FORD SIERRA 1993 2.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

Weber 2V (28/30 DFTH) carburettor
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .775 to 825 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 to 1.25%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1600 to 1800 rpm
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 to 6.5 mm (0.22 to 0.26 in)
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .6.0 to 6.5 mm (0.24 to 0.26 in)
PrimarySecondary
Throttle barrel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28.0 mm30.0 mm
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.0 mm23.0 mm
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5040 (70*)
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 (95*)110 (115*)
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 (195*)190 (170*)
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F59F22
*Re-jetting sizes for improved economy
Weber 2V (32/36 DGAV) carburettor
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 ±25 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 ±0.2%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2900 ±100 rpm
Float level (without gasket):
Brass float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41.0 mm (1.61 in)
Plastic float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.3 mm (1.39 in)
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 ±0.25 mm (0.26 ±0.01 in)
Automatic choke phasing dimension . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 ±0.25 mm (0.06 ±0.01 in)
PrimarySecondary
Throttle barrel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.0 mm36.0 mm
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.0 mm27.0 mm
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4545
Main jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130130
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130132
Air correction jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165120
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170120
Emulsion tube:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F66F66
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F50F66
Weber 2V (30/34 DFTH) carburettor (Part Nos 85HF 9510 CA and DA)
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 rpm (electronically controlled)
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 to 1.25%
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 to 8.5 mm (0.30 to 0.33 in)
Automatic choke vacuum pull-down:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.0 mm (0.35 in)
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 mm (0.32 in)
Throttle barrel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30.0 mm34.0 mm
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.0 mm27.0 mm
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4545
Main jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112135
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110135
Air correction jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165150
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160150
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F22F22
Weber 2V (30/34 DFTH) carburettor (Part Nos 85HF 9510 CB and DB)
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .875 rpm (electronically controlled)
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 ±0.25%
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 ±0.5 mm (0.32 ±0.02 in)
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
PrimarySecondary
Throttle barrel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30.0 mm34.0 mm
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.0 mm27.0 mm
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4245
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110130
Air correction jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160160
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170160
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F22F22
4A•2Fuel and exhaust systems - carburettor

Pierburg 2V (2E3) carburettor - SOHC models (Part No 85HF 9510 AB)
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 ±20 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .830 ±30 rpm
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 mm (0.12 in)
Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.0 mm26.0 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.5130
Pierburg 2V (2E3) carburettor - SOHC models (Part Nos 85HF 9510 JB and KC)
Idle speed:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 to 900 rpm
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .775 to 825 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 to 1.5%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1850 to 1950 rpm
Automatic choke vacuum pull-down:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 mm (0.16 in)
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 mm (0.15 in)
Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Idle air bleed:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.0 mm26.0 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.5130
Pierburg 2V (2E3) carburettor- CVH models
Idle speed:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 to 900 rpm
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .775 to 825 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 to 1.25%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 rpm
Automatic choke vacuum pull-down:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 mm (0.09 in)
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 mm (0.10 in)
Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.5
Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.0 mm23.0 mm
Main jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100105
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97.5105
Weber 2V (TLD) carburettor
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±25 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 ±0.25%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1800 ±50 rpm
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.0 ±0.5 mm
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .5.0 ±0.5 mm
Throttle kicker speed (see text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 ±50 rpm
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.0 mm25.0 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115157
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175145
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F114F3
Torque wrench settingsNmlbf ft
All models except 2.0 litre DOHC
Fuel pump bolts (mechanical pump) . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 1810 to 13
Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Exhaust manifold-to-downpipe nuts . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Exhaust downpipe-to-main system nuts . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Exhaust U-bolt clamp nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 to 4528 to 33
Fuel and exhaust systems - carburettor 4A•3
4A

2.0 litre DOHC models
Inlet manifold nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2415 to 18
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2515 to 18
Carburettor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 106 to 7
General information
The fuel system on carburettor models
may comprise a fuel tank, a fuel pump, a fuel
pressure regulator and/or vapour separator, a
downdraught carburettor and a
thermostatically-controlled air cleaner.
On Saloon, Hatchback and Estate models,
the fuel tank is mounted under the rear of the
vehicle, on the right-hand side. On P100
models, the fuel tank is mounted behind the
cab, between the chassis frame and the load
area. The tank is ventilated, and has a simple
filler pipe and a fuel gauge sender unit.
The mechanical fuel pump is a diaphragm
type, actuated by a pushrod bearing on an
eccentric cam on the auxiliary shaft on SOHC
models, or on the camshaft on CVH models.
DOHC models and models with air
conditioning have an electric fuel pump
mounted under the rear of the vehicle, next to
the fuel tank. DOHC models have a combined
pump and fuel level sender unit.
The fuel pressure regulator and/or vapour
separator is used to stabilise the fuel supply
to the carburettor. The pressure regulator
provides a constant fuel pressure, and hence
maintains a constant float level in the
carburettor which reduces exhaust emission
levels. The vapour separator purges vapour
from the carburettor fuel supply, thus
improving hot starting qualities. All models up
to 1985 are fitted with a fuel pressure
regulator. All models from 1985 except 2.0
litre SOHC models and CVH models are fitted
with a combined fuel pressure regu-
lator/vapour separator. 2.0 litre models from
1985 and CVH models are fitted with a vapour
separator only. DOHC models have no
pressure regulator or vapour separator fitted.
The carburettor may be either a Ford
variable venturi (VV) type, a Weber twin venturi
(2V or 2V TLD) type, or a Pierburg twin venturi
(2V) type, depending on model. Each type ofcarburettor is available in several versions to
suit particular engine and equipment
combinations.
The air cleaner has a vacuum or waxstat
controlled air inlet supplying a blend of hot
and cold air to suit the prevailing engine
operating conditions.
Precautions
Tamperproof adjustment screws -
caution
Certain adjustment points in the fuel system
(and elsewhere) are protected by
“tamperproof” caps, plugs or seals. The
purpose of such tamperproofing is to
discourage, 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.
Work proceedures
When working on fuel system components,
scrupulous cleanliness must be observed,
and care must be taken not to introduce any
foreign matter into fuel lines or components.
Carburettors in particular are delicateinstruments, and care should be taken not to
disturb any components unnecessarily.
Before attempting work on a carburettor,
ensure that the relevant spares are available.
Full overhaul procedures for carburettors have
not been given in this Chapter, as complete
strip-down of a carburettor is unlikely to cure
a fault which is not immediately obvious,
without introducing new problems. If
persistent problems are encountered, it is
recommended that the advice of a Ford dealer
or carburettor specialist is sought. Most
dealers will be able to provide carburettor re-
jetting and servicing facilities, and if necessary
it should be possible to purchase a
reconditioned carburettor of the relevant type.
Refer to Chapter 1, Section 38.
Removal
1On CVH models, disconnect the battery
negative lead.
2Remove the screws from the top of the air
cleaner cover (see illustration).
3Disconnect 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
(see illustration).
4Disconnect the hot air inlet hose from the
air cleaner spout or the hot air shroud on the
exhaust manifold (see illustration).
5Disconnect the vacuum hose from the inlet
manifold (see illustration).
6On DOHC models, disconnect the
camshaft cover breather hose
7Where applicable, on OHC models remove
the screw securing the air cleaner body to the
camshaft cover.
8Withdraw the air cleaner, and on CVH
models, disconnect the wiring plug from the
3Air cleaner - removal and
refitting
2Air cleaner element - renewal
1General information and
precautions
4A•4Fuel and exhaust systems - carburettor
3.4 Hot air intake hose on hot air shroud3.3 Disconnecting the cold air intake hose
from the air cleaner spout3.2 Air cleaner securing screws (arrowed)
Warning - Fuel - Many of the
procedures given in this
Chapter involve the
disconnection of fuel pipes and
system components which may result in
some fuel spillage. Before carrying out
any operation on the fuel system, refer to
the precautions given in the “Safety first”
Section at the beginning of this manual
and follow them implicitly. Petrol Is a
highly dangerous and volatile substance,
and the precautions necessary when
handling it cannot be over stressed.

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.

Removal
1Disconnect the battery negative lead.
2Remove the lower facia panel from the
driver’s side.
3Prise off the securing clip and disconnect
the end of the throttle cable from the top of
the pedal (see illustration).
4Remove the two securing nuts, one
accessible from the driver’s footwell, the other
from the engine compartment, and withdraw
the pedal and bracket assembly (see
illustration).
Refitting
5Refitting is a reversal of removal, but on
completion check the throttle cable
adjustment.
Removal
1Disconnect the battery negative lead.
2Working inside the vehicle, remove the
lower facia panel from the driver’s side.
3Prise off the securing clip and disconnect
the end of the throttle cable from the top of
the pedal.
4Working in the engine compartment, free
the cable sheath from the bulkhead, and pull
the cable through into the engine
compartment. It will probably be necessary to
pull the cable grommet from the bulkhead in
order to free the cable sheath.
5For improved access, remove the air
cleaner.
6Disconnect the cable end from the throttle
linkage. The cable end may be attached to the
linkage with a balljoint and spring clip, a
spring clip only, or the cable end may simplylocate in a slot in the throttle lever (see
illustration).
7Prise off the spring clip securing the cable
sheath to the cable bracket at the carburettor
inlet manifold. Depress the four lugs on the
plastic cable retainer simultaneously so that
the retainer can be slid from the bracket, or
remove the retainer securing clip, as
applicable (see illustration). Take care not to
damage the cable sheath.
Refitting
8Refitting is a reversal of removal, but before
refitting the air cleaner, adjust the cable as
follows.
Adjustment
9Have an assistant fully depress the throttle
pedal and hold it in this position. On models
with automatic transmission, where
applicable ensure that the kickdown cable
does not restrict the pedal movement. Turn
the adjusting sleeve at the carburettor inlet
manifold cable bracket until the throttle is just
fully open. Have the assistant release and
then fully depress the throttle pedal, and
check that the throttle is again fully open.
Adjust if necessary, then refit the air cleaner.
On models with automatic transmission,
where applicable check the operation of the
kickdown cable, and adjust if necessary.1A complete strip-down of a carburettor is
unlikely to cure a fault which is not
immediately obvious without introducing new
problems. If persistent carburation problems
are encountered, it is recommended that the
advice of a Ford dealer or carburettor
specialist is sought.
2If it is decided to go ahead and service a
carburettor, check the cost and availability of
spare parts before commencement. Obtain a
carburettor repair kit, which will contain the
necessary gaskets, diaphragms and other
renewable items.
3When working on carburettors, scrupulous
cleanliness must be observed and care must
be taken not to introduce any foreign matter
into components. Carburettors are delicate
instruments and care should be taken not to
disturb any components unnecessarily.
4Referring to the relevent exploded view of
the carburettor(see illustrations),remove
each component part whilst making a note of
its fitted position. Make alignment marks on
linkages etc.
5Reassemble the carburettor in the reverse
order to dismantling, using new gaskets, O-
rings etc. Be careful not to kink any
diaphragms.
13Carburettors (all types) -
dismantling and reassembly
12Throttle cable - removal,
refitting and adjustment
11Throttle pedal - removal and
refitting
4A•8Fuel and exhaust systems - carburettor
11.3 Throttle pedal assembly - cable
connection arrowed
12.6 Disconnecting the throttle cable end from the throttle lever -
Weber 2V carburettor12.7 Removing the throttle cable sheath retainer securing clip -
CVH model
11.4 Throttle pedal securing nut (arrowed)
in engine compartment

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