fuse box FORD SIERRA 1989 2.G Reference Workshop Manual

The vehicle owner who does his or her own maintenance according
to the recommended service schedules should not have to use this
section of the manual very often. Modern component reliability is such
that, provided those items subject to wear or deterioration are
inspected or renewed at the specified intervals, sudden failure is
comparatively rare. Faults do not usually just happen as a result of
sudden failure, but develop over a period of time. Major mechanical
failures in particular are usually preceded by characteristic symptoms
over hundreds or even thousands of miles. Those components which
do occasionally fail without warning are often small and easily carried
in the vehicle.
With any fault-finding, the first step is to decide where to begin
investigations. Sometimes this is obvious, but on other occasions, alittle detective work will be necessary. The owner who makes half a
dozen haphazard adjustments or replacements may be successful in
curing a fault (or its symptoms), but will be none the wiser if the fault
recurs, and ultimately may have spent more time and money than was
necessary. A calm and logical approach will be found to be more
satisfactory in the long run. Always take into account any warning
signs or abnormalities that may have been noticed in the period
preceding the fault - power loss, high or low gauge readings, unusual
smells, etc - and remember that failure of components such as fuses or
spark plugs may only be pointers to some underlying fault.
The pages which follow provide an easy-reference guide to the more
common problems which may occur during the operation of the
vehicle. These problems and their possible causes are grouped under
Fault diagnosisREF•11
REF
Engine
MEngine fails to rotate when attempting to start
MStarter motor turns engine slowly
MEngine rotates, but will not start
MEngine difficult to start when cold
MEngine difficult to start when hot
MStarter motor noisy or excessively-rough in engagement
MEngine starts, but stops immediately
MEngine idles erratically
MEngine misfires at idle speed
MEngine misfires throughout the driving speed range
MEngine hesitates on acceleration
MEngine stalls
MEngine lacks power
MEngine backfires
MOil pressure warning light illuminated with engine running
MEngine runs-on after switching off
MEngine noises
Cooling system
MOverheating
MOvercooling
MExternal coolant leakage
MInternal coolant leakage
MCorrosion
Fuel and exhaust systems
MExcessive fuel consumption
MFuel leakage and/or fuel odour
MExcessive noise or fumes from exhaust system
Clutch
MPedal travels to floor - no pressure or very little resistance
MClutch fails to disengage (unable to select gears)
MClutch slips (engine speed increases; no increase in vehicle speed)
MJudder as clutch is engaged
MNoise when depressing or releasing clutch pedal
Manual gearbox
MNoisy in neutral with engine running
MNoisy in one particular gear
MDifficulty engaging gears
MJumps out of gear
MVibration
MLubricant leaks
Automatic transmission
MFluid leakage
MTransmission fluid brown, or has burned smellMGeneral gear selection problems
MTransmission will not downshift (kickdown) with acceleration
MEngine will not start in any gear, or starts in gears other than Park
or Neutral
MTransmission slips, shifts roughly, is noisy, or has no drive in forward
or reverse gears
Propeller shaft
MClunking or knocking noise when taking up drive
MVibration when accelerating or decelerating
Final drive and driveshafts
MExcessive final drive noise
MOil leakage from final drive
MGrating, knocking or vibration from driveshafts
Braking system
MVehicle pulls to one side under braking
MNoise (grinding or high-pitched squeal) when brakes applied
MExcessive brake pedal travel
MBrake pedal feels spongy when depressed
MExcessive brake pedal effort required to stop vehicle
MJudder felt through brake pedal or steering wheel when braking
MPedal pulsates when braking hard
MBrakes binding
MRear wheels locking under normal braking
Suspension and steering systems
MVehicle pulls to one side
MWheel wobble and vibration
MExcessive pitching and/or rolling around corners, or during braking
MWandering or general instability
MExcessively-stiff steering
MExcessive play in steering
MLack of power assistance
MTyre wear excessive
Electrical system
MBattery will not hold a charge for more than a few days
MIgnition/no-charge warning light remains on with engine running
MIgnition/no-charge warning light fails to come on
MLights inoperative
MInstrument readings inaccurate or erratic
MHorn inoperative, or unsatisfactory in operation
MWindscreen/tailgate wipers inoperative, or unsatisfactory in operation
MWindscreen/tailgate washers inoperative, or unsatisfactory in
operation
MElectric windows inoperative, or unsatisfactory in operation
MCentral locking system inoperative, or unsatisfactory in operation
Introduction

Note:Due to the complexity of the automatic transmission, it is difficult
for the home mechanic to properly diagnose and service this unit. For
problems other than the following, the vehicle should be taken to a
dealer service department or automatic transmission specialist.
Fluid leakage
MAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by air flow.
MTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using a
degreasing agent or by steam-cleaning. Drive the vehicle at low speed,
so that air flow will not blow the leak far from its source. Raise and
support the vehicle, and determine where the leak is coming from. The
following are common areas of leakage.
a)Fluid pan ( transmission “sump”).
b)Dipstick tube (Chapter 1).
c)Transmission-to-fluid cooler fluid pipes/unions (Chapter 7).
Transmission fluid brown, or has burned smell
MTransmission fluid level low, or fluid in need of renewal (Chapter 1).
General gear selection problems
MThe most likely cause of gear selection problems is a faulty or
poorly-adjusted gear selector mechanism. The following are common
problems associated with a faulty selector mechanism.
a)Engine starting in gears other than Park or Neutral.
b)Indicator on gear selector lever pointing to a gear other than the
one actually being used.
c)Vehicle moves when in Park or Neutral.
d)Poor gear shift quality, or erratic gear changes.
MRefer any problems to a Ford dealer, or transmission specialist.
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
MLow transmission fluid level (Chapter 1).
MIncorrect selector adjustment (Chapter 7).
Noisy in neutral with engine running
MInput shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7).*
MClutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 6).
Noisy in one particular gear
MWorn, damaged or chipped gear teeth (Chapter 7).*
Difficulty engaging gears
MClutch fault (Chapter 6).
MWorn or damaged gear linkage (Chapter 7).
MWorn synchroniser units (Chapter 7).*
Jumps out of gear
MWorn or damaged gear linkage (Chapter 7).MWorn synchroniser units (Chapter 7).*
MWorn selector forks (Chapter 7).*
Vibration
MLack of oil (Chapter 1).
MWorn bearings (Chapter 7).*
Lubricant leaks
MLeaking oil seal (Chapter 7).
MLeaking housing joint (Chapter 7).*
*Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.
Pedal travels to floor - no pressure or very little
resistance
MBadly stretched or broken cable (Chapter 6).
MStripped pawl on pedal (Chapter 6).
MBroken clutch release bearing or arm (Chapter 6).
MBroken diaphragm spring in clutch pressure plate (Chapter 6).
Clutch fails to disengage (unable to select gears)
MCable free play excessive (Chapter 6).
MClutch driven plate sticking on gearbox input shaft splines
(Chapter 6).
MClutch driven plate sticking to flywheel or pressure plate (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MClutch release mechanism worn or incorrectly assembled (Chapter 6).
Clutch slips (engine speed increases, with no
increase in vehicle speed)
MClutch driven plate linings excessively worn (Chapter 6).MClutch driven plate linings contaminated with oil or grease (Chapter 6).
MFaulty pressure plate or weak diaphragm spring (Chapter 6).
Judder as clutch is engaged
MClutch driven plate linings contaminated with oil or grease (Chapter 6).
MClutch driven plate linings excessively worn (Chapter 6).
MFaulty or distorted pressure plate or diaphragm spring (Chapter 6).
MWorn or loose engine or gearbox mountings (Chapter 2).
MClutch driven plate hub or gearbox input shaft splines worn
(Chapter 6).
Noise when depressing or releasing clutch pedal
MWorn clutch release bearing (Chapter 6).
MWorn or dry clutch pedal pivot (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MPressure plate diaphragm spring broken (Chapter 6).
MBroken clutch driven plate cushioning springs (Chapter 6).
REF•14Fault diagnosis
Clutch
Manual gearbox
Automatic transmission

refitting - 2A•10, 2B•7, 2C•9
removal - 2A•8, 2B•4, 2C•6
SOHC engines- 2A•1et seq
spark plugs - 1•2, 1•14, 5•12
sump - 2A•20, 2B•15, 2C•19
timing belt/chain and sprockets - 2A•12,
2B•8, 2C•10
timing and sprockets - 2A•12, 2B•8, 2C•10
valves - 1•15
Engine electrical systems - 5•1 et seq
Environmental considerations- REF•4
Exhaust gas oxygen sensor (HEGO)- 4B•15
Exhaust gas recirculation valve- 4B•14
Exhaust manifold- 4A•17, 4B•15
Exhaust pressure transducer- 4B•14
Exhaust system- 1•11, 4A•18, 4B•15
Expansion tank/coolant sensor- 3•8
FFacia panel- 12•16
Facia panel switches- 13•4
Fan (radiator)- 3•7
Fault diagnosis- REF•11
automatic transmission - REF•14
braking system - REF•15
clutch - REF•14
cooling system - REF•13
driveshafts - REF•15
electrical system - REF•16
engine - REF•12
final drive - REF•15
fuel and exhaust systems - REF•13
manual gearbox - REF•14
propeller shaft - REF•15
steering - REF•16
suspension - REF•16
Final drive and driveshafts- 9•1 et seq
Final drive fault diagnosis- REF•11, REF•15
Final drive unit- 9•2, 9•3, 9•4
Fluids- 0•17
Flywheel/driveplate- 2A•18, 2B•15, 2C•19
Foglamps- 13•15
Ford VV carburettor- 1•12, 4A•13
Front suspension crossmember- 11•3
Front suspension strut- 11•4
Fuel systems- carburettor - 4A•1 et seq
Fuel systems- fuel injection - 4B•1 et seq
Fuel system:
accelerator cable - 4A•8
accelerator pedal - 4A•8
air cleaner - 1•18, 1•19, 4A•4, 4B•4
airflow meter - 4B•8
catalytic converter - 4B•3, 4B•14
CFI unit- 4B•10
depressurising fuel injection system - 4B•4
dismantling and reassembly - 4A•8
electronic vacuum regulator - 4B•11
exhaust gas recirculation valve - 4B•14
exhaust gas oxygen sensor (HEGO) - 4B•15
exhaust manifold - 4A•17, 4B•15
exhaust pressure transducer - 4B•14
exhaust system - 4A•18, 4B•15
fuel filler cap - 12•14
fuel filter - 1•2, 1•20
fuel level sender unit - 4A•7, 4B•7fuel pressure regulator - 4A•5, 4B•5
fuel pump - 4A•5, 4A•6, 4B•6
fuel tank - 4A•7
fuel vapour separator - 4A•5
fuel gauges - 13•8
idle speed control valve - 4B•7
injector(s) - 4B•8
inlet manifold - 4A•15, 4B•12
mixture adjustment potentiometer - 4B•7
pulse-air - 4B•10
throttle body - 4B•12
throttle control motor - 4B•11
throttle position sensor - 4B•11
throttle valve control motor - 4B•11
Fuses- 13•3
GGear linkage- 7A•4
Gear selector mechanism- 7B•5
Gearbox - see Manual gearbox or
Automatic transmission
Gearbox oil- 0•17, 1•3
Glass- 12•11
HHandbrake check/adjustment- 1•16, 10•21
Handbrake cables- 10•20, 10•21
Handbrake lever - 10•22
Handbrake warning lamp switch- 13•6
Handles (door)- 12•9
Hazard warning flasher switch- 13•4
Headlamp alignment- 13•14
Headlamp unit- 13•13
Headlamp washers- 13•12
Headlining - 12•19
Heated rear window- 13•20
Heated seat- 13•19
Heater- 3•9
Hinges and locks- 1•14
Horn- 13•11
Horn switch- 13•5
Hose and fluid leak check- 0•8, 1•10,
Hoses brake- 10•19
Hoses power steering- 11•18
HT coil- 5•13
HT leads- 5•12
Hub carrier (front) - 11•5
Hydraulic fluid- 0•17
Hydraulic system (brakes) bleeding- 10•2
Hydraulic unit, pump, motor (ABS)- 10•15,
10•16
IIdle speed control valve- 4B•7
Idle speed/mixture- 1•11, 1•12, see
Specifications in Chapter 4A, and refer to
specific carburettor type
Ignition electronic modules- 5•3, 5•19
Ignition HT coil- 5•13
Ignition switch- 13•4
Ignition system check- 1•20
Ignition timing adjustment- 5•17
Indicator lamps- 13•15Indicator switch/relay- 13•4
Injector(s)- 4B•8
Inlet manifold- 4A•15, 4B•12
Instrument panel- 13•7
Interior trim- 12•15
Introduction to the Ford Sierra- 0•4
JJacking and vehicle support- 0•6
Jump starting- 0•9
KKickdown cable - 7B•3
LLeaf springs- 11•13
Leak, checking- 0•8, 1•10
Lights- 13•14
Locks:
bootlid - 12•5
door - 12•9, 12•10
tailgate - 12•6
Loudspeakers- 13•20
Lower arm (suspension)- 11•4, 11•7, 11•8
Lubricants and fluids- 0•17
Luggage area light switch- 13•5
MMain bearings- 2A•23, 2B•17, 2C•23
Maintenance and servicing - see Routine
maintenance
Manifolds- 4A•15, 4A•17, 4B•12, 4B•15
Manual gearbox- 7A•1 et seq
fault diagnosis - REF•11, REF•14
gear linkage - 7A•4
gearbox oil - 0•17, 1•3
oil level check - 1•13
removal and refitting - 7A•2
Master cylinder (brake)- 10•13
Mirrors- 12•12
Mixture (CO)- see Idle speed/mixture
Mixture adjustment potentiometer- 4B•7
MOT test checks- REF•7
Mountings, engine-2A•11, 2B•7, 2C•9
NNumber plate lamp- 13•16
OOil change/filter- 1•1, 1•9,
Oil pressure warning switch- 13•6
Oil pump- 2A•21, 2B•16, 2C•20
Oil seals- REF •4
Oil seals crankshaft- 2A•19, 2B•15, 2C•19
Oils- engine and gearbox- 0•17, 1•3
PPads (brake) - 10•3
Paintwork damage- 12•2
Parts- REF•3
REF•24Index