Ford Sierra Manual

Cylinder head - removal and refitting (engine in vehicle)
SOHC engines / Cylinder head - removal and refitting (engine in vehicle)


Note: Refer to the note at the beginning of Section 20 before proceeding.

1.8 litre (R2A type)
Removal
1 Disconnect the battery negative lead.

2 Drain the cooling system.

3 Disconnect the heater coolant hose from the coolant pump elbow, and the coolant bypass hose from the left-hand side of the cylinder head, then unclip the hoses from the timing cover and move them to one side out of the way (see illustrations).

19.3a Disconnecting the heater coolant hose from the coolant pump elbow - 1.8
19.3a Disconnecting the heater coolant hose from the coolant pump elbow - 1.8 litre (R2A)

19.3b Coolant bypass hose connection at cylinder head - 1.8 litre (R2A)
19.3b Coolant bypass hose connection at cylinder head - 1.8 litre (R2A)

4 Remove the air cleaner.

5 Disconnect the HT leads from the spark plugs and coil, identifying them for position if necessary, unclip the leads from the camshaft cover, then remove the distributor cap, rotor arm and housing. Remove the spark plugs.

6 Disconnect the cylinder head earth lead from the battery tray.

7 The cylinder head can be removed either with or without the manifolds. If desired, the inlet manifold can be unbolted and moved to one side, leaving the wires, hoses, pipes and cables connected, but care must be taken not to strain any of the wires, hoses, pipes or cables.

8 Unscrew the three securing nuts and disconnect the exhaust downpipe from the manifoid flange. Recover the gasket.

9 If desired, remove the exhaust manifold.

10 If the inlet manifold is to be removed with the cylinder head, disconnect all relevant wires, hoses, pipes and cables, otherwise unbolt the manifold and move it to one side, ensuring that it is adequately supported (see illustration).

19.10 Withdraw the inlet manifold - 1.8 litre (R2A)
19.10 Withdraw the inlet manifold - 1.8 litre (R2A)

11 If desired, remove the fuel pump and operating pushrod.

12 Proceed as described in Section 20 to complete cylinder head removal.

Refitting
13 With the cylinder head refitted as described in Section 20, proceed as follows.

14 Where applicable, refit the fuel pump and operating pushrod.

15 Refit the manifolds and/or reconnect all wires, hoses, pipes and cables, as applicable.

16 Reconnect the exhaust downpipe to the manifold, using a new gasket.

17 Reconnect the earth lead to the battery tray.

18 Refit the spark plugs, then refit the distributor cap, rotor arm and housing, and reconnect the HT leads.

19 Refit the air cleaner.

20 Reconnect the coolant hoses to the coolant pump elbow and the cylinder head, and locate them in the clip on the timing cover.

21 Fill the cooling system.

22 Reconnect the battery negative lead.

1.6 and 1.8 litre (R6A type) Removal
23 Disconnect the battery negative lead.

24 Drain the cooling system.

25 Disconnect the coolant hoses from the thermostat housing, and the bypass hose from the left-hand side of the cylinder head, then move them to one side out of the way.

26 Remove the air cleaner.

27 Disconnect the HT leads from the spark plugs, identifying them for position if necessary. Unclip them from the camshaft cover, and move them to one side out of the way.

28 Remove the spark plugs.

29 Disconnect the cylinder head earth lead from the battery tray.

30 The cylinder head can be removed either with or without the manifolds. If desired, the inlet manifold can be unbolted and moved to one side (after unbolting the dipstick tube), leaving the wires, hoses, pipes and cables connected. However, care must be taken not to strain any of the wires, hoses or cables.

31 Disconnect the exhaust gas oxygen sensor wiring connector (see illustration)

19.31 Disconnecting the exhaust gas oxygen sensor wiring connector - 1.6/1.8
19.31 Disconnecting the exhaust gas oxygen sensor wiring connector - 1.6/1.8 litre (R6A)

then unscrew the three securing bolts and disconnect the exhaust downpipe from the manifold flange. Recover the gasket.

32 If desired, remove the exhaust manifold.

33 If the inlet manifold is to be removed with the cylinder head, disconnect all relevant wires, hoses, pipes and cables, otherwise unbolt the manifold and move it to one side, ensuring that it is adequately supported.

34 Note the information given in paragraphs 18 to 21 inclusive of Section 20.

Refitting
35 With the cylinder head refitted, proceed as follows.

36 Refit the manifolds and/or reconnect all wires, hoses, pipes and cables as applicable.

37 Reconnect the exhaust downpipe to the manifold using a new gasket, and reconnect the exhaust gas oxygen sensor wiring connector.

38 Reconnect the earth lead to the battery tray.

39 Refit the spark plugs and reconnect the HT leads.

40 Refit the air cleaner.

41 Reconnect the coolant hoses to the thermostat housing and cylinder head.

42 Fill the cooling system.

43 Reconnect the battery negative lead.


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