1992 FORD SIERRA gas type

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