battery FORD SIERRA 1992 2.G Introduction Workshop Manual

LIVING WITH YOUR FORD SIERRAIntroduction to the Ford SierraPage0•4
AcknowledgementsPage0•4
Safety first!Page0•5
ROADSIDE REPAIRSJacking, vehicle support and wheel changingPage0•6
TowingPage0•7
Identifying leaksPage0•8
Jump startingPage0•9
Weekly Checks
IntroductionPage0•10
Underbonnet check pointsPage0•10
Engine Oil levelPage0•12
Coolant levelPage0•12
Screen washer fluid levelPage0•13
Brake fluid levelPage0•13
Power steering fluid levelPage0•14
Electrical systemsPage0•14
BatteryPage0•15
Wiper bladesPage0•15
Tyre condition and pressurePage0•16
Lubricants and fluidsPage0•17
Tyre pressuresPage0•18
MAINTENANCE
Routine Maintenance and ServicingPage1•1
Maintenance schedulePage1•4
Maintenance proceduresPage1•9
Contents

0•5Safety First!
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Specia hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400
0C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.

0•9Roadside repairs
When jump-starting a car using a
booster battery, observe the following
precautions:
4Before connecting the booster
battery, make sure that the ignition is
switched off.
4Ensure that all electrical equipment
(lights, heater, wipers, etc) is
switched off.
4Make sure that the booster battery is
the same voltage as the discharged
one in the vehicle.
4If the battery is being jump-started
from the battery in another vehicle,
the two vehcles MUST NOT TOUCH
each other.
4Make sure that the transmission is in
neutral (or PARK, in the case of
automatic transmission).
Jump starting will get you out
of trouble, but you must correct
whatever made the battery go
flat in the first place. There are
three possibilities:
1The battery has been drained by
repeated attempts to start, or by
leaving the lights on.
2The charging system is not working
properly (alternator drivebelt slack
or broken, alternator wiring fault or
alternator itself faulty).
3The battery itself is at fault
(electrolyte low, or battery worn out).
Connect one end of the red jump lead to
the positive (+) terminal of the flat
batteryConnect the other end of the red lead to
the positive (+) terminal of the booster
battery.Connect one end of the black jump lead
to the negative (-) terminal of the
booster battery
Connect the other end of the black
jump lead to a bolt or bracket on the
engine block, well away from the
battery, on the vehicle to be started.
123
4
Make sure that the jump leads will not
come into contact with the fan, drive-
belts or other moving parts of the
engine.5
Start the engine using the booster
battery, then with the engine running at
idle speed, disconnect the jump leads in
the reverse order of connection.6
Jump starting

0•10
There are some very simple checks which
need only take a few minutes to carry out, but
which could save you a lot of inconvenience
and expense.
These "Weekly checks" require no great skill
or special tools, and the small amount of time
they take to perform could prove to be very
well spent, for example;MKeeping an eye on tyre condition and
pressures, will not only help to stop them
wearing out prematurely, but could also save
your life.
MMany breakdowns are caused by electrical
problems. Battery-related faults are
particularly common, and a quick check on a
regular basis will often prevent the majority of
these.MIf your car develops a brake fluid leak, the
first time you might know about it is when your
brakes don't work properly. Checking the level
regularly will give advance warning of this kind
of problem.
MIf the oil or coolant levels run low, the cost
of repairing any engine damage will be far
greater than fixing the leak, for example.
Underbonnet check points
§2.0 litre OHC
Carburettor model
(air cleaner removed for clarity)
ALocation of oil level dipstick
BEngine oil filler cap
CCoolant expansion tank
DBrake fluid reservoir
EWindscreen washer reservoir
FBattery
§2.0 litre OHC
Fuel injection model
AOil level dipstick
BEngine oil filler cap
CCoolant expansion tank
DBrake fluid reservoir
EWindscreen washer reservoir
FBattery
Introduction
Weekly checks

0•11
§1.8 litre CVH
Air cleaner removed for clarity
AOil level dipstick
BEngine oil filler cap
CCoolant expansion tank
DBrake fluid reservoir
EWindscreen washer reservoir
FBattery
§2.0 litre DOHC
AOil level dipstick
BEngine oil filler cap
CCoolant expansion tank
DPower steering fluid reservoir
EWindscreen washer reservoir
FBattery
Weekly checks

0•15
To remove a wiper blade, pull the arm
fully away from the glass until it locks.
Swivel the blade through 90°, press the
locking tab(s) with your fingers, and slide the
blade out of the arm's hooked end. On
refitting, ensure that the blade locks securely
into the arm.Check the condition of the wiper blades;
if they are cracked or show any signs of
deterioration, or if the glass swept area is
smeared, renew them. For maximum clarity of
vision, wiper blades should be renewed
annually, as a matter of course.21Weekly checks
Battery
Caution:Before carrying out any work on the
vehicle battery, read the precautions given in
“Safety first” at the start of this manual.
4Make sure that the battery tray is in good
condition, and that the clamp is tight.
Corrosion on the tray, retaining clamp and the
battery itself can be removed with a solution
of water and baking soda. Thoroughly rinse all
cleaned areas with water. Any metal parts
damaged by corrosion should be covered with
a zinc-based primer, then painted.
4Periodically (approximately every three
months), check the charge condition of the
battery as described in Chapter 5A.
4If the battery is flat, and you need to jump
start your vehicle, see “Roadside Repairs”.The battery is located on the left-hand
side of the engine compartment. The
exterior of the battery should be inspected
periodically for damage such as a cracked
case or cover.
Check the tightness of battery clamps (A)
to ensure good electrical connections.
You should not be able to move them. Also
check each cable (B) for cracks and frayed
conductors.
If corrosion (white, fluffy deposits) is
evident, remove the cables from the
battery terminals, clean them with a small wire
brush, then refit them. Accessory stores sell a
useful tool for cleaning the battery post ...
12
3... as well as the battery cable clamps4
Battery corrosion can be kept to a
minimum by applying a layer of
petroleum jelly to the clamps and
terminals after they are reconnected.
Wiper blades