air filter FORD SIERRA 1985 1.G Fuel And Exhaust Systems Carburettor Workshop Manual

General
Fuel tank capacity:
All models except P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 litres (13.2 gals)
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.0 litres (14.5 gals)
Fuel octane rating:
Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 RON (4-star)
Unleaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON (Premium)
Air filter element
1.3 litre and 1.6 litre (Ford carburettor) . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W110
1.6 litre (Weber carburettor) and 1.8 litre (SOHC engine) . . . . . . . . . . . . Champion W118
1.6 litre (1984-on) and 2.0 litre (SOHC engine) . . . . . . . . . . . . . . . . . . . . Champion W152
1.8 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W219
2.0 litre DOHC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W152
Carburettor type:
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ford VV
1.6 litre models (engine codes LCS and LCT) . . . . . . . . . . . . . . . . . . . . Ford VV
1.6 litre models (engine codes LSD and LSE) . . . . . . . . . . . . . . . . . . . . Weber 2V (28/30 DFTH)
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg 2V (2E3)
2.0 litre SOHC models up to 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber 2V (32/36 DGAV)
2.0 litre SOHC models from 1985 (except P100) . . . . . . . . . . . . . . . . . . Weber 2V (30/34 DFTH)
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ford VV
2.0 litre DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber 2V(TLD)
Ford VV carburettor
Idle speed:
1.3 and 1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 50 rpm
Idle mixture (CO content):
1.3 and 1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 ± 0.5%
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.5%
Chapter 4 Part A:
Fuel and exhaust systems - carburettor
Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Air cleaner inlet air temperature control - testing . . . . . . . . . . . . . . . . .4
Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Carburettors (all types) - dismantling and reassembly . . . . . . . . . . . .13
Carburettor (Ford VV type) - idle speed and mixture adjustment . . . .15
Carburettor (Ford VV type) - removal and refitting . . . . . . . . . . . . . . .14
Carburettor (Pierburg 2V type) - fast idle speed adjustment . . . . . . .21
Carburettor (Pierburg 2V type) - idle speed and mixture adjustment .20
Carburettor (Pierburg 2V type) - removal and refitting . . . . . . . . . . . .19
Carburettor (Weber 2V type) - fast idle speed adjustment . . . . . . . . .18
Carburettor (Weber 2V type) - idle speed and mixture adjustment . .17
Carburettor (Weber 2V type) - removal and refitting . . . . . . . . . . . . .16
Carburettor (Weber 2V TLD type) - fast idle speed adjustment . . . . .24
Carburettor (Weber 2V TLD type) - idle speed and mixture
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Carburettor (Weber 2V TLD type) - removal and refitting . . . . . . . . . .22
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . .26
Exhaust system - inspection, removal and refitting . . . . . . . . . . . . . .27
Fuel level sender unit - removal and refitting . . . . . . . . . . . . . . . . . . .10
Fuel pressure regulator (models up to 1985) - removal and refitting . .5
Fuel pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fuel pump - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fuel vapour separator (models from 1985) - removal and refitting . . .6
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .25
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . .12
Throttle pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .11
Vacuum valves, ported vacuum switches and fuel traps - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4A•1
Specifications Contents
4A
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

air charge temperature sensor mounted in the
base of the air cleaner body, and disconnect
the breather hose from the camshaft cover.
Refitting
9Refitting is a reversal of removal, ensuring
that the disturbed hoses are securely
connected.
Refer to Chapter 1, Section 36.
Removal
1The fuel pressure regulator is located on the
left-hand side of the engine compartment
(see illustration).2Disconnect the battery negative lead.
3Identify the fuel hose locations, as an aid to
refitting. Note that there are three hose
connections on models without a fuel flow
sensor unit, and two hose connections on
models with a fuel flow sensor unit.
4Disconnect and plug the fuel hoses.
5Remove the two securing screws and
withdraw the regulator.Refitting
6Refitting is a reversal of removal, ensuring
that the fuel hoses are correctly connected. If
the hoses were originally secured with
crimped type clips, discard them and use new
worm drive clips.
Removal
1On SOHC models, the vapour separator is
located on the left-hand side of the engine
compartment. On CVH models, the vapour
separator is located on the right-hand side of
the engine compartment (see illustrations).
2Disconnect the battery negative lead.3Identify the fuel hose locations as an aid to
refitting, then disconnect and plug the hoses.
4Remove the two securing screws and
withdraw the vapour separator.
Refitting
5Refitting is a reversal of removal, ensuring
that the fuel hoses are correctly connected. If
the hoses were originally secured with
crimped type clips, discard them and use new
worm drive clips.
Mechanical pump
1On SOHC engines, the fuel pump is located
on the left-hand side of the cylinder block,
next to the oil filter. On CVH engines the fuel
pump is located on the rear right-hand corner
of the cylinder head.
2To test the pump, disconnect the ignition
coil LT “-/1” lead to prevent the engine from
firing.
3Disconnect the outlet hose from the pump,
and place a wad of rag next to the pump
outlet (see illustration). Take appropriate fire
precautions.
4Have an assistant crank the engine on the
starter motor, and check that well-defined
spurts of petrol are ejected from the fuel
pump outlet. If not, the pump is faulty.
Dispose of the petrol-soaked rag safely.
7Fuel pump - testing
6Fuel vapour separator (models
from 1985) - removal and
refitting
5Fuel pressure regulator
(models up to 1985) - removal
and refitting
4Air cleaner inlet air temperature
control - testing
Fuel and exhaust systems - carburettor 4A•5
4A
6.1a Fuel vapour separator location -
2.0 litre SOHC models from 1985
A Fuel return hose
B Fuel supply hose
C Carburettor fuel feed hose
5.1 Fuel pressure regulator location -
models up to 19853.5 Disconnecting the air cleaner vacuum
hose from the inlet manifold
7.3 Disconnecting outlet hose from fuel
pump - SOHC model
6.1c Fuel vapour separator location -
CVH models
A Fuel supply hose
B Carburettor fuel feed hose
C Fuel return hose
6.1b Fuel pressure regulator/vapour
separator location -
SOHC models from 1985
A Fuel supply hose
B Carburettor fuel feed hose
C Fuel return hose
Caution: Refer to the
precautions in Section 1 before
proceeding.
Caution: Refer to the
precautions in Section 1 before
proceeding.
Caution: Refer to the
precautions in Section 1 before
proceeding.

5On some early pumps, the top cover can be
removed for access to the filter. Removing the
pump and cleaning the filter may cure the
problem. On models with a sealed pump, or
where cleaning the interior of the pump and
filter does not solve the problem, the pump
should be renewed, as no spares are
available. Check that there is petrol in the fuel
tank before condemning the pump!
6On completion of the test, reconnect the
outlet hose to the pump. If the hose was
originally secured with a crimped type clip,
discard this and use a new worm drive clip.
Reconnect the coil LT lead.
Electric pump
SOHC and CVH models with air
conditioning
7The fuel pump is located under the rear of
the vehicle, next to the fuel tank (see
illustration).
8If the 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.
9If the pump appears to have failed
completely, check the fuse and relay.
10To test the pump, disconnect the fuel
supply hose from the pressure regulator or
vapour separator (as applicable) in the engine
compartment. Lead the hose into a measuring
cylinder.
11Take appropriate fire precautions, then
switch on the ignition for 30 seconds (do notstart the engine), and measure the quantity of
petrol delivered: it should be at least 400 ml
(0.7 pint). If not, the pump is faulty and should
be renewed, as no spares are available.
12On completion of the test, reconnect the
hose to the pressure regulator or vapour
separator, as applicable, and if the hose was
originally secured with a crimped type clip,
discard this and fit a new worm drive clip.
2.0 litre DOHC models
13If 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.
14If 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.
15The inertia cut-off switch is located in the
spare wheel well. 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.
16To test the fuel pump, special equipment
is required, and it is recommended that any
suspected faults are referred to a Ford dealer.
Mechanical pump
Note: A new gasket must be used when
refitting the pump.
1Disconnect the battery negative lead.
2For improved access on CVH models,
remove the air cleaner.
3Identify the hose locations as an aid to
refitting, then disconnect the hoses from the
pump and plug them.
4Remove the two securing bolts and
withdraw the pump from the cylinder block or
cylinder head, as applicable (see illustration).
5Recover the gasket, and if desired remove
the operating pushrod (see illustration).6Clean the exterior of the pump with paraffin
and wipe dry. Clean all traces of gasket from
the pump flange and the cylinder block or
cylinder head, as applicable.
7On early pumps with a removable top
cover, remove the securing screw and
withdraw the cover and the nylon mesh filter
with seal (see illustration). Clean the filter,
the cover and the pump with petrol. Locate
the filter in the cover and fit the cover to the
pump, so that the indentations on the cover
and pump are aligned. Tighten the cover
securing screw.
8Refitting is a reversal of removal, but fit a
new gasket, and tighten the securing bolts to
the specified torque. Ensure that the hoses
are correctly connected, and if the hoses were
originally secured with crimped type clips,
discard these and use new worm drive clips.
Electric pump
SOHC and CVH models with air
conditioning
9Disconnect the battery negative lead.
10Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands.
(see “Jacking and Vehicle Support”).
11Clean the area around the pump
mounting, and position a suitable container
under the pump.
12Using a hose clamping tool or self-locking
pliers, clamp the fuel tank-to pump hose to
prevent excessive petrol spillage, or
alternatively make arrangements to collect the
contents of the fuel tank which will otherwise
be released. Disconnect the hose from the
pump.
13Disconnect the fuel outlet hose from the
pump and plug the hose to prevent petrol
spillage.
14Disconnect the wiring plug from the
pump.
15Slacken the clamping bolt, and slide the
pump from the bracket assembly.
16Refitting is a reversal of removal, but
make sure that the rubber sleeve is correctly
located around the pump body in the bracket,
and ensure that the fuel hoses are securely
8Fuel pump - removal and
refitting
4A•6Fuel and exhaust systems - carburettor
7.7 Electric fuel pump - SOHC and CVH
models with air conditioning
A Clamping bracket
B Fuel inletC Fuel outlet
D Wiring plug
8.5 Withdrawing the fuel pump operating
pushrod - CVH model8.4 Withdrawing the fuel pump from the
cylinder head - CVH model8.7 Removing the top cover from an early
type fuel pump for access to the mesh
filter
Caution: Refer to the
precautions in Section 1 before
proceeding.
Caution:Petrol under pressure
may spray out of the outlet as
the hose is disconnected.

connected. If the hoses were originally
secured with crimped type clips, discard
these and use new worm drive clips.
2.0 litre DOHC models
17On these models the fuel pump is
mounted in the fuel tank, on the same
mounting as the fuel level sender unit(see
illustration).
18To remove the pump, first remove the fuel
tank.
19Unscrew 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.
20Refitting is a reversal of removal. It is
necessary to fit a new seal.
1Run the fuel level as low as possible before
removing the tank.
2Disconnect the battery negative lead.
3Remove the tank filler cap, then syphon or
pump out the tank contents (there is no drain
plug). It may be necessary to disconnect the
fuel tank-to-fuel pump hose in order to fully
drain the tank. Store the petrol in a suitable
sealed container.
Saloon, Hatchback and Estate
models
4Working in the fuel filler recess, remove the
two screws on models up to 1987, or the
single screw on models from 1987, securing
the upper end of the fuel filler pipe to the body
panel.
5Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands
(see “Jacking and Vehicle Support”).
6Unscrew the two securing bolts from the
left-hand tank flange, and on models from
1987, the single bolt from the right-hand tank
flange.7Support the tank, then remove the bolt from
the securing strap. Unhook the remaining end
of the strap from the underbody.
8Lower the tank sufficiently to disconnect
the two wiring plugs from the fuel level sender
(pump) unit (see illustration).
9Identify the fuel hose locations for use when
refitting, then disconnect the hoses from the
sender unit and plug them.
10Withdraw the fuel tank from under the
vehicle.
11The fuel filler and ventilation pipes can be
removed from the tank by loosening the
securing clips.
12If the tank is contaminated with sediment
or water, swill it out with clean petrol. If the
tank has a leak, or is damaged, it should be
repaired by a specialist, or alternatively
renewed. Do not under any circumstances
attempt to solder or weld a fuel tank.
13Refitting is a reversal of removal, but
ensure that the ventilation pipe is correctly
positioned in its groove in the tank, and is not
trapped between the tank and the vehicle
underbody. Ensure that the fuel hoses and the
fuel filler and ventilation pipes are correctly
connected, and if the hoses or pipes were
originally secured with crimped type clips,
discard these and use new worm drive clips.
P100 models
14Remove the cargo area (Chapter 12).
15Disconnect the wiring plug from the fuel
level sender unit, and release the wiring from
the clip on the fuel tank flange.
16Identify the fuel hose locations for use
when refitting, then disconnect the hoses
from the sender unit and plug them.
17Detach the fuel pipes from their clips on
the tank.
18Remove the five tank securing bolts, and
lift the tank from the chassis frame (see
illustration).
19Proceed as described in paragraphs 11
and 12.
20Commence refitting by loosening the
bolts securing the front tank mounting
brackets to the chassis frame.
21Lower the tank into position and loosely
refit the securing bolts. Tighten the three rear
securing bolts.
22Pull down on the front of the tank and
tighten the bolts securing the front tank
mounting brackets to the chassis frame whenthe brackets contact the insulating pads, then
tighten the front tank securing bolts.
23Further refitting is a reversal of removal,
but ensure that all hoses and pipes are
correctly connected, and if the hoses or pipes
were originally secured with crimped type
clips, discard these and use new worm drive
clips. Refit the cargo area.
Saloon, Hatchback and Estate
models
All models except 2.0 litre DOHC
1Remove the fuel tank.
2Unscrew the sender unit from the tank by
engaging two crossed screwdrivers in the
slots on either side of the sender unit
mounting flange. Recover the seal. Check the
condition of the gauze filter on the fuel pick-
up pipe, and renew it if there is any sign of
deterioration.
3Refitting is a reversal of removal, but fit a
new seal.
2.0 litre DOHC models
4On these models the sender unit is
combined with the fuel pump. See Section 8
for unit removal and refitting.
P100 models
5Remove the cargo area (Chapter 12).
6Disconnect the wiring plug from the sender
unit.
7Identify the fuel hose locations, as an aid to
refitting, then disconnect the hoses from the
sender unit and plug them.
8Proceed as described in paragraph 2.
9Refitting is a reversal of removal, but fit a
new seal, and ensure that the fuel hoses are
correctly connected. If the hoses were
originally secured with crimped type clips,
discard these and use new worm drive clips.
Refit the cargo area.
10Fuel level sender unit -
removal and refitting
9Fuel tank - removal and refitting
Fuel and exhaust systems - carburettor 4A•7
4A
9.8 Fuel level sender unit connections -
Saloon, Hatchback and Estate models
A Wiring plugs
B Fuel outlet pipeC Fuel inlet pipe
9.18 Fuel tank securing bolts (arrowed) -
P100 models
8.17 Combined fuel pump/fuel level sender
unit - 1.6/1.8 litre (R6A) CVH models
A Fuel pumpB Fuel level sender
unit
Caution: Refer to the
precautions in Section 1 before
proceeding.
Caution: Refer to the
precautions in Section 1 before
proceeding. A new seal must
be used when refitting the
sender unit.

Fuel and exhaust systems - carburettor 4A•9
4A
13.4a Exploded view of Ford VV carburettor
A Throttle spindle
B Mixture screw
C By-pass leak adjuster
D Float
E Needle valve
F Main jet body
G Metering rod
H Air valve
J Automatic choke unit
K Bi-metal coil
L Carburettor control diaphragm
M Accelerator pump diaphragm
13.4b Exploded view of Weber 2V
carburettor - 1.6 models
A Top cover assembly
B Automatic choke assembly
C Automatic choke bi-metal housing
assembly
D Secondary idle jet
E Secondary throttle valve vacuum unit
F Idle speed screw
G Idle mixture screw
H Accelerator pump assembly
J Power valve diaphragm
K Float
L Primary emulsion tube
M Primary idle jet
N Needle valve
P Fuel filter
Q Secondary emulsion tube

4A•10Fuel and exhaust systems - carburettor
13.4c Exploded view of Weber 2V carburettor - 2.0 litre models up to 1985
A Top cover assembly
B Fuel filter
C Power valve assembly
D Float
E Needle Valve
F Gasket
G Main jet
H Main body assembly
J Primary idle jet assemblyK Accelerator pump diaphragm
L Accelerator pump gasket
M Automatic choke bi-metal housing
assembly
N Automatic choke assembly
P Vacuum pull-down diaphragm
assembly
Q Idle mixture screw
R Idle speed screwS Emulsion tube
T Accelerator pump jet
U Air correction jet
V Accelerator pump outlet check ball
valve assembly
W Low vacuum enrichment diaphragm
X Secondary idle jet and holder