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

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

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