working inside the vehicle, place a wooden block under the clutch pedal to raise it fully against its stop which will hold the automatic adjuster pawl clear of the toothed quadrant. 28 Disconnect the clutch cable from the clutch release arm, and pass the cable through the bellhousing. Where applicable, remove the clip securing the clutch cable to the right-hand engine mounting bracket. Note the cable routing for use when refitting. 29 Lower the vehicle to the ground, and support the gearbox with a trolley jack, using a block of wood between the jack and the gearbox to spread the load. 30 Make a final check to ensure that all relevant wires, pipes and hoses have been disconnected to facilitate engine removal.
9 Engine - removal leaving
manual gearbox in vehicle
8 Method of engine removal
7 Major operations requiring
engine removal
6 Major operations possible with
the engine in the vehicle
2A•8 SOHC engines
9.25 Engine adapter plate bolt (A) and engine-to-gearbox brace (B)
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.
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