headlamp FORD SIERRA 1983 1.G Routine Manintenance And Servicing Workshop Manual

4Carefully check the condition of all coolant,
fuel, power steering and brake hoses. Renew
any hose which is cracked, swollen or
deteriorated. Cracks will show up better if the
hose is squeezed. Pay close attention to the
hose clips that secure the hoses to the system
components. Hose clips can pinch and
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.
5With the vehicle raised, inspect the fuel
tank and filler neck for punctures, cracks and
other damage. The connection between the
filler neck and tank is especially critical.
Sometimes a rubber filler neck or connecting
hose will leak due to loose retaining clamps or
deteriorated rubber.
6Similarly, inspect all brake hoses and metal
pipes. If any damage or deterioration is
discovered, do not drive the vehicle until the
necessary repair work has been carried out.
Renew any damaged sections of hose or pipe.
7Carefully check all rubber hoses and metal
fuel lines leading away from the petrol tank.
Check for loose connections, deteriorated
hoses, crimped lines and other damage. Pay
particular attention to the vent pipes and
hoses which often loop up around the filler
neck and can become blocked or crimped.
Follow the lines to the front of the vehicle
carefully inspecting them all the way. Renew
damaged sections as necessary.
8From within the engine compartment,
check the security of all fuel hose attachments
and pipe unions, and inspect the fuel hoses
and vacuum hoses for kinks, chafing and
deterioration.
9Where applicable, check the condition of
the oil cooler hoses and pipes.
10Check the condition of all exposed wiring
harnesses.
1Periodically check the belts for fraying or
other damage. If evident, renew the belt.
2If the belts become dirty, wipe them with a
damp cloth using a little detergent only.
3Check 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.
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
corrosion are evident, renew the system
complete or in sections, as applicable, using
the information given in Chapter 4.With the wheels on the ground, slacken each
wheel nut by a quarter turn, then retighten it
immediately to the specified torque.
Remove and clean the oil filler cap of any
sludge build-up using paraffin.
Inspect the vent hose for blockage or
damage. A blocked hose can cause a build-
up of crankcase pressure, which in turn can
cause oil leaks.
Ford VV carburettor
1Ensure that the air cleaner is correctly fitted,
and that all vacuum hoses and pipes are
securely connected and free from restrictions,
then run the engine until it is at normal
operating temperature.
2Stop the engine, and connect a tachometer
and an exhaust gas analyser in accordance
with the manufacturer’s instructions.
3Start the engine and run it at 3000 rpm for
30 seconds, ensuring that all electrical loads
are switched off (headlamps, heater blower
etc), then allow the engine to idle and check
the idle speed and CO content. Note that the
CO reading will initially rise, then fall and finally
stabilise after between 5 and 25 seconds.4If necessary, adjust the idle speed screw to
give the specified idle speed (see
illustration).
5Checking and adjustment should be
completed within 30 seconds of the meter
readings stabilising. If this has not been
possible, repeat paragraphs 3 and 4, ignoring
the reference to starting the engine.
Weber 2V carburettor
Models without stepper motor
6Proceed as described for the Ford VV
carburettor but note the following:
7It is permissible to loosen the air cleaner
securing screws to allow easier access to the
carburettor adjustment screws but ensure
that all vacuum hoses and pipes are securely
connected. For adjustment screw location
(see illustrations).
Models with stepper motor (ESC II
system)
8The idle speed is controlled by the ESC II
module via the stepper motor. The only idle
speed adjustment possible is provided by the
“idle speed adjustment” wire, which can be
earthed to raise the idle speed by 75 rpm. No
other method of idle speed adjustment should
be attempted. If the idle speed is incorrect,
the problem should be referred to a Ford
dealer, as the problem probably lies in the
ESC II module for which special diagnostic
equipment is required.
15Engine idle speed check
14Oil filler cap check
13Roadwheel security check
12Exhaust system check
11Seat belt check
Every 6000 miles or 6 months 1•11
1
15.7b Weber 2V carburettor adjustment
screw locations - 1.6 litre models
A Idle mixture screwB Idle speed screw
15.7a Weber 2V carburettor adjustment
screw locations - 2.0 litre models up to 1985
A Idle speed screwB Idle mixture screw
15.4 Ford VV carburettor adjustment screw
locations
A Idle speed screwB Idle mixture screw
Caution: Refer to the
precautions in Section 1,
Chapter 4, Part A or B (as
applicable), before proceeding.
Before carrying out any carburettor
adjustments, ensure that the ignition
timing and spark plug gaps are set as
specified. To carry out the adjustments an
accurate tachometer and an exhaust gas
analyser (CO meter) will be required.

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

25Start the engine and run it at 3000 rpm for
15 seconds, ensuring that all electrical loads
(headlamps, heater blower etc) are switched
off, then allow the engine to idle and check
the CO content. Note that the CO reading will
initially rise, then fall and finally stabilise.
26If adjustment is necessary, remove the
tamperproof cap from the base of the airflow
meter, and turn the mixture screw using a
suitable Allen key to give the specified CO
content (see illustration).
27Checking and adjustment should be
completed within 30 seconds of the meter
readings stabilising. If this has not been
possible, run the engine at 3000 rpm, for 15
seconds, then allow the engine to idle. Re-
check the CO content and carry out further
adjustment if necessary.
28On completion of adjustment, stop the
engine and disconnect the tachometer and
exhaust gas analyser. Fit a new tamperproof
cap to the mixture screw.2.0 litre DOHC models
29On models with a catalytic converter, the
mixture is controlled by the EEC IV module.
No manual adjustment is possible.
30On models without a catalytic converter,
the idle mixture can be adjusted as follows:
31Run the engine until it is at normal
operating temperature.
32Stop the engine, and connect a
tachometer and an exhaust gas analyser in
accordance with the equipment
manufacturer’s instructions.
33Start the engine and run it at 3000 rpm for
15 seconds, ensuring that all electrical loads
(headlamps, heater blower, etc) are switched
off. Allow the engine to idle, and check the CO
content. Note that the reading will initially rise,
then fall and finally stabilise.
34If adjustment is necessary, remove the
cover from the mixture adjustment
potentiometer (located at the rear right-handside of the engine compartment, behind the
MAP sensor), and turn the screw to give the
specified CO content (see illustrations).
35If adjustment does not produce a change
in reading, the potentiometer may be at the
extreme of its adjustment range. To centralise
the potentiometer, turn the adjustment screw
20 turns clockwise followed by 10 turns anti-
clockwise, then repeat the adjustment proce-
dure.
36Checking and adjustment should be
completed within 30 seconds of the meter
readings stabilising. If this has not been
possible, run the engine at 3000 rpm for 15
seconds, then allow the engine to idle. Re-
check the CO content, and carry out further
adjustments if necessary.
37On completion of adjustment, stop the
engine, and disconnect the tachometer and
the exhaust gas analyser. Refit the cover to
the adjustment screw.
1Fluid level should be checked with the
transmission at operating temperature (after a
run) and with the vehicle parked on level
ground.
2Open and prop the bonnet. With the engine
idling and the handbrake and footbrake applied,
move the gear selector through all positions
three times, finishing up in position “P”,
3Wait 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.
4If topping-up is necessary, do so via the
dipstick tube, using clean transmission fluid of
the specified type (see illustration).Do not
overfill.
5Stop the engine, refit the dipstick and close
the bonnet.6Note that if the fluid level was below the
minimum mark when checked or is in
constant need of topping-up, check around
the transmission for any signs of excessive
fluid leaks.If present, leaks must be rectified
without delay.
7If the colour of the fluid is dark brown or
black this denotes the sign of a worn brake
band or transmission clutches, in which case
have your Ford dealer check the transmission
at the earliest opportunity.1Place the vehicle over a pit, or raise and
support it at front and rear. The vehicle must
be level for an accurate check.
2If the gearbox is hot after a run, allow it to
cool for a few minutes. This is necessary
because the oil can foam when hot and give a
false level reading.
18Manual gearbox oil level
check17Automatic transmission fluid
level check
Every 12 000 miles or 12 months 1•13
1
16.34b . . . to enable mixture adjustment -
DOHC models
17.4 Topping-up the transmission fluid17.3 Automatic transmission dipstick
location and markings
16.34a Remove the cover from the mixture
adjustment potentiometer . . .16.26 Adjusting the idle mixture -
SOHC models
Every 12 000 miles (20 000 km) or 12 months