retard FORD SIERRA 1988 2.G Engine Electrical Systems Workshop Manual

General information
The electrical system is of the 12 volt
negative earth type, and consists of a 12 volt
battery, alternator with integral voltage
regulator, starter motor and related electrical
accessories, components and wiring. The
battery is of the low maintenance or
maintenance-free “sealed for life” type and is
charged by an alternator which is belt-driven
from the crankshaft pulley. The starter motor
is of the pre-engaged type, incorporating an
integral solenoid. On starting the solenoid
moves the drive pinion into engagement with
the flywheel ring gear before the starter motor
is energised. Once the engine has started, a
one-way clutch prevents the motor armature
being driven by the engine until the pinion
disengages from the flywheel.
The ignition system is responsible for
igniting the air/fuel mixture in each cylinder at
the correct moment in relation to engine
speed and load. A number of different ignition
systems are fitted to models within the
Sierra/P100 range, ranging from a basic
breakerless electronic system to a fully
integrated engine management system
controlling ignition and fuel injection systems.
The ignition system is based on feeding low
tension voltage from the battery to the coil
where it is converted to high tension voltage.
The high tension voltage is powerful enough
to jump the spark plug gap in the cylinders
many times a second under high compression
pressures, providing that the system is in
good condition. The low tension (or primary)
circuit consists of the battery, the lead to the
ignition switch, the lead from the ignition
switch to the low tension coil windings
(terminal + /15) and also to the supply terminal
on the electronic module, and the lead from
the low tension coil windings (terminal -/1) to
the control terminal on the electronic module.
The high tension (or secondary) circuit
consists of the high tension coil windings, the
HT (high tension) lead from the coil to the
distributor cap, the rotor arm, the HT leads to
the spark plugs, and the spark plugs.
The system functions in the following
manner. Current flowing through the low
tension coil windings produces a magnetic
field around the high tension windings. As the
engine rotates, a sensor produces an
electrical impulse which is amplified in the
electronic module and used to switch off the
low tension circuit.
The subsequent collapse of the magnetic
field over the high tension windings produces
high tension voltage which is then fed to the
relevant spark plug via the distributor cap and
rotor arm. The low tension circuit is
automatically switched on again by the
electronic module, to allow the magnetic field
to build up again before the firing of the next
spark plug. The ignition is advanced and
retarded automatically to ensure that thespark occurs at the correct instant in relation
to the engine speed and load.
To improve driveability during warm-up
conditions and to reduce exhaust emission
levels, a vacuum-operated,
temperature-sensitive spark control system is
fitted to certain vehicles.Inductive discharge system
This is the least sophisticated system fitted
to the Sierra/P100 range, and comprises a
breakerless distributor and an electronic
switching/amplifier module in addition to the
coil and spark plugs.
The electrical impulse which is required to
switch off the low tension circuit is generated
by a magnetic trigger coil in the distributor. A
trigger wheel rotates within a magnetic stator,
the magnetic field being provided by a
permanent magnet. The magnetic field across
the two poles (stator arm and trigger wheel) is
dependent on the air gap between the two
poles. When the air gap is at its minimum, the
trigger wheel arm is directly opposite the
stator arm, and this is the trigger point. As the
magnetic flux between the stator arm and
trigger wheel varies, a voltage is induced in
the trigger coil mounted below the trigger
wheel, and this voltage is sensed and then
amplified by the electronic module and used
to switch off the low tension circuit. There is
one trigger wheel arm and one stator arm for
each cylinder (4).
The ignition advance is a function of the
distributor and is controlled both mechanically
and by a vacuum operated system. The
mechanical governor mechanism consists of
two weights which move out from the
distributor shaft as the engine speed rises due
to centrifugal force. As they move outwards,
they rotate the trigger wheel relative to the
distributor shaft and so advance the spark.
The weights are held in position by two light
springs and it is the tension of the springs
which is largely responsible for correct spark
advancement.
The vacuum control consists of a
diaphragm, one side of which is connected
via a small bore hose to the carburettor or
inlet manifold and the other side to the
distributor. Depression in the inlet manifold
and/or carburettor, which varies with engine
speed and throttle position, causes the
diaphragm to move, so moving the baseplate
and advancing or retarding the spark. A fine
degree of control is achieved by a spring in
the diaphragm assembly.
ESC (Electronic Spark Control) system
This system is only fitted to early
“Economy” models, and comprises a “Hall
effect” distributor, and an ESC module, in
addition to the coil and spark plugs.
The electrical impulse which is required to
switch off the low tension circuit is generated
by a sensor in the distributor. A trigger vane
rotates in the gap between a permanent
magnet and the sensor. The trigger vane has
four cut-outs, one for each cylinder. When
one of the trigger vane cut-outs is in line with
the sensor, magnetic flux can pass betweenthe magnet and the sensor. When a trigger
vane segment is in line with the sensor, the
magnetic flux is diverted through the trigger
vane away from the sensor. The sensor
senses the change in magnetic flux and sends
an impulse to the ESC module, which
switches off the low tension circuit.
The ignition advance is a function of the
ESC module and is controlled by vacuum. The
module is connected to the inlet manifold by a
vacuum pipe, and a transducer in the module
translates the vacuum signal into electrical
voltage. From the vacuum signal, the ESC
module determines engine load, and engine
speed is determined from the interval
between impulses supplied by the distributor
sensor. The module has a range of spark
advance settings stored in its memory, and a
suitable setting is selected for the relevant
engine speed and load. The degree of
advance can thus be constantly varied to suit
the prevailing engine speed and load
conditions.
ESC II (Electronic Spark Control II)
system
1.8 and 2.0 litre SOHC carburettor models
This system is a development of the ESC
system described previously in this Section,
but it enables more accurate control of engine
operation due to the inclusion of additional
monitoring features and control outputs.
Vehicles fitted with the ESC II system have an
electric inlet manifold heater which warms the
air/fuel mixture when the engine is cold, thus
reducing the amount of fuel enrichment
required, lowering fuel consumption and
improving driveability when the engine is cold.
The heater is operated by the ESC II module
receiving information on the engine temperature
from an engine coolant temperature sensor
mounted in the inlet manifold.
On 2.0 litre SOHC models, the ESC II
module operates a carburettor stepper motor
to control the engine idle speed. Using
information on engine speed, load,
temperature and throttle position (supplied by
a switch on the carburettor), the module
operates the stepper motor to maintain a
constant idle speed. On models equipped
with automatic transmission and/or air
conditioning, additional inputs are supplied to
the module to allow it to operate the stepper
motor to compensate for the additional engine
load imposed by the automatic
transmission/air conditioning. The ESC II
module also operates a “power hold” relay
which allows the stepper motor to function
briefly after the ignition has been switched off
in order to perform an anti-run-on and
manifold ventilation cycle.
2.0 litre DOHC carburettor models
A development of the ESC II system is used
to control the operation of the engine. The
module receives information from a
crankshaft speed/position sensor (similar to
that described for the ESC Hybrid system),
except that the sensor is activated by a
toothed disc on the rear of the crankshaft,
inside the cylinder block), and an engine
coolant temperature sensor.
1General information and
precautions
Engine electrical systems 5•3
5

Refitting
13Commence refitting by checking that No 1
cylinder is still at the firing point. The relevant
timing marks should be aligned. If the engine
has been turned whilst the distributor has
been removed, check that No 1 cylinder is on
its firing stroke by removing the No 1 cylinder
spark plug and placing a finger over the plug
hole. Turn the crankshaft until compression
can be felt, which indicates that No 1 piston is
rising on its firing stroke. Continue turning the
crankshaft until the relevant timing marks are
in alignment.
14Turn the rotor arm to the position noted in
paragraph 11. If a new distributor is being
fitted, and no alignment marks are present,
transfer the marks from the old distributor to
the new distributor.
15Hold the distributor directly over the
aperture in the cylinder block with the
previously made marks on the distributor
body and cylinder block aligned, then lower
the distributor into position. Again, if a new
distributor is being fitted, transfer the
alignment mark from the old distributor body
to the new distributor body. As the skew gear
drive meshes, the rotor arm will turn
anti-clockwise.
16With the distributor fitted and the marks
on the distributor body and cylinder block
aligned, check that the rotor arm is positioned
as described in paragraph 7 -if not, withdraw
the distributor, re-position the driveshaft and
try again.
17Refit the clamp, then insert and tighten
the bolt. Do not fully tighten the bolt at this
stage.
18Refit the distributor wiring plug, and
where applicable reconnect the vacuum pipe,
and refit the dust cover and/or rotor arm.
19Refit the distributor cap, and reconnect
the HT leads to the spark plugs and coil.
Ensure that the leads are refitted to their
correct cylinders.
20Where applicable, refit the screening can
to the top of the distributor and reconnect the
earth strap. On fuel injection models,
reconnect the air inlet hose, ensuring that the
clips are correctly aligned (refer to illustration,
Section 15, Chapter 4, PartB).21Reconnect the battery negative lead.
22Check and if necessary adjust the ignition
timing.
Early “Economy” models
Removal
23Removal of the distributor fitted to these
models is a similar process to that described
above.
Refitting
24Turn the crankshaft to bring No 1 cylinder
to the firing point, with the 16º BTDC mark on
the crankshaft pulley aligned with the pointer
on the crankshaft front oil seal housing, as
described above.
25Fit the new distributor to the engine as
described above, then proceed as follows.
26Cut the original distributor wiring plug
from the wiring loom. Make the cut close to
the connector.
27Strip back 10 mm of insulation from each
of the wires on the wiring loom, and on the
adapter loom supplied with the new
distributor.
28Solder the adapter loom wires to the
corresponding identically coloured wires in
the main loom.
29Carefully insulate each individual soldered
joint using insulating tape, then apply tape to
cover the join between the looms.
30Fit a new distributor cap (and screening
can, where applicable), and connect the HT
leads.31Connect the adapter loom to the
distributor.
32Start the engine, and adjust the ignition
timing to the value given in the Specifications
at the beginning of this Chapter. Work as
described above whilst noting that the
vacuum pipe must be left connected.
Note: During production the ignition timing is
accurately set using a microwave process,
and sealant is applied to the distributor clamp
bolt. Because the electronic components
require no maintenance, checking the ignition
timing does not constitute part of the routine
maintenance schedule, and the procedure is
therefore only necessary after removal and
refitting of the distributor. A timing light will be
required for this procedure. For details of
ignition timing adjustment in order to operate
vehicles on unleaded petrol refer to the
appropriate Section of this Chapter.
All models except 2.0 litre DOHC
1Before checking the ignition timing, the
following conditions must be met:
a)The engine must be at normal operating
temperature
b)Where applicable, the vacuum pipe to the
distributor vacuum unit or electronic
module (as applicable) must be
disconnected from the vacuum unit or
electronic module and plugged
c)The idle speed must be below 900 rpm
(isolate “idle speed adjustment” wire if
necessary)
d)Any earthed “octane adjustment” wires
must be temporarily isolated
2Wipe clean the crankshaft pulley timing
marks and the pointer on the crankshaft front
oil seal housing. Note that two alternative
types of pulley may be fitted (see
illustration).The desired timing values are
given in the Specifications. If necessary, use
white paint or chalk to highlight the relevant
timing mark(s) (see illustration).
3Connect a stroboscope timing light to the
No 1 cylinder HT lead, following the
manufacturer’s instructions.
4With the engine idling at normal operating
temperature, point the timing light at the
marks on the crankshaft pulley, and check
that the appropriate timing mark appears
stationary in line with the timing cover pointer.
Take care not to get the timing light leads,
clothing etc tangled in the cooling fan blades
or other moving parts of the engine.
5If adjustment is necessary, stop the engine,
slacken the distributor clamp bolt, and turn
the distributor body slightly. Turn the
distributor body clockwise to retard the
ignition timing (move the timing closer to TDC)
and anti-clockwise to advance the timing.
16Ignition timing (OHC models)
- adjustment
Engine electrical systems 5•17
5
15.12 Removing distributor driveshaft O-
ring - Motorcraft distributor15.10 Unscrewing distributor clamp bolt -
Bosch distributor
16.2a Highlighted timing marks - SOHC
engine with cast crankshaft pulley

Note that the required distributor body
movement will be half of the required
crankshaft movement (ie an adjustment of 5º
in ignition timing will require the distributor
body to be turned 2º. Tighten the clamp bolt
and re-check the timing.
6On models with inductive discharge ignition
systems, the mechanical and vacuum
advance mechanisms can be checked as
follows. On all other models, proceed to
paragraph 10.
7With the engine idling, timing light
connected, and vacuum pipe disconnected as
described in the preceding paragraphs,
increase the engine speed to approximately
2000 rpm (if desired, connect a tachometer to
the engine in accordance with the
manufacturer”s instructions). Note the
approximate distance which the relevant pulley
mark moves out of alignment with the pointer.
8Reconnect the vacuum pipe to the
distributor or electronic module, as
applicable, and repeat the procedure given in
the previous paragraph, when for the same
increase in engine speed, the alignment
differential between the pulley mark and
pointer should be greater than previously
observed.
9If the pulley mark does not appear to move
during the first part of the check, a fault in the
distributor mechanical advance mechanism is
indicated. No increased movement of the
mark during the second part of the check
indicates a punctured diaphragm in the
distributor vacuum unit, or a leak in the
vacuum line.
10On completion of the adjustments and
checks, stop the engine and disconnect the
timing light. Where applicable, reconnect the
vacuum pipe, if not already done, and
reconnect any “octane adjustment” and “idle
speed adjustment” wires. Make a final check
to ensure that the distributor clamp bolt is
tight.
11Finally, the idle speed and mixture should
be checked and adjusted.2.0 litre DOHC carburettor model
12The ignition timing is controlled by the
ESC II module, and no adjustment is possible.
2.0 litre DOHC fuel injection
model
13The ignition timing is controlled by the
EEC IV module, and no adjustment is
possible.
Note: Refer to the Specifications Section at
the beginning of this Chapter for ignition
timing values for use with unleaded petrol.
1To run an engine on unleaded petrol,
certain criteria must be met, and it may be
helpful to first describe the various terms used
for the different types of petrol:
Normal leaded petrol (4-star, 97 RON):
Petrol which has a low amount of lead added
during manufacture (0.15 g/litre), in addition to
the natural lead found in crude oil.
Unleaded petrol (Premium, 95 RON):
Has no lead added during manufacture, but
still has the natural lead content of crude oil.
Lead free petrol: Contains no lead. It has
no lead added during manufacture, and the
natural lead content is refined out. This
type of petrol is not currently available for
general use in the UK and should not be
confused with unleaded petrol.
2To run an engine continuously on unleaded
petrol, suitable hardened valve seat inserts
must be fitted to the cylinder head.
3The OHC engines fitted to the Sierra/P100
range which have suitable valve seat inserts
fitted at manufacture can be identified by
letters stamped on the cylinder head next to
No 4 spark plug as follows:
1.6 litre enginesM, MM, N, or NN
1.6 litre enginesS or SS
2.0 litre enginesL, P, PP, R, or RR4All CVH engines have suitable valve seat
inserts fitted.
5Vehicles which have no identification letter
stamped on the cylinder head, and are not
fitted with suitable valve seat inserts, may still
be run on unleaded petrol (although
continuous use is not recommended),
provided that every fourth tank filling is of
normal leaded petrol, ie: three tanks of
unleaded petrol followed by one tank of
normal leaded petrol.
6When running an OHC engine on unleaded
petrol (Premium, 95 RON), the ignition timing
must be retarded as described in the
following sub-Sections. There is no
requirement for ignition timing adjustment
when running CVH engines on unleaded
petrol.
Inductive discharge ignition
system and ESC system
7On vehicles fitted with an inductive
discharge ignition system, or the ESC system,
the ignition timing should be retarded as
specified.
ESC II and EEC IV systems
8On vehicles fitted with the ESC II or EEC IV
systems, there is a facility for retarding the
ignition timing without physically disturbing
the distributor.
9Adjustment is made by earthing one or two
wires (“octane adjustment” wires) which
terminate in a wiring plug next to the ignition
coil. Ideally a service adjustment lead,
available from a Ford dealer should be used
(see illustration). One end of the lead plugs
into the “octane adjustment” wiring plug, and
the other end should be earthed by fixing to
one of the ignition coil securing screws.
10Cut and insulate the wires in the service
lead which are not to be earthed.
17Ignition timing -adjustmentfor
usewithunleadedpetrol
5•18Engine electrical systems
17.9 Service adjustment lead and plug -
ESC II and EEC IV systems
A Red, blue and yellow wires
B Plug
C Wire cutting point
16.2b Crankshaft pulley timing marks - SOHC engine
A Cast pulleyB Pressed steel pulley

11The amount of ignition retardation
provided by earthing the wire(s) is as shown in
the table above.
12Once the ignition timing has been
retarded, the vehicle can be operated on
either leaded or unleaded petrol.
13On 2.0 litre models, if the yellow wire (“idle
speed adjustment” wire) in the service lead is
earthed, the idle speed will be raised by 75
rpm. If the vehicle already has a single yellow
fly lead connected prior to connecting the
service lead, ensure that the yellow wire in the
service lead is earthed.
14Note that some early models have
coloured “Lucar” connectors fitted in place of
the “octane adjustment” wiring plug (see
illustration). The principle for ignition timing
adjustment on these vehicles is as described
previously for vehicles with the “octane
adjustment” wiring plug.15On completion of ignition timing
adjustment, the idle speed and mixture should
be checked and adjusted as necessary.
Note: Refer to Section 1 for precautions to be
observed when working with electronic
modules.
1Disconnect the battery negative lead.
All ESC modules except ESC
(early “Economy” models)
2All modules except the ESC Hybrid module
are mounted on the left-hand side of the
engine compartment(see illustration).The
ESC Hybrid module is mounted on the
right-hand side of the engine compartment.
3Disconnect the module wiring plug by
pulling on the plug, not the wiring. On ESC IImodules, except those fitted to 1.8 litre
models from February 1987, a locking tab at
the lower end of the wiring plug must be
depressed before unhooking the upper end of
the plug from the module. On ESC II modules
fitted to 1.8 litre models from February 1987
(see illustration)and ESC Hybrid modules,
the wiring plug is secured by a screw which is
integral with the plug (see illustrations).
4Where applicable, disconnect the vacuum
pipe from the module (see illustration).
5Remove the two or three securing screws,
as applicable, and withdraw the module from
the engine compartment. Note that the top
securing screw of the ESC module also
secures the ignition coil strap.
6Refitting is a reversal of removal, but ensure
that the underside of the module and the
corresponding area of the body panel are clean.
ESC module (early “Economy”
models)
7Remove the module complete with its
securing bracket, as described above.
8Fit the new module, slightly behind the old
module position, on the flat vertical surface of
the body panel, and secure with the two
screws supplied. Note that the module must
be mounted against the flat area of the body
panel to prevent distortion of the module, and
to ensure good heat transfer from the module
to the body.
9Reconnect the module vacuum pipe.
10Connect the adapter loom supplied with
the new module between the module and the
old module’s wiring plug.
11Where applicable, refit the coil to its
original location.
18Electronic modules - removal
and refitting
Engine electrical systems 5•19
5
18.4 Disconnecting ESC II module vacuum
pipe18.3c Disconnecting ESC Hybrid module
wiring plug18.3b Disconnecting ESC II module wiring
plug
18.2 ESC module securing screws (arrowed)
A Wiring plug B Vacuum pipe18.3a ESC II module - 1.8 litre models from
February 1987
SystemDegrees of retardation
Blue wireRed wireBlue and red
wires
ESC II (except 1.8 litre)
models from February1987246
ESC II (1.8 litre models from
February 1987)426
EEC IV42617.14 Lucar type “octane
adjustment” connectors -
early models with ESC II
and EEC IV systems
A Red, blue and yellow connectors
B Coil securing screw (earthing point)