height FORD SIERRA 1992 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

Special tools
The tools in this list are those which are not
used regularly, are expensive to buy, or which
need to be used in accordance with their
manufacturers’ instructions. Unless relatively
difficult mechanical jobs are undertaken
frequently, it will not be economic to buy
many of these tools. Where this is the case,
you could consider clubbing together with
friends (or joining a motorists’ club) to make a
joint purchase, or borrowing the tools against
a deposit from a local garage or tool hire
specialist. It is worth noting that many of the
larger DIY superstores now carry a large
range of special tools for hire at modest rates.
The following list contains only those tools
and instruments freely available to the public,
and not those special tools produced by the
vehicle manufacturer specifically for its dealer
network. You will find occasional references to
these manufacturers’ special tools in the text of
this manual. Generally, an alternative method
of doing the job without the vehicle
manufacturers’ special tool is given. However,
sometimes there is no alternative to using
them. Where this is the case and the relevant
tool cannot be bought or borrowed, you will
have to entrust the work to a franchised
garage.
MValve spring compressor
MValve grinding tool
MPiston ring compressor
MPiston ring removal/installation tool
MCylinder bore hone
MBalljoint separator
MCoil spring compressors (where applicable)
MTwo/three-legged hub and bearing puller
MImpact screwdriver
MMicrometer and/or vernier calipers
MDial gauge
MStroboscopic timing light
MDwell angle meter/tachometer
MUniversal electrical multi-meter
MCylinder compression gauge
MHand-operated vacuum pump and gauge
MClutch plate alignment set
MBrake shoe steady spring cup removal tool
MBush and bearing removal/installation set
MStud extractors
MTap and die set
MLifting tackle
MTrolley jack
Buying tools
For practically all tools, a tool factor is the
best source, since he will have a very
comprehensive range compared with the
average garage or accessory shop. Having
said that, accessory shops often offer
excellent quality tools at discount prices, so it
pays to shop around.
Remember, you don’t have to buy the most
expensive items on the shelf, but it is always
advisable to steer clear of the very cheap
tools. There are plenty of good tools around at
reasonable prices, but always aim to
purchase items which meet the relevant
national safety standards. If in doubt, ask the
proprietor or manager of the shop for advice
before making a purchase.
Care and maintenance of tools
Having purchased a reasonable tool kit, it is
necessary to keep the tools in a clean and
serviceable condition. After use, always wipe
off any dirt, grease and metal particles using a
clean, dry cloth, before putting the tools away.
Never leave them lying around after they have
been used. A simple tool rack on the garage
or workshop wall for items such as
screwdrivers and pliers is a good idea. Store
all normal spanners and sockets in a metal
box. Any measuring instruments, gauges,
meters, etc, must be carefully stored where
they cannot be damaged or become rusty.
Take a little care when tools are used.
Hammer heads inevitably become marked, and
screwdrivers lose the keen edge on their blades
from time to time. A little timely attention withemery cloth or a file will soon restore items like
this to a good serviceable finish.
Working facilities
Not to be forgotten when discussing tools
is the workshop itself. If anything more than
routine maintenance is to be carried out,
some form of suitable working area becomes
essential.
It is appreciated that many an owner-
mechanic is forced by circumstances to
remove an engine or similar item without the
benefit of a garage or workshop. Having done
this, any repairs should always be done under
the cover of a roof.
Wherever possible, any dismantling should
be done on a clean, flat workbench or table at
a suitable working height.
Any workbench needs a vice; one with a
jaw opening of 100 mm is suitable for most
jobs. As mentioned previously, some clean
dry storage space is also required for tools, as
well as for any lubricants, cleaning fluids,
touch-up paints and so on, which become
necessary.
Another item which may be required, and
which has a much more general usage, is an
electric drill with a chuck capacity of at least 8
mm. This, together with a good range of twist
drills, is virtually essential for fitting
accessories.
Last, but not least, always keep a supply of
old newspapers and clean, lint-free rags
available, and try to keep any working area as
clean as possible.
REF•6Tools and working facilities
Stroboscopic timing lightCylinder compression gaugeClutch plate alignment set
Micrometer setVernier calipers

REF•8MOTtest checks
Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
MExamine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible
from inside the vehicle.
MThe front seats themselves must be
securely attached and the backrests must
lock in the upright position.
Doors
MBoth front doors must be able to be opened
and closed from outside and inside, and must
latch securely when closed.
Vehicle identification
MNumber plates must be in good condition,
secure and legible, with letters and numbers
correctly spaced – spacing at (A) should be
twice that at (B).
MThe VIN plate (A) and homologation plate
(B) must be legible.
Electrical equipment
MSwitch on the ignition and check the
operation of the horn.
MCheck the windscreen washers and wipers,
examining the wiper blades; renew damaged
or perished blades. Also check the operation
of the stop-lights.
MCheck the operation of the sidelights and
number plate lights. The lenses and reflectors
must be secure, clean and undamaged.
MCheck the operation and alignment of the
headlights. The headlight reflectors must not
be tarnished and the lenses must be
undamaged.
MSwitch on the ignition and check the
operation of the direction indicators (including
the instrument panel tell-tale) and the hazard
warning lights. Operation of the sidelights and
stop-lights must not affect the indicators - if it
does, the cause is usually a bad earth at the
rear light cluster.
MCheck the operation of the rear foglight(s),
including the warning light on the instrument
panel or in the switch.
Footbrake
MExamine the master cylinder, brake pipes
and servo unit for leaks, loose mountings,
corrosion or other damage.
MThe fluid reservoir must be secure and the
fluid level must be between the upper (A) and
lower (B) markings.MInspect both front brake flexible hoses for
cracks or deterioration of the rubber. Turn the
steering from lock to lock, and ensure that the
hoses do not contact the wheel, tyre, or any
part of the steering or suspension mechanism.
With the brake pedal firmly depressed, check
the hoses for bulges or leaks under pressure.
Steering and suspension
MHave your assistant turn the steering wheel
from side to side slightly, up to the point where
the steering gear just begins to transmit this
movement to the roadwheels. Check for
excessive free play between the steering
wheel and the steering gear, indicating wear or
insecurity of the steering column joints, the
column-to-steering gear coupling, or the
steering gear itself.
MHave your assistant turn the steering wheel
more vigorously in each direction, so that the
roadwheels just begin to turn. As this is done,
examine all the steering joints, linkages,
fittings and attachments. Renew any
component that shows signs of wear or
damage. On vehicles with power steering,
check the security and condition of the
steering pump, drivebelt and hoses.
MCheck that the vehicle is standing level,
and at approximately the correct ride height.
Shock absorbers
MDepress each corner of the vehicle in turn,
then release it. The vehicle should rise and
then settle in its normal position. If the vehicle
continues to rise and fall, the shock absorber
is defective. A shock absorber which has
seized will also cause the vehicle to fail.
2Checks carried out
WITH THE VEHICLE ON THE
GROUND