fuel cap 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

manual mixture adjustment is possible.
On models with a catalytic converter, an
evaporative emission control (EVAP) system is
fitted. This prevents the release of fuel vapour
into the atmosphere. With the ignition
switched off, vapours from the fuel tank are
fed to a carbon canister, where they are
absorbed. When the engine is started, the
EEC IV module opens a purge solenoid valve,
and the fuel vapours are fed into the inlet
manifold and mixed with fresh air. This cleans
the carbon filter. A blow-back valve prevents
inlet air being forced back into the fuel tank.
A fuel pump inertia 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.
A “limited operation strategy” (LOS) means
that the vehicle will still be driveable, albeit at
reduced power and efficiency, in the event of
a failure in the EEC IV module or its sensors.
1.6 and 1.8 litre (R6A type) CVH 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 to the
Central Fuel Injection (CFI) unit. A fuel
pressure regulator, mounted on the CFI unit,
maintains a constant fuel pressure to the fuel
injector. Excess fuel is returned from the
regulator to the tank.
The CFI unit, resembling a carburettor,
houses the throttle valve, throttle valve control
motor, throttle position sensor, air charge
temperature sensor, fuel injector, and
pressure regulator.
The duration of the electrical pulse supplied
to the fuel injector 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.
The fuel injector receives a pulse twice per
crankshaft revolution under normal operating
conditions, and once per crankshaft
revolution under engine idle conditions. A
ballast resistor is used in the fuel injector
control circuit on 1.6 litre engines.
Inlet air passes through the air cleaner into
the CFI unit. The volume of air entering the
engine is calculated by the EEC IV module from
information supplied by various sensors. These
sensors include the air charge temperature
sensor and throttle position sensor, mounted in
the CFI unit; a crankshaft speed/position
sensor which supplies information on engine
speed; and a manifold absolute pressure (MAP)
sensor which measures the pressure of the air
entering the engine.
Additional sensors inform the EEC IV module
of engine coolant temperature, and vehicle
speed (from a gearbox-mounted sensor).
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
manual mixture adjustment is possible.
Idle speed is controlled by a throttle valvecontrol motor, which controls the position of
the throttle valve under conditions of idling,
deceleration/part-throttle, and engine start-up
and shut-down.
On 1.6 litre engines, a pulse-air system is
fitted to reduce the exhaust gas emissions
during engine warm-up. The system is con-
trolled by a vacuum-operated valve, which is
operated by the EEC IV module via a solenoid.
The system introduces air into the exhaust
manifold to increase the exhaust gas
temperature, which oxidises more of the
pollutants, and brings the catalyst up to
working temperature more quickly. The
system operates until the catalyst reaches
operating temperature, when the control
solenoid shuts off the system.
On 1.8 litre engines, an exhaust gas
recirculation (EGR) system is used to
recirculate a small amount of exhaust gas into
the inlet manifold. This process lowers the
combustion temperature, resulting in a
reduction of NOx (oxides of nitrogen)
emissions. The EGR system is controlled by
the EEC IV module in conjunction with an
Electronic Pressure Transducer (EPT) and an
Electronic Vacuum Regulator (EVR).
On certain models, an evaporative emission
control system may be fitted. This prevents
the release of fuel vapour into the
atmosphere. With the ignition switched off,
vapours from the fuel tank are fed to a carbon
canister, where they are absorbed. When the
engine is started the EEC IV module opens a
purge solenoid valve, and the fuel vapours are
fed into the inlet manifold and mixed with
fresh air. This cleans the carbon filter. A blow-
back valve prevents inlet air being forced
back into the fuel tank.
A fuel pump inertia 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.
A “limited operation strategy” (LOS) means
that the vehicle will still be driveable, albeit at
reduced power and efficiency, in the event of
a failure in the EEC IV module or its sensors.
Precautions
Many of the procedures in this Chapter
require the removal of fuel lines and
connections which may result in some fuel
spillage. Before carrying out any operation on
the fuel system refer to the precautions given
in “Safety first!” at the beginning of this
Manual and follow them implicitly. Petrol is a
highly dangerous and volatile liquid and the
precautions necessary when handling it
cannot be overstressed.
Residual pressure will remain in the fuel
lines long after the vehicle was last used,
therefore extra care must be taken when
disconnecting a fuel line hose. Loosen any
fuel hose slowly to avoid a sudden release of
pressure which may cause fuel spray. As an
added precaution place a rag over each union
as it is disconnected to catch any fuel which is
forcibly expelled.
Certain adjustment points in the fuel system
(and elsewhere) are protected by
“tamperproof” caps, plugs or seals. The
purpose of such tamperproofing is todiscourage, 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.
Catalytic converter - precautions
The catalytic converter is a reliable and simple
device which needs no maintenance in itself,
but there are some facts of which an owner
should be aware if the converter is to function
properly for the full service life.
a)DO NOT use leaded petrol in a car
equipped with a catalytic converter the
lead will coat the precious metals,
reducing their converting efficiency and
will eventually destroy the converter.
b)Always keep the ignition and fuel systems
well-maintained in accordance with the
manufacturers schedule, ensure that the
air cleaner filter element, the fuel filter
(where fitted) and the spark plugs are
renewed at the correct interval if the inlet
air/fuel mixture is allowed to become too
rich due to neglect, the unburned surplus
will enter and burn in thecatalytic
converter, overheating the element and
eventually destroying the converter.
c)If the engine develops a misfire, do not
drive the car at all (or at least as little as
possible) until the fault is cured - the
misfire will allow unburned fuel to enter
the converter, which will result in
overheating, as noted above.
d)DO NOT push- or tow-start the car - this
will soak the catalytic converter in
unburned fuel, causing it to overheat when
the engine does start - see b) above.
e)DO NOT switch off the ignition at high
engine speeds - if the ignition is switched
off at anything above idle speed,
unburned fuel will enter the (very hot)
catalytic converter, with the possible risk
of igniting on the element and damaging
the converter.
f)DO NOT use fuel or engine oil additives -
these may contain substances harmful to
the catalytic converter.
g)DO NOT continue to use the car if the
engine burns oil to the extent of leaving a
visible trail of blue smoke - the unburned
carbon deposits will clog the converter
passages and reduce the efficiency; in
severe cases the element will overheat.
h)Remember that the catalytic converter
operates at very high temperatures - hence
the heat shields on the car’s underbody
and the casing will become hot enough to
ignite combustible materials which brush
against it - DO NOT, therefore, park the car
in dry undergrowth, over long grass or
piles of dead leaves.
i)Remember that the catalytic converter is
FRAGILE, do not strike it with tools during
servicing work, take great care when
Fuel and exhaust systems - fuel injection 4B•3
4B

Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. New seals and
retaining clips must be used when refitting the
injectors, and special grease will be required -
see relevant paragraph. If the injectors are
thought to be faulty, it may be worth trying the
effect of a fuel injector cleaning agent before
removing them.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Disconnect the crankcase ventilation hose
from the air inlet hose, then disconnect the air
inlet hose from the inlet manifold and the
airflow meter.
3Disconnect the HT lead from the coil, then
remove the distributor cap and position the
cap and HT leads clear of the fuel rail
assembly.
4Disconnect the wiring plugs from the idle
speed control valve, the throttle position sensor
and the engine coolant temperature sensor.
5Remove the fuel pressure regulator.
6Unscrew the securing bolt and remove the
throttle return spring bracket. Disconnect the
throttle return spring.7Disconnect the fuel supply hose from the
fuel rail. Be prepared for petrol spillage.
8Disconnect the wiring plugs from the fuel
injectors, noting their locations for use when
refitting.
9Remove the three securing bolts and
withdraw the fuel rail and fuel injectors from
the inlet manifold as an assembly (see
illustrations).
10To remove a fuel injector from the fuel rail,
remove the retaining clip and withdraw the
injector (see illustration).
11Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed.
12Commence refitting by fitting new seals to
both ends of each fuel injector. Even if only
one injector has been removed, new seals
must be fitted to all four injectors (see
illustration). Coat the seals with silicone
grease to Ford specification ESEM - ICI71 A.
Similarly, renew all four fuel injector retaining
clips.
13Further refitting is a reversal of removal,
ensuring that all hoses, wiring plugs and leads
are correctly connected. When reconnecting
the air inlet hose, make sure that the hose
clips are correctly aligned - see illustration,
Section 15.
14On completion, check and if necessary
adjust the idle mixture.
2.0 litre DOHC models
15Disconnect the battery negative lead.
16If desired, to improve access, disconnectthe wiring from the inlet air temperature
sensor in the inlet manifold. Similarly, the
throttle cable can be moved to one side by
disconnecting the cable from the throttle
linkage. The spark plug HT leads can be
disconnected and moved to one side, noting
their locations and routing to aid refitting.
17Slowly loosen the fuel rail fuel feed union
to relieve the pressure in the system. Be
prepared for fuel spillage, and take adequate
fire precautions.
18Disconnect the fuel feed hose from the
fuel rail (see illustration).
19Disconnect the fuel return hose from the
fuel pressure regulator. Again, be prepared for
fuel spillage.
20Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
21Disconnect the wiring plugs from the fuel
temperature sensor and the fuel injectors,
noting their locations to assist with refitting.
22Unscrew the two securing bolts, and
withdraw the fuel rail.
23Lift the fuel injectors from their locations
in the cylinder head (see illustration).
24Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed (refer to the note
at the start of this procedure before
condemning an injector).
25Commence refitting by fitting new seals to
both ends of each fuel injector. It is advisable
to fit new seals to all the injectors, even if only
one has been removed. Lubricate the seals
with clean engine oil.
18Fuel injectors - removal and
refitting
Fuel and exhaust systems - fuel injection 4B•9
4B
18.9b . . . and rear securing bolts
18.18 Disconnecting the fuel feed hose
from the fuel rail18.12 Fuel injector with seals removed18.10 Fuel injector retaining clip (A)
18.9a Fuel rail front securing bolt
(arrowed) . . .17.1 Fuel injector ballast resistor location
(arrowed)
Caution: Refer to the
precautions in Section 1 before
proceeding.

4Remove the three screws securing the
motor and the throttle position sensor
assembly mounting bracket to the CFI unit,
and withdraw the assembly.
5Remove the three motor securing screws,
and withdraw the motor from the bracket.
6Refitting is a reversal of removal, bearing in
mind the following points.
7Ensure that the throttle position sensor
actuating arm locates correctly on the throttle
valve spindle, and that the mounting bracket
aligns with its locating pegs.
8On completion, the idle speed should be
checked by a Ford dealer at the earliest
opportunity.
1.8 litre
9Disconnect the battery negative lead.
10Remove the air cleaner assembly.
11Disconnect the wiring connector from the
throttle valve control motor.
12Remove the three screws securing the
motor and the mounting bracket to the CFI
unit, and withdraw the assembly.
13Remove the three motor securing screws,
and withdraw the motor from the bracket.
14Refitting is a reversal of removal, ensuring
that the motor is located on the throttle
linkage, and that the bracket and locating
pegs are aligned.
Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. A new gasket must be
used when refitting the throttle body.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Free the throttle position sensor wiring plug
from the retaining clip on the underside of the
throttle body. Disconnect the wiring plug
halves by releasing the locktabs and pulling
on the plug halves, not the wiring.
3Disconnect the throttle cable from the lever.
4Disconnect the crankcase ventilation hose
from the air inlet hose, then disconnect the air
inlet hose from the throttle body and the
airflow meter.
5Remove the four securing bolts and
withdraw the throttle body from the inlet
manifold. Recover the gasket.
6Refitting is a reversal of removal, bearing in
mind the following points.
7Ensure that all mating faces are clean, and
fit a new gasket.
8When reconnecting the air inlet hose, make
sure that the hose clips are correctly aligned,
see illustration, Section 15.
9On completion, adjust the throttle cable and
check and if necessary adjust the idle mixture.
2.0 litre DOHC models
10Disconnect the battery negative lead.
11Free the throttle position sensor wiring
plug from the retaining clip located on the
underside of the throttle body. Disconnect thewiring plug halves by releasing the locktabs
and pulling on the plug halves, not the wiring.
12Disconnect the throttle cable from the
linkage.
13Loosen the securing clip, and disconnect
the air inlet hose from the throttle body.
14Unscrew the four securing bolts, and
withdraw the throttle body from the inlet
manifold. Recover the gasket.
15Refitting is a reversal of removal, bearing
in mind the following points.
16Ensure that the mating faces of the
throttle body and the inlet manifold are clean,
and fit a new gasket.
17On completion, adjust the throttle cable.
Where applicable, check and if necessary
adjust the idle mixture.
Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. A new gasket must be
used when refitting the manifold.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Partially drain the cooling system.
3Disconnect the crankcase ventilation hose
from the air inlet hose. Disconnect the air inlethose from the inlet manifold and the airflow
meter.
4Disconnect the HT lead from the coil, then
remove the distributor cap and position the
cap and HT leads clear of the inlet manifold
assembly.
5Unscrew the two securing bolts and remove
the throttle cable bracket (see illustration).
Disconnect the cable end from the throttle
lever, and move the bracket to one side.
6Disconnect the fuel injection harness wiring
plugs at the bulkhead end of the manifold
(see illustration).
7Disconnect the oil pressure warning lamp
switch wire from below the manifold.
8Disconnect the fuel supply hose from the
fuel rail. Loosen the union nut slowly to relieve
the pressure in the fuel system, and be
prepared for petrol spillage.
9Disconnect the fuel return hose from the
fuel pressure regulator. Be prepared for fuel
spillage.
10Disconnect the coolant hose and the
brake servo vacuum hose from the inlet
manifold.
11Unscrew the two securing nuts and
remove the bracing strut which runs from the
manifold to the right-hand side of the cylinder
head (see illustration).
12Unscrew the two bolts securing the lower
manifold bracket to the left-hand side of the
cylinder block (see illustration).
13Remove the four bolts and two nuts
securing the inlet manifold to the cylinder
head, and carefully withdraw the manifold. If
the distributor obstructs removal, extract the
front manifold stud by locking two nuts
30Inlet manifold - removal and
refitting
29Throttle body - removal and
refitting
4B•12Fuel and exhaust systems - fuel injection
30.5 Unscrew the securing bolts and
remove the throttle cable bracket
30.12 Lower inlet manifold bracket
(arrowed)30.11 Unscrew the two securing nuts
(arrowed) and remove the inlet manifold
bracing strut
30.6 Disconnecting a fuel injection harness
wiring plug
Caution: Refer to the
precautions in Section 1 before
proceeding.