battery FORD SIERRA 1993 2.G Fuel And Exhaust Systems Fuel Injection Workshop Manual

working on the exhaust system, ensure
that the converter is well clear of any
jacks or other lifting gear used to raise the
car and do not drive the car over rough
ground, road humps, etc., in such a way
as to “ground” the exhaust system.
j)In some cases, particularly when the car is
new and/or is used for stop/start driving, a
sulphurous smell (like that of rotten eggs)
may be noticed from the exhaust. This is
common to many catalytic converter-
equipped cars and seems to be due to the
small amount of sulphur found in some
petrols reacting with hydrogen in the
exhaust to produce hydrogen sulphide
(H2S) gas; while this gas is toxic, it is not
produced in sufficient amounts to be a
problem. Once the car has covered a few
thousand miles the problem should
disappear - in the meanwhile a change of
driving style or of the brand of petrol used
may effect a solution.
k)The catalytic converter, used on a well-
maintained and well-driven car, should
last for between 50 000 and 100 000
miles - from this point on, careful checks
should be made at all specified service
intervals of the CO level to ensure that the
converter is still operating efficiently - if
the converter is no longer effective it must
be renewed.
EEC IV module - warning
Following disconnection of the battery, the
information stored in the EEC IV module
memory will be erased. After reconnecting the
battery, the engine should be allowed to idle for
three minutes. Once the engine has reached
normal operating temperature, the idle speed
should be increased to 1200 rpm and
maintained for approximately 2 minutes, which
will allow the module to “re-learn” the optimum
idle values. It may be necessary to drive the
vehicle in order for the module to “re-learn” the
values under load. The module should complete
its learning process after approximately 5 miles
(8 kilometres) of varied driving.
Refer to Chapter 1, Section 38.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Depress the locking clip on the airflow
meter wiring plug and disconnect the plug.
Pull on the plug, not the wiring.
3Loosen the securing clip and disconnect
the air inlet hose from the airflow meter.
4Release the four securing clips and lift off
the air cleaner lid with the airflow meter.
5Remove the left-hand front wheel arch liner.
6Working under the wheel arch, unscrew the
three air cleaner securing nuts and washers.
7Disconnect the air inlet tube, and withdrawthe air cleaner from the engine compartment.
8Refitting is a reversal of removal.
2.0 litre DOHC models
9Disconnect the battery negative lead.
10Disconnect the wiring plug from the idle
speed control valve at the front of the plenum
chamber.
11Loosen the clamp, and detach the air inlet
hose from the air inlet tubing.
12Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel.
13Release 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.
14Lift out the air cleaner element then wipe
the inside of the air cleaner lid and casing clean.
15Remove the left-hand front wheel arch liner.
16Working under the wheel arch, unscrew the
three air cleaner securing nuts and washers.
17Disconnect the air inlet tube, and
withdraw the air cleaner from the engine
compartment.
18Refitting is a reversal of removal.
1.6 and 1.8 litre (R6A type) CVH
models
1.6 litre
19Remove the screws from the top of the air
cleaner cover.
20Disconnect the cold air inlet hose from the
air cleaner spout or the inlet on the front body
panel. The hose is secured by toggle clips.
21Disconnect the hot air inlet hose from the
air cleaner spout or the hot air shroud on the
exhaust manifold.
22Where applicable, remove the screw
securing the air cleaner body to the camshaft
cover.
23Withdraw the air cleaner and disconnect
the breather hose from the camshaft cover.
24Refitting is a reversal of removal, ensure
the disturbed hoses are securely connected.
1.8 litre
25Undo the two nuts, lift off the air cleaner
cover, and remove the element.26Disconnect the engine breather hose and
the oil separator hose, then undo the three
nuts and lift up the air cleaner casing (see
illustrations).
27Disconnect the yellow striped vacuum
hose from the underside of the casing, detach
the air inlet hose, and remove the air cleaner
assembly.
28Refitting is a reversal of removal, ensuring
all hoses are correctly attached.
1Disconnect the battery negative lead.
2Remove the air cleaner assembly.
3Position a suitable container (or a sufficient
quantity of absorbent cloth) beneath the fuel
inlet connection on the CFI unit.
4Use an open-ended spanner on the flats of
the inlet union screwed into the CFI unit, to
prevent it from turning while the inlet pipe
union is loosened (see illustration). Allow all
pressure/fuel seepage to dissipate before fully
unscrewing the union if it is to be
disconnected, or tightened if another part of
the system is to be worked on.
4Fuel system (1.6 and 1.8 litre
(R6A type) CVH) - depressurisation
3Air cleaner - removal and
refitting
2Air cleaner element - renewal
4B•4Fuel and exhaust systems - fuel injection
3.26b Air cleaner casing attachments - 1.8
litre (R6A) CVH
A Casing retaining nuts (arrowed)
B Vacuum hose (arrowed)
3.26a Air cleaner cover and hose
attachments - 1.8 litre (R6A) CVH
A Cover retaining nuts
B Engine breather hose
C Oil separator hose
Remember to depressurise the
fuel system before loosening any
connections.
Refer to the precautions in
Section 1 before proceeding. The fuel
system will remain pressurised after the
engine is switched off.
4.4 CFI unit fuel inlet union (arrowed)

5The system will remain depressurised until
the fuel pump is primed prior to starting the
engine. Remove the container or cloth, as
applicable, on completion.
Refer to Chapter 1, Section 41.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Slowly loosen the fuel feed union to relieve
the pressure in the fuel lines.
3Disconnect the fuel feed and return lines.
Be prepared for petrol spillage.
4Disconnect the vacuum pipe from the top
of the pressure regulator.
5Unscrew the securing nut from the base of
the pressure regulator and withdraw the unit
(see illustration).
6Refitting is a reversal of removal, but if the
fuel return line was originally secured with a
crimped type clip, discard this and use a new
worm drive clip.
7On completion check the fuel line
connections for leaks. Pressurise the system by
switching the ignition on and off several times.
2.0 litre DOHC models
Note: A new pressure regulator seal will be
required on refitting.
8Disconnect the battery negative lead.
9Slowly loosen the fuel rail fuel feed union to
relieve the pressure in the system (see
illustration). Be prepared for fuel spillage,
and take adequate fire precautions.
10Disconnect the fuel return hose from the
pressure regulator (see illustration). Again,
be prepared for fuel spillage.
11Disconnect the vacuum pipe from the top
of the pressure regulator.
12Unscrew the two securing bolts, and
withdraw the regulator from the fuel rail.
Recover the seal.13Fit a new seal to the regulator, and
lubricate with clean engine oil.
14Fit both the securing bolts to the
regulator, then position the regulator on the
fuel rail, and tighten the securing bolts.
15Further refitting is a reversal of removal. If
the fuel return line was originally secured with
a crimped-type clip, discard this, and use a
new worm-drive clip.
16On completion, pressurise the system by
switching the ignition on and off several times,
and check the fuel line connections for leaks.
1.6 and 1.8 litre (R6A type) CVH
models
Note:On completion of refitting, the fuel
system pressure should be checked by a Ford
dealer at the earliest opportunity.
1.6 litre
17Remove the CFI unit.
18Remove the four screws securing the
regulator housing to the CFI unit, then
carefully lift off the housing and recover the
ball, cup, large spring, diaphragm, valve, and
small spring, noting the position and
orientation of all components (see
illustration). Do not attempt to prise the plug
from the regulator housing, or adjust the Allen
screw (if no plug is fitted); this will alter the fuel
system pressure.
19Check all components, and renew any
faulty items as necessary.
20Commence reassembly by supporting the
CFI unit on its side, so that the regulator
components can be fitted from above.
6Fuel pressure regulator -
removal and refitting
5Fuel filter - renewal
Fuel and exhaust systems - fuel injection 4B•5
4B
6.9 Fuel rail fuel feed union (arrowed)
6.10 Disconnecting the fuel return hose
(arrowed) from the pressure regulator
6.5 Withdrawing the fuel pressure
regulator
6.18 Exploded view of Central Fuel Injection (CFI) unit
1.6 litre CVH engine application shown - 1.8 litre similar
1 Fuel injector assembly
2 Fuel pressure regulator
components
3 Fuel inlet connector
4 Air charge temperature
(ACT) sensor
5 Throttle valve control
motor
6 Throttle position sensor
7 Fuel injector wiring
Caution: Refer to the
precautions in Section 1 before
proceeding.

21Fit the small spring, valve, diaphragm
(ensuring that it locates correctly), large
spring, and the spring cup.
22Carefully place the ball into position on
the spring cup, and ensure that it locates
correctly.
23Refit the regulator housing, taking great
care to avoid disturbing the ball, and once
correctly in position, tighten the screws evenly
to avoid distorting the diaphragm.
24Refit the CFI unit.
25On completion, the fuel system pressure
should be checked by a Ford dealer at the
earliest opportunity.
1.8 litre
26Disconnect the battery negative lead.
27Remove the air cleaner assembly.
28Depressurise the fuel system and
disconnect the fuel inlet pipe from the CFI unit
(see illustration).
29Disconnect the fuel injector/regulator
wiring plug, and move the wiring harness
clear.
30Undo the four screws, and carefully lift the
injector/regulator assembly off the CFI unit.31Refitting is a reversal of removal. On
completion, the fuel system pressure should
be checked by a Ford dealer at the earliest
opportunity.
1If the fuel pump is functioning, it should be
possible to hear it “buzzing” by listening
under the rear of the vehicle when the ignition
is switched on. Unless the engine is started,
the fuel pump should switch off after
approximately one second. If the noise
produced is excessive, this may be due to a
faulty fuel flow damper (not fitted to 2.0 litre
DOHC models). The damper can be renewed
by unscrewing it from the pump outlet union.
2If the pump appears to have failed
completely, check the appropriate fuse and
relay, and where applicable check the state of
the fuel pump inertia cut-off switch as follows.
3The inertia cut-off switch is fitted to all
models from mid-1986 onwards, and can be
found behind the passenger compartment
left-hand side trim panel on Hatchback and
Estate models up to the 1987 model year (see
illustration). The location of the switch for all
other models is in the spare wheel well (see
illustration). The switch incorporates a reset
button, which should normally be in the
depressed position. Check the position of the
reset button before assuming that a fault
exists in the fuel pump.
4To test the fuel pump, special equipment is
required, and it is recommended that any
suspected faults are referred to a Ford dealer.
Removal
1The fuel pump is located under the rear of
the vehicle next to the fuel tank (see
illustration).
2Disconnect the battery negative lead.
3Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands
(see “Jacking and Vehicle Support”).
4Clean the area around the pump mounting,
and position a suitable container under the
pump.
5Using a hose clamping tool or self-locking
pliers, clamp the fuel tank-to-pump hose to
prevent excessive petrol spillage, or
8Fuel pump (2.0 litre SOHC) -
removal and refitting
7Fuel pump - testing
4B•6Fuel and exhaust systems - fuel injection
7.3a Fuel pump inertia cut-off switch - pre-
1987 SOHC Hatchback and Estate models
A Activated mode (fuel cut-off)
B Normal mode (fuel flowing)
C Trim panel access hole
8.1 Fuel pump location
A Inlet hose
B Outlet hoseC Electrical feed
D Flow damper7.3b Fuel pump inertia cut-off switch
location (arrowed) under spare wheel
6.28 Fuel injector/pressure regulator attachments - 1.8 litre (R6A) CVH
A Pressure regulator assembly
B Fuel inlet pipeC Injector/regulator wiring plug
D Injector/regulator screws
Caution: Refer to the
precautions in Section 1 before
proceeding.

alternatively make arrangements to collect the
contents of the fuel tank which will otherwise
be released. Disconnect the hose from the
pump.
6Slowly loosen the fuel flow damper fitted to
the pump outlet union, to relieve the pressure
in the fuel line, then remove the damper and
disconnect the outlet pipe from the pump.
Plug the end of the pipe to prevent excessive
petrol spillage.
7Disconnect the wiring plug(s), then slacken
the clamp bolt and slide the pump from the
bracket assembly.
Refitting
8Refitting is a reversal of removal, noting the
following.
9When refitting the flow damper to the pump
ensure that the pump outlet pipe is correctly
routed (see illustration). It is possible to
inadvertently rotate the banjo union through
180º, which routes the outlet pipe too close to
the exhaust.
10After refitting and securing the pump, but
before lowering the vehicle, reconnect the
battery and switch the ignition on and off
several times to pressurise the fuel system.
Check for leaks around the pump; if all is
satisfactory, switch off the ignition and lower
the vehicle.1Remove the fuel tank.
2Unscrew the fuel pump/fuel level sender
unit by engaging two crossed screwdrivers in
the slots on either side of the unit mounting
flange. Recover the seal.
3Refitting is a reversal of removal but fit a
new seal.
Refer to Chapter 4 Part A, Section 9.
Refer to Chapter 4 Part A, Section 10.
Refer to Chapter 1, Sections 15 and 16.
Note: A new gasket must be used when
refitting the valve.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Disconnect the idle speed control valve
wiring plug by releasing the retaining clip and
pulling on the plug, not the wiring (see
illustration).
3Unscrew the two retaining nuts and
withdraw the valve from the inlet manifold
(see illustration). Recover the gasket.4Clean the valve and manifold mating faces
before refitting, taking care not to allow dirt to
enter the manifold.
5Refitting is a reversal of removal, using a
new gasket.
6On completion, start the engine and check
that the idle speed is stable if not, check for
air leaks around the valve. Switch on all
available electrical loads and check that the
idle speed is maintained - if not, suspect a
faulty valve.
2.0 litre DOHC models
7Disconnect the battery negative lead.
8Loosen the securing clip, and disconnect
the air inlet hose from the throttle body.
9Unscrew the securing nut, and release the
air inlet tube from the bracket on the engine
compartment front panel.
10Disconnect the wiring plug from the idle
speed control valve.
11Release the air cleaner lid securing clips
then remove the air inlet tube, plenum
chamber, and air cleaner lid as an assembly,
disconnecting the breather hose from the air
inlet tube.
12Unscrew the two securing bolts, and
withdraw the valve from the air inlet tube.
Recover the gasket (see illustration).
13Clean the valve and air inlet tube mating
faces before refitting, taking care not to allow
dirt to enter the air inlet tube.
14Refitting is a reversal of removal, using a
new gasket.
15On completion, start the engine and
check that the idle speed is stable if not,
check for air leaks around the valve. Switch
on all available electrical loads, and check
that the idle speed is maintained - if not,
suspect a faulty valve.
1The potentiometer is located at the rear
right-hand side of the engine compartment,
behind the MAP sensor.
2Disconnect the battery negative lead.
3Remove the screw, then withdraw the
potentiometer and disconnect the wiring plug.
4Refitting is a reversal of removal.
14Mixture adjustment
potentiometer (2.0 litre
DOHC) - removal and refitting
13Idle speed control valve -
removal and refitting
12Idle speed and mixture -
adjustment
11Fuel level sender unit (2.0 litre
SOHC) - removal and refitting
10Fuel tank - removal and refitting
9Fuel pump/fuel level sender
unit (2.0 litre DOHC/1.6 & 1.8
litre (R6A type) CVH) - removal
and refitting
Fuel and exhaust systems - fuel injection 4B•7
4B
13.2 Disconnecting the idle speed control
valve wiring plug13.12 Withdrawing the idle speed control
valve and gasket13.3 Unscrewing an idle speed control
valve retaining nut
8.9 Correct and incorrect routing of fuel
pump outlet pipe
A Fuel pump
B Outlet pipe
C Exhaust pipeX = 30.0 mm (1.2 in)
Y = 100.0 mm (3.9 in)
Caution: Refer to the
precautions in Section 1 before
proceeding.

Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion.
1Disconnect the battery negative lead.
2Depress the locking clip on the airflow
meter wiring plug and disconnect the plug.
Pull on the plug, not the wiring.
3Loosen the securing clip and disconnect
the air inlet hose from the airflow meter.
4Release the four securing clips and lift off
the air cleaner lid with the airflow meter.
5Remove the four securing bolts and
separate the airflow meter from the air cleaner
lid (see illustration). Recover the seal.
6Refitting is a reversal of removal, ensuring
that the seal is correctly located on the air
cleaner lid, and that the air inlet hose clip is
correctly aligned (see illustration).7On completion, check and if necessary
adjust the idle mixture.
1.6 litre
Note: New fuel injector seals must be used on
refitting.
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Depressurise the fuel system.
4Release the securing lugs, and disconnect
the fuel injector wiring plug (see illustration).
5Bend back the injector retaining collar
securing bolt locktabs, then unscrew the
bolts. Remove the injector retaining collar
(see illustrations).
6Withdraw the injector from the CFI unit (see
illustration), noting its orientation, then
withdraw the injector seals.
7Remove the seal from the injector retaining
collar (see illustration).
8Refitting is a reversal of removal, noting the
following points.
9Use new injector seals, and lubricate them
with clean engine oil before fitting.
10Ensure that the locating peg on the
injector is correctly positioned (see
illustration).
1.8 litre
11On these engines, the fuel pressure
regulator and injector are one assembly.
Proceed as described for the fuel pressure
regulator.
1The ballast resistor is located on the right-
hand side of the engine compartment, and is
only fitted to 1.6 litre engines (see
illustration).
2Disconnect the battery negative lead.
3Disconnect the ballast resistor wiring
connector, then remove the securing screw,
and withdraw the ballast resistor from the
body panel.
4Refitting is a reversal of removal.
17Fuel injector ballast resistor
(1.6 litre CVH) - removal and
refitting
16Fuel injector (1.6 and 1.8 litre
(R6A type) CVH) - removal and
refitting
15Airflow meter - removal and
refitting
4B•8Fuel and exhaust systems - fuel injection
15.5 Airflow meter-to-air cleaner lid bolts
(arrowed)
16.4 Disconnecting the fuel injector wiring
plug
16.10 Align locating peg on injector with
slot in CFI unit on refitting - 1.6 litre CVH16.7 Removing the seal from the injector
retaining collar16.6 Withdrawing the fuel injector
16.5b Removing the injector retaining
collar16.5a Removing an injector retaining collar
securing bolt and locktab
15.6 Air intake hose clip correctly aligned
Caution: Refer to the
precautions in Section 1 before
proceeding.

Note: A tachometer and an exhaust gas
analyser will be required to check the idle
mixture on completion. New seals and
retaining clips must be used when refitting the
injectors, and special grease will be required -
see relevant paragraph. If the injectors are
thought to be faulty, it may be worth trying the
effect of a fuel injector cleaning agent before
removing them.
2.0 litre SOHC models
1Disconnect the battery negative lead.
2Disconnect the crankcase ventilation hose
from the air inlet hose, then disconnect the air
inlet hose from the inlet manifold and the
airflow meter.
3Disconnect the HT lead from the coil, then
remove the distributor cap and position the
cap and HT leads clear of the fuel rail
assembly.
4Disconnect the wiring plugs from the idle
speed control valve, the throttle position sensor
and the engine coolant temperature sensor.
5Remove the fuel pressure regulator.
6Unscrew the securing bolt and remove the
throttle return spring bracket. Disconnect the
throttle return spring.7Disconnect the fuel supply hose from the
fuel rail. Be prepared for petrol spillage.
8Disconnect the wiring plugs from the fuel
injectors, noting their locations for use when
refitting.
9Remove the three securing bolts and
withdraw the fuel rail and fuel injectors from
the inlet manifold as an assembly (see
illustrations).
10To remove a fuel injector from the fuel rail,
remove the retaining clip and withdraw the
injector (see illustration).
11Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed.
12Commence refitting by fitting new seals to
both ends of each fuel injector. Even if only
one injector has been removed, new seals
must be fitted to all four injectors (see
illustration). Coat the seals with silicone
grease to Ford specification ESEM - ICI71 A.
Similarly, renew all four fuel injector retaining
clips.
13Further refitting is a reversal of removal,
ensuring that all hoses, wiring plugs and leads
are correctly connected. When reconnecting
the air inlet hose, make sure that the hose
clips are correctly aligned - see illustration,
Section 15.
14On completion, check and if necessary
adjust the idle mixture.
2.0 litre DOHC models
15Disconnect the battery negative lead.
16If desired, to improve access, disconnectthe wiring from the inlet air temperature
sensor in the inlet manifold. Similarly, the
throttle cable can be moved to one side by
disconnecting the cable from the throttle
linkage. The spark plug HT leads can be
disconnected and moved to one side, noting
their locations and routing to aid refitting.
17Slowly loosen the fuel rail fuel feed union
to relieve the pressure in the system. Be
prepared for fuel spillage, and take adequate
fire precautions.
18Disconnect the fuel feed hose from the
fuel rail (see illustration).
19Disconnect the fuel return hose from the
fuel pressure regulator. Again, be prepared for
fuel spillage.
20Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
21Disconnect the wiring plugs from the fuel
temperature sensor and the fuel injectors,
noting their locations to assist with refitting.
22Unscrew the two securing bolts, and
withdraw the fuel rail.
23Lift the fuel injectors from their locations
in the cylinder head (see illustration).
24Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed (refer to the note
at the start of this procedure before
condemning an injector).
25Commence refitting by fitting new seals to
both ends of each fuel injector. It is advisable
to fit new seals to all the injectors, even if only
one has been removed. Lubricate the seals
with clean engine oil.
18Fuel injectors - removal and
refitting
Fuel and exhaust systems - fuel injection 4B•9
4B
18.9b . . . and rear securing bolts
18.18 Disconnecting the fuel feed hose
from the fuel rail18.12 Fuel injector with seals removed18.10 Fuel injector retaining clip (A)
18.9a Fuel rail front securing bolt
(arrowed) . . .17.1 Fuel injector ballast resistor location
(arrowed)
Caution: Refer to the
precautions in Section 1 before
proceeding.

26Further refitting is a reversal of removal,
ensuring that all hoses, pipes and wiring plugs
are correctly connected.
27On completion, where applicable, check
and if necessary adjust the idle mixture.
Removal
1Disconnect the battery negative lead.
2Remove the air cleaner assembly.
3Depressurise the fuel system and
disconnect the fuel inlet pipe from the CFI unit.
4Disconnect the fuel return pipe from the CFI
unit. Be prepared for fuel spillage.
5Disconnect the throttle cable from the
linkage on the CFI unit.
6On 1.6 litre models, either partially drain the
cooling system or clamp the coolant hoses as
close as possible to the CFI unit to minimise
coolant loss, then disconnect the hoses from
the unit.
7Disconnect the wiring plugs for the throttle
position sensor, throttle valve control motor,
fuel injector and, on 1.6 litre models, the air
charge temperature sensor.
8Disconnect the vacuum pipe from the CFI
unit.9Unscrew the four (1.6 litre), or three (1.8
litre) securing bolts, and lift the CFI unit from
the inlet manifold (see illustration). Recover
the gasket.
Refitting
10Refitting is a reversal of removal, bearing
in mind the following points.
11Ensure that all mating faces are clean, and
use a new gasket.
12Top-up the cooling system.
13On completion, turn the ignition on and off
five times to pressurise the system, and check
for fuel leaks.
Refer to Chapter 1, Section 37.
1The valve is mounted at the end of the
pulse-air filter housing (see illustration).
2Disconnect the vacuum hose from the top
of the valve, then loosen the hose clips at
either end of the valve, and remove the valve.
Note the orientation of the arrow on the valve
body, which denotes the direction of flow.
3Refitting is a reversal of removal, ensuring
that the arrow on the valve body is orientated
as noted before removal.1Remove the air cleaner assembly.
2Loosen the hose clips, and disconnect the
air hoses from the check valves next to the
exhaust manifold (see illustration).
3Remove the two bolts securing the check
valve bracket to the exhaust manifold.
4Unscrew the unions securing the air tubes
to the manifold, then carefully withdraw the
tubing assembly, taking care not to distort the
tubes (see illustration).
5Refitting is a reversal of removal.
1The solenoid is located at the right-hand
side of the engine compartment.
2Disconnect the battery negative lead.
3Disconnect the vacuum pipe connector from
the pulse-air control solenoid (see illustration).
4Disconnect the solenoid wiring plug, pulling
on the plug, not the wiring.
5Unscrew the securing screw, and withdraw
the solenoid from the body panel.
6Refitting is a reversal of removal, ensuring
that the locating lug is correctly positioned,
and noting that the vacuum pipes will only fit
in one position.
23Pulse-air control solenoid
(1.6 litre CVH) - removal and
refitting
22Pulse-air delivery tubing
(1.6 litre CVH) - removal and
refitting
21Pulse-air system vacuum-
operated air valve (1.6 litre
CVH) - removal and refitting
20Pulse-air filter element (1.6 litre
CVH) - renewal
19CFI unit (1.6 and 1.8 litre (R6A
type) CVH) - removal and
refitting
4B•10Fuel and exhaust systems - fuel injection
18.23 Lifting a fuel injector from the
cylinder head21.1 Pulse air system vacuum-operated air
valve (arrowed)
23.3 Disconnect the vacuum pipe
connector from the solenoid22.4 Unscrewing a pulse-air delivery tube
union22.2 Pulse-air delivery check valves
(arrowed)
19.9 CFI unit securing bolts (arrowed) -
1.6 litre CVH
Caution: Refer to the
precautions in Section 1 before
proceeding. A new gasket must
be used on refitting.

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