Sump - removal and refitting
Note: A new gasket and new sump bolts must be used when refitting, and suitable sealant will be required (available from a Ford dealer). Note that it is preferable to keep the engine upright until the sump has been removed to prevent sludge from entering the engine internals.
1.8 litre (R2A type)
1 With the engine removed, proceed as follows.
2 Remove the flywheel/driveplate and the engine adapter plate.
3 Unscrew the fourteen securing bolts and withdraw the two reinforcing strips and the sump. If the sump is stuck, carefully tap it sideways to free it. Do not prise between the mating faces.
4 Recover the gasket.
5 Thoroughly clean the mating faces of the cylinder block and sump.
6 Commence refitting by applying sealing compound (available from a Ford dealer) to the cylinder block, oil pump housing and crankshaft rear oil seal housing mating faces at the points shown (see illustration).
27.6 Apply sealing compound to the areas shown before fitting the sump gasket - 1.8 litre (R2A)
Note that the sump must be fitted within ten minutes of applying the sealing compound.
7 Fit a new gasket, ensuring that it engages correctly in the grooves in the crankshaft rear oil seal carrier and the oil pump housing (see illustration).
27.7 Ensure that the gasket locates correctly on the oil pump housing - 1.8 litre (R2A)
8 Locate the sump on the gasket and loosely fit the securing bolts.
9 Tighten all the bolts slightly to obtain a light and even gasket preload.
10 Tighten the bolts to the specified torque in the sequence shown (see illustration).
27.10 Sump bolt tightening sequence - 1.8 litre (R2A)
that the ten M8 bolts and the four M6 bolts are tightened to different torques.
11 Refit the engine adapter plate and the flywheel/driveplate.
1.6 and 1.8 litre (R6A type) Note: The following procedure applies to the 1.6 litre CVH engine. For the 1.8 litre (R6A type) engine, proceed as described above for the 1.8 litre (R2A type).
12 Sump removal and refitting is easier if the engine is removed from the vehicle. However, if the engine is in the vehicle, proceed as follows. If the engine has been removed from the vehicle, proceed to paragraph 15.
13 Remove the clutch.
14 Drain the engine oil into a suitable container.
15 Remove the flywheel and the engine adapter plate.
16 Unscrew the eighteen securing bolts and withdraw the sump. If the sump is stuck, carefully tap it sideways to free it. Do not prise between the mating faces. Recover the gasket.
17 Thoroughly clean the mating faces of the cylinder block and sump.
18 Apply sealing compound to the joints between the oil pump and the cylinder block, and the crankshaft rear oil seal housing and the cylinder block, as shown (see illustration).
27.18 Apply sealing compound at the points arrowed before refitting the sump - 1.6 litre
A Oil pump/cylinder block joint B Crankshaft rear oil seal housing/cylinder block joint
19 Without applying any further sealer, locate the gasket into the grooves of the oil pump and the rear oil seal housing. To hold the gasket in position, studs can be inserted temporarily in the bolt hole positions circled in the illustration indicating the bolt tightening sequence. Make sure that the gasket spacing pips are seated correctly.
20 Locate the sump on the gasket, taking care not to displace the gasket, then loosely fit the securing bolts. With the sump in position, where applicable remove the studs from the bolt holes, and loosely fit the remaining securing bolts.
21 Tighten the bolts to the torque given in the Specifications at the beginning of this Chapter, in two stages, and in the sequence shown (see illustration).
27.21 Sump bolt tightening sequence - 1.6 litre
Arrow indicates front of engine
22 Refit the engine adapter plate and the flywheel.
23 If the engine is in the vehicle, refit the clutch. Refill the engine with oil.
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