Haynes Ford Sierra Service And Repair Manual

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1•1

Chapter 1
Routine maintenance and servicing
Contents
Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Air cleaner inlet air temperature control check . . . . . . . . . . . . . . . . . .36 Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Air conditioner refrigerant charge check . . . . . . . . . . . . . . . . . . . . . .26 Ford Sierra maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Automatic transmission brake band adjustment . . . . . . . . . . . . . . . .40 Front and rear brake pad/shoe check . . . . . . . . . . . . . . . . . . . . . . . . .9
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . .17 Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Automatic transmission selector lubrication . . . . . . . . . . . . . . . . . . .28 Handbrake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . . .19
Battery electrolyte level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Idle speed linkage clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Battery terminal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Ignition system component check . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Brake system seal and hose renewal . . . . . . . . . . . . . . . . . . . . . . . . .43 Manual gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 1
Brake pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Mixture adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Camshaft drivebelt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Oil filler cap check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Crankcase ventilation system check . . . . . . . . . . . . . . . . . . . . . . . . .35 Pulse air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Crankcase ventilation vent valve renewal . . . . . . . . . . . . . . . . . . . . . .42 Radiator matrix and air conditioner condenser clean . . . . . . . . . . . . .25
Driveshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Roadwheel security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine idle speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Steering and suspension security check . . . . . . . . . . . . . . . . . . . . . .29
Engine valve clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Underbody inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Final drive oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult, Difficult, suitable for Very difficult,
novice with little for beginner with suitable for competent experienced DIY suitable for expert
experience some experience DIY mechanic mechanic DIY or professional

Specifications
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)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.03 mm (0.010 ± 0.001 in)
DOHC and CVH:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)

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1•2 Servicing specifications
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
 Servicing specifications 1•3

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) 1
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)

1 Ford Sierra maintenance schedule

The maintenance intervals in this manual wish to perform some of these procedures speeds (idling in traffic) or on short journeys,
are provided with the assumption that you will more often. We encourage frequent more frequent maintenance intervals are
be carrying out the work yourself. These are maintenance, because it enhances the recommended.
the minimum maintenance intervals efficiency, performance and resale value of When the vehicle is new, it should be
recommended by the manufacturer for your vehicle. serviced by a factory-authorised dealer
vehicles driven daily. If you wish to keep your If the vehicle is driven in dusty areas, used service department, in order to preserve the
vehicle in peak condition at all times, you may to tow a trailer, or driven frequently at slow factory warranty.
1•4 Maintenance schedule
Every 250 miles (400 km) or weekly Every 12 000 miles (20 000 km) or
m Check the engine oil level (Section 3) 12 months - whichever comes sooner
m Check the engine coolant level (Section 3)
m Check the brake fluid level (Section 3) (continued)
m Check the power steering fluid level (Section 3) m Clean radiator matrix and air conditioning condenser
m Check the screen washer fluid level (Section 3) fins (where applicable) (Section 25)
m Visually examine the tyres for tread depth, and wear m Check air conditioning refrigerant charge (where
or damage (Section 4) applicable) (Section 26)
m Check and if necessary adjust the tyre pressures m Check final drive oil level (Section 27)
(Section 4) m Lubricate automatic transmission selector/kickdown
m Check and if necessary top-up the battery electrolyte linkage (Section 28)
level - where applicable (Section 6) m Check security and condition of steering and
m Check the operation of the horn, all lights, and the suspension components, gaiters and boots
wipers and washers (Sections 5 and 7) (Section 29)
m Check condition and security of driveshaft joints and
gaiters (Section 30)
m Inspect underbody and panels for corrosion or other
Every 6000 miles (10 000 km) or damage (Section 31)
6 months - whichever comes sooner m Inspect brake pipes and hoses (Section 32)
m Clean idle speed control linkage at throttle (where
m Renew engine oil and filter (Section 8)
applicable) (Section 33)
m Check brake pads or shoes for wear (front and rear)
m Road test and check operation of ABS (Section 34)
(Section 9)
m Check crankcase ventilation system (Section 35)
m Check operation of brake fluid level warning indicator
(Section 9)
m Inspect engine bay and underside of vehicle for fluid
leaks or other signs of damage (Section 10)
m Check function and condition of seat belts
Every 24 000 miles (40 000 km) or
(Section 11) 2 years - whichever comes sooner
m Check condition and security of exhaust system m Check air cleaner inlet air temperature control
(Section 12) operation (carburettor models) (Section 36)
m Check tightness of wheel nuts (Section 13) m Renew pulse air filter element (1.6 litre CVH)
m Clean oil filler cap (Section 14) (Section 37)
m Check idle speed (where applicable) (Section 15) m Renew air cleaner element (Section 38)
m Check mixture adjustment (where applicable) m Clean and inspect distributor cap and HT leads
(Section 16) (Section 39)
m Check automatic transmission brake band
adjustment (Section 40)
m Renew fuel filter (fuel-injection models only)
Every 12 000 miles (20 000 km) or (Section 41)
12 months - whichever comes sooner m Renew crankcase ventilation vent valve (SOHC and
m Check automatic transmission fluid level (engine hot) DOHC) (Section 42)
(Section 17)
m Check manual gearbox oil level (Section 18)
m Check operation of latches, check straps and locks;
lubricate if necessary (Section 19)
m Renew spark plugs (Section 20)
Every 36 000 miles (60 000 km) or
m Check condition and tension of auxiliary drivebelt(s); 3 years - whichever comes sooner
adjust or renew as necessary (Section 21) m Renew brake hydraulic system seals and hoses if
m Check tightness of battery terminals, clean and necessary (Section 43)
neutralise corrosion if necessary (Section 22) m Renew brake hydraulic fluid (Section 44)
m Check engine valve clearances - SOHC only m Renew camshaft drivebelt (optional on SOHC
(Section 23) models - compulsory on CVH) (Section 45)
m Check handbrake mechanism (Section 24) m Renew coolant (Section 46)
Maintenance - component location 1•5

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

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
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

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

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
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
 Maintenance procedures 1•9

suspension and steering components. improve the performance of the engine, and
The first step in this maintenance may prove a waste of time and money, unless
2 Introduction programme is to prepare yourself before the extensive overhaul work is carried out first.
actual work begins. Read through all the The following series of operations are those
Sections relevant to the work to be carried most often required to improve the
General information out, then make a list and gather together all performance of a generally poor-running
This Chapter is designed to help the home the parts and tools required. If a problem is engine:
mechanic maintain his/her vehicle for safety, encountered, seek advice from a parts
Primary operations
specialist, or a dealer service department.
economy, long life and peak performance. a) Clean, inspect and test the battery
The Chapter contains a master Intensive maintenance b) Check all the engine-related fluids
maintenance schedule, followed by Sections c) Check the condition and tension of the
If, from the time the vehicle is new, the
dealing specifically with each task in the auxiliary drivebelt
routine maintenance schedule is followed
schedule. Visual checks, adjustments, d) Renew the spark plugs
closely, and frequent checks are made of fluid
component renewal and other helpful items levels and high-wear items, as suggested e) Inspect the distributor cap and HT leads -
are included. Refer to the accompanying throughout this manual, the engine will be as applicable
illustrations of the engine compartment and kept in relatively good running condition, and f) Check the condition of the air cleaner
the underside of the vehicle for the locations the need for additional work will be minimised. filter element, and renew if necessary
of the various components. It is possible that there will be times when g) Renew the fuel filter
Servicing your vehicle in accordance with the engine is running poorly due to the lack of h) Check the condition of all hoses, and
the mileage/time maintenance schedule and regular maintenance. This is even more likely check for fluid leaks
the following Sections will provide a planned if a used vehicle, which has not received i) Check the idle speed and mixture settings
maintenance programme, which should result regular and frequent maintenance checks, is - as applicable
in a long and reliable service life. This is a purchased. In such cases, additional work If the above operations do not prove fully
comprehensive plan, so maintaining some may need to be carried out, outside of the effective, carry out the following secondary
items but not others at the specified service regular maintenance intervals. operations:
intervals, will not produce the same results. If engine wear is suspected, a compression
As you service your vehicle, you will discover test will provide valuable information
Secondary operations
that many of the procedures can - and should - regarding the overall performance of the main a) Check the charging system
be grouped together, because of the particular internal components. Such a test can be used b) Check the ignition system 1
procedure being performed, or because of the as a basis to decide on the extent of the work c) Check the fuel system
close proximity of two otherwise-unrelated to be carried out. If, for example, a d) Renew the distributor cap and rotor arm -
components to one another. For example, if compression test indicates serious internal as applicable
the vehicle is raised for any reason, the exhaust engine wear, conventional maintenance as f) Renew the ignition HT leads - as
can be inspected at the same time as the described in this Chapter will not greatly applicable

Every 250 miles (400 km) or weekly

3 Fluid level checks 5 Electrical system check 7 Wiper blade check

See “Weekly checks”. See “Weekly checks”. See “Weekly checks”.

4 Tyre checks 6 Battery electrolyte level check

See “Weekly checks”. See “Weekly checks”.

Every 6000 miles (10 000 km) or 6 months

sludge will be removed with it. Take care,
however, not to touch the exhaust or any
8 Engine oil and filter renewal other hot parts of the engine when working
under the vehicle. To avoid any possibility of
1 Frequent oil and filter changes are the most scalding, and to protect yourself from
possible skin irritants and other harmful
important preventative maintenance
contaminants in used engine oils, it is
procedures which can be undertaken by the
advisable to wear gloves when carrying out
DIY owner. As engine oil ages, it becomes
this work. Access to the underside of the
diluted and contaminated, which leads to vehicle will be greatly improved if it can be
premature engine wear. raised on a lift, driven onto ramps, or jacked
2 Before starting this procedure, gather up and supported on axle stands (see
together all the necessary tools and materials. “Jacking and vehicle support”). Whichever
Also make sure that you have plenty of clean method is chosen, make sure that the vehicle
rags and newspapers handy, to mop up any remains level, or if it is at an angle, so that the
spills. Ideally, the engine oil should be warm, drain plug is at the lowest point (see 8.2 Sump drain plug location
as it will drain better, and more built-up illustration).
1•10 Every 6000 miles or 6 months
10 Remove the old oil and all tools from 4 For a comprehensive check, the brake disc
under the car, then lower the car to the pads should be removed and cleaned. The
ground (if applicable). operation of the caliper can then also be
11 Remove the oil filler cap and withdraw the checked, and the condition of the brake discs
dipstick. Fill the engine, using the correct can be fully examined on both sides. Refer to
grade and type of oil (see “Lubricants and Chapter 10 for further information.
fluids”). An oil can spout or funnel may help to 5 On rear drum brake models, the brake shoe
reduce spillage. Pour in half the specified friction material can be inspected for wear
quantity of oil first, then wait a few minutes for without removing the roadwheels. Working
the oil to fall to the sump. Continue adding oil beneath the vehicle, prise the plug from the
a small quantity at a time until the level is up to brake backplate, and using an inspection
the lower mark on the dipstick. Finally, bring lamp or torch, check that the friction material
the level up to the upper mark on the dipstick. thickness is not less than the minimum given
8.7 Unscrewing the oil filter Insert the dipstick, and refit the filler cap. in the Specifications (see illustration). If any
12 Start the engine and run it for a few one of the shoes has worn below the
minutes; check for leaks around the oil filter specified limit, the shoes must be renewed as
3 Slacken the drain plug about half a turn.
seal and the sump drain plug. Note that there an axle set (4 shoes).
Position the draining container under the drain
may be a delay of a few seconds before the oil 6 At the same interval, check the function of the
plug, then remove the plug completely. If
pressure warning light goes out when the brake fluid level warning light. Chock the wheels,
possible, try to keep the plug pressed into the
engine is first started, as the oil circulates release the handbrake and switch on the
sump while unscrewing it by hand the last
through the engine oil galleries and the new oil ignition. Unscrew and raise the brake fluid
couple of turns. As the plug releases from the
filter, before the pressure builds up. reservoir cap whilst an assistant observes the
threads, move it away sharply so the stream
13 Switch off the engine, and wait a few warning light: it should come on as the level
of oil issuing from the sump runs into the
minutes for the oil to settle in the sump once sensor is withdrawn from the fluid. Refit the cap.
container, not up your sleeve! Recover the
more. With the new oil circulated and the filter 7 On completion, refit the wheels and lower
sealing washer from the drain plug.
completely full, recheck the level on the the car to the ground.
4 Allow some time for the old oil to drain,
dipstick, and add more oil as necessary.
noting that it may be necessary to reposition
14 Dispose of the used engine oil safely, with
the container as the oil flow slows to a trickle.
5 After all the oil has drained, wipe off the
reference to “General repair procedures” in 10 Fluid leak check
the Reference section of this manual.
drain plug with a clean rag. Check the sealing
washer for condition, and renew it if 1 Visually inspect the engine joint faces,
necessary. Clean the area around the drain 9 Front and rear brake pad/shoe gaskets and seals for any signs of water or oil
plug opening, and refit the plug. Tighten the check leaks. Pay particular attention to the areas
plug to the specified torque. around the rocker cover, cylinder head, oil
6 Move the container into position under the 1 Firmly apply the handbrake, then jack up filter and sump joint faces. Bear in mind that
oil filter. the front and rear of the car and support it over a period of time some very slight
7 Using an oil filter removal tool if necessary, securely on axle stands (see “Jacking and seepage from these areas is to be expected
slacken the filter initially, then unscrew it by vehicle support”). but what you are really looking for is any
hand the rest of the way (see illustration). 2 For a quick check, the front brake disc pads indication of a serious leak. Should a leak be
Empty the oil from the old filter into the can be inspected without removing the front found, renew the offending gasket or oil seal
container, and discard the filter. wheels by inserting a mirror between each by referring to the appropriate Chapter(s) in
8 Use a clean rag to remove all oil, dirt and caliper and roadwheel (see illustration). If any this manual.
sludge from the filter sealing area on the one pad is worn down to the minimum 2 Similarly, check the transmission for oil
engine. Check the old filter to make sure that specified thickness, all four pads (on both leaks, and investigate and rectify and
the rubber sealing ring hasn’t stuck to the front wheels) must be renewed. problems found.
engine. If it has, carefully remove it. 3 It is necessary to remove the rear wheels in 3 Check the security and condition of all the
9 Apply a light coating of clean engine oil to order to inspect the rear disc pads. The pads engine related pipes and hoses. Ensure that
the sealing ring on the new filter, then screw it can be viewed through the top of the caliper all cable-ties or securing clips are in place and
into position on the engine. Tighten the filter after removing the blanking spring clip (see in good condition. Clips which are broken or
firmly by hand only - do not use any tools. illustration). If any one pad is worn down to missing can lead to chafing of the hoses,
Wipe clean the filter and sump drain plug. the minimum specified, all four pads (on both pipes or wiring which could cause more
rear wheels) must be renewed. serious problems in the future.

9.2 Using a mirror to inspect the disc pad

friction material for wear 9.3 Disc pads viewed through caliper 9.5 Brake shoe inspection hole plug
A Brake disc B Brake disc pads inspection hole (roadwheel removed) (arrowed)
 Every 6000 miles or 6 months 1•11

4 Carefully check the condition of all coolant,

fuel, power steering and brake hoses. Renew
any hose which is cracked, swollen or 13 Roadwheel security check
deteriorated. Cracks will show up better if the
hose is squeezed. Pay close attention to the With the wheels on the ground, slacken each
hose clips that secure the hoses to the system wheel nut by a quarter turn, then retighten it
components. Hose clips can pinch and immediately to the specified torque.
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. 14 Oil filler cap check
5 With the vehicle raised, inspect the fuel
tank and filler neck for punctures, cracks and
other damage. The connection between the Remove and clean the oil filler cap of any
filler neck and tank is especially critical. sludge build-up using paraffin. 15.4 Ford VV carburettor adjustment screw
Sometimes a rubber filler neck or connecting Inspect the vent hose for blockage or locations
hose will leak due to loose retaining clamps or damage. A blocked hose can cause a build-
up of crankcase pressure, which in turn can A Idle speed screw B Idle mixture screw
deteriorated rubber.
cause oil leaks.
6 Similarly, inspect all brake hoses and metal
4 If necessary, adjust the idle speed screw to
pipes. If any damage or deterioration is
give the specified idle speed (see
discovered, do not drive the vehicle until the
necessary repair work has been carried out.
15 Engine idle speed check illustration).
5 Checking and adjustment should be
Renew any damaged sections of hose or pipe.
completed within 30 seconds of the meter
7 Carefully check all rubber hoses and metal Caution: Refer to the readings stabilising. If this has not been
fuel lines leading away from the petrol tank. precautions in Section 1, possible, repeat paragraphs 3 and 4, ignoring
Check for loose connections, deteriorated Chapter 4, Part A or B (as the reference to starting the engine.
hoses, crimped lines and other damage. Pay applicable), before proceeding.
particular attention to the vent pipes and Before carrying out any carburettor Weber 2V carburettor
hoses which often loop up around the filler adjustments, ensure that the ignition 1
neck and can become blocked or crimped.
Models without stepper motor
timing and spark plug gaps are set as
Follow the lines to the front of the vehicle specified. To carry out the adjustments an 6 Proceed as described for the Ford VV
carefully inspecting them all the way. Renew accurate tachometer and an exhaust gas carburettor but note the following:
damaged sections as necessary. analyser (CO meter) will be required. 7 It is permissible to loosen the air cleaner
8 From within the engine compartment, securing screws to allow easier access to the
check the security of all fuel hose attachments carburettor adjustment screws but ensure
and pipe unions, and inspect the fuel hoses
Ford VV carburettor that all vacuum hoses and pipes are securely
and vacuum hoses for kinks, chafing and 1 Ensure that the air cleaner is correctly fitted, connected. For adjustment screw location
deterioration. and that all vacuum hoses and pipes are (see illustrations).
9 Where applicable, check the condition of securely connected and free from restrictions, Models with stepper motor (ESC II
the oil cooler hoses and pipes. then run the engine until it is at normal system)
10 Check the condition of all exposed wiring operating temperature. 8 The idle speed is controlled by the ESC II
harnesses. 2 Stop the engine, and connect a tachometer module via the stepper motor. The only idle
and an exhaust gas analyser in accordance speed adjustment possible is provided by the
with the manufacturer’s instructions. “idle speed adjustment” wire, which can be
11 Seat belt check 3 Start the engine and run it at 3000 rpm for earthed to raise the idle speed by 75 rpm. No
30 seconds, ensuring that all electrical loads other method of idle speed adjustment should
are switched off (headlamps, heater blower be attempted. If the idle speed is incorrect,
1 Periodically check the belts for fraying or etc), then allow the engine to idle and check the problem should be referred to a Ford
other damage. If evident, renew the belt. the idle speed and CO content. Note that the dealer, as the problem probably lies in the
2 If the belts become dirty, wipe them with a CO reading will initially rise, then fall and finally ESC II module for which special diagnostic
damp cloth using a little detergent only. stabilise after between 5 and 25 seconds. equipment is required.
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.

12 Exhaust system check

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 15.7a Weber 2V carburettor adjustment 15.7b Weber 2V carburettor adjustment
corrosion are evident, renew the system screw locations - 2.0 litre models up to 1985 screw locations - 1.6 litre models
complete or in sections, as applicable, using A Idle speed screw B Idle mixture screw A Idle mixture screw B Idle speed screw
the information given in Chapter 4.
1•12 Every 6000 miles or 6 months
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. 15.9 Pierburg 2V carburettor adjustment 15.13 Weber 2V TLD carburettor
13 For adjustment screw location (see screw locations adjustment screw locations
illustration). A Idle speed screw B Idle mixture screw A Idle mixture screw B Idle speed screw
Fuel injection
2.0 litre SOHC models 6 Run the engine at 3000 rpm for 30 seconds, Models with stepper motor (ESC II
then allow the engine to idle, and using a system)
14 Idle speed is controlled by the EEC IV small screwdriver or a 4.0 mm Allen key, as
module and the only means of adjustment 13 If necessary, the mixture can be adjusted
applicable, adjust the mixture screw to give as described for the Ford VV carburettor with
provided is by the yellow “idle speed the specified CO content.
adjustment” wire (Chapter 5, Section 17) which reference to paragraphs 11 and 12 of this
7 Checking and adjustment should be
allows the idle speed to be raised by 75 rpm. Section. Do not attempt to adjust the idle
completed within 30 seconds of the meter
speed on completion of mixture adjustment.
2.0 litre DOHC models readings stabilising. If this has not been
For adjustment screw location (see
15 Idle speed is controlled by the EEC IV possible, then repeat paragraph 6.
illustration).
module, and manual adjustment is not 8 If necessary adjust the idle speed, then
possible. recheck the CO content. Pierburg 2V carburettor
16 The “base” idle speed can be adjusted, 9 On completion of the adjustments, stop the 14 Proceed as described for the Ford VV
but only by a Ford dealer, using special engine and disconnect the tachometer and carburettor.
equipment. exhaust gas analyser. Fit a new tamperproof
seal to the mixture screw. Weber 2V TLD carburettor
Weber 2V carburettor 15 Proceed as described for the Ford VV
16 Mixture adjustment check carburettor, noting the following points:
Models without stepper motor 16 Ensure that the vacuum pipe and the
10 Proceed as described for the Ford VV camshaft cover breather hose are securely
Caution: Refer to the
carburettor but note the following: connected to the air cleaner and are free from
precautions in Section 1,
11 To remove the mixture screw tamperproof restrictions.
Chapter 4, Part A or B (as
seal, it will be necessary to drill the seal in 17 When warming-up the engine, run the
applicable), before proceeding.
order to prise it from the mixture screw engine until the cooling fan cuts in.
Before carrying out any carburettor
housing. Alternatively a self-tapping screw 18 If adjustment of the mixture (CO content)
adjustments, ensure that the ignition
can be used to draw out the seal. If the is required, the air cleaner must be removed
timing and spark plug gaps are set as
tamperproof seal is to be renewed, ensure for access to the adjustment screw, as
specified. To carry out the adjustments an
that a blue-coloured replacement seal is follows.
accurate tachometer and an exhaust gas
fitted. 19 Remove the air cleaner, and prise the
analyser (CO meter) will be required.
12 It is permissible to loosen the air cleaner tamperproof seal from the mixture screw.
securing screws to allow easier access to the 20 Loosely refit the air cleaner, ensuring that
Ford VV carburettor carburettor adjustment screws, but ensure the vacuum pipe and the camshaft cover
1 Ensure that the air cleaner is correctly fitted that all vacuum hoses and pipes are securely breather hose are securely connected and
and that all vacuum hoses and pipes are connected. free from restrictions (there is no need to
securely connected and free from restrictions, secure the air cleaner in position).
then run the engine until it is at normal 21 On completion, fit a new tamperproof seal
operating temperature. to the mixture screw (the service replacement
2 Stop the engine, and connect a tachometer plug is coloured blue), and refit the air cleaner
and an exhaust gas analyser in accordance assembly.
with the manufacturer’s instructions.
3 Start the engine and run it at 3000 rpm for 30 Fuel injection
seconds, ensuring that all electrical loads are 2.0 litre SOHC models
switched off (headlamps, heater blower etc),
then allow the engine to idle and check the idle 22 The idle mixture can be checked and if
speed and CO content. Note that the CO necessary adjusted as follows:
reading will initially rise, then fall and finally 23 Run the engine until it is at normal
stabilise after between 5 and 25 seconds. operating temperature.
4 If the reading noted in paragraph 3 is not as 24 Stop the engine and connect a
specified, proceed as follows. 16.13 Weber 2V carburettor idle mixture tachometer and an exhaust gas analyser in
5 Using a thin screwdriver, remove the adjustment screw location (arrowed) - accordance with the manufacturer’s
tamperproof seal from the mixture screw. 2.0 litre models from 1985 instructions.
 Every 12 000 miles or 12 months 1•13

16.26 Adjusting the idle mixture - 16.34a Remove the cover from the mixture 16.34b . . . to enable mixture adjustment -
SOHC models adjustment potentiometer . . . DOHC models
25 Start the engine and run it at 3000 rpm for 2.0 litre DOHC models side of the engine compartment, behind the
15 seconds, ensuring that all electrical loads 29 On models with a catalytic converter, the MAP sensor), and turn the screw to give the
(headlamps, heater blower etc) are switched specified CO content (see illustrations).
mixture is controlled by the EEC IV module.
off, then allow the engine to idle and check 35 If adjustment does not produce a change
No manual adjustment is possible.
the CO content. Note that the CO reading will in reading, the potentiometer may be at the
30 On models without a catalytic converter,
initially rise, then fall and finally stabilise. extreme of its adjustment range. To centralise
the idle mixture can be adjusted as follows:
26 If adjustment is necessary, remove the the potentiometer, turn the adjustment screw
31 Run the engine until it is at normal
tamperproof cap from the base of the airflow 20 turns clockwise followed by 10 turns anti-
meter, and turn the mixture screw using a operating temperature.
32 Stop the engine, and connect a clockwise, then repeat the adjustment proce-
suitable Allen key to give the specified CO dure.
content (see illustration). tachometer and an exhaust gas analyser in
accordance with the equipment 36 Checking and adjustment should be
27 Checking and adjustment should be completed within 30 seconds of the meter
completed within 30 seconds of the meter manufacturer’s instructions.
33 Start the engine and run it at 3000 rpm for readings stabilising. If this has not been 1
readings stabilising. If this has not been
15 seconds, ensuring that all electrical loads possible, run the engine at 3000 rpm for 15
possible, run the engine at 3000 rpm, for 15
(headlamps, heater blower, etc) are switched seconds, then allow the engine to idle. Re-
seconds, then allow the engine to idle. Re-
off. Allow the engine to idle, and check the CO check the CO content, and carry out further
check the CO content and carry out further
adjustment if necessary. content. Note that the reading will initially rise, adjustments if necessary.
28 On completion of adjustment, stop the then fall and finally stabilise. 37 On completion of adjustment, stop the
engine and disconnect the tachometer and 34 If adjustment is necessary, remove the engine, and disconnect the tachometer and
exhaust gas analyser. Fit a new tamperproof cover from the mixture adjustment the exhaust gas analyser. Refit the cover to
cap to the mixture screw. potentiometer (located at the rear right-hand the adjustment screw.

Every 12 000 miles (20 000 km) or 12 months

6 Note that if the fluid level was below the
17 Automatic transmission fluid minimum mark when checked or is in 18 Manual gearbox oil level
level check constant need of topping-up, check around check
the transmission for any signs of excessive
1 Fluid level should be checked with the fluid leaks.If present, leaks must be rectified 1 Place the vehicle over a pit, or raise and
transmission at operating temperature (after a without delay. support it at front and rear. The vehicle must
7 If the colour of the fluid is dark brown or be level for an accurate check.
run) and with the vehicle parked on level
black this denotes the sign of a worn brake 2 If the gearbox is hot after a run, allow it to
ground.
band or transmission clutches, in which case cool for a few minutes. This is necessary
2 Open and prop the bonnet. With the engine
have your Ford dealer check the transmission because the oil can foam when hot and give a
idling and the handbrake and footbrake applied, at the earliest opportunity. false level reading.
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 17.3 Automatic transmission dipstick 17.4 Topping-up the transmission fluid
the bonnet. location and markings
1•14 Every 12 000 miles or 12 months
Gearbox type Oil level
All four-speed gearboxes 0 to 5.0 mm (0 to 0.2 in) below lower edge of
filler/level hole

All five-speed gearboxes up to April 1984 (build Level with bottom edge of filler/level hole
code E6) except those subsequently fitted with
a modified extension housing

All five-speed gearboxes from May 1984 (build 20.0 to 25.0 mm (0.79 to 0.99 in) below lower
code EC) to end of April 1985 (build code FP) edge of filler/level hole
and all vehicles built up to April 1984 (build
code E6) subsequently fitted with a modified
gearbox extension housing
18.3 Gearbox filler/level plug location
(arrowed) - N type gearbox All five-speed gearboxes from May 1985 0 to 5.0 mm (0 to 0.2 in)below lower edge of
filler/level hole
3 Wipe clean around the filler/level plug.
Unscrew the plug and remove it (see Note: The vehicle build code appears as the twelfth and thirteenth characters of the VIN number
illustration). on the plate in the engine compartment.
4 Using a suitably marked piece of bent wire
as a dipstick, check that the oil level is as 8 On DOHC models before refitting the spark
shown in the table at the top of this page, Number each HT lead using plugs, coat their threads with suitable anti-
according to gearbox type. sticky tape or paint before seize compound, taking care not to
5 Top-up the level if necessary, using clean removal so as to avoid contaminate the electrodes.
oil of the specified type. Do not overfill, as this confusion when refitting. 9 Screw in the spark plugs by hand, then
can lead to leakage and difficult gear tighten them to the specified torque. Do not
changing. Allow excess oil to drip out of the 3 Where necessary, for improved access exceed the torque figure.
filler/level hole if necessary. Refit and tighten remove the air cleaner and/or the inlet hose. 10 Push the HT leads firmly onto the spark
the filler/level plug on completion. 4 Disconnect the leads from the plugs by plugs, and where applicable refit the air
6 The frequent need for topping-up can only pulling on the connectors, not the leads. cleaner and/or inlet hose.
be due to leaks, which should be rectified. 5 On 2.0 litre DOHC carburettor models, the
The most likely sources of leaks are the rear location of the spark plugs and the close
extension housing and input shaft oil seals. proximity of the carburettor makes spark plug 21 Auxiliary drivebelt check
7 No periodic oil changing is specified, and access difficult, particularly when removing
no drain plug is fitted. the plugs from cylinders 2 and 3. It is
suggested that a 3/8 inch ratchet drive spark 1 Refer to the Specifications at the beginning
plug socket with rubber insert and long of this Chapter and check the tension of each
19 Hinge and lock check and drivebelt at the point stated. Check the full
extension bar is used, possibly in conjunction
lubrication with a universal joint adapter. It is also length of each drivebelt for cracks and
advisable to disconnect No 3 cylinder HT lead deterioration. It will be necessary to turn the
1 Work around the vehicle, and lubricate the from the distributor first, to allow some slack engine in order to check that portion of the
bonnet, door and tailgate hinges with a light for disconnection at the spark plug. drivebelt in contact with the pulleys. Renew or
machine oil. 6 Clean the area around each spark plug tension each belt as necessary as follows,
2 Lightly lubricate the bonnet release using a small brush, then using a plug according to model type:
mechanism and exposed sections of inner spanner (preferably with a rubber insert),
cable with a smear of grease. SOHC models
unscrew and remove the plugs (see
3 Check the security and operation of all 2 Note that two drivebelts are fitted to models
illustration). Cover the spark plug holes with
hinges, latches and locks, adjusting them equipped with power steering and both
a clean rag to prevent the ingress of any
where required. Where applicable, check the should be renewed if either one is
foreign matter.
operation of the central locking system. unserviceable. Where fitted, the air
7 Before fitting new spark plugs, check that
4 Check the condition and operation of the conditioning compressor is driven by a
the threaded connector sleeves are tight. As
tailgate struts, renewing them if either is separate belt.
the plugs incorporate taper seats, make sure
leaking or is no longer able to support the 3 Disconnect the battery negative lead.
that the threads and seats are clean.
tailgate securely when raised. 4 Where applicable, remove the air
conditioning compressor drivebelt.
5 Loosen the alternator mounting and
20 Spark plug renewal adjustment nuts and bolts, and pivot the
alternator towards the cylinder block.
6 Slip the drivebelt(s) from the alternator,
1 The correct functioning of the spark plugs is water pump, crankshaft and (where
vital for the correct running and efficiency of applicable) the power steering pump pulleys.
the engine. It is essential that the plugs fitted 7 Fit the new drivebelt(s) over the pulleys,
are appropriate for the engine. then lever the alternator away from the
2 Make sure that the ignition is switched off cylinder block until the specified belt tension
before inspecting the HT leads to see if they is achieved. Lever the alternator using a
carry their cylinder numbers. Note that the wooden or plastic lever at the pulley end to
position of No 1 cylinder HT lead in the prevent damage and straining the brackets. It
distributor cap is marked with either a pip, or 20.6 Removing a spark plug - CVH engine is helpful to partially tighten the adjustment
a number “1 “. link bolt before tensioning the drivebelt(s).
 Every 12 000 miles or 12 months 1•15

steering, the drivebelt is tensioned by moving maintenance apart from having the case kept
the alternator. On models with power steering, clean, and the terminals clean and tight.
the power steering pump is also driven by the 2 To clean the battery terminals disconnect
coolant pump/alternator drivebelt and an them, after having first removed the cover
automatic belt tensioner is fitted (see (later models) - negative earth first. Use a wire
illustration). On models with air conditioning, brush or abrasive paper to clean the
the drivebelt drives the alternator, coolant terminals. Bad corrosion should be treated
pump, power steering pump and air with a solution of bicarbonate of soda, applied
conditioning compressor, and an automatic with an old toothbrush. Do not let this solution
belt tensioner is fitted. get inside the battery.
13 On models without power steering, loosen 3 Coat the battery terminals with petroleum
the alternator mounting and adjustment bolts, jelly or a proprietary anti-corrosive compound
and pivot the alternator towards the cylinder before reconnecting them. Reconnect and
21.8 Alternator mounting tightening block. Slip the drivebelt from the pulleys. tighten the positive (live) lead first, followed by
sequence - SOHC engines 14 On models with power steering, the the negative (earth) lead. Do not overtighten.
automatic tensioner can be released using a 4 Keep the top of the battery clean and dry.
8 Tighten the alternator mounting and
17 mm socket and a wrench on the boss in Inspect the battery tray for corrosion, and
adjustment nuts and bolts in the order shown
the centre of the pulley. Lever the tensioner make good as necessary.
(see illustration).
assembly clockwise, slide the belt from the
9 Where applicable, refit and tension the air
pulleys, then slowly release the tensioner.
conditioning compressor drivebelt. 23 Engine valve clearance
15 To fit a new belt on models without
10 Reconnect the battery negative lead.
power steering, slide the belt over the pulleys, check
11 Drivebelt tension should be rechecked
then lever the alternator away from the
and if necessary adjusted after the engine has
cylinder block until the correct belt tension is
been run for a minimum of ten minutes. It will be easier to turn the
achieved. Lever the alternator using a plastic
engine by hand if the spark
DOHC models or wooden lever at the pulley end to prevent
plugs are removed but take
damage. It is helpful to partially tighten the
12 Three different types of drivebelt care not to allow dirt to enter
adjustment link bolt before tensioning the
arrangement are used, depending on model the spark plug holes. 1
drivebelt. When the correct tension is
(see illustrations). On models without power
achieved, tighten all the bolts.
16 To fit a new belt on models with power SOHC engines
steering, lever the tensioner clockwise as
during removal, then slide the belt over the 1 The valve clearances must be checked with
pulleys, and slowly release the tensioner. 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
22 Battery terminal check
camshaft cover.
3 On fuel injection models, unbolt and
Caution: Before carrying out remove the bracing strut securing the inlet
any work on the vehicle battery, manifold to the right-hand side of the cylinder
read through the precautions head.
21.12a Coolant pump/alternator drivebelt
given in “Safety first!” at the 4 Where applicable, unclip any hoses and
arrangement - 2.0 litre DOHC engine
beginning of this manual. wires from the camshaft cover, then unscrew
without power steering
the securing bolts and remove the camshaft
1 Alternator 3 Crankshaft 1 The battery fitted as original equipment is cover and gaskets. Take care not to lose the
2 Coolant pump pulley “maintenance-free”, and requires no spacer plates which fit under the bolt heads,
where applicable.

21.12b Coolant pump/alternator drivebelt 21.12c Coolant pump/alternator drivebelt

arrangement - 2.0 litre DOHC engine with arrangement - 2.0 litre DOHC engine with
power steering power steering and air conditioning
21.12d Alternator/coolant pump drivebelt
1 Alternator 4 Crankshaft pulley 1 Alternator 4 Air conditioning tensioner indicator position -
2 Automatic belt 5 Power steering 2 Automatic belt compressor 2.0 litre DOHC engine
tension pump tensioner 5 Crankshaft pulley
6 Power steering Inset shows tensioner at maximum
3 Coolant pump 3 Coolant pump
pump adjustment
1•16 Every 12 000 miles or 12 months

23.6 Cam lobe correctly positioned for 23.7a Using a feeler gauge to check a 23.7b Adjusting a valve clearance
checking valve clearance. Insert feeler valve clearance
gauge as shown by arrow
5 Numbering from the front (camshaft nut, then tighten the locknut (see
sprocket) end of the engine, the exhaust illustrations). Allowance must be made for 25 Radiator matrix and air
valves are 1, 3, 5 and 7, and the inlet valves tightening the locknut, as this tends to conditioner condenser clean
are 2, 4, 6 and 8. decrease the valve clearance. Recheck the
6 Turn the engine clockwise using a suitable adjustment after tightening the locknut. Gain access to the radiator matrix by
socket on the crankshaft pulley bolt, until the 8 Repeat the procedure given in paragraphs removing the surrounding body panels, fan
exhaust valve of No 1 cylinder (valve No 1) is 6 and 7 for the remaining valves. With the shrouds, etc. Clean dirt and debris from the
fully closed; ie the cam lobe is pointing carburettor/inlet manifold fitted, some diffi- matrix using an air jet or water and a soft
vertically upwards (see illustration). culty may be experienced when adjusting the brush. Be careful not to damage the fins or
7 Insert a feeler blade of the correct thickness exhaust valve clearances, and a suitable cut your fingers.
(see Specifications) between the cam follower open-ended spanner bent to 90º will be found Remove the protecting grille and clean any
and the heel of the No 1 valve cam lobe. The helpful. leaves, insects etc. from the air conditioner
feeler blade should be a firm sliding fit. If not, 9 Check the condition of the camshaft cover condenser coil and fins. Be very careful not to
loosen the locknut and adjust the ball-pin gasket, and renew if necessary. Fit the gasket damage the condenser fins: use a soft brush, or
position accordingly by turning the adjuster to the camshaft cover ensuring that the a compressed air jet, along (not across) the fins.
locating tabs and dovetails are correctly
located (see illustration), then refit the 26 Air conditioner refridgerant
camshaft cover and tighten the securing bolts
charge check
in the order shown (see illustration), ensuring
that the spacer plates are in position under
1 If applicable, remove the radiator grille
the bolt heads, where applicable.
being careful not to damage the condenser
10 On fuel injection models, refit the inlet
fins.
manifold bracing strut.
2 Check the refrigerant charge as follows.
11 Where applicable refit the spark plugs. The engine should be cold and the ambient
Reconnect the HT leads and locate them in temperature should be between 64° and 77°F
the clips on the camshaft cover. (18° and 25°C).
12 Where applicable, refit any wires and 3 Start the engine and allow it to idle.
hoses to the clips on the camshaft cover and Observe the refrigerant sight glass (see
23.9a Camshaft cover gasket dovetails on carburettor models, refit the air cleaner. illustration) and have an assistant switch on
DOHC and CVH engines the air conditioning to fan speed III. A few
bubbles should be seen in the sight glass as
13 These engines are fitted with hydraulic the system starts up, but all bubbles should
cam followers therefore no adjustment is disappear within 10 seconds. Persistent
necessary. bubbles, or no bubbles at all, mean that the
refrigerant charge is low. Switch off the

24 Handbrake check

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
23.9b Camshaft cover bolts (A) and spacer “bind” is evident. The handbrake lever travel
plates (B) should be between two and four clicks of the
Tighten bolts in following stages: ratchet. If brake “bind” or excessive lever
Stage 1 Bolts 1 to 6 travel is evident, check the handbrake cable
Stage 2 Bolts 7 and 8 routing and check the self-adjuster
Stage 3 Bolts 9 and 10 mechanism for wear or damage. Refer to 26.3 Air conditioning system refrigerant
Stage 4 Bolts 7 and 8 (again) Chapter 10 for full service information. sight glass (arrowed)
 Every 12 000 miles or 12 months 1•17

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.

27 Final drive oil level check

27.3a Final drive unit filler plug location 27.3b Rear axle filler plug location -
(arrowed) - P100 models
1 Check the final drive oil level as follows. Saloon, Hatchback and Estate models
2 Position the vehicle over a pit, or raise it at 2 Steam-cleaning is available at many
front and rear on ramps or axle stands. The 4 Wheel bearings can be checked for wear by garages and is necessary for the removal of
vehicle must be level. spinning the relevant roadwheel. Any the accumulation of oily grime which
3 Wipe clean around the final drive filler/level roughness or excessive noise indicates worn sometimes is allowed to become thick in
plug (see illustrations) and unscrew the bearings, which must be renewed, as no certain areas. If steam-cleaning facilities are
plug. Using a piece of bent wire as a dipstick, adjustment is possible. It is unlikely that any not available, there are some excellent grease
check that the oil is no more than 10 mm (0.4 wear will be evident unless the vehicle has solvents available which can be brush-
covered a very high mileage. It should be applied; the dirt can then be simply hosed off.
in) below the plug hole.
noted that it is normal for the bearings to 3 After cleaning, position the vehicle over a
4 If topping-up is necessary, use clean gear
exhibit slight endfloat, which is perceptible as pit, or raise it at front and rear on ramps or axle
oil of the specified type. Do not overfill.
wheel rock at the wheel rim. stands (see “Jacking and vehicle support”).
Frequent need for topping-up can only be due
4 Using a strong light, work around the
to leaks, which should be rectified. underside of the vehicle, inspecting it for
5 When the level is correct, refit the filler/level
30 Driveshaft check corrosion or damage. If either is found, refer 1
plug and tighten it to the specified torque to Chapter 12 for details of repair.
loading.
6 There is no requirement for periodic oil 1 Position the vehicle over a pit, or raise it at
changing, and no drain plug is provided. front and rear on ramps or axle stands (see 32 Brake pipe and hose check
“Jacking and vehicle support”).
28 Automatic transmission 2 Examine the driveshaft joint rubber gaiters.
Flex the gaiters by hand and inspect the folds Periodically inspect the rigid brake pipes for
selector linkage lubrication rust and other damage, and the flexible hoses
and clips. Damaged or leaking gaiters must
be renewed without delay to avoid damage for cracks, splits or “ballooning”. Have an
Lubricate the transmission selector and assistant depress the brake pedal (ignition on)
occurring to the joint itself
kickdown linkages with engine oil or aerosol and inspect the hose and pipe unions for leaks.
3 Check the tightness of the final drive
lubricant. Renew any defective item without delay.
mounting bolts and the driveshaft flange screws.

29 Steering and suspension

security check 31 Underbody inspection 33 Idle speed linkage clean

1 Check the shock absorbers by bouncing On carburettor models which incorporate a

1 Except on vehicles with a wax-based
the vehicle up and down at each corner in stepper motor (ie. Weber 2V from 1985), good
underbody protective coating, have the whole
turn. When released, it should come to rest electrical contact between the motor plunger
of the underframe of the vehicle steam-
within one complete oscillation. Continued and the adjusting screw is essential to
cleaned, engine compartment included, so
movement, or squeaking and groaning noises maintain a regular idle speed.
that a thorough inspection can be carried out
from the shock absorber suggests that Clean the plunger and adjusting screw
to see what minor repairs and renovations are
renewal is required . contact faces with abrasive paper followed by
necessary.
2 Raise and support the vehicle. Examine all switch cleaning fluid. Switch cleaning fluid is
steering and suspension components for available from electronic component shops.
wear and damage. Pay particular attention to
dust covers and gaiters, which if renewed
promptly when damaged can save further 34 Road test
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).
Instruments and electrical
Balljoint free movement must not exceed 0.5
equipment
mm (0.02 in). The track rod end balljoints can 1 Check the operation of all instruments and
be checked in a similar manner, or by electrical equipment.
observing them whilst an assistant rocks the 2 Make sure that all instruments read
steering wheel back and forth. If the lower arm correctly, and switch on all electrical
balljoint is worn, the complete lower arm must 29.3 Levering up lower arm to check equipment in turn to check that it functions
be renewed . balljoint for wear properly.
1•18 Every 24 000 miles or 2 years
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.
35.1 Loosening the crankcase ventilation 35.3 Oil separator (1) and mushroom valve After about four or five applications, no further
hose clip - CVH models (2) locations in air cleaner - CVH models hissing should be heard, and the pedal should
feel considerably firmer.
Steering and suspension 9 Where applicable, check that the clutch
action is smooth and progressive, that the
3 Check for any abnormalities in the steering, 35 Crankcase ventilation system
drive is taken up smoothly, and that the pedal
suspension, handling or road “feel”. check
travel is not excessive. Also listen for any
4 Drive the vehicle, and check that there are
noises when the clutch pedal is depressed.
no unusual vibrations or noises. 10 Check that all gears can be engaged 1 Inspect the crankcase ventilation system
5 Check that the steering feels positive, with smoothly, without noise, and that the gear lever for blockage or damage. A blocked hose can
no excessive “sloppiness”, or roughness, and action is not abnormally vague or “notchy”. cause a build-up of crankcase pressure,
check for any suspension noises when which in turn can cause oil leaks (see
cornering, or when driving over bumps. Check the operation and illustration).
performance of the braking 2 On carburettor model SOHC engines, clean
Drivetrain system the oil filler cap with paraffin and check that
6 Check the performance of the engine, 11 Make sure that the vehicle does not pull to the vent valve is not blocked by pulling it from
clutch, transmission and driveshafts. one side when braking, and that the wheels the oil separator and loosening the hose clip
7 Listen for any unusual noises from the do not lock prematurely when braking hard. (Section 42).
engine, clutch and transmission. 12 Check that there is no vibration through 3 On CVH engines, check that the oil
8 Make sure that the engine runs smoothly the steering when braking. separator and mushroom valve are not
when idling, and that there is no hesitation 13 Check that the handbrake operates blocked, and clean if necessary (see
when accelerating. correctly, without excessive movement of the illustration).

Every 24 000 miles (40 000 km) or 2 years

2 To check the operation of the air 4 Working under the base of the air cleaner
36 Air cleaner inlet air temperature control, the engine must be cold. body, disconnect the diaphragm unit-to-heat
temperature control check First observe the position of the flap valve sensor vacuum pipe at the sensor end, and
which should be fully closed prior to starting connect a vacuum pump to the diaphragm unit.
the engine (see illustration). The position of Apply a vacuum of 100.0 mm (4.0 in) of mercury.
SOHC and DOHC carburettor the flap can be observed by disconnecting the 5 If the flap opens, then the heat sensor is
models cold air inlet hose from the air cleaner spout faulty and should be renewed. If the flap
1 A vacuum pump will be required to test the and looking into the spout. remains closed, then the diaphragm unit is
control components. 3 Start the engine and allow it to idle. Check faulty, and a new air cleaner body will have to
that the flap is now fully open to admit hot air be obtained, as the diaphragm unit is not
from the exhaust manifold shroud. If the flap available separately.
does not fully open, stop the engine and 6 On completion of the checks, disconnect
check the vacuum diaphragm unit and heat the vacuum pump, and reconnect the vacuum
sensor as follows (see illustrations). pipe and cold air inlet hose.

36.2 Air cleaner flap valve operation -

OHC models
A Flap fully open to admit hot air 36.3a Air cleaner vacuum diaphragm unit - 36.3b Air cleaner heat sensor viewed from
B Flap fully closed to admit cold air OHC models inside air cleaner - OHC models
 Every 24 000 miles or 2 years 1•19

37 Pulse air filter element

renewal (1.6 litre CVH)
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.
36.7 Air cleaner flap valve operation - CVH models
A Flap fully open to admit hot air 3 Flap valve
B Flap fully closed to admit cold air 4 Link arm 38 Air cleaner element renewal
1 Air inlet spout 5 Waxstat
2 Hot air inlet hose 6 Air cleaner body
Carburettor models
CVH carburettor models 1 Remove the screws from the top of the air
7 To test the unit the engine must initially be cleaner cover (see illustration).
cold. Disconnect the hot air inlet hose from 2 Where applicable release the spring clips
the air cleaner spout and observe the position around the edge of the cover, then lift or prise
of the flap which should be fully open to allow off the cover (see illustration).
only hot air to enter (see illustration). 3 Lift out the air cleaner element. Wipe the
8 Refit the hose and warm up the engine to inside of the air cleaner body clean, taking
normal operating temperature. care not to allow dirt to enter the carburettor
throat. Also clean the inside of the cover.
9 Disconnect the hot air inlet hose again, and
4 Place a new element in position, then refit 1
observe the position of the flap which should
the air cleaner cover.
be fully closed to admit only cold air.
10 If the flap positions are not as described, Fuel-injection models
the waxstat is defective and the complete air
cleaner must be renewed as the waxstat is All models except 2.0 litre DOHC
37.2 Withdrawing the pulse-air filter not available separately. 5 Disconnect the battery negative lead.
element and gauze - 1.6 litre CVH models 11 On completion of the checks, stop the 6 Depress the locking clip on the airflow
engine and reconnect the hot air inlet hose. 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
38.1 Remove the air cleaner cover 38.2 . . . release the spring clips, and lift off correctly aligned (see illustration). Reconnect
screws . . . the cover for access to the element the wiring plug.

38.6 Disconnecting the airflow meter 38.9 Unclip the lid and remove the air 38.12 Air intake hose clip correctly aligned
wiring plug cleaner element
Haynes Ford Sierra Service And Repair Manual
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1•20 Every 24 000 miles or 2 years
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
38.17 Air intake tube securing nut 38.19 Lifting out the air cleaner element screw several turns.
(arrowed) 5 Using the Ford special tool or a suitable
equivalent, tighten the adjuster screw to the
13 Reconnect the battery negative lead. deposits from the connectors and terminals.
specified torque, then back off the screw two
2.0 litre DOHC models Also clean the coil tower.
complete turns, and tighten the locknut.
5 Renew the HT leads if they are cracked,
14 Disconnect the battery negative lead. Ensure that the adjuster screw does not turn
burnt or otherwise damaged. If a multi-meter
15 Disconnect the wiring plug from the idle as the locknut is tightened.
is available, measure the resistance of the
speed control valve at the front of the plenum 6 Repeat the procedure given in paragraphs
leads. The desired value is given in the
chamber. 4 and 5 for the remaining adjuster screw on
Specifications of Chapter 5.
16 Loosen the clamp, and detach the air inlet A4LD type transmissions, but on all models
6 Renew the distributor cap if it is cracked or
hose from the air inlet tubing. where the part number on the transmission
badly burnt inside, or if there is evidence of
17 Unscrew the securing nut, and release the identification tag starts with “88” (see
“tracking” (black lines marking the path of HT
air inlet tube from the bracket on the engine illustration) and additionally on all 1.8 CVH
leakage). If there is a carbon brush at the
compartment front panel (see illustration). engine models, the adjuster screw should be
centre of the cap, make sure that it moves
18 Release the air cleaner lid securing clips, backed off two and a half turns after
freely, and is not excessively worn (see
then lift away the air inlet tube, plenum tightening to the specified torque. On all other
illustration).
chamber and air cleaner lid as an assembly, models, the adjuster screw should be backed
7 Clean the metal track of the rotor arm with
disconnecting the breather hose from the air off two turns.
fine abrasive paper. Renew the arm if it is
inlet tube. 7 Reconnect the kickdown cable, and lower
cracked or badly burnt.
19 Lift out the air cleaner element (see the vehicle to the ground on completion.
8 Refit the rotor arm and distributor cap.
illustration), then wipe the inside of the air 9 Reconnect the HT leads to the spark plugs
cleaner lid and casing clean. and coil.
20 Fit the new element with the sealing lip 10 Reconnect the battery and run the engine.
41 Fuel filter renewal
uppermost.
21 Further refitting is a reversal of removal.
40 Automatic transmission Caution: Refer to the
precautions in Chapter 4, Part
39 Ignition system component brake band adjustment
B, Section 1 before proceeding.
check Note: A brake band torque wrench - Ford tool 2.0 litre SOHC fuel injection
No 17-005, or a conventional torque wrench models
1 Before disturbing any part of the ignition and a splined socket of suitable size to fit the
system, disconnect the battery negative lead. 1 The fuel filter is located on the left-hand
square section head of the adjuster screw(s) side of the engine compartment (see
2 Identify and clearly mark all HT leads before will be required for this operation.
disconnecting them from the spark plugs. illustration).
1 For improved access, apply the handbrake, 2 Disconnect the battery negative lead.
3 Refer to the appropriate Section in Chapter then jack up the front of the vehicle and
5 and, where applicable, remove the 3 Position a suitable container beneath the
support on axle stands (see “Jacking and filter, then slowly loosen the fuel inlet union to
distributor cap and rotor arm. vehicle support”).
4 Clean the HT leads and distributor cap with relieve the pressure in the fuel lines.
a dry cloth. Scrape any corrosion or other 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.

40.2 Brake band adjustment - A4LD type

transmission
39.6 Bosch distributor cap showing HT A Adjuster screws C Kickdown lever 40.6 Transmission identification tag with
segments (A) and carbon brush (B) B Locknuts part number starting with “88”

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