oil level FORD SIERRA 1993 2.G Reference Workshop Manual

REF•10MOTtest checks
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test
can be carried out later to check that the
vehicle pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-
bearing areas. (These include chassis box
sections, side sills, cross-members, pillars,
and all suspension, steering, braking system
and seat belt mountings and anchorages.)
Any corrosion which has seriously reduced
the thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allow
the engine speed to return to idle, and watchfor smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time of writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000
rpm; if the HC level is then 1200 ppm or less,
this counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM

MFuel filter choked (Chapter 1).
MFuel pump faulty, or delivery pressure low (Chapter 4).
MFuel tank vent blocked, or fuel pipes restricted (Chapter 4).
MFuel injection system fault (Chapter 4).
Engine lacks power
MFuel filter choked (Chapter 1).
MFuel pump faulty, or delivery pressure low (Chapter 4).
MUneven or low cylinder compressions (Chapter 2).
MWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
MVacuum leak at the throttle body, inlet manifold or associated
hoses (Chapter 4).
MFuel injection system fault (Chapter 4).
MBrakes binding (Chapters 1 and 10).
MClutch slipping (Chapter 6).
Engine backfires
MVacuum leak at the throttle body, inlet manifold or associated
hoses (Chapter 4).
MFuel injection system fault (Chapter 4).
Oil pressure warning light illuminated with engine
running
MLow oil level, or incorrect oil grade (Chapter 1).
MFaulty oil pressure sensor (Chapter 2).
MWorn engine bearings and/or oil pump (Chapter 2).
MExcessively high engine operating temperature (Chapter 3).
MOil pressure relief valve defective (Chapter 2).
MOil pick-up strainer clogged (Chapter 2).
Note:Low oil pressure in a high-mileage engine at tickover is not
necessarily a cause for concern. Sudden pressure loss at speed is far
more significant. In any event, check the gauge or warning light sender
before condemning the engine.
Engine runs-on after switching off
MExcessive carbon build-up in engine (Chapter 2).
MExcessively high engine operating temperature (Chapter 3).
Engine noises
Pre-ignition (pinking) or knocking during acceleration or
under load
MIgnition timing incorrect/ignition system fault (Chapters 1 and 5).
MIncorrect grade of spark plug (Chapter 1).
MIncorrect grade of fuel (Chapter 1).
MVacuum leak at throttle body, inlet manifold or associated hoses
(Chapter 4).
MExcessive carbon build-up in engine (Chapter 2).
MFuel injection system fault (Chapter 4).
Whistling or wheezing noises
MLeaking inlet manifold or throttle body gasket (Chapter 4).
MLeaking exhaust manifold gasket (Chapter 4).
MLeaking vacuum hose (Chapters 4 and 10).
MBlowing cylinder head gasket (Chapter 2).
Tapping or rattling noises
MWorn valve gear, timing chain, camshaft or hydraulic tappets
(Chapter 2).
MAncillary component fault (water pump, alternator, etc) (Chapters 3, 5)
Knocking or thumping noises
MWorn big-end bearings (regular heavy knocking, perhaps less
under load) (Chapter 2).
MWorn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2).
MPiston slap (most noticeable when cold) (Chapter 2).
MAncillary component fault (water pump, alternator, etc) (Chapters 3, 5)
Overheating
MAuxiliary drivebelt broken or incorrectly adjusted (Chapter 1).
MInsufficient coolant in system (Chapter 1).
MThermostat faulty (Chapter 3).
MRadiator core blocked, or grille restricted (Chapter 3).
MElectric cooling fan or thermostatic switch faulty (Chapter 3).
MViscous-coupled fan faulty (Chapter 3).
MIgnition timing incorrect, or ignition system fault (Chapters 1 and 5).
MInaccurate temperature gauge sender unit (Chapter 3).
MAirlock in cooling system (Chapter 3).
Overcooling
MThermostat faulty (Chapter 3).
MInaccurate temperature gauge sender unit (Chapter 3).
External coolant leakage
MDeteriorated or damaged hoses or hose clips (Chapter 1).
MRadiator core or heater matrix leaking (Chapter 3).
MPressure cap faulty (Chapter 3).
MWater pump internal seal leaking (Chapter 3).
MWater pump-to-block seal leaking (Chapter 3).
MBoiling due to overheating (Chapter 3).
MCore plug leaking (Chapter 2).
Internal coolant leakage
MLeaking cylinder head gasket (Chapter 2).
MCracked cylinder head or cylinder block (Chapter 2).
Corrosion
MInfrequent draining and flushing (Chapter 1).
MIncorrect coolant mixture or inappropriate coolant type (Chapter 1).
Fault diagnosisREF•13
REF
Cooling system
Excessive fuel consumption
MAir filter element dirty or clogged (Chapter 1).
MFuel injection system fault (Chapter 4).
MIgnition timing incorrect or ignition system fault (Chapters 1 and 5).
MBrakes binding (Chapter 10).
MTyres under-inflated (Chapter 1).
Fuel leakage and/or fuel odour
MDamaged fuel tank, pipes or connections (Chapters 1 and 4).
Excessive noise or fumes from exhaust system
MLeaking exhaust system or manifold joints (Chapters 1 and 4).
MLeaking, corroded or damaged silencers or pipe (Chapters 1 and 4).
MBroken mountings causing body or suspension contact (Chapter 4).
Fuel and exhaust systems

Note:Due to the complexity of the automatic transmission, it is difficult
for the home mechanic to properly diagnose and service this unit. For
problems other than the following, the vehicle should be taken to a
dealer service department or automatic transmission specialist.
Fluid leakage
MAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by air flow.
MTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using a
degreasing agent or by steam-cleaning. Drive the vehicle at low speed,
so that air flow will not blow the leak far from its source. Raise and
support the vehicle, and determine where the leak is coming from. The
following are common areas of leakage.
a)Fluid pan ( transmission “sump”).
b)Dipstick tube (Chapter 1).
c)Transmission-to-fluid cooler fluid pipes/unions (Chapter 7).
Transmission fluid brown, or has burned smell
MTransmission fluid level low, or fluid in need of renewal (Chapter 1).
General gear selection problems
MThe most likely cause of gear selection problems is a faulty or
poorly-adjusted gear selector mechanism. The following are common
problems associated with a faulty selector mechanism.
a)Engine starting in gears other than Park or Neutral.
b)Indicator on gear selector lever pointing to a gear other than the
one actually being used.
c)Vehicle moves when in Park or Neutral.
d)Poor gear shift quality, or erratic gear changes.
MRefer any problems to a Ford dealer, or transmission specialist.
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
MLow transmission fluid level (Chapter 1).
MIncorrect selector adjustment (Chapter 7).
Noisy in neutral with engine running
MInput shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7).*
MClutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 6).
Noisy in one particular gear
MWorn, damaged or chipped gear teeth (Chapter 7).*
Difficulty engaging gears
MClutch fault (Chapter 6).
MWorn or damaged gear linkage (Chapter 7).
MWorn synchroniser units (Chapter 7).*
Jumps out of gear
MWorn or damaged gear linkage (Chapter 7).MWorn synchroniser units (Chapter 7).*
MWorn selector forks (Chapter 7).*
Vibration
MLack of oil (Chapter 1).
MWorn bearings (Chapter 7).*
Lubricant leaks
MLeaking oil seal (Chapter 7).
MLeaking housing joint (Chapter 7).*
*Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.
Pedal travels to floor - no pressure or very little
resistance
MBadly stretched or broken cable (Chapter 6).
MStripped pawl on pedal (Chapter 6).
MBroken clutch release bearing or arm (Chapter 6).
MBroken diaphragm spring in clutch pressure plate (Chapter 6).
Clutch fails to disengage (unable to select gears)
MCable free play excessive (Chapter 6).
MClutch driven plate sticking on gearbox input shaft splines
(Chapter 6).
MClutch driven plate sticking to flywheel or pressure plate (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MClutch release mechanism worn or incorrectly assembled (Chapter 6).
Clutch slips (engine speed increases, with no
increase in vehicle speed)
MClutch driven plate linings excessively worn (Chapter 6).MClutch driven plate linings contaminated with oil or grease (Chapter 6).
MFaulty pressure plate or weak diaphragm spring (Chapter 6).
Judder as clutch is engaged
MClutch driven plate linings contaminated with oil or grease (Chapter 6).
MClutch driven plate linings excessively worn (Chapter 6).
MFaulty or distorted pressure plate or diaphragm spring (Chapter 6).
MWorn or loose engine or gearbox mountings (Chapter 2).
MClutch driven plate hub or gearbox input shaft splines worn
(Chapter 6).
Noise when depressing or releasing clutch pedal
MWorn clutch release bearing (Chapter 6).
MWorn or dry clutch pedal pivot (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MPressure plate diaphragm spring broken (Chapter 6).
MBroken clutch driven plate cushioning springs (Chapter 6).
REF•14Fault diagnosis
Clutch
Manual gearbox
Automatic transmission

Excessive final drive noise
MOil level low, or incorrect grade (Chapter 1)
MWorn bearings (Chapter 9)
MWorn or badly adjusted crownwheel and pinion (Chapter 9)
MLoose or deteriorated final drive mountings (Chapter 9)
Oil leakage from final drive
MPinion or output flange oil seal leaking (Chapter 9)MRear cover leaking (Chapter 9)
MCover or casing cracked (Chapter 9)
Grating, knocking or vibration from driveshafts
MFlange screws loose (Chapter 9)
MCV joints worn (Chapter 9)
MDriveshaft bent (Chapter 9)
Note:Before assuming that a brake problem exists, make sure that the
tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an
unequal manner. Apart from checking the condition of all pipe and
hose connections, any faults occurring on the anti-lock braking system
should be referred to a Ford dealer for diagnosis.
Vehicle pulls to one side under braking
MWorn, defective, damaged or contaminated front or rear brake
pads on one side (Chapters 1 and 10).
MSeized or partially-seized front or rear brake caliper piston
(Chapter 10).
MA mixture of brake pad lining materials fitted between sides
(Chapter 10).
MBrake caliper mounting bolts loose (Chapter 10).
MWorn or damaged steering or suspension components (Chapters 1
and 11).
Noise (grinding or high-pitched squeal) when brakes
applied
MBrake pad friction lining material worn down to metal backing
(Chapters 1 and 10).
MExcessive corrosion of brake disc - may be apparent after the
vehicle has been standing for some time (Chapters 1 and 10).
Excessive brake pedal travel
MFaulty master cylinder (Chapter 10).
MAir in hydraulic system (Chapter 10).MFaulty vacuum servo unit (Chapter 10).
Brake pedal feels spongy when depressed
MAir in hydraulic system (Chapter 10).
MDeteriorated flexible rubber brake hoses (Chapters 1 and 10).
MMaster cylinder mountings loose (Chapter 10).
MFaulty master cylinder (Chapter 10).
Excessive brake pedal effort required to stop vehicle
MFaulty vacuum servo unit (Chapter 10).
MDisconnected, damaged or insecure brake servo vacuum hose
(Chapters 1 and 10).
MPrimary or secondary hydraulic circuit failure (Chapter 10).
MSeized brake caliper piston(s) (Chapter 10).
MBrake pads incorrectly fitted (Chapter 10).
MIncorrect grade of brake pads fitted (Chapter 10).
MBrake pads contaminated (Chapter 10).
Judder felt through brake pedal or steering wheel
when braking
MExcessive run-out or distortion of brake disc(s) (Chapter 10).
MBrake pad linings worn (Chapters 1 and 10).
MBrake caliper mounting bolts loose (Chapter 10).
MWear in suspension or steering components or mountings
(Chapters 1 and 11).
Pedal pulsates when braking hard
MNormal feature of ABS - no fault
Clunking or knocking noise when taking up drive
MWorn universal joints (Chapter 8).
MLoose flange bolt (Chapter 8).
Vibration when accelerating or decelerating
MWorn centre bearing or universal joints (Chapter 8).
MBent or distorted shaft (Chapter 8).
MDeteriorated rubber insulator on centre bearing ( Chapter 8)
Engine will not start in any gear, or starts in gears
other than Park or Neutral
MFaulty starter inhibitor switch (Chapter 7).
MIncorrect selector adjustment (Chapter 7).
Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears
MThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility - fluid
level. Before taking the vehicle to a dealer or transmission specialist,
check the fluid level and condition of the fluid as described in Chapter
1. Correct the fluid level as necessary, or change the fluid and filter if
needed. If the problem persists, professional help will be necessary.
Fault diagnosisREF•15
REF
Propeller shaft
Final drive and driveshafts
Braking system

Brakes binding
MSeized brake caliper piston(s) (Chapter 10).
MIncorrectly-adjusted handbrake mechanism (Chapter 10).
MFaulty master cylinder (Chapter 10).
Rear wheels locking under normal braking
MSeized brake caliper piston(s) (Chapter 10).
MFaulty brake pressure regulator (Chapter 10).
Note:For problems associated with the starting system, refer to the
faults listed under “Engine” earlier in this Section.
Battery will not hold a charge for more than a few
days
MBattery defective internally (Chapter 5).
MBattery electrolyte level low - where applicable (Chapter 1).
MBattery terminal connections loose or corroded (Chapter 1).
MAuxiliary drivebelt worn - or incorrectly adjusted (Chapter 1).
MAlternator not charging at correct output (Chapter 5).MAlternator or voltage regulator faulty (Chapter 5).
MShort-circuit causing continual battery drain (Chapters 5 and 13).
Ignition/no-charge warning light remains illuminated
with engine running
MAuxiliary drivebelt broken, worn, or incorrectly adjusted (Chapter 1).
MAlternator brushes worn, sticking, or dirty (Chapter 5).
MAlternator brush springs weak or broken (Chapter 5).
MInternal fault in alternator or voltage regulator (Chapter 5).
MBroken, disconnected, or loose wiring in charging circuit (Chapter 5). Note:Before diagnosing suspension or steering faults, be sure that the
trouble is not due to incorrect tyre pressures, mixtures of tyre types, or
binding brakes.
Vehicle pulls to one side
MDefective tyre (Chapter 1).
MExcessive wear in suspension or steering components (Chapters 1
and 11).
MIncorrect front wheel alignment (Chapter 11).
MAccident damage to steering or suspension components (Chapters 1
and 11).
Wheel wobble and vibration
MFront roadwheels out of balance (vibration felt mainly through the
steering wheel) (Chapter 11).
MRear roadwheels out of balance (vibration felt throughout the
vehicle) (Chapter 11).
MRoadwheels damaged or distorted (Chapter 11).
MFaulty or damaged tyre (Chapter 1).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 11).
MWheel bolts loose (Chapter 11).
Excessive pitching and/or rolling around corners, or
during braking
MDefective shock absorbers (Chapters 1 and 11).
MBroken or weak coil spring and/or suspension component
(Chapters 1 and 11).
MWorn or damaged anti-roll bar or mountings (Chapter 11).
Wandering or general instability
MIncorrect front wheel alignment (Chapter 11).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 11).
MRoadwheels out of balance (Chapter 11).
MFaulty or damaged tyre (Chapter 1).
MWheel bolts loose (Chapter 11).
MDefective shock absorbers (Chapters 1 and 11).
Excessively-stiff steering
MLack of steering gear lubricant (Chapter 11).
MSeized track rod end balljoint or suspension balljoint (Chapters 1
and 11).MBroken or incorrectly adjusted auxiliary drivebelt (Chapter 1).
MIncorrect front wheel alignment (Chapter 11).
MSteering rack or column bent or damaged (Chapter 11).
Excessive play in steering
MWorn steering column universal joint(s) (Chapter 11).
MWorn steering track rod end balljoints (Chapters 1 and 11).
MWorn rack-and-pinion steering gear (Chapter 11).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 11).
Lack of power assistance
MBroken or incorrectly-adjusted auxiliary drivebelt (Chapter 1).
MIncorrect power steering fluid level (Chapter 1).
MRestriction in power steering fluid hoses (Chapter 11).
MFaulty power steering pump (Chapter 11).
MFaulty rack-and-pinion steering gear (Chapter 11).
Tyre wear excessive
Tyres worn on inside or outside edges
MTyres under-inflated (wear on both edges) (Chapter 1).
MIncorrect camber or castor angles (wear on one edge only)
(Chapter 11).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 11).
MExcessively-hard cornering.
MAccident damage.
Tyre treads exhibit feathered edges
MIncorrect toe setting (Chapter 11).
Tyres worn in centre of tread
MTyres over-inflated (Chapter 1).
Tyres worn on inside and outside edges
MTyres under-inflated (Chapter 1).
MWorn shock absorbers (Chapters 1 and 11).
Tyres worn unevenly
MTyres out of balance (Chapter 1).
MExcessive wheel or tyre run-out (Chapter 1).
MWorn shock absorbers (Chapters 1 and 11).
MFaulty tyre (Chapter 1).
REF•16Fault diagnosis
Steering and suspension
Electrical system

AAccelerator cable- 4A•8
Accelerator pedal- 4A•8
Acknowledgements- 0•4
Aerial- 13•20
Air cleaner- 1•18, 1•19, 4A•4, 4B•4
Air conditioning systems- 1•16, 3•1 et seq
Airflow meter- 4B•8
Alarm system- 13•19
Alternator- 5•6
Anti-roll bars- 11•6, 11•13
Anti-theft alarm- 13•19
Antifreeze- 0•17, 1•21, 3•3
ATF- 0•17, 1•3
Automatic transmission- 7B•1 et seq
extension housing oil seal - 7B•5
fault diagnosis - REF•11, REF•14
fluid - 0•17, 1•3
fluid checks - 1•13
gear selector mechanism - 7B•5
kickdown cable - 7B•3
removal and refitting - 7B•2
reversing lamp switch - 7B•6
selector rod - 7B•5
starter inhibitor switch - 7B•6
vacuum diaphragm unit - 7B•6
Auxiliary drivebelts- 1•14, 1•21
Auxiliary shaft- 2A•18
BBattery- 0•15, 1•15, 5•5
Bearings (engine) - 2A•23, 2B•17, 2C•23
Bleeding the power steering- 11•18
Bleeding the brakes- 10•2
Body damage- 12•2, 12•4
Body electrical systems - 13•1 et seq
Bodywork and fittings- 12•1 et seq
Bonnet release cable- 12•4
Bonnet lock- 12•4, 12•5
Boot lid lock- 12•5
Brake checks- 1•10
Brake fluid- 0•13, 0•1, 1•21
Braking system- 10•1 et seq
backplate - 10•12
bleeding the brakes - 10•2
brake caliper - 10•8, 10•10
brake disc - 10•3, 10•11
brake drum - 10•12
brake fluid pipes and hoses - 10•19
brake fluid reservoir - 10•15
brake lamp switch - 13•6
brake pads - 10•3
brake pedal - 10•22
brake shoes - 10•6
computer module (ABS) - 10•17
deceleration valve - 10•18
fault diagnosis - REF•11, REF•15
handbrake adjustment - 1•16, 10•20, 10•21
handbrake cables - 1•16, 10•20, 10•21
handbrake lever - 10•22
hoses brake - 10•19
hydraulic unit pressure switch - 10•17
hydraulic unit/pump/motor (ABS) - 10•15, 10•16
load apportioning valve - 10•19master cylinder (brake) - 10•13
pressure switch - 10•17
vacuum servo unit - 10•14
valve block (ABS) - 10•17
wheel cylinder - 10•12
wheel sensor - 10•18
Bulbs exterior- 13•16
Bulbs interior- 13•10
Bulbs ratings- 13•2
Bumpers- 12•13
Buying spare parts - REF•3
CCables:
accelerator - 4A•8
bonnet release - 12•4
clutch - 6•2
handbrake - 10•20, 10•21
kickdown - 7B•3
speedometer - 13•11
tailgate/boot lid/filler cap - 12•6
Caliper (brake) front/rear- 10•8, 10•10
Camshaft and followers- 2A•17, 2B•14, 2C•16
Capacities- 1•3
Carburettor:
Ford VV type - 1•12, 4A•8, 4A•13
Pierburg 2V type - 1•12, 4A•8, 4A•14
Weber 2V type - 1•12, 4A•8, 4A•14
Weber 2V TLD type - 1•12, 4A•8, 4A•15
Cargo area- 12•10
Carpets- 12•2
Catalytic converter- 4B•3, 4B•14
Central locking system- 13•18
Centre/overhead console- 12•18, 12•19
CFI unit- 4B•10
Charging system- 5•5
Cigarette lighter- 13•6
Clock- 13•6
Clutch- 6•1 et seq
assembly - 6•3
cable - 6•2
fault diagnosis - REF•11, REF•14
pedal - 6•2
release bearing - 6•5
Coil- 5•13
Coil spring (rear) - 11•10
Compression test- 2A•7
Computer module (ABS)- 10•17
Connecting rods- 2A•22, 2B•17, 2C•21
Contents- 0•2
Coolant- 0•12, 0•17, 1•21, 3•3
Coolant level- 0•12
Cooling, heating and air conditioning
systems- 3•1 et seq
antifreeze - 0•12, 0•17, 1•21, 3•3
coolant pump - 3•5
coolant temperature sender and sensor - 3•8
cooling fan - 3•7
draining - 1•21
drivebelt tensioner - 3•7
expansion tank/coolant sensor - 3•8
fan (radiator) - 3•7
fault diagnosis - REF•11, REF•13
filling - 1•21
flushing - 1•21heater - 3•9
radiator - 3•3
switches - 3•8
temperature gauge and sender unit - 3•8
thermostat - 3•4
Courtesy lamp switch- 13•5
Crankshaft oil seals- 2A•19, 2B•15, 2C•19
Crankshaft bearings- 2A•23, 2B•17, 2C•23
Cylinder bores- 2A•24
Cylinder head- 2A•14, 2B•10, 2C•13
DDents- 12•2
Depressurising fuel injection system- 4B•4
Dimensions and weights- REF•1
Disc brake - 10•3, 10•11
Distributor- 5•14, 5•15, 5•16
Door- 12•6
Door inner trim panel- 12•7
Door mirror switch- 13•5
Drivebelts check- 1•14, 1•21, 3•7
Driveplate- 2A•18, 2B•15, 2C•19
Driveshafts:
check - 1•17
fault diagnosis - REF•11, REF•15
overhaul - 9•5
removal and refitting - 9•4
Drum (brake)- 10•12
EEarth fault finding- 13•3
Electric windows- 13•18
Electrical fault finding- 13•2
Electrical system (body)- 13•1 et seq
Electrical system:
weekly checks - 0•14
fault diagnosis - REF•11, REF•16
Electronic vacuum regulator- 4B•11
Engine:
auxiliary shaft - 2A•18
bearings - 2A•23, 2B•17, 2C•23
bores - 2A•24
camshaft followers - 2A•17, 2B•14, 2C•16
codes - 2A•1, 2B•1, 2C•1
compartment views - 0•10, 1•5
compression test - 2A•7
connecting rods - 2A•22, 2B•17, 2C•21
crankshaft bearings - 2A•23, 2B•17, 2C•23
crankshaft oil seals - 2A•19, 2B•15, 2C•19
cylinder bores - 2A•24
cylinder head - 2A•14, 2B•10, 2C•13
dismantling - 2A•11, 2B•8, 2C•10
DOHC engines- 2B•1 et seq
driveplate - 2A•18, 2B•15, 2C•19
fault diagnosis - REF•11, REF•12
flywheel - 2A•18, 2B•15, 2C•19
main bearings - 2A•23, 2B•17, 2C•23
mountings - 2A•11, 2B•7, 2C•9
oils - 0•17, 1•3
oil and filter renewal - 1•9
oil level - 0•12
oil pump - 2A•21, 2B•16, 2C•20
oil seals crankshaft - 2A•19, 2B•15, 2C•19
piston - 2A•22, 2B•17, 2C•21
IndexREF•23
REF
Note: References throughout this index are in the form - “Chapter number” • “page number”

refitting - 2A•10, 2B•7, 2C•9
removal - 2A•8, 2B•4, 2C•6
SOHC engines- 2A•1et seq
spark plugs - 1•2, 1•14, 5•12
sump - 2A•20, 2B•15, 2C•19
timing belt/chain and sprockets - 2A•12,
2B•8, 2C•10
timing and sprockets - 2A•12, 2B•8, 2C•10
valves - 1•15
Engine electrical systems - 5•1 et seq
Environmental considerations- REF•4
Exhaust gas oxygen sensor (HEGO)- 4B•15
Exhaust gas recirculation valve- 4B•14
Exhaust manifold- 4A•17, 4B•15
Exhaust pressure transducer- 4B•14
Exhaust system- 1•11, 4A•18, 4B•15
Expansion tank/coolant sensor- 3•8
FFacia panel- 12•16
Facia panel switches- 13•4
Fan (radiator)- 3•7
Fault diagnosis- REF•11
automatic transmission - REF•14
braking system - REF•15
clutch - REF•14
cooling system - REF•13
driveshafts - REF•15
electrical system - REF•16
engine - REF•12
final drive - REF•15
fuel and exhaust systems - REF•13
manual gearbox - REF•14
propeller shaft - REF•15
steering - REF•16
suspension - REF•16
Final drive and driveshafts- 9•1 et seq
Final drive fault diagnosis- REF•11, REF•15
Final drive unit- 9•2, 9•3, 9•4
Fluids- 0•17
Flywheel/driveplate- 2A•18, 2B•15, 2C•19
Foglamps- 13•15
Ford VV carburettor- 1•12, 4A•13
Front suspension crossmember- 11•3
Front suspension strut- 11•4
Fuel systems- carburettor - 4A•1 et seq
Fuel systems- fuel injection - 4B•1 et seq
Fuel system:
accelerator cable - 4A•8
accelerator pedal - 4A•8
air cleaner - 1•18, 1•19, 4A•4, 4B•4
airflow meter - 4B•8
catalytic converter - 4B•3, 4B•14
CFI unit- 4B•10
depressurising fuel injection system - 4B•4
dismantling and reassembly - 4A•8
electronic vacuum regulator - 4B•11
exhaust gas recirculation valve - 4B•14
exhaust gas oxygen sensor (HEGO) - 4B•15
exhaust manifold - 4A•17, 4B•15
exhaust pressure transducer - 4B•14
exhaust system - 4A•18, 4B•15
fuel filler cap - 12•14
fuel filter - 1•2, 1•20
fuel level sender unit - 4A•7, 4B•7fuel pressure regulator - 4A•5, 4B•5
fuel pump - 4A•5, 4A•6, 4B•6
fuel tank - 4A•7
fuel vapour separator - 4A•5
fuel gauges - 13•8
idle speed control valve - 4B•7
injector(s) - 4B•8
inlet manifold - 4A•15, 4B•12
mixture adjustment potentiometer - 4B•7
pulse-air - 4B•10
throttle body - 4B•12
throttle control motor - 4B•11
throttle position sensor - 4B•11
throttle valve control motor - 4B•11
Fuses- 13•3
GGear linkage- 7A•4
Gear selector mechanism- 7B•5
Gearbox - see Manual gearbox or
Automatic transmission
Gearbox oil- 0•17, 1•3
Glass- 12•11
HHandbrake check/adjustment- 1•16, 10•21
Handbrake cables- 10•20, 10•21
Handbrake lever - 10•22
Handbrake warning lamp switch- 13•6
Handles (door)- 12•9
Hazard warning flasher switch- 13•4
Headlamp alignment- 13•14
Headlamp unit- 13•13
Headlamp washers- 13•12
Headlining - 12•19
Heated rear window- 13•20
Heated seat- 13•19
Heater- 3•9
Hinges and locks- 1•14
Horn- 13•11
Horn switch- 13•5
Hose and fluid leak check- 0•8, 1•10,
Hoses brake- 10•19
Hoses power steering- 11•18
HT coil- 5•13
HT leads- 5•12
Hub carrier (front) - 11•5
Hydraulic fluid- 0•17
Hydraulic system (brakes) bleeding- 10•2
Hydraulic unit, pump, motor (ABS)- 10•15,
10•16
IIdle speed control valve- 4B•7
Idle speed/mixture- 1•11, 1•12, see
Specifications in Chapter 4A, and refer to
specific carburettor type
Ignition electronic modules- 5•3, 5•19
Ignition HT coil- 5•13
Ignition switch- 13•4
Ignition system check- 1•20
Ignition timing adjustment- 5•17
Indicator lamps- 13•15Indicator switch/relay- 13•4
Injector(s)- 4B•8
Inlet manifold- 4A•15, 4B•12
Instrument panel- 13•7
Interior trim- 12•15
Introduction to the Ford Sierra- 0•4
JJacking and vehicle support- 0•6
Jump starting- 0•9
KKickdown cable - 7B•3
LLeaf springs- 11•13
Leak, checking- 0•8, 1•10
Lights- 13•14
Locks:
bootlid - 12•5
door - 12•9, 12•10
tailgate - 12•6
Loudspeakers- 13•20
Lower arm (suspension)- 11•4, 11•7, 11•8
Lubricants and fluids- 0•17
Luggage area light switch- 13•5
MMain bearings- 2A•23, 2B•17, 2C•23
Maintenance and servicing - see Routine
maintenance
Manifolds- 4A•15, 4A•17, 4B•12, 4B•15
Manual gearbox- 7A•1 et seq
fault diagnosis - REF•11, REF•14
gear linkage - 7A•4
gearbox oil - 0•17, 1•3
oil level check - 1•13
removal and refitting - 7A•2
Master cylinder (brake)- 10•13
Mirrors- 12•12
Mixture (CO)- see Idle speed/mixture
Mixture adjustment potentiometer- 4B•7
MOT test checks- REF•7
Mountings, engine-2A•11, 2B•7, 2C•9
NNumber plate lamp- 13•16
OOil change/filter- 1•1, 1•9,
Oil pressure warning switch- 13•6
Oil pump- 2A•21, 2B•16, 2C•20
Oil seals- REF •4
Oil seals crankshaft- 2A•19, 2B•15, 2C•19
Oils- engine and gearbox- 0•17, 1•3
PPads (brake) - 10•3
Paintwork damage- 12•2
Parts- REF•3
REF•24Index

Pedals:
accelerator - 4A•8
brake - 10•22
clutch - 6•2
Pierburg 2V carburettor- 1•12, 4A•14
Pipes/hoses (braking system)- 10•19
Pistons- 2A•22, 2B•17, 2C•21
Plastic components- 12•3
Plugs- 1•2, 1•14, 5•12
Power operated windows- 13•18
Power steering fluid- 0•17
Power steering fluid level- 0•14
Power steering fluid hoses-11•18
Power steering pump- 11•18
Power steering system bleeding- 11•18
Pressure switch (hydraulic unit)- 10•17
Propeller shaft- 8•1 et seq
centre bearing - 8•2
fault diagnosis - REF•11, REF•15
front rubber coupling - 8•3
removal and refitting - 8•2
vibration damper - 8•4
Pulse-air system- 4B•10
Punctures- 0•6
RRadiator- 1•16, 3•3
Radiator cooling fan- 3•7
Radiator grille- 12•14
Radio/cassette player- 13•21
Rear axle- 9•7, 9•8, 11•13
Relays- 13•3
Release bearing (clutch)- 6•5
Repair procedures- REF •4
Respraying- 12•2
Reversing lamp switch- 7B•6, 13•4
Roadtest- 1•17
Roadwheel check- 1•11
Roll bars- 11•6, 11•13
Rotor arm- 5•14, 5•15
Routine maintenance and servicing- 1•1 et seq
Routine maintenance procedures- 1•9
Routine maintenance schedule- 1•3
SSafety first!- 0•5
Scratches- 12•2
Seat belts- 1•11, 12•21
Seat heating pad- 13•19
Seats- 12•19
Selector rod- 7B•5
Sender unit fuel level- 4A•7, 4B•7
Sender units coolant temperature- 3•8
Servicing -see Routine maintenance
Servo unit (braking system)- 10•14
Shock absorber- 11•9
Shoes (brake)- 10•6
Short-circuit finding- 13•3
Spare parts- REF•3
Spark plugs- 1•2, 1•14, 5•12
Speakers- 13•20Specifications- see start of relevant Chapter
Speedometer- 13•8
Speedometer cable- 13•11
Spoiler- 12•6
Starter inhibitor switch- 7B•6
Starter motor- 5•8
Steering- 11•1 et seq
check -1•17, 1•18
column/adjustment - 11•15
fault diagnosis - REF•11, REF•16
gear - 11•16, 11•18
hoses - 11•18
power steering system bleeding - 11•18
pump - 11•18
tie-rod end - 11•18
wheel - 11•14
wheel alignment - 11•1, 11•19
Sump- 2A•20, 2B•15, 2C•19
Sunroof- 12•15, 13•6
Support struts (tailgate)- 12•6
Suspension and steering- 11•1 et seq
anti-roll bars - 11•6, 11•13
check - 1•17, 1•18
coil spring (rear) - 11•10
crossmember (front) - 11•3
fault diagnosis - REF•11, REF•16
hub carrier (front) - 11•5
leaf springs - 11•13
lower arm (front/rear) - 11•4, 11•7, 11•8
mountings - 11•12
rear axle assembly - 11•13
shock absorber - 11•9
strut (front) - 11•4
wheel bearings - 11•6, 11•10
Switches:
brake lamp - 13•6
cooling system - 3•8
courtesy lamp - 13•5
direction indicator - 13•4
electric door mirror - 13•5
facia panel - 13•4
handbrake warning lamp - 13•6
hazard warning lamp - 13•4
horn - 13•5
hydraulic pressure (brakes) - 10•17
ignition/lockbarrel - 13•4
luggage area light - 13•5
oil pressure warning - 13•6
reversing - 7B•6, 13•4
starter inhibitor - 7B•6
TTachometer- 13•8
Tailboard- 12•11
Tailgate struts- 12•6
Tailgate/lock- 12•5, 12•6
Temperature gauge and sender unit- 3•8
Thermostat- 3•4
Throttle body- 4B•12
Throttle cable- 4A•8
Throttle position sensor- 4B•11
Throttle valve control motor- 4B•11Tie-rod end- 11•18
Timing adjustment- 5•17
Timing belt/chain and sprockets- 2A•12,
2B•8, 2C•10
Tools and working facilities- REF•5
Towing- 0•7
Transmission housing oil seal- 7B•5
Trim panel (door)- 12•7
Tyre checks and pressures- 0•16, 0•18
UUnderbody- 1•7 1•8, 1•17, 12•2
Underbonnet views -0•10, 1•5
Unleaded petrol- 5•18
Upholstery and carpets- 12•2
VVacuum diaphragm unit- 7B•6
Vacuum servo unit (braking system)- 10•14
Valve block (ABS)- 10•17
Valves- 1•15
Vehicle identification numbers- REF•3
Ventilation system- 3•1 et seq
WWarning system components- 13•9
Washer fluid level- 0•13
Washers- 13•12
Weatherstrip- 12•15
Weber 2V carburettor- 1•12, 4A•14
Weber 2V TLD carburettor- 1•12, 4A•15
Weekly checks- 0•10
Wheel (steering) - 11•14
Wheel alignment- 11•1, 11•19
Wheel arch liners- 12•14
Wheel bearings- 11•6, 11•10
Wheel changing- 0•6
Wheel cylinder- 10•12
Wheel sensor(ABS)- 10•18
Window glass- 12•11
Window regulator- 12•12
Windscreen- 12•11, 12•14
Windscreen washers- 13•12
Windscreen wiper motor- 13•12
Wiper arms- 13•11
Wiper blades- 0•15, 13•11
Wiper motor (headlamp)- 13•13
Wiper motor (rear)- 13•12
Wiper motor (windscreen)- 13•12
Wiring diagrams- WD•1 et seq
Working facilities- REF•5
IndexREF•25
REF