engine 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

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.

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•13
4A
13.4f Exploded view of Weber 2V TLD carburettor
A Anti-dieselling valve
B Emulsion tubes
C Air correction jets
D Choke pull-down diaphragm assembly
E Choke linkage
F Needle valve
G Float
H Fast idle adjustment screw
J Idle speed adjustment screw
K Idle mixture adjustment screw
L Throttle valves
M Power valve assembly
N Accelerator pump assembly
P Low vacuum enrichment device
Q Throttle kicker
R Gasket
S Main jets
Note: A new gasket must be used when
refitting the carburettor. A tachometer and an
exhaust gas analyser will be required to check
the idle speed and mixture on completion.
Removal
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Relieve the pressure in the cooling system
by unscrewing the expansion tank cap. If the
engine is warm, place a thick rag over the cap
and unscrew the cap slowly as a precaution
against scalding. Refit the cap after relieving
the pressure.4Identify the automatic choke coolant hose
locations, as an aid to refitting, then
disconnect the hoses (being prepared for
coolant spillage.) Either plug the hoses or
secure them with their ends facing upwards to
prevent loss of coolant.
5Disconnect the wiring from the anti-dieselling (anti-run-on) valve.
6Disconnect the fuel hose and vacuum pipe
(see illustration). Plug the end of the fuel
hose to minimise petrol spillage.
7Disconnect the throttle cable from the
carburettor throttle lever (see illustration).
8Remove the two securing nuts and
14Carburettor (Ford VV type) -
removal and refitting
14.7 Disconnecting the throttle cable from
the throttle lever - Ford VV carburettor14.6 Disconnecting the fuel hose - Ford VV
carburettor
Caution: Refer to the
precautions in Section 1 before
proceeding.

washers, and lift the carburettor from the inlet
manifold studs (see illustrations). Recover
the gasket.
Refitting
9Refitting is a reversal of removal, bearing in
mind the following points.
10Ensure that the mating faces of the inlet
manifold and carburettor are clean, and use a
new gasket.
11Ensure that the coolant hoses, fuel hose,
and vacuum pipe are correctly routed and free
from restrictions. If any of the hoses were
originally secured with crimped type clips,
discard these and use new worm drive clips
on refitting.
12On completion, check and if necessary
top-up the coolant level. Check and if
necessary adjust the idle speed and mixture.
Refer to Chapter 1, Sections 15 and 16.
1Proceed as described for the Ford VV
carburettor but note the following.
2On models with an electrically-heated
automatic choke, ignore all references to the
cooling system and coolant hoses.3Not all Weber carburettors are fitted with an
anti-dieselling valve.
4Disconnect all relevant wiring plugs and
vacuum pipes, if necessary noting their
locations for use when refitting.
5Disconnect the link arm from the throttle
linkage instead of disconnecting the throttle
cable.
6The carburettor is secured to the inlet
manifold by four nuts and washers.
Refer to Chapter 1, Sections 15 and 16.
1This procedure does not apply to models
fitted with a carburettor stepper motor, for
which no adjustment is possible.
2Check the idle speed and mixture. The idle
speed must be correct before attempting to
check or adjust the fast idle speed.
3With the engine at normal operating
temperature, and a tachometer connected in
accordance with the manufacturer’s
instructions, proceed as follows.
4Remove the air cleaner.
5Partially open the throttle, hold the choke
plate(s) fully closed, then release the throttle
so that on 1.6 litre models the fast idle
adjustment screw rests on the third (middle)
step of the fast idle cam (see illustration)and
on 2.0 litre models the fast idle adjustment
screw rests on the highest step of the fast idle
cam (see illustration).
6Release the choke plate(s), checking that
it/they remain(s) fully open; if not, the
automatic choke mechanism is faulty, or the
engine is not at normal operating temperature.
7Without touching the throttle pedal, start
the engine and check that the fast idle speed
is as specified. If adjustment is necessary,
turn the fast idle adjustment screw until the
correct speed is obtained.
8On completion of adjustment, stop the
engine and disconnect the tachometer, then
refit the air cleaner.1Proceed as described for the Ford VV
carburettor but note the following.
2The Pierburg carburettor is not fitted with
an anti-dieselling valve.
3Disconnect all relevant wiring plugs and
vacuum pipes, if necessary noting their
locations as an aid to refitting.
4Disconnect the throttle arm from the throttle
lever by removing the retaining clip instead of
disconnecting the cable (see illustration).
5The carburettor is secured to the inlet
manifold by three Torx type screws (see
illustration).
6On CVH models an insulator block is fitted
between the carburettor and the inlet manifold
in place of a gasket. There is no need to
renew the insulator block on refitting.
19Carburettor (Pierburg 2V
type) - removal and refitting
18Carburettor (Weber 2V type) -
fast idle speed adjustment
17Carburettor (Weber 2V type) -
idle speed and mixture adjustment16Carburettor (Weber 2V type) -
removal and refitting
15Carburettor (Ford VV type) - idle
speed and mixture adjustment
4A•14Fuel and exhaust systems - carburettor
14.8a Remove the securing nuts and
washers . . .
19.4 Throttle arm retaining clip (arrowed) -
Pierburg 2V carburettor
19.5 Removing the carburettor securing
screws (arrowed) - Pierburg 2V carburettor18.5b Fast idle speed adjustment - Weber
2V carburettor (2.0 litre models)
18.5a Fast idle speed adjustment - Weber
2V carburettor (1.6 litre models)
A Screw on third (middle) step of cam
B Fast idle screw
14.8b . . . and lift the carburettor from the
inlet manifold - Ford VV carburettor

Refer to Chapter 1, Sections 15 and 16.
1Check the idle speed and mixture
adjustment. The idle speed must be correct
before attempting to check or adjust the fast
idle speed.
2With the engine at normal operating
temperature, and a tachometer connected in
accordance with the manufacturer’s
instructions proceed as follows.
3Remove the air cleaner.
4Position the fast idle speed adjustment
screw on the lowest (6th) step of the fast idle
cam (see illustration).
5Check that the fast idle speed is as
specified. If adjustment is required, stop the
engine and proceed as follows.
6Remove the tamperproof cap from the fast
idle speed adjustment screw.
7Ensure that the adjustment screw is still
resting on the lowest step of the fast idle cam,
then open the throttle so that a small
screwdriver can be used to adjust the screw
from below the carburettor.
8Start the engine and recheck the fast idle
speed.
9If necessary, repeat the procedure given in
paragraphs 7 and 8 until the correct fast idle
speed is obtained.
10On completion of adjustment, stop the
engine and disconnect the tachometer, then
refit the tamperproof cap to the adjustment
screw, and refit the air cleaner.Note: A new gasket must be used when
refitting the carburettor. A tachometer and an
exhaust gas analyser will be required to check
the idle speed and mixture on completion.Removal
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Disconnect the wiring from the anti-
dieselling (anti-run-on) valve.
4Disconnect the wiring from the automatic
choke heater.
5Disconnect the fuel supply and return
hoses, noting their locations to aid refitting.
Plug the ends of the hoses to minimise petrol
spillage.
6Disconnect the link arm from the throttle
linkage.
7Disconnect the vacuum pipe.
8Release the coolant hose from the bracket
under the automatic choke housing.
9Unscrew the four Torx screws, and lift the
carburettor from the inlet manifold. Recover
the gasket.
Refitting
11Refitting is a reversal of removal, bearing
in mind the following points.
12Ensure that the mating faces of the inlet
manifold and the carburettor are clean, and
use a new gasket.
13Ensure that all hoses, pipes and wiring are
correctly routed, and free from restrictions. If
any of the hoses were originally secured with
crimped-type clips, discard these, and use
new worm-drive clips on refitting.
14Make sure that the coolant hose is
correctly positioned in the bracket under the
automatic choke housing.
15On completion, check and if necessary
adjust the idle speed and mixture.
Refer to Chapter 1, Sections 15 and 16.1Proceed as described for the Weber 2V
carburettor, noting the following.
2The fast idle adjustment screw should be
positioned on the third (middle) step of the
fast idle cam (see illustration).
3Refer to the Specifications at the beginning
of this Chapter for the correct fast idle speed.
SOHC models
Removal
1Disconnect the battery negative lead.
2Partially drain the cooling system.
3Remove the air cleaner.
4Disconnect the coolant hoses from the
automatic choke (where applicable), and the
inlet manifold. Identify the hose locations for
use when refitting.
5Disconnect the fuel supply hose at the
carburettor and plug the end to minimise
petrol spillage.
6Disconnect all relevant wiring and vacuum
pipes from the carburettor, if necessary noting
the locations for use when refitting.
7Disconnect the throttle cable from the
throttle linkage.
8Disconnect the crankcase ventilation and
brake servo vacuum hoses from the inlet
manifold. The brake servo vacuum hose is
secured with a union nut (see illustrations).
9Disconnect any remaining wiring and
vacuum pipes from the inlet manifold, if
necessary noting the locations as an aid to
refitting.
10Where necessary, unbolt the throttle cable
bracket from the top of the inlet manifold for
improved access, and unbolt the dipstick tube
bracket.
11Unscrew the two nuts and four bolts
securing the manifold to the cylinder head,
noting the location of the rear engine lifting
25Inlet manifold - removal and
refitting
24Carburettor (Weber 2V TLD) -
fast idle speed adjustment
23Carburettor (Weber 2V TLD) -
idle speed and mixture adjustment
22Carburettor (Weber 2V TLD) -
removal and refitting
21Carburettor (Pierburg 2V type)
- fast idle speed adjustment
20Carburettor (Pierburg 2V type) -
idle speed and mixture adjustment
Fuel and exhaust systems - carburettor 4A•15
4A
25.8a Disconnecting the crankcase
ventilation . . .
24.2 Fast idle speed adjustment - Weber
2V TLD carburettor
A Fast idle cam
B Adjustment screw on middle step of cam21.4 Fast idle speed adjustment - Pierburg
2V carburettor
Screw (arrowed) should rest on lowest (6th)
step of cam
Caution: Refer to the
precautions in Section 1 before
proceeding.

bracket (see illustration).
12Lift the inlet manifold from the cylinder
head, and recover the gasket (see
illustration).
13If desired, the carburettor can be removed
from the inlet manifold by unscrewing the
securing nuts or screws. Refer to the relevant
Section describing carburettor removal and
refitting. Recover the gasket.
Refitting
14Refitting is a reversal of removal bearing
in mind the following points.
15Ensure that all mating faces are clean.
16Renew the gasket(s), and apply a bead of
sealant at least 5.0 mm (0.2 in) wide around
the central coolant aperture on both sides of
the manifold-to-cylinder head gasket.
17Tighten the manifold securing nuts and
bolts progressively to the specified torque,
ensuring that the engine lifting bracket is in
place.
18Make sure that all hoses, pipes and wires
are correctly reconnected, and if the fuel
supply hose was originally secured with a
crimped type clip, discard this and use a new
worm drive clip on refitting.
19On completion, refill the cooling system,
adjust the throttle cable and check and if
necessary adjust the idle speed and mixture.
DOHC models
Removal
20Disconnect the battery negative lead.
21Partially drain the cooling system.
22Remove the air cleaner.
23Disconnect the coolant hoses from the
thermostat housing and the inlet manifold,
noting their locations to assist with refitting.
24Disconnect the fuel supply and return
hoses from the carburettor. Plug their ends to
minimise petrol spillage.
25Release the coolant hose from the bracket
under the automatic choke housing.
26Disconnect the HT leads from the spark
plugs, and move them to one side.
27Disconnect all relevant wiring and vacuum
pipes from the carburettor, thermostat
housing and inlet manifold, noting the
locations as an aid to refitting.
28Disconnect the crankcase breather hose
from the inlet manifold. 29Disconnect the throttle cable from the
throttle linkage.
30Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate removal of the
manifold.
31Unscrew the ten bolts and two nuts
securing the manifold to the cylinder head.
32Lift the manifold clear of the cylinder
head. Recover the gasket.
33Recover the two plastic spark plug
spacers from the recesses in the cylinder
head.
34If desired, the carburettor can be removed
from the manifold by unscrewing the securing
screws. Refer to the carburettor removal and
refitting Sections as necessary.
Refitting
35Refitting is a reversal of removal, bearing
in mind the following points.
36Ensure that all mating faces are clean.
37Ensure that the spark plug spacers are in
position in the cylinder head recesses before
refitting the manifold.
38Renew all gaskets.
39Tighten all manifold securing nuts and
bolts progressively to the specified torque.
40Make sure that all hoses, pipes and wires
are securely reconnected in their original
positions.
41On completion, refill the cooling system.
Check the adjustment of the throttle cable.
Check, and if necessary adjust, the idle speed
and mixture.
CVH models
Removal
42Proceed as described in paragraphs 1 to
3 inclusive.
43Disconnect the coolant hoses from the
automatic choke, thermostat housing and
inlet manifold, noting their locations for use
when refitting.
44Disconnect the fuel supply hose at the
carburettor and plug the end to minimise
petrol spillage.
45Disconnect all relevant wiring and vacuum
pipes from the carburettor, thermostat
housing and inlet manifold, noting the
locations as an aid to refitting.
46Disconnect the throttle cable from the
throttle linkage.
47Unbolt the dipstick tube from the inlet
manifold and withdraw the dipstick and
dipstick tube from the cylinder block.
48Unscrew the seven nuts securing the
manifold to the cylinder head, then lift the
manifold from the cylinder head, and recover
the gasket.
49If desired, the carburettor can be removed
from the manifold by removing the securing
screws. Recover the insulator block (see
illustrations).
50The carburettor intermediate plate can be
removed from the manifold by unscrewing the
three securing screws. Recover the gasket.
51If necessary, the thermostat and housing
can be removed from the manifold.
4A•16Fuel and exhaust systems - carburettor
25.8b . . . and brake servo vacuum hoses
from the inlet manifold - SOHC models25.12 Lifting the inlet manifold from the
cylinder head - SOHC models
25.49b . . . and the insulator block from the
inlet manifold - CVH models25.49a Removing the carburettor . . .
25.11 Rear engine lifting bracket location -
SOHC models

Refitting
52Refitting is a reversal of removal, bearing
in mind the following points.
53Ensure that all mating faces are clean and
renew the gasket(s).
54Tighten the manifold securing nuts
progressively to the specified torque.
55Make sure that all hoses, pipes and wires
are correctly reconnected, and if the fuel
supply hose was originally secured with a
crimped type clip, discard this and use a new
worm drive clip on refitting.
56On completion, refill the cooling system,
adjust the throttle cable and check and if
necessary adjust the idle speed and mixture.
Removal
1Disconnect the battery negative lead.
2Remove the air cleaner and pull the hot air
pick-up pipe from the exhaust manifold hot air
shroud.
3Remove the securing screws (1 screw on
DOHC models, 2 screws on SOHC models, 3
screws on CVH models) and lift the hot air
shroud from the manifold. Note the position of
the coolant hose bracket which is secured by
the front hot air shroud securing screw on
SOHC models (see illustration).
4Unscrew the securing nuts, and disconnect
the exhaust downpipe from the manifold (see
illustration). Recover the gasket. Support the
exhaust downpipe from underneath thevehicle, with an axle stand for example, to
avoid placing unnecessary strain on the
exhaust system.
5Disconnect the HT leads from the spark
plugs, if necessary identifying them for
locations, and place them to one side out of
the way.
6Unscrew the eight securing nuts, noting the
location of the front engine lifting bracket
secured by the front two nuts on SOHC
models, and lift the manifold from the cylinder
head. Recover the gasket(s) where applicable
(see illustrations).
Refitting
7Refitting is a reversal of removal, bearing in
mind the following.
8Ensure that all mating faces are clean, and
renew all gaskets. Note that on CVH models,
no gasket is fitted between the manifold andcylinder head in production, but a gasket
must be used when refitting. Where
applicable, remove the plastic spacer from the
rear manifold stud before fitting the gasket
(see illustrations).
26Exhaust manifold - removal
and refitting
Fuel and exhaust systems - carburettor 4A•17
4A
26.6a Unscrew the exhaust manifold
securing nuts . . .
26.8c Fitting the exhaust manifold -
DOHC models26.8b Remove the plastic spacer (arrowed)
before fitting exhaust manifold gasket -
CVH models26.8a Exhaust manifold gaskets in position
on cylinder head - DOHC models
26.6d SOHC models have separate
manifold gaskets for each exhaust port26.6c . . . and lift off the exhaust manifold -
SOHC models26.6b . . . noting the location of the front
engine bracket . . .
26.4 Unscrewing an exhaust downpipe
securing nut26.3 Exhaust manifold hot air shroud
showing securing screws (1 and 3) and
coolant hose clip (2) - SOHC models