1982 FORD SIERRA Cooling And Air Conditioning Systems Workshop Manual

2With the engine cold, slowly unscrew the
expansion tank cap to release any remaining
pressure from the cooling system, then refit
the cap.
3Disconnect the wiring from the sender
terminal (see illustrations).
4Unscrew and remove the sender, and
temporarily plug the aperture.
Refitting
5Refitting is a reversal of removal, but smear
a little sealing compound on the sender unit
threads before fitting.
6On completion, check and if necessary top-
up the coolant level.
Removal
1Disconnect the battery negative lead.
2Remove the securing screws and unclip the
lower and upper steering column shrouds.
3Remove the four securing screws and
withdraw the instrument panel surround. Note
that the bottom right-hand screw is covered
by a plastic panel which must be prised out.
4Remove the passenger side lower facia
panel.
5Where necessary for improved access,
detach the two vent hoses from the left-hand
side of the heater, then detach the lower ends
of the two control cables from the heater by
removing the retaining screws (see
illustration).
6Unscrew the three securing screws, and
remove the heater control panel by sliding it
through the facia panel and withdrawing it
downwards. Disconnect the wiring from the
control panel illumination bulb.
7If necessary, the bulb can be removed with
its holder.
Refitting
8Refitting is a reversal of removal, bearing in
mind the following points.
9When reconnecting the wiring to the control
panel illumination bulb, wrap insulating tapearound the wiring loom over a length of
approximately 330.0 mm (13.0 in) starting
from the bulbholder. Route the loom, ensuring
that it is located in the two retaining clips,
bend it over and secure it to the bulbholder
with insulating tape as shown (see
illustration). This procedure will prevent the
wiring loom from chafing against the heater
control levers.
10When reconnecting the control cables to
the heater, move the control levers on the
control panel to the fully up position, then
attach the cables to the clips on the heater.
The cable ends should project from the clips
by between 0 and 4.0 mm (0 and 0.16 in). The
cables are adjusted automatically by moving
the control levers fully downwards. It is
possible that considerable resistance may
have to be overcome when moving the control
levers.
Removal
1Disconnect the battery negative lead.
2If the coolant is still hot, release the
pressure in the system by slowly unscrewing
the expansion tank cap. Place a thick rag over
the cap to prevent scalding as the pressure is
released.
3Note the location of the two heater hoseson the engine compartment bulkhead, then
disconnect and plug them (see illustration).
Alternatively, the hoses can be secured high
enough to prevent the coolant from draining.
4To prevent unnecessary spillage of coolant
when the heater unit is removed, blow into the
upper heater pipe until all the coolant has
been expelled through the lower pipe.
5Remove the two securing screws and
withdraw the heater pipe cover from the
bulkhead (see illustration). Recover the
gasket.
6Working inside the vehicle, remove the
passenger side lower facia panel.
7Disconnect the ends of the two control
cables from the heater by removing the two
retaining screws.
8Detach the five vent hoses from the heater.
9Unscrew the two mounting bolts, and move
the heater to the rear until the pipes are clear
of the bulkhead, then withdraw the heater to
the left. If necessary, remove the lower facia
bracket (see illustration).
Refitting
10Refitting is a reversal of removal, but
adjust the control cables by moving the levers
on the control panel to the top and then the
bottom stops. Considerable resistance may
be encountered when moving the levers
towards the bottom stops, which should be
overcome.
11On completion, top-up the coolant level.
18Heater unit - removal and
refitting
17Heater controls - removal and
refitting
Cooling, heating and air conditioning systems 3•9
3
18.3 Location of heater hoses on engine
compartment bulkhead18.9 Withdrawing the heater18.5 Heater pipe cover
17.9 Heater control panel illumination bulb
wiring loom correctly routed17.5 Heater control cable lower end fittings
(arrowed)

1With the heater unit removed from the
vehicle, remove the two securing screws and
withdraw the heater matrix from the casing
(see illustrations).
2Cut the heater casing gasket in line with the
casing joint, then use two suitable
screwdrivers to prise off the retaining clips
and separate the casing halves. Withdraw the
lower part of the casing to the side.
3Remove the air flap valves, then press the
control levers from the casing. Note that the
“up/down” control lever can only be removed
when the marks are aligned as shown (see
illustration).
4Clean all components and hose through the
matrix to remove any debris. If necessary usea chemical cleaner to clear the inner passage
of the matrix. Renew the components as
necessary.
5Reassembly is a reversal of dismantling.
Removal
1Disconnect the battery negative lead.
2Where necessary, unclip the brake servo
vacuum hose for improved access.
3On models from 1987, unclip the
windscreen washer hoses and wiring from the
motor cover, and secure them to the
bodywork out of the way.
4Unscrew the two securing bolts from the
motor cover, pull off the rubber moulding,
then withdraw the cover (see illustration).
5Disconnect the wiring from the motor, and
detach the earth lead from its bracket. 6Unscrew the two motor securing nuts, and
withdraw the motor assembly (see illustration).
7Unclip the casing halves, then prise open
the motor retaining strap using a screwdriver,
or if necessary a drift.
8Detach the wiring from the motor, then
remove the motor and fan wheels from the
casing. Refitting
9Refitting is a reversal of removal.
1Only those items which can be renewed
without discharging the system are described
here(see illustration).Other items must be
dealt with by a Ford dealer or air conditioning
specialist.
21Air conditioning system -
component renewal
20Heater motor - removal and
refitting
19Heater unit - overhaul
3•10Cooling, heating and air conditioning systems
19.1a Remove the securing screws . . .19.3 Heater “up/down” control lever must
be aligned as shown before removal
Note that the cross marks are for right-hand
drive vehicles
1 De-ice thermostat
2 Evaporator
3 Expansion valve
4 Compressor
5 Compressor clutch6 Pressure switch
7 Sight glass
8 Dehydrator/collector
9 Cooling fan
10 Condenser
21.1 Layout of air conditioning system components
20.6 Heater motor and wiring
20.4 Unscrew the securing bolts and
withdraw the heater motor cover
19.1b . . . and withdraw the heater matrix

Compressor drivebelt
2Disconnect the battery negative lead.
3On SOHC models, remove the thermo-
viscous cooling fan.
4Slacken the compressor mounting and
pivot bolts, move the compressor towards the
engine and remove the old drivebelt (see
illustration).
5Fit the new drivebelt, position the
compressor to achieve the correct belt
tension, then tighten the mounting and pivot
bolts.
6On SOHC models, refit the thermo-viscous
cooling fan.
7Reconnect the battery negative lead.
Condenser fan and motor
Models up to 1987
8Disconnect the battery negative lead, and
remove the radiator grille. On Ghia models,
remove the front bumper.9Disconnect the fan wiring connector at the
side of the condenser.
10Remove the three securing bolts and
withdraw the fan assembly. Turn the frame to
position the fan wiring on the dehydrator side
to avoid damaging the wiring. Take care also
not to damage the condenser fins or tube.
11To remove the fan blades from the motor,
remove the retaining nut and circlip. The nut
has a left-hand thread, ie, it is undone in a
clockwise direction.
12With the blades removed, the motor can
be unscrewed from the frame.
13Reassemble and refit in the reverse order
of dismantling and removal.
Models from 1987
14Disconnect the battery negative lead.
15Remove the bonnet lock.
16Unclip the guard from the fan frame.
17Disconnect the fan wiring connector (see
illustration).
18Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
19Unscrew the two lower condenser
securing bolts and disengage the condenser
from the top of the radiator by releasing the
three clips.
20Unscrew the four securing bolts and
detach the fan assembly from the condenser.
Withdraw the fan assembly from underneath
the vehicle.
21Proceed as described in paragraphs 11 to
13 inclusive.
De-ice thermostat
22Disconnect and remove the battery.23Disconnect any vacuum hoses,
windscreen washer hoses and electrical
wiring as necessary, then unscrew the four
securing bolts and on models up to 1987 the
single nut, and remove the right-hand plenum
chamber cover plate from the bulkhead.
24Disconnect the thermostat from the
evaporator casing and withdraw it. Also
withdraw the thermostat probe from the
casing.
25Refitting is a reversal of removal.
Heating/air conditioning controls
26The procedure is similar to that described
for the heater controls but additionally the
vacuum hoses must be disconnected from
the control unit vacuum valve during removal,
and reconnected when refitting.
Cooling, heating and air conditioning systems 3•11
3
21.17 Air conditioning condenser fan
wiring connector location (arrowed) -
models from 198721.4 Typical air conditioning compressor
mounting and pivot bolts (arrowed)

3•12Notes