AUX FORD SIERRA 1991 2.G Routine Manintenance And Servicing Workshop Manual

Engine
Oil filter type:
SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C102
CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104
Valve clearances (cold):
SOHC:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.03 mm (0.008 ± 0.001 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.03 mm (0.010 ± 0.001 in)
DOHC and CVH:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable (hydraulic cam followers)
Chapter 1
Routine maintenance and servicing
Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Air cleaner inlet air temperature control check . . . . . . . . . . . . . . . . . .36
Air conditioner refrigerant charge check . . . . . . . . . . . . . . . . . . . . . .26
Automatic transmission brake band adjustment . . . . . . . . . . . . . . . .40
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . .17
Automatic transmission selector lubrication . . . . . . . . . . . . . . . . . . .28
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Battery electrolyte level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Battery terminal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Brake system seal and hose renewal . . . . . . . . . . . . . . . . . . . . . . . . .43
Brake pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Camshaft drivebelt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Crankcase ventilation system check . . . . . . . . . . . . . . . . . . . . . . . . .35
Crankcase ventilation vent valve renewal . . . . . . . . . . . . . . . . . . . . . .42
Driveshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Engine idle speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine valve clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Final drive oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Ford Sierra maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Front and rear brake pad/shoe check . . . . . . . . . . . . . . . . . . . . . . . . .9
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Handbrake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . . .19
Idle speed linkage clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Ignition system component check . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Manual gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Mixture adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Oil filler cap check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pulse air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Radiator matrix and air conditioner condenser clean . . . . . . . . . . . . .25
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Roadwheel security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Steering and suspension security check . . . . . . . . . . . . . . . . . . . . . .29
Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Underbody inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1•1
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
Specifications Contents
1

1•4Maintenance schedule
Every 250 miles (400 km) or weekly
m mCheck the engine oil level (Section 3)
m mCheck the engine coolant level (Section 3)
m mCheck the brake fluid level (Section 3)
m mCheck the power steering fluid level (Section 3)
m mCheck the screen washer fluid level (Section 3)
m mVisually examine the tyres for tread depth, and wear
or damage (Section 4)
m mCheck and if necessary adjust the tyre pressures
(Section 4)
m mCheck and if necessary top-up the battery electrolyte
level - where applicable (Section 6)
m mCheck the operation of the horn, all lights, and the
wipers and washers (Sections 5 and 7)
Every 6000 miles (10 000 km) or
6 months - whichever comes sooner
m mRenew engine oil and filter (Section 8)
m mCheck brake pads or shoes for wear (front and rear)
(Section 9)
m mCheck operation of brake fluid level warning indicator
(Section 9)
m mInspect engine bay and underside of vehicle for fluid
leaks or other signs of damage (Section 10)
m mCheck function and condition of seat belts
(Section 11)
m mCheck condition and security of exhaust system
(Section 12)
m mCheck tightness of wheel nuts (Section 13)
m mClean oil filler cap (Section 14)
m mCheck idle speed (where applicable) (Section 15)
m mCheck mixture adjustment (where applicable)
(Section 16)
Every 12 000 miles (20 000 km) or
12 months - whichever comes sooner
m mCheck automatic transmission fluid level (engine hot)
(Section 17)
m mCheck manual gearbox oil level (Section 18)
m mCheck operation of latches, check straps and locks;
lubricate if necessary (Section 19)
m mRenew spark plugs (Section 20)
m mCheck condition and tension of auxiliary drivebelt(s);
adjust or renew as necessary (Section 21)
m mCheck tightness of battery terminals, clean and
neutralise corrosion if necessary (Section 22)
m mCheck engine valve clearances - SOHC only
(Section 23)
m mCheck handbrake mechanism (Section 24)
Every 24 000 miles (40 000 km) or
2 years - whichever comes sooner
m mCheck air cleaner inlet air temperature control
operation (carburettor models) (Section 36)
m mRenew pulse air filter element (1.6 litre CVH)
(Section 37)
m mRenew air cleaner element (Section 38)
m mClean and inspect distributor cap and HT leads
(Section 39)
m mCheck automatic transmission brake band
adjustment (Section 40)
m mRenew fuel filter (fuel-injection models only)
(Section 41)
m mRenew crankcase ventilation vent valve (SOHC and
DOHC) (Section 42)
m mClean radiator matrix and air conditioning condenser
fins (where applicable) (Section 25)
m mCheck air conditioning refrigerant charge (where
applicable) (Section 26)
m mCheck final drive oil level (Section 27)
m mLubricate automatic transmission selector/kickdown
linkage (Section 28)
m mCheck security and condition of steering and
suspension components, gaiters and boots
(Section 29)
m mCheck condition and security of driveshaft joints and
gaiters (Section 30)
m mInspect underbody and panels for corrosion or other
damage (Section 31)
m mInspect brake pipes and hoses (Section 32)
m mClean idle speed control linkage at throttle (where
applicable) (Section 33)
m mRoad test and check operation of ABS (Section 34)
m mCheck crankcase ventilation system (Section 35)
Every 36 000 miles (60 000 km) or
3 years - whichever comes sooner
m mRenew brake hydraulic system seals and hoses if
necessary (Section 43)
m mRenew brake hydraulic fluid (Section 44)
m mRenew camshaft drivebelt (optional on SOHC
models - compulsory on CVH) (Section 45)
m mRenew coolant (Section 46)
Every 12 000 miles (20 000 km) or
12 months - whichever comes sooner
(continued)

General information
This Chapter is designed to help the home
mechanic maintain his/her vehicle for safety,
economy, long life and peak performance.
The Chapter contains a master
maintenance schedule, followed by Sections
dealing specifically with each task in the
schedule. Visual checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the engine compartment and
the underside of the vehicle for the locations
of the various components.
Servicing your vehicle in accordance with
the mileage/time maintenance schedule and
the following Sections will provide a planned
maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
items but not others at the specified service
intervals, will not produce the same results.
As you service your vehicle, you will discover
that many of the procedures can - and should -
be grouped together, because of the particular
procedure being performed, or because of the
close proximity of two otherwise-unrelated
components to one another. For example, if
the vehicle is raised for any reason, the exhaust
can be inspected at the same time as thesuspension and steering components.
The first step in this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
Sections relevant to the work to be carried
out, then make a list and gather together all
the parts and tools required. If a problem is
encountered, seek advice from a parts
specialist, or a dealer service department.
Intensive maintenance
If, from the time the vehicle is new, the
routine maintenance schedule is followed
closely, and frequent checks are made of fluid
levels and high-wear items, as suggested
throughout this manual, the engine will be
kept in relatively good running condition, and
the need for additional work will be minimised.
It is possible that there will be times when
the engine is running poorly due to the lack of
regular maintenance. This is even more likely
if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
If engine wear is suspected, a compression
test will provide valuable information
regarding the overall performance of the main
internal components. Such a test can be used
as a basis to decide on the extent of the work
to be carried out. If, for example, a
compression test indicates serious internal
engine wear, conventional maintenance as
described in this Chapter will not greatlyimprove the performance of the engine, and
may prove a waste of time and money, unless
extensive overhaul work is carried out first.
The following series of operations are those
most often required to improve the
performance of a generally poor-running
engine:
Primary operations
a)Clean, inspect and test the battery
b)Check all the engine-related fluids
c)Check the condition and tension of the
auxiliary drivebelt
d)Renew the spark plugs
e)Inspect the distributor cap and HT leads -
as applicable
f)Check the condition of the air cleaner
filter element, and renew if necessary
g)Renew the fuel filter
h)Check the condition of all hoses, and
check for fluid leaks
i)Check the idle speed and mixture settings
- as applicable
If the above operations do not prove fully
effective, carry out the following secondary
operations:
Secondary operations
a)Check the charging system
b)Check the ignition system
c)Check the fuel system
d)Renew the distributor cap and rotor arm -
as applicable
f)Renew the ignition HT leads - as
applicable
2Introduction
See “Weekly checks”.
See “Weekly checks”.See “Weekly checks”.
See “Weekly checks”.See “Weekly checks”.
7Wiper blade check
6Battery electrolyte level check
5Electrical system check
4Tyre checks
3Fluid level checks
1Frequent oil and filter changes are the most
important preventative maintenance
procedures which can be undertaken by the
DIY owner. As engine oil ages, it becomes
diluted and contaminated, which leads to
premature engine wear.
2Before starting this procedure, gather
together all the necessary tools and materials.
Also make sure that you have plenty of clean
rags and newspapers handy, to mop up any
spills. Ideally, the engine oil should be warm,
as it will drain better, and more built-upsludge will be removed with it. Take care,
however, not to touch the exhaust or any
other hot parts of the engine when working
under the vehicle. To avoid any possibility of
scalding, and to protect yourself from
possible skin irritants and other harmful
contaminants in used engine oils, it is
advisable to wear gloves when carrying out
this work. Access to the underside of the
vehicle will be greatly improved if it can be
raised on a lift, driven onto ramps, or jacked
up and supported on axle stands (see
“Jacking and vehicle support”). Whichever
method is chosen, make sure that the vehicle
remains level, or if it is at an angle, so that the
drain plug is at the lowest point (see
illustration).
8Engine oil and filter renewal
Maintenance procedures 1•9
1
8.2 Sump drain plug location
Every 250 miles (400 km) or weekly
Every 6000 miles (10 000 km) or 6 months

3Wipe clean around the filler/level plug.
Unscrew the plug and remove it(see
illustration).
4Using a suitably marked piece of bent wire
as a dipstick, check that the oil level is as
shown in the table at the top of this page,
according to gearbox type.
5Top-up the level if necessary, using clean
oil of the specified type. Do not overfill, as this
can lead to leakage and difficult gear
changing. Allow excess oil to drip out of the
filler/level hole if necessary. Refit and tighten
the filler/level plug on completion.
6The frequent need for topping-up can only
be due to leaks, which should be rectified.
The most likely sources of leaks are the rear
extension housing and input shaft oil seals.
7No periodic oil changing is specified, and
no drain plug is fitted.
1Work around the vehicle, and lubricate the
bonnet, door and tailgate hinges with a light
machine oil.
2Lightly lubricate the bonnet release
mechanism and exposed sections of inner
cable with a smear of grease.
3Check the security and operation of all
hinges, latches and locks, adjusting them
where required. Where applicable, check the
operation of the central locking system.
4Check the condition and operation of the
tailgate struts, renewing them if either is
leaking or is no longer able to support the
tailgate securely when raised.
1The correct functioning of the spark plugs is
vital for the correct running and efficiency of
the engine. It is essential that the plugs fitted
are appropriate for the engine.
2Make sure that the ignition is switched off
before inspecting the HT leads to see if they
carry their cylinder numbers. Note that the
position of No 1 cylinder HT lead in the
distributor cap is marked with either a pip, or
a number “1 “.3Where necessary, for improved access
remove the air cleaner and/or the inlet hose.
4Disconnect the leads from the plugs by
pulling on the connectors, not the leads.
5On 2.0 litre DOHC carburettor models, the
location of the spark plugs and the close
proximity of the carburettor makes spark plug
access difficult, particularly when removing
the plugs from cylinders 2 and 3. It is
suggested that a 3/8 inch ratchet drive spark
plug socket with rubber insert and long
extension bar is used, possibly in conjunction
with a universal joint adapter. It is also
advisable to disconnect No 3 cylinder HT lead
from the distributor first, to allow some slack
for disconnection at the spark plug.
6Clean the area around each spark plug
using a small brush, then using a plug
spanner (preferably with a rubber insert),
unscrew and remove the plugs(see
illustration).Cover the spark plug holes with
a clean rag to prevent the ingress of any
foreign matter.
7Before fitting new spark plugs, check that
the threaded connector sleeves are tight. As
the plugs incorporate taper seats, make sure
that the threads and seats are clean.8On DOHC models before refitting the spark
plugs, coat their threads with suitable anti-
seize compound, taking care not to
contaminate the electrodes.
9Screw in the spark plugs by hand, then
tighten them to the specified torque. Do not
exceed the torque figure.
10Push the HT leads firmly onto the spark
plugs, and where applicable refit the air
cleaner and/or inlet hose.
1Refer to the Specifications at the beginning
of this Chapter and check the tension of each
drivebelt at the point stated. Check the full
length of each drivebelt for cracks and
deterioration. It will be necessary to turn the
engine in order to check that portion of the
drivebelt in contact with the pulleys. Renew or
tension each belt as necessary as follows,
according to model type:
SOHC models
2Note that two drivebelts are fitted to models
equipped with power steering and both
should be renewed if either one is
unserviceable. Where fitted, the air
conditioning compressor is driven by a
separate belt.
3Disconnect the battery negative lead.
4Where applicable, remove the air
conditioning compressor drivebelt.
5Loosen the alternator mounting and
adjustment nuts and bolts, and pivot the
alternator towards the cylinder block.
6Slip the drivebelt(s) from the alternator,
water pump, crankshaft and (where
applicable) the power steering pump pulleys.
7Fit the new drivebelt(s) over the pulleys,
then lever the alternator away from the
cylinder block until the specified belt tension
is achieved. Lever the alternator using a
wooden or plastic lever at the pulley end to
prevent damage and straining the brackets. It
is helpful to partially tighten the adjustment
link bolt before tensioning the drivebelt(s).
21Auxiliary drivebelt check
20Spark plug renewal
19Hinge and lock check and
lubrication
1•14Every 12 000 miles or 12 months
18.3 Gearbox filler/level plug location
(arrowed) - N type gearbox
20.6 Removing a spark plug - CVH engine
Note: The vehicle build code appears as the twelfth and thirteenth characters of the VIN number
on the plate in the engine compartment.
Gearbox type
All four-speed gearboxes
All five-speed gearboxes up to April 1984 (build
code E6) except those subsequently fitted with
a modified extension housing
All five-speed gearboxes from May 1984 (build
code EC) to end of April 1985 (build code FP)
and all vehicles built up to April 1984 (build
code E6) subsequently fitted with a modified
gearbox extension housing
All five-speed gearboxes from May 1985Oil level
0 to 5.0 mm (0 to 0.2 in) below lower edge of
filler/level hole
Level with bottom edge of filler/level hole
20.0 to 25.0 mm (0.79 to 0.99 in) below lower
edge of filler/level hole
0 to 5.0 mm (0 to 0.2 in)below lower edge of
filler/level hole
Number each HT lead using
sticky tape or paint before
removal so as to avoid
confusion when refitting.