service FORD SIERRA 1993 2.G Fuel And Exhaust Systems Carburettor Workshop Manual

Removal
1Disconnect the battery negative lead.
2Remove the lower facia panel from the
driver’s side.
3Prise off the securing clip and disconnect
the end of the throttle cable from the top of
the pedal (see illustration).
4Remove the two securing nuts, one
accessible from the driver’s footwell, the other
from the engine compartment, and withdraw
the pedal and bracket assembly (see
illustration).
Refitting
5Refitting is a reversal of removal, but on
completion check the throttle cable
adjustment.
Removal
1Disconnect the battery negative lead.
2Working inside the vehicle, remove the
lower facia panel from the driver’s side.
3Prise off the securing clip and disconnect
the end of the throttle cable from the top of
the pedal.
4Working in the engine compartment, free
the cable sheath from the bulkhead, and pull
the cable through into the engine
compartment. It will probably be necessary to
pull the cable grommet from the bulkhead in
order to free the cable sheath.
5For improved access, remove the air
cleaner.
6Disconnect the cable end from the throttle
linkage. The cable end may be attached to the
linkage with a balljoint and spring clip, a
spring clip only, or the cable end may simplylocate in a slot in the throttle lever (see
illustration).
7Prise off the spring clip securing the cable
sheath to the cable bracket at the carburettor
inlet manifold. Depress the four lugs on the
plastic cable retainer simultaneously so that
the retainer can be slid from the bracket, or
remove the retainer securing clip, as
applicable (see illustration). Take care not to
damage the cable sheath.
Refitting
8Refitting is a reversal of removal, but before
refitting the air cleaner, adjust the cable as
follows.
Adjustment
9Have an assistant fully depress the throttle
pedal and hold it in this position. On models
with automatic transmission, where
applicable ensure that the kickdown cable
does not restrict the pedal movement. Turn
the adjusting sleeve at the carburettor inlet
manifold cable bracket until the throttle is just
fully open. Have the assistant release and
then fully depress the throttle pedal, and
check that the throttle is again fully open.
Adjust if necessary, then refit the air cleaner.
On models with automatic transmission,
where applicable check the operation of the
kickdown cable, and adjust if necessary.1A complete strip-down of a carburettor is
unlikely to cure a fault which is not
immediately obvious without introducing new
problems. If persistent carburation problems
are encountered, it is recommended that the
advice of a Ford dealer or carburettor
specialist is sought.
2If it is decided to go ahead and service a
carburettor, check the cost and availability of
spare parts before commencement. Obtain a
carburettor repair kit, which will contain the
necessary gaskets, diaphragms and other
renewable items.
3When working on carburettors, scrupulous
cleanliness must be observed and care must
be taken not to introduce any foreign matter
into components. Carburettors are delicate
instruments and care should be taken not to
disturb any components unnecessarily.
4Referring to the relevent exploded view of
the carburettor(see illustrations),remove
each component part whilst making a note of
its fitted position. Make alignment marks on
linkages etc.
5Reassemble the carburettor in the reverse
order to dismantling, using new gaskets, O-
rings etc. Be careful not to kink any
diaphragms.
13Carburettors (all types) -
dismantling and reassembly
12Throttle cable - removal,
refitting and adjustment
11Throttle pedal - removal and
refitting
4A•8Fuel and exhaust systems - carburettor
11.3 Throttle pedal assembly - cable
connection arrowed
12.6 Disconnecting the throttle cable end from the throttle lever -
Weber 2V carburettor12.7 Removing the throttle cable sheath retainer securing clip -
CVH model
11.4 Throttle pedal securing nut (arrowed)
in engine compartment

9Tighten the manifold securing nuts
progressively to the specified torque, and
similarly tighten the exhaust downpipe
securing nuts. Do not forget to fit the engine
lifting bracket on SOHC models.
10Ensure that the HT leads are reconnected
to their correct cylinders.
Inspection
1The exhaust system should be examined for
leaks, damage, and security at regular
intervals. To do this, apply the handbrake, then
start the engine and allow it to idle. Lie down on
each side of the vehicle in turn and check the
full length of the exhaust system for leaks,
while an assistant temporarily places a wad of
cloth over the tailpipe. If a leak is evident, stop
the engine and use a proprietary repair kit to
seal it. If an excessive leak or damage is
evident, renew the relevant section of the
exhaust system. Check the rubber mountings
for deterioration and renew if necessary.
Removal
2To remove the exhaust system, jack up the
front and rear of the vehicle and support on
axle stands (see “Jacking and Vehicle
Support”).
3If desired, the exhaust downpipe can be
removed independently of the remainder of
the system, and similarly the main part of the
system can be removed, leaving the
downpipe in place.
4To remove the downpipe, unscrew the
securing nuts and disconnect the downpipe
from the manifold. Recover the gasket.
Unscrew the two nuts and bolts, and separate
the downpipe flanged joint from the remainder
of the system. Withdraw the downpipe (see
illustrations).
5To remove the main section of the exhaust
system leaving the downpipe in place,
unscrew the two securing nuts and bolts and
separate the flanged joint from the downpipe.
Unhook the rubber mountings and withdraw
the system from underneath the vehicle. The
number and type of rubber mountings variesaccording to model (see illustrations). If
necessary to avoid confusion, note how the
mountings are fitted to enable correct
refitting. Note that on P100 models the
system must be manipulated to pass over the
rear axle.
Refitting
6Refitting is a reversal of removal, but ensure
that all mating faces are clean, and fit a new
gasket between the downpipe and manifold
(see illustration). Do not fully tighten the joint
27Exhaust system - inspection,
removal and refitting
4A•18Fuel and exhaust systems - carburettor
27.4a Exhaust downpipe-to-manifold
flanged joint viewed from underneath
vehicle27.5a Rear exhaust section mounting -
Hatchback model
27.9a Cutting point when fitting a service replacement exhaust system section - Saloon,
Hatchback and Estate models
X = 1639 mm for all models up to 1987 except 1.3 and 1.6 litre Hatchback
X = 1681 mm for 1.3 and 1.6 litre Hatchback models up to 1987
X = 2063 mm for all models from 1987
27.6 Fit a new downpipe-to-manifold
gasket27.5b Rear exhaust mounting - P100 model
27.4b Exhaust downpipe-to-main system
flanged joint

fittings until the system is in position and
correctly aligned in its mountings under the
vehicle. Ensure that no part of the exhaust
system is closer than 25.0 mm (1.0 in) to the
underbody.
7Service replacement exhaust systems are
available in three sections; downpipe, centre
section and rear section. The service replace-
ment sections fit together using socket joints,
therefore the centre section of a production
exhaust system cannot be renewed without
also renewing the rear section.
8To renew the centre and/or rear section(s)
of the exhaust system, first remove the main
system as described in paragraph 5.9To fit a service replacement rear section to
a production system, use a hacksaw to cut
through the pipe at the applicable point
shown (see illustrations). Apply exhaust
sealant to the mating surfaces of the two
sections, then push the two sections together
and fit a U-bolt clamp to the centre of the
joint. Do not fully tighten the U-bolt clamp
nuts until the system is in position and
correctly aligned in its mountings under the
vehicle.
10To renew a service replacement section,
unscrew the nuts and remove the U-bolt
clamp from the joint. Tap around the joint to
break the seal, and separate the centre andrear sections. Ensure that the joint mating
surfaces are clean, then apply exhaust
sealant, push the new section onto the
remaining section, and fit the U-bolt clamp to
the centre of the joint. Do not fully tighten the
U-bolt clamp nuts until the system is in
position and correctly aligned in its mountings
under the vehicle.
Refer to Chapter 5, Section 22 (see
illustration).
28Vacuum valves, ported vacuum
switches and fuel traps -
removal and refitting
Fuel and exhaust systems - carburettor 4A•19
4A
28.1 Low vacuum enrichment ported vacuum switch location in
inlet manifold - model with Weber 2V carburettor27.9b Cutting point when fitting a service replacement exhaust
system section - P100 models
X = 226 mm