spark plugs FORD SIERRA 1992 2.G Routine Manintenance And Servicing Workshop Manual

Cooling system
Drivebelt tensions:
Air conditioning system compressor . . . . . . . . . . . . . . . . . . . . . . . . .10.0 mm (0.4 in) deflection at the midpoint of the belt’s longest run
under firm thumb pressure
Coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.0 mm (0.4 in) deflection midway between coolant pump and
alternator (or power steering pump) pulleys under firm thumb pressure
Fuel system
Air filter element:
Carburettor type:
1.3 and 1.6 litre (SOHC - Ford carburettor) . . . . . . . . . . . . . . . . . .Champion W110
1.6 litre (SOHC - Weber carburettor) and 1.8 litre SOHC . . . . . . . .Champion W118
1.6 litre (SOHC - 1984-on) and 2.0 litre SOHC . . . . . . . . . . . . . . . .Champion W152
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W219
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W152
Fuel injection type:
2.0 litre SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U507
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W219
Fuel filter:
All fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion L204
Ignition system
Spark plugs:
Make and type:
All except 1.8 CVH, CVH (R6A), 2.0 DOHC and P100 . . . . . . . . . . . .Champion RF7YCC or RF7YC
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC7YCC or RC7YC
P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RF7YC or F7YC
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC7YCC
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC7YCC
Electrode gap*:
Champion F7YCC or RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm (0.032 in)
Champion RF7YC, F7YC or RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 mm (0.028 in)
Ignition HT leads
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 k ohms maximum per lead
Type:
All SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion LS-09 or LS-10 boxed set
1.8 litre CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion LS-10 boxed set
1.6 and 1.8 litre (R6A type) CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion LS-30 boxed set
2.0 litre DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion LS-29 boxed set
*The spark plug gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other type are to be
fitted, refer to their manufacturer’s recommendations.
Brakes
Brake pad friction material minimum thickness . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in)
Brake shoe friction material minimum thickness . . . . . . . . . . . . . . . . . .1.0 mm (0.04 in)
Torque wrench settingsNmlbf ft
Engine oil drain plug:
SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2816 to 21
CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3015 to 22
Engine block coolant drain plug (where fitted) . . . . . . . . . . . . . . . . . . . .21 to 25 16 to 18
Manual gearbox:
Oil filler/level plug:
A,B,C and N types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 to 4124 to 30
MT75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 to 4121 to 30
Oil drain plug:
MT75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 to 4121 to 30
Final drive oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4526 to 33
Roadwheel nuts:
Saloon, Hatchback and Estate models (steel and alloy wheels) . . . .70 to 10052 to 74
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 to 9063 to 66
Spark plugs:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2815 to 21
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 to 3313 to 24
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 to 2111 to 15
Brake caliper guide bolts:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 to 3523 to 26
1•2Servicing specifications

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.

8Tighten the alternator mounting and
adjustment nuts and bolts in the order shown
(see illustration).
9Where applicable, refit and tension the air
conditioning compressor drivebelt.
10Reconnect the battery negative lead.
11Drivebelt tension should be rechecked
and if necessary adjusted after the engine has
been run for a minimum of ten minutes.
DOHC models
12Three different types of drivebelt
arrangement are used, depending on model
(see illustrations).On models without powersteering, the drivebelt is tensioned by moving
the alternator. On models with power steering,
the power steering pump is also driven by the
coolant pump/alternator drivebelt and an
automatic belt tensioner is fitted (see
illustration).On models with air conditioning,
the drivebelt drives the alternator, coolant
pump, power steering pump and air
conditioning compressor, and an automatic
belt tensioner is fitted.
13On models without power steering, loosen
the alternator mounting and adjustment bolts,
and pivot the alternator towards the cylinder
block. Slip the drivebelt from the pulleys.
14On models with power steering, the
automatic tensioner can be released using a
17 mm socket and a wrench on the boss in
the centre of the pulley. Lever the tensioner
assembly clockwise, slide the belt from the
pulleys, then slowly release the tensioner.
15To fit a new belt on models without
power steering, slide the belt over the pulleys,
then lever the alternator away from the
cylinder block until the correct belt tension is
achieved. Lever the alternator using a plastic
or wooden lever at the pulley end to prevent
damage. It is helpful to partially tighten the
adjustment link bolt before tensioning the
drivebelt. When the correct tension is
achieved, tighten all the bolts.
16To fit a new belt on models with power
steering, lever the tensioner clockwise as
during removal, then slide the belt over the
pulleys, and slowly release the tensioner.
1The battery fitted as original equipment is
“maintenance-free”, and requires nomaintenance apart from having the case kept
clean, and the terminals clean and tight.
2To clean the battery terminals disconnect
them, after having first removed the cover
(later models) - negative earth first. Use a wire
brush or abrasive paper to clean the
terminals. Bad corrosion should be treated
with a solution of bicarbonate of soda, applied
with an old toothbrush. Do not let this solution
get inside the battery.
3Coat the battery terminals with petroleum
jelly or a proprietary anti-corrosive compound
before reconnecting them. Reconnect and
tighten the positive (live) lead first, followed by
the negative (earth) lead. Do not overtighten.
4Keep the top of the battery clean and dry.
Inspect the battery tray for corrosion, and
make good as necessary.
SOHC engines
1The valve clearances must be checked with
the engine cold. On carburettor models
remove the air cleaner.
2Disconnect the HT leads from the spark
plugs and release them from the clips on the
camshaft cover.
3On fuel injection models, unbolt and
remove the bracing strut securing the inlet
manifold to the right-hand side of the cylinder
head.
4Where applicable, unclip any hoses and
wires from the camshaft cover, then unscrew
the securing bolts and remove the camshaft
cover and gaskets. Take care not to lose the
spacer plates which fit under the bolt heads,
where applicable.
23Engine valve clearance
check
22Battery terminal check
Every 12 000 miles or 12 months 1•15
1
21.12b Coolant pump/alternator drivebelt
arrangement - 2.0 litre DOHC engine with
power steering
1 Alternator
2 Automatic belt
tension
3 Coolant pump4 Crankshaft pulley
5 Power steering
pump21.12d Alternator/coolant pump drivebelt
tensioner indicator position -
2.0 litre DOHC engine
Inset shows tensioner at maximum
adjustment
1 Alternator
2 Automatic belt
tensioner
3 Coolant pump4 Air conditioning
compressor
5 Crankshaft pulley
6 Power steering
pump
21.12c Coolant pump/alternator drivebelt
arrangement - 2.0 litre DOHC engine with
power steering and air conditioning
21.12a Coolant pump/alternator drivebelt
arrangement - 2.0 litre DOHC engine
without power steering
1 Alternator
2 Coolant pump3 Crankshaft
pulley
21.8 Alternator mounting tightening
sequence - SOHC engines
Caution: Before carrying out
any work on the vehicle battery,
read through the precautions
given in “Safety first!” at the
beginning of this manual.
It will be easier to turn the
engine by hand if the spark
plugs are removed but take
care not to allow dirt to enter
the spark plug holes.

5Numbering from the front (camshaft
sprocket) end of the engine, the exhaust
valves are 1, 3, 5 and 7, and the inlet valves
are 2, 4, 6 and 8.
6Turn the engine clockwise using a suitable
socket on the crankshaft pulley bolt, until the
exhaust valve of No 1 cylinder (valve No 1) is
fully closed; ie the cam lobe is pointing
vertically upwards (see illustration).
7Insert a feeler blade of the correct thickness
(see Specifications) between the cam follower
and the heel of the No 1 valve cam lobe. The
feeler blade should be a firm sliding fit. If not,
loosen the locknut and adjust the ball-pin
position accordingly by turning the adjusternut, then tighten the locknut (see
illustrations). Allowance must be made for
tightening the locknut, as this tends to
decrease the valve clearance. Recheck the
adjustment after tightening the locknut.
8Repeat the procedure given in paragraphs
6 and 7 for the remaining valves. With the
carburettor/inlet manifold fitted, some diffi-
culty may be experienced when adjusting the
exhaust valve clearances, and a suitable
open-ended spanner bent to 90º will be found
helpful.
9Check the condition of the camshaft cover
gasket, and renew if necessary. Fit the gasket
to the camshaft cover ensuring that the
locating tabs and dovetails are correctly
located (see illustration), then refit the
camshaft cover and tighten the securing bolts
in the order shown (see illustration), ensuring
that the spacer plates are in position under
the bolt heads, where applicable.
10On fuel injection models, refit the inlet
manifold bracing strut.
11Where applicable refit the spark plugs.
Reconnect the HT leads and locate them in
the clips on the camshaft cover.
12Where applicable, refit any wires and
hoses to the clips on the camshaft cover and
on carburettor models, refit the air cleaner.
DOHCand CVH engines
13These engines are fitted with hydraulic
cam followers therefore no adjustment is
necessary.
Chock the front roadwheels and jack the
rear wheels clear of the ground, supporting
the vehicle with axlestands.
Check that with the handbrake released,
the rear wheels are free to rotate and no brake
“bind” is evident. The handbrake lever travel
should be between two and four clicks of the
ratchet. If brake “bind” or excessive lever
travel is evident, check the handbrake cable
routing and check the self-adjuster
mechanism for wear or damage. Refer to
Chapter 10 for full service information. Gain access to the radiator matrix by
removing the surrounding body panels, fan
shrouds, etc. Clean dirt and debris from the
matrix using an air jet or water and a soft
brush. Be careful not to damage the fins or
cut your fingers.
Remove the protecting grille and clean any
leaves, insects etc. from the air conditioner
condenser coil and fins. Be very careful not to
damage the condenser fins: use a soft brush, or
a compressed air jet, along (not across) the fins.
1If applicable, remove the radiator grille
being careful not to damage the condenser
fins.
2Check the refrigerant charge as follows.
The engine should be cold and the ambient
temperature should be between 64°and 77°F
(18°and 25°C).
3Start the engine and allow it to idle.
Observe the refrigerant sight glass(see
illustration)and have an assistant switch on
the air conditioning to fan speed III. A few
bubbles should be seen in the sight glass as
the system starts up, but all bubbles should
disappear within 10 seconds. Persistent
bubbles, or no bubbles at all, mean that the
refrigerant charge is low. Switch off the
26Air conditioner refridgerant
charge check
25Radiator matrix and air
conditioner condenser clean
24Handbrake check
1•16Every 12 000 miles or 12 months
23.6 Cam lobe correctly positioned for
checking valve clearance. Insert feeler
gauge as shown by arrow23.7b Adjusting a valve clearance
26.3 Air conditioning system refrigerant
sight glass (arrowed)
23.9b Camshaft cover bolts (A) and spacer
plates (B)
Tighten bolts in following stages:
Stage 1 Bolts 1 to 6
Stage 2 Bolts 7 and 8
Stage 3 Bolts 9 and 10
Stage 4 Bolts 7 and 8 (again)
23.9a Camshaft cover gasket dovetails
23.7a Using a feeler gauge to check a
valve clearance

13Reconnect the battery negative lead.
2.0 litre DOHC models
14Disconnect the battery negative lead.
15Disconnect the wiring plug from the idle
speed control valve at the front of the plenum
chamber.
16Loosen the clamp, and detach the air inlet
hose from the air inlet tubing.
17Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel (see illustration).
18Release the air cleaner lid securing clips,
then lift away the air inlet tube, plenum
chamber and air cleaner lid as an assembly,
disconnecting the breather hose from the air
inlet tube.
19Lift out the air cleaner element (see
illustration), then wipe the inside of the air
cleaner lid and casing clean.
20Fit the new element with the sealing lip
uppermost.
21Further refitting is a reversal of removal.
1Before disturbing any part of the ignition
system, disconnect the battery negative lead.
2Identify and clearly mark all HT leads before
disconnecting them from the spark plugs.
3Refer to the appropriate Section in Chapter
5 and, where applicable, remove the
distributor cap and rotor arm.
4Clean the HT leads and distributor cap with
a dry cloth. Scrape any corrosion or otherdeposits from the connectors and terminals.
Also clean the coil tower.
5Renew the HT leads if they are cracked,
burnt or otherwise damaged. If a multi-meter
is available, measure the resistance of the
leads. The desired value is given in the
Specifications of Chapter 5.
6Renew the distributor cap if it is cracked or
badly burnt inside, or if there is evidence of
“tracking” (black lines marking the path of HT
leakage). If there is a carbon brush at the
centre of the cap, make sure that it moves
freely, and is not excessively worn (see
illustration).
7Clean the metal track of the rotor arm with
fine abrasive paper. Renew the arm if it is
cracked or badly burnt.
8Refit the rotor arm and distributor cap.
9Reconnect the HT leads to the spark plugs
and coil.
10Reconnect the battery and run the engine.
Note: A brake band torque wrench - Ford tool
No 17-005, or a conventional torque wrench
and a splined socket of suitable size to fit the
square section head of the adjuster screw(s)
will be required for this operation.
1For improved access, apply the handbrake,
then jack up the front of the vehicle and
support on axle stands (see “Jacking and
vehicle support”).2The brake band adjuster screw(s) is/are
situated on the left-hand side of the
transmission housing, forward of the
kickdown lever. Note that the C3 type
transmission has a single adjuster screw for
adjustment of the front brake band, whereas
the A4LD type transmission has two adjuster
screws for adjustment of the front and
intermediate brake bands(see illustration).
3Disconnect the kickdown cable from the
kickdown lever on the transmission housing.
4Loosen the locknut on the front brake band
adjuster screw, and back off the adjuster
screw several turns.
5Using the Ford special tool or a suitable
equivalent, tighten the adjuster screw to the
specified torque, then back off the screw two
complete turns, and tighten the locknut.
Ensure that the adjuster screw does not turn
as the locknut is tightened.
6Repeat the procedure given in paragraphs
4 and 5 for the remaining adjuster screw on
A4LD type transmissions, but on all models
where the part number on the transmission
identification tag starts with “88”(see
illustration)and additionally on all 1.8 CVH
engine models, the adjuster screw should be
backed off two and a half turns after
tightening to the specified torque. On all other
models, the adjuster screw should be backed
off two turns.
7Reconnect the kickdown cable, and lower
the vehicle to the ground on completion.
2.0 litre SOHC fuel injection
models
1The fuel filter is located on the left-hand
side of the engine compartment(see
illustration).
2Disconnect the battery negative lead.
3Position a suitable container beneath the
filter, then slowly loosen the fuel inlet union to
relieve the pressure in the fuel lines.
4Disconnect the fuel inlet and outlet unions.
Be prepared for petrol spillage. If necessary,
identify the fuel line unions for use when
refitting.
5Loosen the filter clamp screw, and
withdraw the filter from the clamp. Drain the
petrol from the filter into the container.
Dispose of the filter carefully.
41Fuel filter renewal
40Automatic transmission
brake band adjustment
39Ignition system component
check
1•20Every 24 000 miles or 2 years
38.17 Air intake tube securing nut
(arrowed)
39.6 Bosch distributor cap showing HT
segments (A) and carbon brush (B)40.6 Transmission identification tag with
part number starting with “88”
40.2 Brake band adjustment - A4LD type
transmission
A Adjuster screws
B LocknutsC Kickdown lever
38.19 Lifting out the air cleaner element
Caution: Refer to the
precautions in Chapter 4, Part
B, Section 1 before proceeding.