wheel torque 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

3Slacken the drain plug about half a turn.
Position the draining container under the drain
plug, then remove the plug completely. If
possible, try to keep the plug pressed into the
sump while unscrewing it by hand the last
couple of turns. As the plug releases from the
threads, move it away sharply so the stream
of oil issuing from the sump runs into the
container, not up your sleeve! Recover the
sealing washer from the drain plug.
4Allow some time for the old oil to drain,
noting that it may be necessary to reposition
the container as the oil flow slows to a trickle.
5After all the oil has drained, wipe off the
drain plug with a clean rag. Check the sealing
washer for condition, and renew it if
necessary. Clean the area around the drain
plug opening, and refit the plug. Tighten the
plug to the specified torque.
6Move the container into position under the
oil filter.
7Using an oil filter removal tool if necessary,
slacken the filter initially, then unscrew it by
hand the rest of the way (see illustration).
Empty the oil from the old filter into the
container, and discard the filter.
8Use a clean rag to remove all oil, dirt and
sludge from the filter sealing area on the
engine. Check the old filter to make sure that
the rubber sealing ring hasn’t stuck to the
engine. If it has, carefully remove it.
9Apply a light coating of clean engine oil to
the sealing ring on the new filter, then screw it
into position on the engine. Tighten the filter
firmly by hand only - do notuse any tools.
Wipe clean the filter and sump drain plug.10Remove the old oil and all tools from
under the car, then lower the car to the
ground (if applicable).
11Remove the oil filler cap and withdraw the
dipstick. Fill the engine, using the correct
grade and type of oil (see “Lubricants and
fluids”). An oil can spout or funnel may help to
reduce spillage. Pour in half the specified
quantity of oil first, then wait a few minutes for
the oil to fall to the sump. Continue adding oil
a small quantity at a time until the level is up to
the lower mark on the dipstick. Finally, bring
the level up to the upper mark on the dipstick.
Insert the dipstick, and refit the filler cap.
12Start the engine and run it for a few
minutes; check for leaks around the oil filter
seal and the sump drain plug. Note that there
may be a delay of a few seconds before the oil
pressure warning light goes out when the
engine is first started, as the oil circulates
through the engine oil galleries and the new oil
filter, before the pressure builds up.
13Switch off the engine, and wait a few
minutes for the oil to settle in the sump once
more. With the new oil circulated and the filter
completely full, recheck the level on the
dipstick, and add more oil as necessary.
14Dispose of the used engine oil safely, with
reference to “General repair procedures”in
the Reference section of this manual.
1Firmly apply the handbrake, then jack up
the front and rear of the car and support it
securely on axle stands (see “Jacking and
vehicle support”).
2For a quick check, the front brake disc pads
can be inspected without removing the front
wheels by inserting a mirror between each
caliper and roadwheel(see illustration).If any
one pad is worn down to the minimum
specified thickness, all four pads (on both
front wheels) must be renewed.
3It is necessary to remove the rear wheels in
order to inspect the rear disc pads. The pads
can be viewed through the top of the caliper
after removing the blanking spring clip(see
illustration).If any one pad is worn down to
the minimum specified, all four pads (on both
rear wheels) must be renewed.4For a comprehensive check, the brake disc
pads should be removed and cleaned. The
operation of the caliper can then also be
checked, and the condition of the brake discs
can be fully examined on both sides. Refer to
Chapter 10 for further information.
5On rear drum brake models, the brake shoe
friction material can be inspected for wear
without removing the roadwheels. Working
beneath the vehicle, prise the plug from the
brake backplate, and using an inspection
lamp or torch, check that the friction material
thickness is not less than the minimum given
in the Specifications(see illustration).If any
one of the shoes has worn below the
specified limit, the shoes must be renewed as
an axle set (4 shoes).
6At the same interval, check the function of the
brake fluid level warning light. Chock the wheels,
release the handbrake and switch on the
ignition. Unscrew and raise the brake fluid
reservoir cap whilst an assistant observes the
warning light: it should come on as the level
sensor is withdrawn from the fluid. Refit the cap.
7On completion, refit the wheels and lower
the car to the ground.
1Visually inspect the engine joint faces,
gaskets and seals for any signs of water or oil
leaks. Pay particular attention to the areas
around the rocker cover, cylinder head, oil
filter and sump joint faces. Bear in mind that
over a period of time some very slight
seepage from these areas is to be expected
but what you are really looking for is any
indication of a serious leak. Should a leak be
found, renew the offending gasket or oil seal
by referring to the appropriate Chapter(s) in
this manual.
2Similarly, check the transmission for oil
leaks, and investigate and rectify and
problems found.
3Check the security and condition of all the
engine related pipes and hoses. Ensure that
all cable-ties or securing clips are in place and
in good condition. Clips which are broken or
missing can lead to chafing of the hoses,
pipes or wiring which could cause more
serious problems in the future.
10Fluid leak check
9Front and rear brake pad/shoe
check
1•10Every 6000 miles or 6 months
8.7 Unscrewing the oil filter
9.3 Disc pads viewed through caliper
inspection hole (roadwheel removed)9.5 Brake shoe inspection hole plug
(arrowed)9.2 Using a mirror to inspect the disc pad
friction material for wear
A Brake disc B Brake disc pads

4Carefully check the condition of all coolant,
fuel, power steering and brake hoses. Renew
any hose which is cracked, swollen or
deteriorated. Cracks will show up better if the
hose is squeezed. Pay close attention to the
hose clips that secure the hoses to the system
components. Hose clips can pinch and
puncture hoses, resulting in leaks. If wire type
hose clips are used, it may be a good idea to
replace them with screw-type clips.
5With the vehicle raised, inspect the fuel
tank and filler neck for punctures, cracks and
other damage. The connection between the
filler neck and tank is especially critical.
Sometimes a rubber filler neck or connecting
hose will leak due to loose retaining clamps or
deteriorated rubber.
6Similarly, inspect all brake hoses and metal
pipes. If any damage or deterioration is
discovered, do not drive the vehicle until the
necessary repair work has been carried out.
Renew any damaged sections of hose or pipe.
7Carefully check all rubber hoses and metal
fuel lines leading away from the petrol tank.
Check for loose connections, deteriorated
hoses, crimped lines and other damage. Pay
particular attention to the vent pipes and
hoses which often loop up around the filler
neck and can become blocked or crimped.
Follow the lines to the front of the vehicle
carefully inspecting them all the way. Renew
damaged sections as necessary.
8From within the engine compartment,
check the security of all fuel hose attachments
and pipe unions, and inspect the fuel hoses
and vacuum hoses for kinks, chafing and
deterioration.
9Where applicable, check the condition of
the oil cooler hoses and pipes.
10Check the condition of all exposed wiring
harnesses.
1Periodically check the belts for fraying or
other damage. If evident, renew the belt.
2If the belts become dirty, wipe them with a
damp cloth using a little detergent only.
3Check the tightness of the anchor bolts and
if they are ever disconnected, make quite sure
that the original sequence of fitting of
washers, bushes and anchor plates is
retained.
With the vehicle raised on a hoist or
supported on axle stands, check the exhaust
system for signs of leaks, corrosion or
damage and check the rubber mountings for
condition and security. Where damage or
corrosion are evident, renew the system
complete or in sections, as applicable, using
the information given in Chapter 4.With the wheels on the ground, slacken each
wheel nut by a quarter turn, then retighten it
immediately to the specified torque.
Remove and clean the oil filler cap of any
sludge build-up using paraffin.
Inspect the vent hose for blockage or
damage. A blocked hose can cause a build-
up of crankcase pressure, which in turn can
cause oil leaks.
Ford VV carburettor
1Ensure that the air cleaner is correctly fitted,
and that all vacuum hoses and pipes are
securely connected and free from restrictions,
then run the engine until it is at normal
operating temperature.
2Stop the engine, and connect a tachometer
and an exhaust gas analyser in accordance
with the manufacturer’s instructions.
3Start the engine and run it at 3000 rpm for
30 seconds, ensuring that all electrical loads
are switched off (headlamps, heater blower
etc), then allow the engine to idle and check
the idle speed and CO content. Note that the
CO reading will initially rise, then fall and finally
stabilise after between 5 and 25 seconds.4If necessary, adjust the idle speed screw to
give the specified idle speed (see
illustration).
5Checking and adjustment should be
completed within 30 seconds of the meter
readings stabilising. If this has not been
possible, repeat paragraphs 3 and 4, ignoring
the reference to starting the engine.
Weber 2V carburettor
Models without stepper motor
6Proceed as described for the Ford VV
carburettor but note the following:
7It is permissible to loosen the air cleaner
securing screws to allow easier access to the
carburettor adjustment screws but ensure
that all vacuum hoses and pipes are securely
connected. For adjustment screw location
(see illustrations).
Models with stepper motor (ESC II
system)
8The idle speed is controlled by the ESC II
module via the stepper motor. The only idle
speed adjustment possible is provided by the
“idle speed adjustment” wire, which can be
earthed to raise the idle speed by 75 rpm. No
other method of idle speed adjustment should
be attempted. If the idle speed is incorrect,
the problem should be referred to a Ford
dealer, as the problem probably lies in the
ESC II module for which special diagnostic
equipment is required.
15Engine idle speed check
14Oil filler cap check
13Roadwheel security check
12Exhaust system check
11Seat belt check
Every 6000 miles or 6 months 1•11
1
15.7b Weber 2V carburettor adjustment
screw locations - 1.6 litre models
A Idle mixture screwB Idle speed screw
15.7a Weber 2V carburettor adjustment
screw locations - 2.0 litre models up to 1985
A Idle speed screwB Idle mixture screw
15.4 Ford VV carburettor adjustment screw
locations
A Idle speed screwB Idle mixture screw
Caution: Refer to the
precautions in Section 1,
Chapter 4, Part A or B (as
applicable), before proceeding.
Before carrying out any carburettor
adjustments, ensure that the ignition
timing and spark plug gaps are set as
specified. To carry out the adjustments an
accurate tachometer and an exhaust gas
analyser (CO meter) will be required.

system immediately if the charge is low and
do not use it again until it has been recharged.
4Inspect the refrigerant pipes, hoses and
unions for security and good condition. Refit
the radiator grille.
5The air conditioning system will lose a
proportion of its charge through normal
seepage typically up to 100 g (4 oz) per year -
so it is as well to regard periodic recharging
as a maintenance operation.
1Check the final drive oil level as follows.
2Position the vehicle over a pit, or raise it at
front and rear on ramps or axle stands. The
vehicle must be level.
3Wipe clean around the final drive filler/level
plug (see illustrations) and unscrew the
plug. Using a piece of bent wire as a dipstick,
check that the oil is no more than 10 mm (0.4
in) below the plug hole.
4If topping-up is necessary, use clean gear
oil of the specified type. Do not overfill.
Frequent need for topping-up can only be due
to leaks, which should be rectified.
5When the level is correct, refit the filler/level
plug and tighten it to the specified torque
loading.
6There is no requirement for periodic oil
changing, and no drain plug is provided.
Lubricate the transmission selector and
kickdown linkages with engine oil or aerosol
lubricant.
1Check the shock absorbers by bouncing
the vehicle up and down at each corner in
turn. When released, it should come to rest
within one complete oscillation. Continued
movement, or squeaking and groaning noises
from the shock absorber suggests that
renewal is required .
2Raise and support the vehicle. Examine all
steering and suspension components for
wear and damage. Pay particular attention to
dust covers and gaiters, which if renewed
promptly when damaged can save further
damage to the component protected.
3At the same intervals, check the front
suspension lower arm balljoints for wear by
levering up the arms(see illustration).
Balljoint free movement must not exceed 0.5
mm (0.02 in). The track rod end balljoints can
be checked in a similar manner, or by
observing them whilst an assistant rocks the
steering wheel back and forth. If the lower arm
balljoint is worn, the complete lower arm must
be renewed .4Wheel bearings can be checked for wear by
spinning the relevant roadwheel. Any
roughness or excessive noise indicates worn
bearings, which must be renewed, as no
adjustment is possible. It is unlikely that any
wear will be evident unless the vehicle has
covered a very high mileage. It should be
noted that it is normal for the bearings to
exhibit slight endfloat, which is perceptible as
wheel rock at the wheel rim.
1Position the vehicle over a pit, or raise it at
front and rear on ramps or axle stands (see
“Jacking and vehicle support”).
2Examine the driveshaft joint rubber gaiters.
Flex the gaiters by hand and inspect the folds
and clips. Damaged or leaking gaiters must
be renewed without delay to avoid damage
occurring to the joint itself
3Check the tightness of the final drive
mounting bolts and the driveshaft flange screws.
1Except on vehicles with a wax-based
underbody protective coating, have the whole
of the underframe of the vehicle steam-
cleaned, engine compartment included, so
that a thorough inspection can be carried out
to see what minor repairs and renovations are
necessary. 2Steam-cleaning is available at many
garages and is necessary for the removal of
the accumulation of oily grime which
sometimes is allowed to become thick in
certain areas. If steam-cleaning facilities are
not available, there are some excellent grease
solvents available which can be brush-
applied; the dirt can then be simply hosed off.
3After cleaning, position the vehicle over a
pit, or raise it at front and rear on ramps or axle
stands (see “Jacking and vehicle support”).
4Using a strong light, work around the
underside of the vehicle, inspecting it for
corrosion or damage. If either is found, refer
to Chapter 12 for details of repair.
Periodically inspect the rigid brake pipes for
rust and other damage, and the flexible hoses
for cracks, splits or “ballooning”. Have an
assistant depress the brake pedal (ignition on)
and inspect the hose and pipe unions for leaks.
Renew any defective item without delay.
On carburettor models which incorporate a
stepper motor (ie. Weber 2V from 1985), good
electrical contact between the motor plunger
and the adjusting screw is essential to
maintain a regular idle speed.
Clean the plunger and adjusting screw
contact faces with abrasive paper followed by
switch cleaning fluid. Switch cleaning fluid is
available from electronic component shops.
Instruments and electrical
equipment
1Check the operation of all instruments and
electrical equipment.
2Make sure that all instruments read
correctly, and switch on all electrical
equipment in turn to check that it functions
properly.
34Road test
33Idle speed linkage clean
32Brake pipe and hose check
31Underbody inspection
30Driveshaft check
29Steering and suspension
security check
28Automatic transmission
selector linkage lubrication
27Final drive oil level check
Every 12 000 miles or 12 months 1•17
1
29.3 Levering up lower arm to check
balljoint for wear
27.3b Rear axle filler plug location -
P100 models27.3a Final drive unit filler plug location
(arrowed) -
Saloon, Hatchback and Estate models