FORD SIERRA 1982 1.G Fuel And Exhaust Systems Fuel Injection Workshop Manual

General
Fuel tank capacity (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 litres (13.1 gallons)
Fuel octane rating:
Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 RON (4-star)
Unleaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON (Premium)
*Models fitted with a catalytic converter must be operated on unleaded fuel at all times. Do not use leaded fuel in such models, as the catalyst will
be destroyed:
System control pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar
System type:
2.0 litre SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch L-Jetronic
2.0 litre DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-point fuel injection system, controlled by EEC IV engine
management system
1.6 and 1.8 litre (R6A type) CVH models . . . . . . . . . . . . . . . . . . . . . . . . Central fuel injection (CFI) controlled by EEC IV engine management
system
Idle adjustments
All models except 2.0 litre DOHC
Idle speed (dependent on idle speed adjustment wire):
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875 rpm
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.0%
2.0 litre DOHC
Idle speed (not adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875 + 50 rpm
Idle mixture (CO content) - models without catalytic converter . . . . . . . 1.0 to 1.5%
Chapter 4 Part B:
Fuel and exhaust systems - fuel injection
Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Airflow meter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .15
Carbon canister (models with catalytic converter) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Carbon canister-purge solenoid (models with catalytic converter) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
CFI unit (1.6 and 1.8 litre (R6A type) CVH) - removal and refitting . . .19
Electronic vacuum regulator (1.8 litre (R6A type) CVH) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Exhaust gas oxygen (HEGO) sensor (2.0 litre DOHC/1.6 & 1.8 litre
(R6A type) CVH) - removal and refitting . . . . . . . . . . . . . . . . . . . . .35
Exhaust gas recirculation valve (1.8 litre (R6A type) CVH) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . .36
Exhaust pressure transducer (1.8 litre (R6A type) CVH) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Exhaust system - inspection, removal and refitting . . . . . . . . . . . . . .37
Fuel filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fuel injector ballast resistor (1.6 litre CVH) - removal and refitting . .17
Fuel injector (1.6 and 1.8 litre (R6A type) CVH) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fuel injectors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .18
Fuel level sender unit (2.0 litre SOHC) - removal and refitting . . . . . .11Fuel pressure regulator - removal and refitting . . . . . . . . . . . . . . . . . .6
Fuel pump/fuel level sender unit (2.0 litre DOHC/1.6 & 1.8 litre (R6A
type) CVH) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fuel pump (2.0 litre SOHC) - removal and refitting . . . . . . . . . . . . . . .8
Fuel pump - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel system (1.6 and 1.8 litre (R6A type) CVH) - depressurisation . . . .4
Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . .12
Idle speed control valve - removal and refitting . . . . . . . . . . . . . . . . .13
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .30
Mixture adjustment potentiometer (2.0 litre DOHC) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pulse-air control solenoid (1.6 litre CVH) - removal and refitting . . . .23
Pulse-air delivery tubing (1.6 litre CVH) - removal and refitting . . . . .22
Pulse-air filter element (1.6 litre CVH) - renewal . . . . . . . . . . . . . . . . .20
Pulse-air system vacuum-operated air valve (1.6 litre CVH) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Throttle body - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .29
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . .26
Throttle pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .25
Throttle position sensor - removal and refitting . . . . . . . . . . . . . . . . .27
Throttle valve control motor (1.6 and 1.8 litre (R6A type) CVH) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4B•1
Specifications Contents
4B
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

Torque wrench settingsNmlbf ft
2.0 litre SOHC models
Refer to Chapter 4
, PartA Specifications for items not listed here
Fuel pressure regulator fuel feed union nut . . . . . . . . . . . . . . . . . . . . . .15 to 2011 to 15
Fuel pressure regulator securing nut . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Fuel rail securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 106 to 7
Idle speed control valve nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 106 to 7
2.0 litre DOHC models
Inlet manifold nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2415 to 18
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2515 to 18
Exhaust gas oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 7037 to 52
Throttle body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Fuel rail bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2615 to 19
Idle speed control valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Fuel pressure regulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 127 to 9
Fuel filter unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 2010 to 15
1.6 and 1.8 litre (R6A type) CVH models
Inlet manifold nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Exhaust manifold nuts:
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 1710 to 13
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2715 to 20
Exhaust downpipe-to-manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
CFI unit bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Exhaust gas oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 7037 to 52
EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3015 to 22
Fuel filter unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 2010 to 15
Pulse-air tube unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 to 3521 to 26
General information
2.0 litre SOHC models
The fuel injection system fitted to these
models is of the Bosch L-Jetronic type. The
system is under the overall control of an EEC
IV engine management system which also
controls the ignition timing.
Fuel is supplied from the rear-mounted fuel
tank by an electric fuel pump mounted next to
the tank, via a pressure regulator, to the fuel
rail. The fuel rail acts as a reservoir for the four
fuel injectors, which inject fuel into the cylinder
inlet tracts, upstream of the inlet valves. The
fuel injectors receive an electrical pulse once
per crankshaft revolution, which operates all
four injectors simultaneously. The duration of
the electrical pulse determines the quantity of
fuel injected, and pulse duration is computed
by the EEC IV module on the basis of
information received from the various sensors.
Inducted air passes from the air cleaner
through a vane type airflow meter before
passing to the cylinder inlet tracts via the
throttle valve. A flap in the vane airflow meter
is deflected in proportion to the airflow; this
deflection is converted into an electrical signal
and passed to the EEC IV module. An
adjustable air bypass channel provides the
means of idle mixture adjustment.
A throttle position sensor enables the EEC IV
module to compute not only throttle position,
but also its rate of change. Extra fuel can thus
be provided for acceleration when the throttle
is opened suddenly. Information from the
throttle position sensor is also used to cut off
fuel on the overrun, thus improving fueleconomy and reducing exhaust gas emissions.
Idle speed is controlled by a variable orifice
solenoid valve which regulates the amount of
air bypassing the throttle valve. The valve is
controlled by the EEC IV module; there is no
provision for adjustment of the idle speed.
Additional sensors inform the EEC IV
module of engine coolant and air temperature.
On models fitted with automatic transmission,
a sensor registers the change from “P” or “N”
to a drive position, and causes the idle speed
to be adjusted accordingly to compensate for
the additional load. Similarly on models fitted
with air conditioning, a sensor registers when
the compressor clutch is in operation.
A “limited operation strategy” (LOS) means
that the vehicle is still driveable, albeit at
reduced power and efficiency, in the event of
a failure in the EEC IV module or its sensors.
A fuel filter is incorporated in the fuel supply
line to ensure that the fuel supplied to the
injectors is clean.
On models produced from mid-1986
onwards, a fuel pump inertia cut-off switch is
fitted. This switch breaks the electrical circuit
to the fuel pump in the event of an accident or
similar impact, cutting off the fuel supply to
the engine.
2.0 litre DOHC models
The fuel injection system fitted to these
models is under the overall control of an EEC
IV engine management system which also
controls the ignition timing.
Fuel is supplied from the rear-mounted fuel
tank by an electric fuel pump, which is integral
with the fuel level sender unit mounted inside
the fuel tank. Fuel passes via a fuel filter and a
pressure regulator to the fuel rail. The fuel rail
acts as a reservoir for the four fuel injectors,
which inject fuel into the cylinder inlet tracts,
upstream of the inlet valves. The fuel injectorsare operated in pairs by electrical pulses
supplied by the EEC IV module, and fuel is
injected by one pair of injectors every half-
revolution of the crankshaft. The duration of
each electrical pulse determines the quantity of
fuel injected, and pulse duration is computed
by the EEC IV module on the basis of
information received from the various sensors.
Inducted air passes through the air cleaner,
and through a plenum chamber, before
passing on to the cylinder inlet tracts via the
throttle valve and inlet manifold. The volume
of air entering the engine is calculated by the
EEC IV module from information supplied by
various sensors. These sensors include an air
charge temperature sensor mounted in the
inlet manifold, which measures the
temperature of the air entering the engine; a
manifold absolute pressure (MAP) sensor,
which measures the pressure of the air
entering the engine; a throttle position sensor;
and a crankshaft speed/position sensor,
which supplies information on engine speed
and provides a timing reference.
Additional sensors inform the EEC IV
module of fuel temperature, engine coolant
temperature, and vehicle speed (from a
gearbox-mounted sensor).
Idle speed is controlled by a variable-orifice
solenoid valve, which regulates the amount of
air bypassing the throttle valve. The valve is
controlled by the EEC IV module; there is no
provision for direct adjustment of the idle
speed.
On models without a catalytic converter,
idle mixture adjustment is by means of a
potentiometer connected directly to the EEC
IV module. On models with a catalytic
converter, an exhaust gas oxygen (HEGO)
sensor enables the EEC IV module to control
the fuel/air mixture to suit the operating
parameters of the catalytic converter; no
1General information and
precautions
4B•2Fuel and exhaust systems - fuel injection

manual mixture adjustment is possible.
On models with a catalytic converter, an
evaporative emission control (EVAP) system is
fitted. This prevents the release of fuel vapour
into the atmosphere. With the ignition
switched off, vapours from the fuel tank are
fed to a carbon canister, where they are
absorbed. When the engine is started, the
EEC IV module opens a purge solenoid valve,
and the fuel vapours are fed into the inlet
manifold and mixed with fresh air. This cleans
the carbon filter. A blow-back valve prevents
inlet air being forced back into the fuel tank.
A fuel pump inertia switch is fitted. This
switch breaks the electrical circuit to the fuel
pump in the event of an accident or similar
impact, cutting off the fuel supply to the engine.
A “limited operation strategy” (LOS) means
that the vehicle will still be driveable, albeit at
reduced power and efficiency, in the event of
a failure in the EEC IV module or its sensors.
1.6 and 1.8 litre (R6A type) CVH models
The fuel injection system fitted to these
models is under the overall control of an EEC
IV engine management system which also
controls the ignition timing.
Fuel is supplied from the rear-mounted fuel
tank by an electric fuel pump which is integral
with the fuel level sender unit mounted inside
the fuel tank. Fuel passes via a fuel filter to the
Central Fuel Injection (CFI) unit. A fuel
pressure regulator, mounted on the CFI unit,
maintains a constant fuel pressure to the fuel
injector. Excess fuel is returned from the
regulator to the tank.
The CFI unit, resembling a carburettor,
houses the throttle valve, throttle valve control
motor, throttle position sensor, air charge
temperature sensor, fuel injector, and
pressure regulator.
The duration of the electrical pulse supplied
to the fuel injector determines the quantity of
fuel injected, and pulse duration is computed
by the EEC IV module on the basis of
information received from the various sensors.
The fuel injector receives a pulse twice per
crankshaft revolution under normal operating
conditions, and once per crankshaft
revolution under engine idle conditions. A
ballast resistor is used in the fuel injector
control circuit on 1.6 litre engines.
Inlet air passes through the air cleaner into
the CFI unit. The volume of air entering the
engine is calculated by the EEC IV module from
information supplied by various sensors. These
sensors include the air charge temperature
sensor and throttle position sensor, mounted in
the CFI unit; a crankshaft speed/position
sensor which supplies information on engine
speed; and a manifold absolute pressure (MAP)
sensor which measures the pressure of the air
entering the engine.
Additional sensors inform the EEC IV module
of engine coolant temperature, and vehicle
speed (from a gearbox-mounted sensor).
An exhaust gas oxygen (HEGO) sensor
enables the EEC IV module to control the
fuel/air mixture to suit the operating
parameters of the catalytic converter. No
manual mixture adjustment is possible.
Idle speed is controlled by a throttle valvecontrol motor, which controls the position of
the throttle valve under conditions of idling,
deceleration/part-throttle, and engine start-up
and shut-down.
On 1.6 litre engines, a pulse-air system is
fitted to reduce the exhaust gas emissions
during engine warm-up. The system is con-
trolled by a vacuum-operated valve, which is
operated by the EEC IV module via a solenoid.
The system introduces air into the exhaust
manifold to increase the exhaust gas
temperature, which oxidises more of the
pollutants, and brings the catalyst up to
working temperature more quickly. The
system operates until the catalyst reaches
operating temperature, when the control
solenoid shuts off the system.
On 1.8 litre engines, an exhaust gas
recirculation (EGR) system is used to
recirculate a small amount of exhaust gas into
the inlet manifold. This process lowers the
combustion temperature, resulting in a
reduction of NOx (oxides of nitrogen)
emissions. The EGR system is controlled by
the EEC IV module in conjunction with an
Electronic Pressure Transducer (EPT) and an
Electronic Vacuum Regulator (EVR).
On certain models, an evaporative emission
control system may be fitted. This prevents
the release of fuel vapour into the
atmosphere. With the ignition switched off,
vapours from the fuel tank are fed to a carbon
canister, where they are absorbed. When the
engine is started the EEC IV module opens a
purge solenoid valve, and the fuel vapours are
fed into the inlet manifold and mixed with
fresh air. This cleans the carbon filter. A blow-
back valve prevents inlet air being forced
back into the fuel tank.
A fuel pump inertia switch is fitted. This
switch breaks the electrical circuit to the fuel
pump in the event of an accident or similar
impact cutting off the fuel supply to the engine.
A “limited operation strategy” (LOS) means
that the vehicle will still be driveable, albeit at
reduced power and efficiency, in the event of
a failure in the EEC IV module or its sensors.
Precautions
Many of the procedures in this Chapter
require the removal of fuel lines and
connections which may result in some fuel
spillage. Before carrying out any operation on
the fuel system refer to the precautions given
in “Safety first!” at the beginning of this
Manual and follow them implicitly. Petrol is a
highly dangerous and volatile liquid and the
precautions necessary when handling it
cannot be overstressed.
Residual pressure will remain in the fuel
lines long after the vehicle was last used,
therefore extra care must be taken when
disconnecting a fuel line hose. Loosen any
fuel hose slowly to avoid a sudden release of
pressure which may cause fuel spray. As an
added precaution place a rag over each union
as it is disconnected to catch any fuel which is
forcibly expelled.
Certain adjustment points in the fuel system
(and elsewhere) are protected by
“tamperproof” caps, plugs or seals. The
purpose of such tamperproofing is todiscourage, and to detent, adjustment by
unqualified operators.
In some EEC countries (though not yet in
the UK) it is an offence to drive a vehicle with
missing or broken tamperproof seals. Before
disturbing a tamperproof seal, satisfy yourself
that you will not be breaking local or national
anti-pollution regulations by doing so. Fit a
new seal when adjustment is complete when
this is required by law.
Do not break tamperproof seals on a
vehicle which is still under warranty.
Catalytic converter - precautions
The catalytic converter is a reliable and simple
device which needs no maintenance in itself,
but there are some facts of which an owner
should be aware if the converter is to function
properly for the full service life.
a)DO NOT use leaded petrol in a car
equipped with a catalytic converter the
lead will coat the precious metals,
reducing their converting efficiency and
will eventually destroy the converter.
b)Always keep the ignition and fuel systems
well-maintained in accordance with the
manufacturers schedule, ensure that the
air cleaner filter element, the fuel filter
(where fitted) and the spark plugs are
renewed at the correct interval if the inlet
air/fuel mixture is allowed to become too
rich due to neglect, the unburned surplus
will enter and burn in thecatalytic
converter, overheating the element and
eventually destroying the converter.
c)If the engine develops a misfire, do not
drive the car at all (or at least as little as
possible) until the fault is cured - the
misfire will allow unburned fuel to enter
the converter, which will result in
overheating, as noted above.
d)DO NOT push- or tow-start the car - this
will soak the catalytic converter in
unburned fuel, causing it to overheat when
the engine does start - see b) above.
e)DO NOT switch off the ignition at high
engine speeds - if the ignition is switched
off at anything above idle speed,
unburned fuel will enter the (very hot)
catalytic converter, with the possible risk
of igniting on the element and damaging
the converter.
f)DO NOT use fuel or engine oil additives -
these may contain substances harmful to
the catalytic converter.
g)DO NOT continue to use the car if the
engine burns oil to the extent of leaving a
visible trail of blue smoke - the unburned
carbon deposits will clog the converter
passages and reduce the efficiency; in
severe cases the element will overheat.
h)Remember that the catalytic converter
operates at very high temperatures - hence
the heat shields on the car’s underbody
and the casing will become hot enough to
ignite combustible materials which brush
against it - DO NOT, therefore, park the car
in dry undergrowth, over long grass or
piles of dead leaves.
i)Remember that the catalytic converter is
FRAGILE, do not strike it with tools during
servicing work, take great care when
Fuel and exhaust systems - fuel injection 4B•3
4B

working on the exhaust system, ensure
that the converter is well clear of any
jacks or other lifting gear used to raise the
car and do not drive the car over rough
ground, road humps, etc., in such a way
as to “ground” the exhaust system.
j)In some cases, particularly when the car is
new and/or is used for stop/start driving, a
sulphurous smell (like that of rotten eggs)
may be noticed from the exhaust. This is
common to many catalytic converter-
equipped cars and seems to be due to the
small amount of sulphur found in some
petrols reacting with hydrogen in the
exhaust to produce hydrogen sulphide
(H2S) gas; while this gas is toxic, it is not
produced in sufficient amounts to be a
problem. Once the car has covered a few
thousand miles the problem should
disappear - in the meanwhile a change of
driving style or of the brand of petrol used
may effect a solution.
k)The catalytic converter, used on a well-
maintained and well-driven car, should
last for between 50 000 and 100 000
miles - from this point on, careful checks
should be made at all specified service
intervals of the CO level to ensure that the
converter is still operating efficiently - if
the converter is no longer effective it must
be renewed.
EEC IV module - warning
Following disconnection of the battery, the
information stored in the EEC IV module
memory will be erased. After reconnecting the
battery, the engine should be allowed to idle for
three minutes. Once the engine has reached
normal operating temperature, the idle speed
should be increased to 1200 rpm and
maintained for approximately 2 minutes, which
will allow the module to “re-learn” the optimum
idle values. It may be necessary to drive the
vehicle in order for the module to “re-learn” the
values under load. The module should complete
its learning process after approximately 5 miles
(8 kilometres) of varied driving.
Refer to Chapter 1, Section 38.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Depress the locking clip on the airflow
meter wiring plug and disconnect the plug.
Pull on the plug, not the wiring.
3Loosen the securing clip and disconnect
the air inlet hose from the airflow meter.
4Release the four securing clips and lift off
the air cleaner lid with the airflow meter.
5Remove the left-hand front wheel arch liner.
6Working under the wheel arch, unscrew the
three air cleaner securing nuts and washers.
7Disconnect the air inlet tube, and withdrawthe air cleaner from the engine compartment.
8Refitting is a reversal of removal.
2.0 litre DOHC models
9Disconnect the battery negative lead.
10Disconnect the wiring plug from the idle
speed control valve at the front of the plenum
chamber.
11Loosen the clamp, and detach the air inlet
hose from the air inlet tubing.
12Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel.
13Release 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.
14Lift out the air cleaner element then wipe
the inside of the air cleaner lid and casing clean.
15Remove the left-hand front wheel arch liner.
16Working under the wheel arch, unscrew the
three air cleaner securing nuts and washers.
17Disconnect the air inlet tube, and
withdraw the air cleaner from the engine
compartment.
18Refitting is a reversal of removal.
1.6 and 1.8 litre (R6A type) CVH
models
1.6 litre
19Remove the screws from the top of the air
cleaner cover.
20Disconnect the cold air inlet hose from the
air cleaner spout or the inlet on the front body
panel. The hose is secured by toggle clips.
21Disconnect the hot air inlet hose from the
air cleaner spout or the hot air shroud on the
exhaust manifold.
22Where applicable, remove the screw
securing the air cleaner body to the camshaft
cover.
23Withdraw the air cleaner and disconnect
the breather hose from the camshaft cover.
24Refitting is a reversal of removal, ensure
the disturbed hoses are securely connected.
1.8 litre
25Undo the two nuts, lift off the air cleaner
cover, and remove the element.26Disconnect the engine breather hose and
the oil separator hose, then undo the three
nuts and lift up the air cleaner casing (see
illustrations).
27Disconnect the yellow striped vacuum
hose from the underside of the casing, detach
the air inlet hose, and remove the air cleaner
assembly.
28Refitting is a reversal of removal, ensuring
all hoses are correctly attached.
1Disconnect the battery negative lead.
2Remove the air cleaner assembly.
3Position a suitable container (or a sufficient
quantity of absorbent cloth) beneath the fuel
inlet connection on the CFI unit.
4Use an open-ended spanner on the flats of
the inlet union screwed into the CFI unit, to
prevent it from turning while the inlet pipe
union is loosened (see illustration). Allow all
pressure/fuel seepage to dissipate before fully
unscrewing the union if it is to be
disconnected, or tightened if another part of
the system is to be worked on.
4Fuel system (1.6 and 1.8 litre
(R6A type) CVH) - depressurisation
3Air cleaner - removal and
refitting
2Air cleaner element - renewal
4B•4Fuel and exhaust systems - fuel injection
3.26b Air cleaner casing attachments - 1.8
litre (R6A) CVH
A Casing retaining nuts (arrowed)
B Vacuum hose (arrowed)
3.26a Air cleaner cover and hose
attachments - 1.8 litre (R6A) CVH
A Cover retaining nuts
B Engine breather hose
C Oil separator hose
Remember to depressurise the
fuel system before loosening any
connections.
Refer to the precautions in
Section 1 before proceeding. The fuel
system will remain pressurised after the
engine is switched off.
4.4 CFI unit fuel inlet union (arrowed)

5The system will remain depressurised until
the fuel pump is primed prior to starting the
engine. Remove the container or cloth, as
applicable, on completion.
Refer to Chapter 1, Section 41.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Slowly loosen the fuel feed union to relieve
the pressure in the fuel lines.
3Disconnect the fuel feed and return lines.
Be prepared for petrol spillage.
4Disconnect the vacuum pipe from the top
of the pressure regulator.
5Unscrew the securing nut from the base of
the pressure regulator and withdraw the unit
(see illustration).
6Refitting is a reversal of removal, but if the
fuel return line was originally secured with a
crimped type clip, discard this and use a new
worm drive clip.
7On completion check the fuel line
connections for leaks. Pressurise the system by
switching the ignition on and off several times.
2.0 litre DOHC models
Note: A new pressure regulator seal will be
required on refitting.
8Disconnect the battery negative lead.
9Slowly loosen the fuel rail fuel feed union to
relieve the pressure in the system (see
illustration). Be prepared for fuel spillage,
and take adequate fire precautions.
10Disconnect the fuel return hose from the
pressure regulator (see illustration). Again,
be prepared for fuel spillage.
11Disconnect the vacuum pipe from the top
of the pressure regulator.
12Unscrew the two securing bolts, and
withdraw the regulator from the fuel rail.
Recover the seal.13Fit a new seal to the regulator, and
lubricate with clean engine oil.
14Fit both the securing bolts to the
regulator, then position the regulator on the
fuel rail, and tighten the securing bolts.
15Further refitting is a reversal of removal. If
the fuel return line was originally secured with
a crimped-type clip, discard this, and use a
new worm-drive clip.
16On completion, pressurise the system by
switching the ignition on and off several times,
and check the fuel line connections for leaks.
1.6 and 1.8 litre (R6A type) CVH
models
Note:On completion of refitting, the fuel
system pressure should be checked by a Ford
dealer at the earliest opportunity.
1.6 litre
17Remove the CFI unit.
18Remove the four screws securing the
regulator housing to the CFI unit, then
carefully lift off the housing and recover the
ball, cup, large spring, diaphragm, valve, and
small spring, noting the position and
orientation of all components (see
illustration). Do not attempt to prise the plug
from the regulator housing, or adjust the Allen
screw (if no plug is fitted); this will alter the fuel
system pressure.
19Check all components, and renew any
faulty items as necessary.
20Commence reassembly by supporting the
CFI unit on its side, so that the regulator
components can be fitted from above.
6Fuel pressure regulator -
removal and refitting
5Fuel filter - renewal
Fuel and exhaust systems - fuel injection 4B•5
4B
6.9 Fuel rail fuel feed union (arrowed)
6.10 Disconnecting the fuel return hose
(arrowed) from the pressure regulator
6.5 Withdrawing the fuel pressure
regulator
6.18 Exploded view of Central Fuel Injection (CFI) unit
1.6 litre CVH engine application shown - 1.8 litre similar
1 Fuel injector assembly
2 Fuel pressure regulator
components
3 Fuel inlet connector
4 Air charge temperature
(ACT) sensor
5 Throttle valve control
motor
6 Throttle position sensor
7 Fuel injector wiring
Caution: Refer to the
precautions in Section 1 before
proceeding.

21Fit the small spring, valve, diaphragm
(ensuring that it locates correctly), large
spring, and the spring cup.
22Carefully place the ball into position on
the spring cup, and ensure that it locates
correctly.
23Refit the regulator housing, taking great
care to avoid disturbing the ball, and once
correctly in position, tighten the screws evenly
to avoid distorting the diaphragm.
24Refit the CFI unit.
25On completion, the fuel system pressure
should be checked by a Ford dealer at the
earliest opportunity.
1.8 litre
26Disconnect the battery negative lead.
27Remove the air cleaner assembly.
28Depressurise the fuel system and
disconnect the fuel inlet pipe from the CFI unit
(see illustration).
29Disconnect the fuel injector/regulator
wiring plug, and move the wiring harness
clear.
30Undo the four screws, and carefully lift the
injector/regulator assembly off the CFI unit.31Refitting is a reversal of removal. On
completion, the fuel system pressure should
be checked by a Ford dealer at the earliest
opportunity.
1If the fuel pump is functioning, it should be
possible to hear it “buzzing” by listening
under the rear of the vehicle when the ignition
is switched on. Unless the engine is started,
the fuel pump should switch off after
approximately one second. If the noise
produced is excessive, this may be due to a
faulty fuel flow damper (not fitted to 2.0 litre
DOHC models). The damper can be renewed
by unscrewing it from the pump outlet union.
2If the pump appears to have failed
completely, check the appropriate fuse and
relay, and where applicable check the state of
the fuel pump inertia cut-off switch as follows.
3The inertia cut-off switch is fitted to all
models from mid-1986 onwards, and can be
found behind the passenger compartment
left-hand side trim panel on Hatchback and
Estate models up to the 1987 model year (see
illustration). The location of the switch for all
other models is in the spare wheel well (see
illustration). The switch incorporates a reset
button, which should normally be in the
depressed position. Check the position of the
reset button before assuming that a fault
exists in the fuel pump.
4To test the fuel pump, special equipment is
required, and it is recommended that any
suspected faults are referred to a Ford dealer.
Removal
1The fuel pump is located under the rear of
the vehicle next to the fuel tank (see
illustration).
2Disconnect the battery negative lead.
3Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands
(see “Jacking and Vehicle Support”).
4Clean the area around the pump mounting,
and position a suitable container under the
pump.
5Using a hose clamping tool or self-locking
pliers, clamp the fuel tank-to-pump hose to
prevent excessive petrol spillage, or
8Fuel pump (2.0 litre SOHC) -
removal and refitting
7Fuel pump - testing
4B•6Fuel and exhaust systems - fuel injection
7.3a Fuel pump inertia cut-off switch - pre-
1987 SOHC Hatchback and Estate models
A Activated mode (fuel cut-off)
B Normal mode (fuel flowing)
C Trim panel access hole
8.1 Fuel pump location
A Inlet hose
B Outlet hoseC Electrical feed
D Flow damper7.3b Fuel pump inertia cut-off switch
location (arrowed) under spare wheel
6.28 Fuel injector/pressure regulator attachments - 1.8 litre (R6A) CVH
A Pressure regulator assembly
B Fuel inlet pipeC Injector/regulator wiring plug
D Injector/regulator screws
Caution: Refer to the
precautions in Section 1 before
proceeding.

alternatively make arrangements to collect the
contents of the fuel tank which will otherwise
be released. Disconnect the hose from the
pump.
6Slowly loosen the fuel flow damper fitted to
the pump outlet union, to relieve the pressure
in the fuel line, then remove the damper and
disconnect the outlet pipe from the pump.
Plug the end of the pipe to prevent excessive
petrol spillage.
7Disconnect the wiring plug(s), then slacken
the clamp bolt and slide the pump from the
bracket assembly.
Refitting
8Refitting is a reversal of removal, noting the
following.
9When refitting the flow damper to the pump
ensure that the pump outlet pipe is correctly
routed (see illustration). It is possible to
inadvertently rotate the banjo union through
180º, which routes the outlet pipe too close to
the exhaust.
10After refitting and securing the pump, but
before lowering the vehicle, reconnect the
battery and switch the ignition on and off
several times to pressurise the fuel system.
Check for leaks around the pump; if all is
satisfactory, switch off the ignition and lower
the vehicle.1Remove the fuel tank.
2Unscrew the fuel pump/fuel level sender
unit by engaging two crossed screwdrivers in
the slots on either side of the unit mounting
flange. Recover the seal.
3Refitting is a reversal of removal but fit a
new seal.
Refer to Chapter 4 Part A, Section 9.
Refer to Chapter 4 Part A, Section 10.
Refer to Chapter 1, Sections 15 and 16.
Note: A new gasket must be used when
refitting the valve.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Disconnect the idle speed control valve
wiring plug by releasing the retaining clip and
pulling on the plug, not the wiring (see
illustration).
3Unscrew the two retaining nuts and
withdraw the valve from the inlet manifold
(see illustration). Recover the gasket.4Clean the valve and manifold mating faces
before refitting, taking care not to allow dirt to
enter the manifold.
5Refitting is a reversal of removal, using a
new gasket.
6On completion, start the engine and check
that the idle speed is stable if not, check for
air leaks around the valve. Switch on all
available electrical loads and check that the
idle speed is maintained - if not, suspect a
faulty valve.
2.0 litre DOHC models
7Disconnect the battery negative lead.
8Loosen the securing clip, and disconnect
the air inlet hose from the throttle body.
9Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel.
10Disconnect the wiring plug from the idle
speed control valve.
11Release the air cleaner lid securing clips
then remove the air inlet tube, plenum
chamber, and air cleaner lid as an assembly,
disconnecting the breather hose from the air
inlet tube.
12Unscrew the two securing bolts, and
withdraw the valve from the air inlet tube.
Recover the gasket (see illustration).
13Clean the valve and air inlet tube mating
faces before refitting, taking care not to allow
dirt to enter the air inlet tube.
14Refitting is a reversal of removal, using a
new gasket.
15On completion, start the engine and
check that the idle speed is stable if not,
check for air leaks around the valve. Switch
on all available electrical loads, and check
that the idle speed is maintained - if not,
suspect a faulty valve.
1The potentiometer is located at the rear
right-hand side of the engine compartment,
behind the MAP sensor.
2Disconnect the battery negative lead.
3Remove the screw, then withdraw the
potentiometer and disconnect the wiring plug.
4Refitting is a reversal of removal.
14Mixture adjustment
potentiometer (2.0 litre
DOHC) - removal and refitting
13Idle speed control valve -
removal and refitting
12Idle speed and mixture -
adjustment
11Fuel level sender unit (2.0 litre
SOHC) - removal and refitting
10Fuel tank - removal and refitting
9Fuel pump/fuel level sender
unit (2.0 litre DOHC/1.6 & 1.8
litre (R6A type) CVH) - removal
and refitting
Fuel and exhaust systems - fuel injection 4B•7
4B
13.2 Disconnecting the idle speed control
valve wiring plug13.12 Withdrawing the idle speed control
valve and gasket13.3 Unscrewing an idle speed control
valve retaining nut
8.9 Correct and incorrect routing of fuel
pump outlet pipe
A Fuel pump
B Outlet pipe
C Exhaust pipeX = 30.0 mm (1.2 in)
Y = 100.0 mm (3.9 in)
Caution: Refer to the
precautions in Section 1 before
proceeding.

Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion.
1Disconnect the battery negative lead.
2Depress the locking clip on the airflow
meter wiring plug and disconnect the plug.
Pull on the plug, not the wiring.
3Loosen the securing clip and disconnect
the air inlet hose from the airflow meter.
4Release the four securing clips and lift off
the air cleaner lid with the airflow meter.
5Remove the four securing bolts and
separate the airflow meter from the air cleaner
lid (see illustration). Recover the seal.
6Refitting is a reversal of removal, ensuring
that the seal is correctly located on the air
cleaner lid, and that the air inlet hose clip is
correctly aligned (see illustration).7On completion, check and if necessary
adjust the idle mixture.
1.6 litre
Note: New fuel injector seals must be used on
refitting.
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Depressurise the fuel system.
4Release the securing lugs, and disconnect
the fuel injector wiring plug (see illustration).
5Bend back the injector retaining collar
securing bolt locktabs, then unscrew the
bolts. Remove the injector retaining collar
(see illustrations).
6Withdraw the injector from the CFI unit (see
illustration), noting its orientation, then
withdraw the injector seals.
7Remove the seal from the injector retaining
collar (see illustration).
8Refitting is a reversal of removal, noting the
following points.
9Use new injector seals, and lubricate them
with clean engine oil before fitting.
10Ensure that the locating peg on the
injector is correctly positioned (see
illustration).
1.8 litre
11On these engines, the fuel pressure
regulator and injector are one assembly.
Proceed as described for the fuel pressure
regulator.
1The ballast resistor is located on the right-
hand side of the engine compartment, and is
only fitted to 1.6 litre engines (see
illustration).
2Disconnect the battery negative lead.
3Disconnect the ballast resistor wiring
connector, then remove the securing screw,
and withdraw the ballast resistor from the
body panel.
4Refitting is a reversal of removal.
17Fuel injector ballast resistor
(1.6 litre CVH) - removal and
refitting
16Fuel injector (1.6 and 1.8 litre
(R6A type) CVH) - removal and
refitting
15Airflow meter - removal and
refitting
4B•8Fuel and exhaust systems - fuel injection
15.5 Airflow meter-to-air cleaner lid bolts
(arrowed)
16.4 Disconnecting the fuel injector wiring
plug
16.10 Align locating peg on injector with
slot in CFI unit on refitting - 1.6 litre CVH16.7 Removing the seal from the injector
retaining collar16.6 Withdrawing the fuel injector
16.5b Removing the injector retaining
collar16.5a Removing an injector retaining collar
securing bolt and locktab
15.6 Air intake hose clip correctly aligned
Caution: Refer to the
precautions in Section 1 before
proceeding.

Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. New seals and
retaining clips must be used when refitting the
injectors, and special grease will be required -
see relevant paragraph. If the injectors are
thought to be faulty, it may be worth trying the
effect of a fuel injector cleaning agent before
removing them.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Disconnect the crankcase ventilation hose
from the air inlet hose, then disconnect the air
inlet hose from the inlet manifold and the
airflow meter.
3Disconnect the HT lead from the coil, then
remove the distributor cap and position the
cap and HT leads clear of the fuel rail
assembly.
4Disconnect the wiring plugs from the idle
speed control valve, the throttle position sensor
and the engine coolant temperature sensor.
5Remove the fuel pressure regulator.
6Unscrew the securing bolt and remove the
throttle return spring bracket. Disconnect the
throttle return spring.7Disconnect the fuel supply hose from the
fuel rail. Be prepared for petrol spillage.
8Disconnect the wiring plugs from the fuel
injectors, noting their locations for use when
refitting.
9Remove the three securing bolts and
withdraw the fuel rail and fuel injectors from
the inlet manifold as an assembly (see
illustrations).
10To remove a fuel injector from the fuel rail,
remove the retaining clip and withdraw the
injector (see illustration).
11Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed.
12Commence refitting by fitting new seals to
both ends of each fuel injector. Even if only
one injector has been removed, new seals
must be fitted to all four injectors (see
illustration). Coat the seals with silicone
grease to Ford specification ESEM - ICI71 A.
Similarly, renew all four fuel injector retaining
clips.
13Further refitting is a reversal of removal,
ensuring that all hoses, wiring plugs and leads
are correctly connected. When reconnecting
the air inlet hose, make sure that the hose
clips are correctly aligned - see illustration,
Section 15.
14On completion, check and if necessary
adjust the idle mixture.
2.0 litre DOHC models
15Disconnect the battery negative lead.
16If desired, to improve access, disconnectthe wiring from the inlet air temperature
sensor in the inlet manifold. Similarly, the
throttle cable can be moved to one side by
disconnecting the cable from the throttle
linkage. The spark plug HT leads can be
disconnected and moved to one side, noting
their locations and routing to aid refitting.
17Slowly loosen the fuel rail fuel feed union
to relieve the pressure in the system. Be
prepared for fuel spillage, and take adequate
fire precautions.
18Disconnect the fuel feed hose from the
fuel rail (see illustration).
19Disconnect the fuel return hose from the
fuel pressure regulator. Again, be prepared for
fuel spillage.
20Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
21Disconnect the wiring plugs from the fuel
temperature sensor and the fuel injectors,
noting their locations to assist with refitting.
22Unscrew the two securing bolts, and
withdraw the fuel rail.
23Lift the fuel injectors from their locations
in the cylinder head (see illustration).
24Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed (refer to the note
at the start of this procedure before
condemning an injector).
25Commence refitting by fitting new seals to
both ends of each fuel injector. It is advisable
to fit new seals to all the injectors, even if only
one has been removed. Lubricate the seals
with clean engine oil.
18Fuel injectors - removal and
refitting
Fuel and exhaust systems - fuel injection 4B•9
4B
18.9b . . . and rear securing bolts
18.18 Disconnecting the fuel feed hose
from the fuel rail18.12 Fuel injector with seals removed18.10 Fuel injector retaining clip (A)
18.9a Fuel rail front securing bolt
(arrowed) . . .17.1 Fuel injector ballast resistor location
(arrowed)
Caution: Refer to the
precautions in Section 1 before
proceeding.

26Further refitting is a reversal of removal,
ensuring that all hoses, pipes and wiring plugs
are correctly connected.
27On completion, where applicable, check
and if necessary adjust the idle mixture.
Removal
1Disconnect the battery negative lead.
2Remove the air cleaner assembly.
3Depressurise the fuel system and
disconnect the fuel inlet pipe from the CFI unit.
4Disconnect the fuel return pipe from the CFI
unit. Be prepared for fuel spillage.
5Disconnect the throttle cable from the
linkage on the CFI unit.
6On 1.6 litre models, either partially drain the
cooling system or clamp the coolant hoses as
close as possible to the CFI unit to minimise
coolant loss, then disconnect the hoses from
the unit.
7Disconnect the wiring plugs for the throttle
position sensor, throttle valve control motor,
fuel injector and, on 1.6 litre models, the air
charge temperature sensor.
8Disconnect the vacuum pipe from the CFI
unit.9Unscrew the four (1.6 litre), or three (1.8
litre) securing bolts, and lift the CFI unit from
the inlet manifold (see illustration). Recover
the gasket.
Refitting
10Refitting is a reversal of removal, bearing
in mind the following points.
11Ensure that all mating faces are clean, and
use a new gasket.
12Top-up the cooling system.
13On completion, turn the ignition on and off
five times to pressurise the system, and check
for fuel leaks.
Refer to Chapter 1, Section 37.
1The valve is mounted at the end of the
pulse-air filter housing (see illustration).
2Disconnect the vacuum hose from the top
of the valve, then loosen the hose clips at
either end of the valve, and remove the valve.
Note the orientation of the arrow on the valve
body, which denotes the direction of flow.
3Refitting is a reversal of removal, ensuring
that the arrow on the valve body is orientated
as noted before removal.1Remove the air cleaner assembly.
2Loosen the hose clips, and disconnect the
air hoses from the check valves next to the
exhaust manifold (see illustration).
3Remove the two bolts securing the check
valve bracket to the exhaust manifold.
4Unscrew the unions securing the air tubes
to the manifold, then carefully withdraw the
tubing assembly, taking care not to distort the
tubes (see illustration).
5Refitting is a reversal of removal.
1The solenoid is located at the right-hand
side of the engine compartment.
2Disconnect the battery negative lead.
3Disconnect the vacuum pipe connector from
the pulse-air control solenoid (see illustration).
4Disconnect the solenoid wiring plug, pulling
on the plug, not the wiring.
5Unscrew the securing screw, and withdraw
the solenoid from the body panel.
6Refitting is a reversal of removal, ensuring
that the locating lug is correctly positioned,
and noting that the vacuum pipes will only fit
in one position.
23Pulse-air control solenoid
(1.6 litre CVH) - removal and
refitting
22Pulse-air delivery tubing
(1.6 litre CVH) - removal and
refitting
21Pulse-air system vacuum-
operated air valve (1.6 litre
CVH) - removal and refitting
20Pulse-air filter element (1.6 litre
CVH) - renewal
19CFI unit (1.6 and 1.8 litre (R6A
type) CVH) - removal and
refitting
4B•10Fuel and exhaust systems - fuel injection
18.23 Lifting a fuel injector from the
cylinder head21.1 Pulse air system vacuum-operated air
valve (arrowed)
23.3 Disconnect the vacuum pipe
connector from the solenoid22.4 Unscrewing a pulse-air delivery tube
union22.2 Pulse-air delivery check valves
(arrowed)
19.9 CFI unit securing bolts (arrowed) -
1.6 litre CVH
Caution: Refer to the
precautions in Section 1 before
proceeding. A new gasket must
be used on refitting.