Engine dismantling, examination, renovation and reassembly - general information

Dismantling
1 Refer to Chapter 2, Part A, Section 18, paragraphs 1 to 8 inclusive.

2 A suitable selection of splined and Torx sockets will be required to remove many of the bolts when dismantling the engine.

3 Before dismantling the main engine components, the following externallymounted ancillary components can be removed, with reference to the relevant Chapters of this Manual and the relevant Sections of this Chapter, where applicable.

Inlet manifold (and carburettor, if applicable) Exhaust manifold
Alternator.

Coolant pump, and thermostat Alternator/coolant pump drivebelt tensioner Distributor cap, HT leads and spark plugs Oil pressure warning lamp switch Crankshaft speed/position sensor Oil filter
Dipstick
Engine mounting brackets (if not already done) Crankcase ventilation pipe and hoses Clutch
Alternator mounting bracket.

Air conditioning compressor mounting bracket (where applicable).

Engine lifting brackets.

Examination and renovation 4 Refer to Chapter 2, Part A, Section 18, but note that the connecting rod bolts should be renewed on reassembly, and when renewing the cylinder head bolts, the latest type bolts with hexagonal heads should always be used.

Reassembly
5 Proceed as described in Chapter 2, Part A, Section 18, noting the following: 6 If they have been removed, new cylinder head bolts (both M11 and M8, of the latest type with hexagonal heads), flywheel bolts, and connecting rod bolts must be used.

    See also:

    Manifold Absolute Pressure (MAP) sensor - removal and refitting
    Removal 1 Disconnect the battery negative lead. 2 Disconnect the sensor wiring plug (see illustration). Do not pull on the wiring. 16.2 Manifold absolute pressure (MAP) sensor - 1.4 CFI engine ...

    Air cleaner - removal and refitting
    K-Jetronic system Removal 1 Remove the air cleaner element as described in Chapter 1. 2 Detach the fuel filter from the side of the cleaner casing (leave the fuel lines attached to the filter) a ...

    General information
    The 2.0 litre DOHC (Double OverHead Camshaft) engine was introduced in August 1989 to replace the 2.0 litre SOHC engine used previously in the Sierra range. The engine is of four-cylinder, in-line ...