length FORD SIERRA 1991 2.G Reference Workshop Manual

General dimensions and Weights . . . . . . . . . . . .REF•1
Buying Spare Parts . . . . . . . . . . . . . . . . . . . . . . .REF•3
Vehicle Identification Numbers . . . . . . . . . . . . . .REF•3
General Repair Procedures . . . . . . . . . . . . . . . . .REF•4
Tools and Working Facilities . . . . . . . . . . . . . . . .REF•5MOT Test Checks . . . . . . . . . . . . . . . . . . . . . . . .REF•7
Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .REF•11
Glossary of Technical Terms . . . . . . . . . . . . . . .REF•18
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REF•23
ReferenceREF•1
REF
General dimensions and weights
Dimensions
Overall length:
Saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4467.0 mm (176.0 in)
Hatchback:
All models up to 1987 except GLS, 2.0iS and Ghia . . . . . . . . . . . . 4407.0 mm (173.6 in)
GLS and 2.0iS models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . 4460.0 mm (175.7 in)
Ghia models up to 1987 and all models from 1987 . . . . . . . . . . . . 4425.0 mm (174.3 in)
Estate:
All models up to 1987 except Ghia . . . . . . . . . . . . . . . . . . . . . . . . . 4506.0 mm (177.5 in)
Ghia models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4522.0 mm (178.2 in)
All models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4511.0 mm (177.7 in)
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4900.0 mm (193.1 in)
Overall width:
All models up to 1987 except Base, GLS, 2.0iS and Ghia . . . . . . . . . 1867.0 mm (73.6 in)
Base models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1821.0 mm (71.7 in)
GLS, 2.0iS and Ghia models up to 1987 . . . . . . . . . . . . . . . . . . . . . . 1920.0 mm (75.6 in)
All models from 1987 except P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1694.0 mm (66.7 in)
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1920.0 mm (75.6 in)
Saloon models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698.0 mm (66.9 in)
Hatchback models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1694.0 mm (66.7 ln)
Estate models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1720.0 mm (67.8 in)
Overall height:
Saloon:
All models except GLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1359.0 mm (53.5 in)
GLS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1352.0 mm (53.3 in)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407.0 mm (55.4 in)
Hatchback:
All models up to 1987 except GLS and 2.0iS . . . . . . . . . . . . . . . . . 1420.0 mm (55.9 in)
GLS and 2.0iS models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . 1392.0 mm (54.8 in)
All models from 1987 except GLS . . . . . . . . . . . . . . . . . . . . . . . . . 1359.0 mm (53.5 in)
GLS models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1352.0 mm (53.3 in)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407.0 mm (55.4 in)
Estate:
All models up to 1987 except Base and Ghia . . . . . . . . . . . . . . . . . 1443.0 mm (56.9 in)
Base models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1417.0 mm (55.8 in)
Ghia models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1506.0 mm (59.3 in)
Models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1386.0 mm (54.6 in)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1428.0 mm (56.3 in)
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1520.0 mm (59.9 in)
Weights
Kerb weight†:
Saloon:
Models before 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025 to 1135 kg (2260 to 2503 lbs)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065 to 1240 kg (2343 to 2728 lbs)
Hatchback:
Models before 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 to 1145 kg (2227 to 2525 lbs)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065 to 1240 kg (2343 to 2728 lbs)
Estate:
Models before 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065 to 1186 kg (2348 to 2613 lbs)
Models from 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105 to 1190 kg (2431 to 2618 lbs)
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1370 kg (3021 lbs)
Maximum gross vehicle weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to VIN plate
Maximum roof rack load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 kg (165 lbs)
Minimum towing hitch downward load . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kg (55 lbs)
Maximum towing hitch downward load . . . . . . . . . . . . . . . . . . . . . . . . . 50 kg (110 lbs)
†Exact kerb weights depend upon model and specification

REF•10MOTtest checks
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test
can be carried out later to check that the
vehicle pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-
bearing areas. (These include chassis box
sections, side sills, cross-members, pillars,
and all suspension, steering, braking system
and seat belt mountings and anchorages.)
Any corrosion which has seriously reduced
the thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allow
the engine speed to return to idle, and watchfor smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time of writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000
rpm; if the HC level is then 1200 ppm or less,
this counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM

Glossary of Technical termsREF•19
REF
CamshaftA rotating shaft on which a series
of cam lobes operate the valve mechanisms.
The camshaft may be driven by gears, by
sprockets and chain or by sprockets and a
belt.
CanisterA container in an evaporative
emission control system; contains activated
charcoal granules to trap vapours from the
fuel system.
CarburettorA device which mixes fuel with
air in the proper proportions to provide a
desired power output from a spark ignition
internal combustion engine.
CastellatedResembling the parapets along
the top of a castle wall. For example, a
castellated balljoint stud nut.
CastorIn wheel alignment, the backward or
forward tilt of the steering axis. Castor is
positive when the steering axis is inclined
rearward at the top.Catalytic converterA silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
CirclipA ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
groove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
ClearanceThe amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil springA spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
CompressionReduction in volume, and
increase in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compression ratioThe relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) jointA type of
universal joint that cancels out vibrations
caused by driving power being transmitted
through an angle.
Core plugA disc or cup-shaped metal device
inserted in a hole in a casting through which
core was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
CrankcaseThe lower part of the engine
block in which the crankshaft rotates.
CrankshaftThe main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
rods are attached.Crocodile clipSee Alligator clip
DDiagnostic codeCode numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
where a malfunction may be located.
Disc brakeA brake design incorporating a
rotating disc onto which brake pads are
squeezed. The resulting friction converts the
energy of a moving vehicle into heat.
Double-overhead cam (DOHC)An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s)The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor, etc. off the crankshaft pulley.
DriveshaftAny shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brakeA type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pressed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
Castellated nut
Catalytic converter
Crankshaft assembly
Carburettor
Canister
Drum brake assembly
Accessory drivebelts
Driveshaft

REF•20Glossary of Technical terms
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electronic control unit (ECU)A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electronic Fuel Injection (EFI)A computer
controlled fuel system that distributes fuel
through an injector located in each intake port
of the engine.
Emergency brakeA braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depressed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.
EndfloatThe amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS)A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifoldA part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
FFan clutchA viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds.Feeler bladeA thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing orderThe order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
energy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Free playThe amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
FuseAn electrical device which protects a
circuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible linkA circuit protection device
consisting of a conductor surrounded by
heat-resistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.
GGapThe distance the spark must travel in
jumping from the centre electrode to the sideelectrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
Exhaust manifold
Feeler blade
Adjusting spark plug gap
Gasket
EGR valve