FORD SIERRA 1993 2.G Fuel And Exhaust Systems Fuel Injection User Guide

1The EVR unit is located on the right-hand
side of the engine compartment, near the
front of the car.
2Disconnect the battery negative lead.
3Disconnect the EVR wiring plug, and
detach the two vacuum hoses, noting their
correct location for refitting.
4Undo the retaining screws, and remove the
EVR unit from the car (see illustration).
5Refitting is a reversal of removal.Refer to Chapter 4 Part A, Section 11.
Refer to Chapter 4 Part A, Section 12.
Note: During this procedure ensure that the
sensor wiper is not rotated beyond its normal
operating arc.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Free the throttle position sensor wiring plug
from the retaining clip located on the underside
of the throttle body. Disconnect the wiring plug
halves by releasing the locktabs and pulling on
the plug halves (see illustration).
3Bend back the locktabs and unscrew the
two sensor retaining bolts (see illustration).
Withdraw the locking plate and sensor from
the throttle shaft.
4Refitting is a reverse of removal, ensuring that
the moulded side of the sensor faces towards
the inlet manifold. The flat on the sensor wiper
engages with the flat on the throttle shaft.
2.0 litre DOHC models
5Disconnect the battery negative lead.6Free the throttle position sensor wiring plug
from the retaining clip located on the underside
of the throttle body. Disconnect the wiring plug
halves by releasing the locktabs and pulling on
the plug halves (see illustration).
7Unscrew the two sensor securing screws,
and withdraw the sensor from the throttle shaft.
8Refitting is a reversal of removal, noting that
the sensor fits with the wiring at the bottom.
Ensure that the sensor actuating arm engages
correctly with the throttle spindle.
1.6 and 1.8 litre (R6A type) CVH
models
9Disconnect the battery negative lead.
10Remove the air cleaner.
11Unclip and disconnect the sensor wiring
connector, pulling on the plug, not on the
wiring (see illustrations).
12Remove the two screws, and withdraw
the sensor from the throttle valve shaft.
13Refitting is a reversal of removal, but
ensure that the sensor actuating arm locates
correctly on the throttle valve spindle.
1.6 litre
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Disconnect the wiring connectors from the
throttle valve control motor, and the throttle
position sensor, pulling on the plugs, not on
the wiring (see illustration).
28Throttle valve control motor
(1.6 and 1.8 litre (R6A type)
CVH) - removal and refitting
27Throttle position sensor -
removal and refitting
26Throttle cable - removal, refitting
and adjustment
25Throttle pedal - removal and
refitting24Electronic vacuum regulator
(1.8 litre (R6A type) CVH) -
removal and refitting
Fuel and exhaust systems - fuel injection 4B•11
4B
28.3 Throttle valve control motor (A) and
wiring plug (B)27.11b Throttle position sensor location
(arrowed) on CFI unit - 1.8 litre (R6A) CVH27.11a Throttle position sensor location
(arrowed) on CFI unit - 1.6 litre CVH
27.6 Throttle position sensor (A) and wiring
plug (B)
27.3 Unscrewing the throttle position
sensor retaining bolts27.2 Releasing locktabs to disconnect
throttle position sensor wiring plug halves24.4 Electronic vacuum regulator retaining
screws (arrowed) - 1.8 litre (R6A) CVH

4Remove the three screws securing the
motor and the throttle position sensor
assembly mounting bracket to the CFI unit,
and withdraw the assembly.
5Remove the three motor securing screws,
and withdraw the motor from the bracket.
6Refitting is a reversal of removal, bearing in
mind the following points.
7Ensure that the throttle position sensor
actuating arm locates correctly on the throttle
valve spindle, and that the mounting bracket
aligns with its locating pegs.
8On completion, the idle speed should be
checked by a Ford dealer at the earliest
opportunity.
1.8 litre
9Disconnect the battery negative lead.
10Remove the air cleaner assembly.
11Disconnect the wiring connector from the
throttle valve control motor.
12Remove the three screws securing the
motor and the mounting bracket to the CFI
unit, and withdraw the assembly.
13Remove the three motor securing screws,
and withdraw the motor from the bracket.
14Refitting is a reversal of removal, ensuring
that the motor is located on the throttle
linkage, and that the bracket and locating
pegs are aligned.
Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. A new gasket must be
used when refitting the throttle body.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Free the throttle position sensor wiring plug
from the retaining clip on the underside of the
throttle body. Disconnect the wiring plug
halves by releasing the locktabs and pulling
on the plug halves, not the wiring.
3Disconnect the throttle cable from the lever.
4Disconnect the crankcase ventilation hose
from the air inlet hose, then disconnect the air
inlet hose from the throttle body and the
airflow meter.
5Remove the four securing bolts and
withdraw the throttle body from the inlet
manifold. Recover the gasket.
6Refitting is a reversal of removal, bearing in
mind the following points.
7Ensure that all mating faces are clean, and
fit a new gasket.
8When reconnecting the air inlet hose, make
sure that the hose clips are correctly aligned,
see illustration, Section 15.
9On completion, adjust the throttle cable and
check and if necessary adjust the idle mixture.
2.0 litre DOHC models
10Disconnect the battery negative lead.
11Free the throttle position sensor wiring
plug from the retaining clip located on the
underside of the throttle body. Disconnect thewiring plug halves by releasing the locktabs
and pulling on the plug halves, not the wiring.
12Disconnect the throttle cable from the
linkage.
13Loosen the securing clip, and disconnect
the air inlet hose from the throttle body.
14Unscrew the four securing bolts, and
withdraw the throttle body from the inlet
manifold. Recover the gasket.
15Refitting is a reversal of removal, bearing
in mind the following points.
16Ensure that the mating faces of the
throttle body and the inlet manifold are clean,
and fit a new gasket.
17On completion, adjust the throttle cable.
Where applicable, check and if necessary
adjust the idle mixture.
Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. A new gasket must be
used when refitting the manifold.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Partially drain the cooling system.
3Disconnect the crankcase ventilation hose
from the air inlet hose. Disconnect the air inlethose from the inlet manifold and the airflow
meter.
4Disconnect the HT lead from the coil, then
remove the distributor cap and position the
cap and HT leads clear of the inlet manifold
assembly.
5Unscrew the two securing bolts and remove
the throttle cable bracket (see illustration).
Disconnect the cable end from the throttle
lever, and move the bracket to one side.
6Disconnect the fuel injection harness wiring
plugs at the bulkhead end of the manifold
(see illustration).
7Disconnect the oil pressure warning lamp
switch wire from below the manifold.
8Disconnect the fuel supply hose from the
fuel rail. Loosen the union nut slowly to relieve
the pressure in the fuel system, and be
prepared for petrol spillage.
9Disconnect the fuel return hose from the
fuel pressure regulator. Be prepared for fuel
spillage.
10Disconnect the coolant hose and the
brake servo vacuum hose from the inlet
manifold.
11Unscrew the two securing nuts and
remove the bracing strut which runs from the
manifold to the right-hand side of the cylinder
head (see illustration).
12Unscrew the two bolts securing the lower
manifold bracket to the left-hand side of the
cylinder block (see illustration).
13Remove the four bolts and two nuts
securing the inlet manifold to the cylinder
head, and carefully withdraw the manifold. If
the distributor obstructs removal, extract the
front manifold stud by locking two nuts
30Inlet manifold - removal and
refitting
29Throttle body - removal and
refitting
4B•12Fuel and exhaust systems - fuel injection
30.5 Unscrew the securing bolts and
remove the throttle cable bracket
30.12 Lower inlet manifold bracket
(arrowed)30.11 Unscrew the two securing nuts
(arrowed) and remove the inlet manifold
bracing strut
30.6 Disconnecting a fuel injection harness
wiring plug
Caution: Refer to the
precautions in Section 1 before
proceeding.

together and using them to unscrew the stud
(see illustration). Alternatively, the distributor
can be removed, although this is not
recommended unless absolutely essential.
Recover the gasket. Note that an earth strap
may be located on one of the manifold
securing bolts or studs; where applicable,
note its location as an aid to refitting.
14With the manifold removed, the various
fuel injection system components can be
separated from the manifold with reference to
the relevant Sections of this Chapter.
15Refitting is a reversal of removal, bearing
in mind the following points.
16Renew the gasket, and apply a bead of
sealant at least 5.0 mm (0.2 in) wide around
the central coolant aperture on both sides of
the gasket. Ensure that all mating faces are
clean.17Tighten the manifold securing nuts and
bolts progressively to the specified torque,
where applicable ensuring that the earth strap
is in position.
18Make sure that all hoses, cables, wires
and leads are correctly reconnected. When
reconnecting the air inlet hose, make sure that
the hose clips are correctly aligned, see
illustration, Section 15.
19On completion, refill the cooling system,
adjust the throttle cable and check and if
necessary adjust the idle mixture.
2.0 litre DOHC models
Note:New fuel injector seals must be used on
refitting.
20Disconnect the battery negative lead.
21Partially drain the cooling system.
22Disconnect the coolant hoses from the
thermostat housing and the inlet manifold.
23Disconnect the air inlet hose from the
front of the inlet manifold.
24Disconnect the breather hoses and the
vacuum hoses from the inlet manifold noting
their locations when disconnecting the brake
servo vacuum hose.
25Disconnect the throttle cable from the
throttle linkage (see illustrations).
26Disconnect the HT leads from the spark
plugs, noting their locations to aid refitting,
and move them to one side.
27Disconnect the wiring from the cooling fan
switch, the engine coolant temperature
sensor, and the temperature gauge sender.
28Release the throttle position sensor wiring
connector from the clip under the throttle body,
and separate the two halves of the connector.
29Remove the fuel injectors.
30Check that all relevant wiring, hoses and
pipes have been disconnected, to facilitate
removal of the manifold.
31Unscrew the ten bolts and two nuts
securing the inlet manifold to the cylinder
head, and carefully withdraw the manifold.
Recover the gasket.
32Recover the two plastic spark plug
spacers from the recesses in the cylinder
head (see illustration).
33If desired, the manifold can be dismantled
with reference to the relevant paragraphs of
this Chapter.
34Refitting is a reversal of removal, bearing
in mind the following points.35Ensure that the spark plug spacers are in
position in the cylinder head recesses before
refitting the manifold.
36Renew all gaskets.
37Tighten all manifold securing nuts and
bolts progressively to the specified torque.
38Make sure that all hoses, pipes and wires
are securely reconnected in their original
positions.
39On completion, refill the cooling system.
Check the adjustment of the throttle cable
and if necessary adjust the idle speed and
mixture (as applicable).1.6 and 1.8 litre (R6A type) CVH
models
40Disconnect the battery negative lead.
41Remove the air cleaner assembly.
42Depressurise the fuel system and
disconnect the fuel inlet pipe from the CFI unit.
43Disconnect the fuel return pipe from the
CFI unit. Be prepared for fuel spillage.
44Disconnect the throttle cable from the
linkage on the CFI unit.
45Partially drain the cooling system.
46Disconnect the coolant hoses from the
thermostat housing and, whereapplicable,
the CFI unit.
47Disconnect the vacuum and breather
hoses from the inlet manifold and the CFI unit,
noting their locations.
48Disconnect the wiring from the following
components, according to engine type.
Air charge temperature sensor.
Throttle position sensor.
Fuel pressure regulator/injector.
Throttle valve control motor.
Engine coolant temperature sensor.
Cooling fan switch.
Temperature gauge sender.
49Unbolt the dipstick tube from the inlet
manifold, and withdraw the dipstick and
dipstick tube from the cylinder block.
50Make a final check to ensure that all
relevant wires, hoses and pipes have been
disconnected to facilitate removal of the
manifold.
51Unscrew the seven nuts, or six securing
nuts and the single bolt, securing the inlet
manifold to the cylinder head, then lift the
manifold from the cylinder head. Recover the
gasket.
52If desired, the CFI unit can be removed
from the inlet manifold.
53If necessary, the thermostat and housing
can be removed from the manifold.
54Refitting is a reversal of removal, noting
the following points.
55Ensure that all mating faces are clean, and
renew all gaskets.
56Tighten the manifold nuts (and bolt, where
applicable) progressively to the specified
torque.
57Make sure that all wires, hoses and pipes
are reconnected as noted before removal.
58Top-up the cooling system.
59On completion, turn the ignition on and off
five times to pressurise the system, and check
for fuel leaks.
Fuel and exhaust systems - fuel injection 4B•13
4B
30.25b . . . and the throttle linkage30.32 Removing a spark plug spacer from
the cylinder head recess
30.25a Disconnect the throttle cable from
the securing bracket . . .
30.13 Where necessary use two nuts
locked together (arrowed) to remove the
front inlet manifold stud

1The EGR valve is located on the right-hand
side of the engine, below the CFI unit.
2Disconnect the battery negative lead.
3Disconnect the vacuum hose connecting
the EGR valve to the electronic vacuum
regulator (see illustration).
4Undo the nut securing the metal tube to the
underside of the valve. Undo the two bolts,
and remove the valve from the engine.
5Refitting is a reversal of removal, but
loosely fit the metal tube securing nut to the
EGR valve before fitting the valve in position.
Tighten the nut securely on completion.1The EPT unit is located on the right-hand
side of the engine, behind the CFI unit (see
illustration).
2Disconnect the battery negative lead.
3Remove the air cleaner assembly.
4Disconnect the EPT wiring plug, and slip
the unit out of its mounting bracket.
5Detach the vacuum hose, and remove the
unit from the car.
6Refitting is a reversal of removal.2.0 litre DOHC models
1Where fitted, the carbon canister is located
on the right-hand side of the engine
compartment, underneath the coolant
expansion tank.
2Disconnect the battery negative lead.
3Pull the plastic pipe from the canister (the
connector is a push-fit in the canister) (see
illustration).
4Unscrew the securing bolt, and lift the
canister from its location.
5Refitting is a reversal of removal.
1.6 and 1.8 litre (R6A type) CVH
models
6The carbon canister (where fitted) is located
on the right-hand side of the engine
compartment.
7Proceed as detailed in paragraphs 2 to 5
inclusive.
2.0 litre DOHC models
1The purge solenoid is located next to the
carbon canister, on the right-hand side of the
engine compartment.
2Disconnect the battery negative lead.
3Disconnect the solenoid wiring plug halves
by releasing the locktabs and pulling on the
plug halves, not the wiring.
34Carbon canister-purge
solenoid (models with
catalytic converter) - removal
and refitting
33Carbon canister (models with
catalytic converter) - removal
and refitting32Exhaust pressure transducer
(1.8 litre (R6A type) CVH) -
removal and refitting31Exhaust gas recirculation
valve (1.8 litre (R6A type)
CVH) - removal and refitting
4B•14Fuel and exhaust systems - fuel injection
31.3 Exhaust gas recirculation valve attachments -
1.8 litre (R6A) CVH
A Metal tube-to-EGR valve
retaining nut
B Vacuum hoseC EGR valve retaining bolts
D EGR valve metal tube location32.1 Exhaust pressure transducer attachments -
1.8 litre (R6A) CVH
A Exhaust pressure transducerB Vacuum hose
33.3 Carbon canister and purge solenoid locations - DOHC
A Carbon canister
B Purge solenoidC Canister retaining bolt
D Pipe

4Note the locations of the two solenoid
pipes, and the orientation of the solenoid, to
assist with refitting.
5Disconnect the two pipes from the
solenoid, and withdraw the solenoid from its
location.
6Refitting is a reversal of removal. Ensure
that the solenoid pipes are correctly
reconnected, and that the solenoid is
correctly orientated, as noted before removal.
1.6 and 1.8 litre (R6A type) CVH
models
7On 1.6 litre engines, the purge solenoid is
located to the rear of the carbon canister, on
the right-hand side of the engine
compartment. On 1.8 litre engines, the
location varies according to model and
equipment, but can be traced by following the
solenoid pipes back from the carbon canister
(see illustration).
8Proceed as detailed in paragraphs 2 to 6
inclusive.
Note: Do not touch the tip of the HEGO
sensor as this will drastically shorten its
service life.
Note: A new sealing ring should be used on
refitting.
Removal
1Ensure that the engine and the exhaust
system are cold.
2Disconnect the battery negative lead.
3Apply the handbrake, then jack up the front
of the vehicle, and support it securely on axle
stands (see “Jacking and Vehicle Support”).
4Disconnect the sensor wiring plug halves
by releasing the locktabs and pulling on the
plug halves, not the wiring.
5Where fitted, slide the heat shield from the
sensor (see illustration).
6Unscrew the sensor from the exhaust
downpipe, and recover the sealing ring. Do
not touch the tip of the sensor if it is to be
refitted.
Refitting
7Commence refitting by ensuring that the
sensor threads and the corresponding
threads in the downpipe are clean.
8Refit the sensor using a new sealing ring,
and tighten it to the specified torque.
9Further refitting is a reversal of removal, but
on completion start the engine, and check for
leaks around the sensor sealing ring.
2.0 litre SOHC models
1Refer to Chapter 4 Part A, Section 26, but
note the following points.
2Ignore the references to removal and
refitting of the air cleaner and hot air pick-up
pipe, and note that a heat shield is fitted in
place of the hot air shroud.
3Note the location of the inlet manifold
bracing strut which is secured to one of the
manifold studs by an extra nut.
2.0 litre DOHC models
Note: A new manifold gasket must be used on
refitting.
4Disconnect the battery negative lead.
5Disconnect the wiring plug from the idle
speed control valve at the front of the plenum
chamber.
6Loosen the clamp, and detach the air inlet
hose from the air inlet tubing.
7Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel.
8Release 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.
9On models with a catalytic converter,
disconnect the exhaust gas oxygen sensor
wiring plug.
10Unscrew the securing nuts, and
disconnect the exhaust downpipe from the
manifold. Recover the gasket. Support the
exhaust downpipe from underneath the
vehicle (eg with an axle stand) to avoid placing
unnecessary strain on the exhaust system.
11Unscrew the six securing nuts, and lift the
manifold from the cylinder head. Recover the
gasket.
12Refitting is a reversal of removal, bearing
in mind the following points.
13Ensure that all mating faces are clean, and
use a new gasket.
14Tighten the manifold securing nuts and
the downpipe securing nuts progressively to
the specified torque (where given).
1.6 and 1.8 litre (R6A type) CVH
models
Note. A new manifold gasket and downpipe
gaskets must be used on refitting.
15Disconnect the battery negative lead.16Remove the air cleaner and, where fitted,
pull the hot-air pick-up pipe from the exhaust
manifold hot-air shroud.
17On 1.6 litre engines, remove the pulse-air
delivery tubing.
18Remove the securing bolts, and withdraw
the hot-air shroud from the manifold.
19Disconnect the exhaust gas oxygen
sensor wiring plug. Unscrew the securing
nuts, and disconnect the exhaust downpipe
from the manifold. Recover the gasket.
Support the exhaust downpipe from
underneath the vehicle (eg with an axle stand)
to avoid placing unnecessary strain on the
exhaust system.
20Unscrew the securing nuts, and lift the
manifold from the cylinder head. Recover the
gasket.
21Refitting is a reversal of removal, bearing
in mind the following points.
22Ensure that all mating faces are clean, and
renew all gaskets.
23Tighten the manifold securing nuts
progressively to the specified torque, and
similarly tighten the exhaust downpipe
securing nuts.
1Refer to Chapter 4 Part A, Section 27.
2On all models except 2.0 litre SOHC,
flanged joints incorporating gaskets may be
used to join exhaust sections on certain
models. Where applicable, renew the gaskets
on refitting.
3On models fitted with a catalytic converter,
disconnect the battery negative lead and
disconnect the exhaust gas oxygen (HEGO)
sensor wiring plug before removing the
downpipe.
37Exhaust system - inspection,
removal and refitting
36Exhaust manifold - removal
and refitting
35Exhaust gas oxygen (HEGO)
sensor (2.0 litre DOHC/1.6 &
1.8 litre (R6A type) CVH) -
removal and refitting
Fuel and exhaust systems - fuel injection 4B•15
4B
35.5 Sliding the heat shield from the
exhaust gas oxygen sensor34.7 Carbon canister-purge solenoid
location (arrowed) - 1.6/1.8 litre (R6A) CVH

4B•16Notes