1989 FORD FIESTA engine

7Detach the vacuum hose between the
throttle kicker and the inlet manifold at source
(but not the vacuum supply to the ignition
module). Connect a new length of vacuum
hose directly between the manifold and the
kicker unit.
8 Restart the engine and check the engine
speed. The throttle kicker should increase the
engine speed above its normal idle. Check the
speed registered against the specified throttle
kicker operating speed.
9 If required, the throttle kicker speed can be
adjusted by prising free the tamperproof plug
and the adjustment screw turned as
necessary (see illustration 21.3) .
10 When the adjustment is complete, stop
the engine, fit a new tamperproof plug,
disconnect the temporary vacuum hose
(between the manifold and the kicker unit) and
reconnect the original hose (between the
carburettor and the kicker unit).
11 Remove the bridging wire, and reconnect
the cooling fan thermostatic switch multi-
plug. Refit and secure the air cleaner, and
disconnect the tachometer and CO meter to
complete.
22 Throttle kicker control solenoid
(Weber TLDM carburettor) -
removal and refitting
2
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Disconnect the multi-plug from the solenoid
(see illustration) .
3 Remove both vacuum pipes, having
labelled them for correct subsequent refitting.
4 Remove the screw securing the solenoid
and mounting bracket assembly to the
bulkhead panel, then withdraw the assembly
from the vehicle.
Refitting
5 Refitting is a reversal of the removal
procedure, ensuring that the locating lug
snaps into position and that the vacuum pipes
are connected to their correct terminals.
23 Carburettor (Weber TLDM) -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets will be
required on refitting, and a tachometer and an
exhaust gas analyser will be required on
completion.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Disconnect the accelerator cable from the
carburettor (Section 3).
4 Disconnect the choke cable from the
carburettor (Section 6).
5 Disconnect the fuel hose from the
carburettor, and plug its end to prevent fuel
spillage and the ingress of dirt. If a crimped
type hose clip is fitted, cut it free, but take
care not to damage the hose. Crimped clips
must be discarded and replaced with screw
type clips during refitting.
6 Disconnect the wiring from the anti-
dieseling solenoid.
7 Unscrew and remove the four carburettor-
to-manifold retaining Torx head screws, then
carefully lift the carburettor from the manifold
(see illustration) .
Refitting
8Clean the carburettor and manifold gasket
mating faces. 9
Refit in the reverse order of removal. Fit a
new gasket, and tighten the retaining screws
securely. Ensure that the fuel supply hose
connection to the carburettor is
securely fitted, using a new screw type
retaining clip.
10 Reconnect the accelerator cable, and
adjust it as described in Section 3.
11 Reconnect the choke cable, and adjust it
as described in Section 6.
12 Refer to Section 2 and refit the air cleaner.
13 When the battery is reconnected, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.
24 Carburettor (Weber TLDM) -
dismantling, cleaning,
inspection and reassembly
4
Note: Refer to the warning note in Section 1
before proceeding. Check parts avail-
ability before dismantling. If possible, obtain
an overhaul kit containing all the relevant
gaskets, seals, etc, required for reassembly
prior to dismantling the carburettor.
Dismantling
1 With the carburettor removed from the
vehicle, prepare a clean, flat work surface
prior to commencing dismantling. The
following procedures may be used for partial
or complete dismantling, as required.
2 Clean the exterior of the carburettor, then
undo the two retaining screws and lift the
upper carburettor body from the lower section
(see illustration overleaf) .
3 Remove the float and needle valve from the
carburettor upper body, as described in
Section 20.
4 Unscrew and remove the anti-dieseling
solenoid from the upper body, but ensure that
Fuel system – carburettor engines 4A•11
23.7 Four Torx head screws (arrowed) secure the carburettor to the inlet manifold (Weber TLDM carburettor)22.2 Throttle kicker control solenoid
A Multi-plug B Vacuum pipes C Securing screw
4A
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the seal washer is removed together with the
valve (see illustration) .
5 Undo the three screws securing the choke
mechanism, and detach it (see illustration).
6 Unscrew and remove the two air correction
jets from the underside of the upper body.
Note the size and location of each, to ensure
correct refitting.
7 Invert the upper body so that the emulsion
tubes can fall out of their apertures (above the
air correction jets). Remove the emulsion
tubes from their locations, again having noted
the size and location of each.
8 Unscrew and remove the main jets, again
having noted their fitted positions.
9 Dismantle the carburettor lower (main) body
as follows.
10 Prise free the accelerator pump discharge
tube, but take care not to damage it or the
carburettor body (see illustration).
11 Undo the four screws securing the
accelerator pump; remove the cover, followed
by the diaphragm and return spring (see
illustrations) . The valve should come out on
the end of the return spring. Check that the
valve is complete and with its O-ring seal
(where applicable).
12 Undo the three retaining screws, and
remove the power valve unit. Remove the
cover and return spring, followed by the
diaphragm.
13 Where fitted, undo the retaining screws
and remove the throttle kicker unit from the
lower (main) body.
4A•12 Fuel system – carburettor engines
24.11c . . . and the return spring and valve assembly24.11b . . . followed by its diaphragm . . .24.11a Remove the accelerator pumpcover . . .
24.10 Carefully prising out the accelerator
pump discharge tube assembly24.5 Undo the three screws securing the choke mechanism (arrowed)24.4 Withdrawing the anti-dieseling (fuel cut-off) solenoid
1595Ford Fiesta Remake
24.2 Exploded view of the carburettor (Weber TLDM)
A Anti-dieseling (fuel cut-off) solenoid
B Emulsion tubes
C Air-correction jets
D Choke pull-down diaphragm assembly
E Manual choke linkage
F Needle valve
G Float
H Fast-idle adjusting screw
J Idle speed adjusting screw
K Idle mixture adjusting screw
L Throttle plates
M Power valve assembly
N Accelerator pump assembly
P Throttle kicker (if fitted)
Q Upper body gasket
R Main jets
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14Prise free and remove the tamperproof
seal, then unscrew and remove the idle
mixture adjustment screw.
15 Undo the retaining screws, and remove
the throttle housing from the carburettor main
body.
Cleaning and inspection
16 Wash the carburettor components,
drillings and passages with clean petrol, then
blow them dry using a low-pressure air line. A
high-pressure air line must not be applied to
the accelerator pump discharge assembly or
the pump supply valve, as they each contain a
rubber Vernay valve, and these can easily be
damaged under high pressure. Never use a
piece of wire for cleaning purposes.
17 Examine all of the carburettor
components for signs of damage or wear,
paying particular attention to the diaphragms,
throttle spindle and plates, needle valve and
mixture screw; the power valve jet is adjacent
to the primary main jet. Renew all
diaphragms, sealing washers and gaskets as
a matter of course.
Reassembly
18 Refit the throttle housing to the
carburettor main body (fitting a new gasket),
and secure with its retaining screws.
19 Refit the idle mixture adjustment screw.
Make an initial adjustment by screwing it fully
in (but do not overtighten or screw it onto its
seat), then unscrew it two full turns.
20 Where fitted, reassemble the throttle
kicker, ensuring that its diaphragm lies flat,
and that the relative position of the operating
link to the kicker cover is correct.
21 Fit the power valve, ensuring that its
diaphragm lies flat and the vacuum
gallery aligns with the diaphragm and
housing.
22 Refit the accelerator pump. Take care not
damage the valve as it is inserted, and check
that the O-ring seal is correctly located on the
end of the valve. Check that the valve is not
trapped by the spring.
23 Refit the accelerator pump discharge jet.
Take care not to damage the valve and/or the
O-ring seal, and ensure that they are correctly
located.
24 Commence reassembly of the upper body
by inserting the emulsion tubes and the air
correction jets into their respective ports (as
noted during removal).
25 Screw the anti-dieseling solenoid into
position. Ensure that the aluminium washer is
fitted, and take care not to overtighten the
valve.
26 Refit the needle valve and the float, and
adjust the float setting as described in Sec-
tion 20.
27 Refit the choke control mechanism, and
secure with its three retaining screws.
28 Locate a new gasket onto the mating
face, then refit the carburettor upper body to
the main body. As they are reassembled, take
care not to snag the float on the carburettor main body. Fit and tighten the retaining
screws to secure.
29
On completion, refit the carburettor as
described in Section 23. Where applicable,
check and adjust the throttle kicker setting
(Section 21) after adjusting the idle speed and
mixture settings.
25 Carburettor (Weber DFTM) -
description
The carburettor operates in essentially the
same manner as TLDM instrument described
in Section 18, but the following features
should be noted. A throttle kicker is fitted to both manual
transmission, and CTX automatic trans-
mission models, the operation of the unit is
described in Section 18. The secondary venturi (barrel) is vacuum-
operated on manual transmission models. On
CTX automatic transmission equipped models
it is operated sequentially. A bleed back solenoid (if fitted) is used to
control the amount of fuel being delivered to
the venturi by the action of the accelerator
pump. Idle speed and mixture adjustment
procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.
26 Carburettor (Weber DFTM) -
fast-idle speed adjustment
4
Refer to the procedure contained in Sec-
tion 19, but note the following points:
a) When removing the air cleaner, do not disconnect the vacuum supply or
crankcase ventilation hoses; the air
cleaner should be positioned clear of the
carburettor assembly.
b) The fast-idle adjusting screw is located
on the side of the linkage (see
illustration) .
27 Throttle kicker unit (Weber
DFTM carburettor) - removal,
refitting and adjustment
4
Refer to the procedure contained in Sec-
tion 21.
28 Carburettor (Weber DFTM) -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets will be
required on refitting, and a tachometer and an
exhaust gas analyser will be required on
completion.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Disconnect the choke cable from the
carburettor (Section 6).
4 Carefully prise out the accelerator link
retaining clip, remove both securing bolts,
then detach the cable and bracket assembly.
Position the cable and bracket assembly clear
of the carburettor.
5 Disconnect the fuel feed hose at the
carburettor, and plug its end to avoid spillage
and prevent dirt ingress. If a crimped type
hose clip is fitted, cut this free taking care not
to damage the hose.
6 Disconnect all relevant vacuum pipes from
the carburettor, having labelled them for
subsequent refitting.
7 Disconnect the electrical lead from the anti-
dieseling (fuel cut-off) solenoid, and the bleed
back solenoid (if fitted).
8 Remove the four nuts securing the
carburettor to the inlet manifold, then
withdraw it from the vehicle.
Refitting
9 Clean the carburettor and manifold gasket
mating faces.
10 Refit in the reverse order of removal. Fit a
new gasket, and tighten the retaining screws
securely. Ensure that the fuel supply
hose connection to the carburettor is
securely fitted, using a new screw type
retaining clip.
11 Reconnect the choke cable, and adjust it
as described in Section 6.
12 Refer to Section 2 and refit the air
cleaner.
13 When the battery is reconnected, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.
Fuel system – carburettor engines 4A•13
26.1 Manual choke fast-idle adjustment. Inset shows fast-idle adjusting screw (Weber DFTM carburettor)
4A
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29 Carburettor (Weber DFTM)-
dismantling, cleaning,
inspection and reassembly
4
Note: Refer to the warning note in Section 1
before proceeding. Check parts avail-
ability before dismantling. If possible, obtain
an overhaul kit containing all the relevant
gaskets, seals, etc, required for reassembly
prior to dismantling the carburettor.
Dismantling
1 With the carburettor removed from the vehicle, prepare a clean, flat work surface
prior to commencing dismantling. The
following procedures may be used for partial
or complete dismantling, as required.
2
Clean the exterior of the carburettor and
detach all vacuum pipes (where applicable),
having noted their fitted location for correct
subsequent reassembly.
3 Remove the six screws securing the
carburettor upper body, and detach it.
Discard the gasket (see illustration).
4 Dismantle the carburettor upper body as
described in the following paragraphs.
5 Remove the three screws securing the choke pull-down diaphragm and detach it
(see illustration)
.
6 Unscrew the brass nut adjacent to the fuel
feed connection, and remove the fuel feed
filter.
7 Tap out the float retaining pin, then detach
the float and needle valve.
8 Unscrew and remove the needle valve
housing.
9 Dismantle the carburettor main body as
described in the following paragraphs.
10 Remove the main and idle jets, having
noted the size and fitted location of each one
to ensure correct subsequent reassembly.
Note that the main jets are a combined
assembly incorporating air correction jets and
emulsion tubes. Carefully prise out the
accelerator pump discharge tube.
11 Detach the throttle kicker and its
mounting bracket assembly.
12 Remove the anti-dieseling (fuel cut-off)
solenoid.
13 Remove the four screws securing the
accelerator pump assembly, and dismantle
the assembly noting the fitment of its
components (see illustration) .
14 Disconnect the secondary barrel
diaphragm operating rod by pulling the lower
section of rod downwards and twisting to
release it from its retaining socket. Remove its
four cover retaining screws and dismantle the
assembly (see illustration) .
15 Undo the three screws securing the
power valve assembly and remove its
diaphragm (see illustration) .
4A•14 Fuel system – carburettor engines
29.15 Exploded view of the power valve
assembly (Weber DFTM carburettor)
A Vacuum gallery B Diaphragm29.14 Exploded view of the secondary barrel diaphragm assembly
A Diaphragm C Operating rod
B Return spring29.13 Accelerator pump renewal (Weber DFTM carburettor)
A Diaphragm B Housing (cover)
29.5 Choke pull-down assembly (A) and fuel feed filter housing (B) (Weber DFTM carburettor)
29.3 Exploded view of the carburettor (Weber DFTM)
A Manual choke assembly
B Choke vacuum pull-down
C Secondary idle jet
D Secondary barreldiaphragm assembly
E Idle speed adjusting
screw F Idle mixture adjusting
screw
G Accelerator pump
assembly
H Throttle kicker
J Power valve diaphragm
K Float L Primary main jet combined
assembly
M Primary idle jet
N Needle valve
P Fuel feed filter
Q Secondary main jet
combined assembly
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16Prise out the tamperproof seal covering
the fuel mixture screw, then undo and remove
the mixture screw.
Cleaning and inspection
17 Wash the carburettor components,
drillings and passages with clean petrol, then
blow them dry using a low-pressure air line. A
high-pressure air line must not be applied to
the accelerator pump discharge assembly or
the pump supply valve, as they each contain a
rubber Vernay valve, and these can easily be
damaged under high pressure. Never use a
piece of wire for cleaning purposes.
18 Examine all of the carburettor
components for signs of damage or wear,
paying particular attention to the diaphragms,
throttle spindle and plates, needle valve and
mixture screw; the power valve jet is adjacent
to the primary main jet. Renew all
diaphragms, sealing washers and gaskets as
a matter of course.
Reassembly
19 Refit the fuel mixture screw by fully
winding the screw in, then unwinding three
turns to give an approximate setting.
20 Refit the power valve assembly ensuring
that the diaphragm lies flat, and that the
vacuum gallery lines up correctly with the
diaphragm and housing.
21 Reassemble the secondary barrel
diaphragm into its housing, ensuring that
the diaphragm lies flat and that the vacuum
gallery lines up with the diaphragm and
housing. Also, to assist with installation, do
not reconnect its operating rod until the cover
has been secured.
22 Refit the throttle kicker mounting bracket.
23 Refit the anti-dieseling (fuel cut-off)
solenoid, using a new sealing washer.
24 Refit the accelerator pump assembly,
ensuring that the diaphragm lies flat and is not
kinked.
25 Reassemble the throttle kicker, ensuring
that the diaphragm lies flat and that the relative position of the diaphragm operating
link to the throttle kicker cover is correct. Fully
attach the throttle kicker assembly.
26
Refit the main and idle jets, making
reference to the notes taken during
dismantling to ensure correct fitted locations.
27 Reassemble the carburettor upper body
as described in the following paragraphs.
28 Refit the needle valve housing (using a
new washer if applicable).
29 Refit the needle valve and float assembly,
having ensured that the float tag locates
below the spring clip on the needle valve.
Insert the float retaining pin to secure.
30 Adjust the float level as follows. Ensuring
that a new gasket is fitted to the carburettor
upper body, hold the upper body in the
vertical position; the needle valve must be
shut off. Measure the distance shown (see
illustration) , and adjust by bending the float
tag if the measurement is outside the
specification. Recheck the float level
adjustment after bending the float tag, as
necessary.
31 Refit the choke pull-down diaphragm,
ensuring that the diaphragm lies flat and that
the vacuum gallery lines up correctly with the
diaphragm and housing (see illustration).
32 Adjust the choke pull-down as follows.
Fully close the choke, then manually push the
diaphragm operating rod up to its stop;
measure the distance between the
downdraught side of the choke plate and the
venturi, using a gauge rod or the shank of a
twist drill bit (of known size). If the
measurement is outside specification, remove
the tamperproof seal from the housing, and
adjust the now revealed adjustment screw
accordingly. Fit a new tamperproof seal after
successful adjustment.
33 Refit the fuel feed filter, and secure with
its brass nut and sealing washer.
34 Refit the carburettor upper body to the
carburettor main body, ensuring that its new
gasket seats correctly and that the float does
not foul during assembly. Insert and tighten
the securing screws. 35
Reconnect any vacuum pipes removed
during dismantling (where applicable).
36 On completion, refit the carburettor as
described in Section 28. Where applicable,
check and adjust the throttle kicker setting
(Section 27) after adjusting the idle speed and
mixture settings.
30 Carburettor (Weber TLD) -
description
This carburettor incorporates many of the
features of the TLDM type described in
Section 18. The main differences are that a
throttle kicker is not used, the secondary
venturi (barrel) is vacuum-operated, and that a
coolant-heated automatic choke control
system is fitted. The choke system is fully automatic. When
the engine is cold, the bi-metal spring which
controls the position of the choke plate is fully
wound up, and holds the plate closed. As the
engine warms up, the bi-metal spring is
heated by the coolant and begins to unwind,
thereby progressively opening the choke
plate. A vacuum-operated pull-down
mechanism controls the choke plate under
certain operating conditions, and an internal
fast-idle system is incorporated. Idle speed and mixture adjustment
procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.
31 Carburettor (Weber TLD) -
fast-idle speed adjustment
4
Note: Before carrying out any carburettor
adjustments, ensure that the spark plug gaps
are set as specified, and that all electrical and
vacuum connections are secure. To carry out
checks and adjustments, an accurate
Fuel system – carburettor engines 4A•15
29.31 Exploded view of the choke pull-down assembly (Weber DFTM carbur\
ettor)
A Housing B Diaphragm
29.30 Float level adjustment (Weber DFTMcarburettor)
A Float level setting dimension
B Adjusting tag
4A
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tachometer and an exhaust gas analyser (CO
meter) will be required.
1Check that the idle speed and mixture
settings are as specified (as described in
Chapter 1). These must be correct before
checking/adjusting the fast-idle speed.
2 Switch the engine off, then remove the air
cleaner as described in Section 2.
3 With the engine at its normal operating
temperature and a tachometer connected in
accordance with its manufacturer’s
instructions, hold the throttle linkage partly
open, then close the choke plate until the fast-
idle adjusting screw aligns with the third
(middle) step on the fast-idle cam (see
illustration) . Release the throttle linkage so
that the fast-idle speed adjusting screw rests
on the cam. Release the choke plate. The
linkage will hold it in the fast-idle speed
setting position, as long as the accelerator
pedal is not depressed.
4 Without touching the accelerator pedal,
start the engine and record the fast-idle speed
achieved. If adjustment is required, turn the
fast-idle speed adjusting screw until the
specified fast-idle speed is obtained.
5 When the throttle linkage is opened, the
choke plate should return to its fully-open
position. If this does not happen, either the engine is not at its normal operating
temperature, or the automatic choke
mechanism is faulty.
6
Switch off the engine and disconnect the
tachometer. Refit the air cleaner.
32 Needle valve and float (Weber
TLD carburettor) - removal,
refitting and adjustment
4
1 Refer to Section 20 and proceed as
described, noting the following difference.
2 In paragraph 4, ignore the instruction to
detach the choke cable (an automatic choke
is fitted to the TLD type carburettor). Instead,
clamp the coolant supply and return hoses
which lead to the automatic choke unit to
minimise coolant loss, then ensure that the
cooling system is not pressurised (see
Chapter 1). Identify then detach both of the
coolant hoses at the automatic choke
housing. Catch any coolant spillage in a
suitable container .
Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the
engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
3 On completion, reconnect the hoses to the
automatic choke unit, and remove the clamps
from the hoses. Check and top-up the coolant
level on completion (see “Weekly Checks”and
Chapter 1).
33 Automatic choke (Weber TLD carburettor) - adjustment
3
1Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Disconnect the coolant hoses to the choke
unit as described in paragraph 2 of the
previous Section.
4 Note the position of the choke coil housing
alignment marks, then undo the three
retaining screws and withdraw the automatic
choke bi-metal coil housing (see illustration).
5 Remove the inner heat shield (see
illustration) . To check and adjust the choke
vacuum pull-down, secure the choke plate
lever in the closed position by fitting a rubber
band, open the throttle to allow the choke
plate to fully close, then release the throttle.
6 Using a screwdriver, push the operating
arm to the right against its spring, and
measure the clearance between the lower
edge of the choke plate and the venturi using
a twist drill or other suitable gauge rod (see
illustration) . Where the clearance is outside
that specified, remove the plug from the
diaphragm housing, and turn the adjusting
screw (now exposed) in the required direction.
7 Fit a new diaphragm housing plug and
remove the rubber band.
8 Refit the heat shield so that its slotted hole
engages over the choke housing peg.
9 Refit the bi-metal coil housing by first
connecting the bi-metal spring to the choke
lever (ensuring correct engagement), locate
the housing and hand-tighten the three
retaining screws. Rotate the housing to align
the index line on the housing with the dot
mark on the choke main body, then retighten
the retaining screws.
10 Reconnect the coolant hoses with
reference to paragraph 3 in the previous
Section.
11 Refit the air cleaner as described in
Section 2.
4A•16 Fuel system – carburettor engines
33.6 Choke plate pull-down adjustment (Weber TLD carburettor)
A Twist drill C Adjusting screw
B Diaphragm held fully open33.5 Automatic choke internal heatshield (Weber TLD carburettor)33.4 Automatic choke housing alignment(Weber TLD carburettor)
A Dot punch mark
B Choke housing alignment mark
1595Ford Fiesta Remake
31.3 Fast-idle speed adjustment
(Weber TLD carburettor) (Housing cut away for illustration clarity)
A Fast-idle cam
B Fast-idle speed adjusting screw on third step of cam
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34 Automatic choke (WeberTLD carburettor) - removal,
inspection and refitting
4
Note: Refer to the warning note in Section 1
before proceeding. A new carburettor upper
body gasket will be required when
reassembling. On completion, a tachometer
will be required to check the fast-idle speed
adjustment.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 To prevent excess coolant loss, clamp the
coolant supply and return hoses to the
automatic choke unit, and ensure that the
cooling system is not pressurised (see
Chapter 1). Identify then detach both of the
coolant hoses at the automatic choke
housing. Catch any coolant spillage in a
suitable container.
Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the
engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
4 Detach the fuel pipe and the anti-dieseling
solenoid wiring connector. Any crimped type
hose clips must be replaced with a screw
clamp type clips during reassembly.
5 Unscrew and remove the retaining screws (two conventional, and four Torx type), then lift
the carburettor upper body clear and remove it.
6
Note the position of the choke housing
alignment marks, then undo the three retaining
screws and remove the choke bi-metal coil
unit. Remove the internal heat shield.
7 To remove the automatic choke unit, undo
the three retaining screws and detach the
choke link from the operating lever (see
illustration) .
8 Undo the three retaining screws to remove
the vacuum diaphragm unit.
9 If dismantling the choke mechanism any
further, note the component fitment as an aid
to reassembly, but do not detach the choke
spindle.
Inspection
10 Clean and inspect all components for
wear, damage and/or distortion. Pay
particular attention to the condition of the
vacuum (pull-down) diaphragm and the choke
housing O-ring. Renew any items that are
defective (or suspect).
Refitting
11 Reassemble the automatic choke
mechanism, making references to the notes
taken during dismantling. Note that no
lubricants must be used (see illustration).
12 Refit the vacuum unit, making reference to
the notes taken during dismantling. Ensure
that the diaphragm is lying flat before
tightening the housing retaining screws.
13 Locate the O-ring (ensuring that it is
correctly seated), then reconnect the choke
link. Refit the automatic choke unit, and secure
with the retaining screws. Check and adjust
the choke vacuum pull-down as described
in the previous Section (paragraphs 5 and 6).
14 Refit the inner heat shield, ensuring that
the location peg is securely engaged in its
notch.
15 Refit the automatic choke housing and the
bi-metal spring unit as described in the
previous Section (paragraph 9).
16 Refit the carburettor upper body, ensuring
that a new gasket is used and that the mating
surfaces are clean. Fit the retaining screws to
secure.
17 Reconnect the fuel hose to the carburettor,
using new screw type hose clips to secure it.
18 Reconnect the anti-dieseling solenoid
wiring connector.
19 Reconnect the coolant hoses to the
automatic choke unit, then check and if necessary top-up the cooling system as
described in “
Weekly Checks ” and Chapter 1.
20 Reconnect the battery negative lead, then
check and adjust the fast-idle speed as
described in Section 31.
21 Refit the air cleaner (Section 2).
35 Carburettor (Weber TLD) -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets will be required
on refitting and a tachometer and an exhaust gas
analyser will be required on completion.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Release any pressure remaining in the
cooling system (see Chapter 1), and then
detach the two coolant hoses from the
automatic choke unit. Catch any coolant
spillage in a suitable container. Identify each
hose for subsequent refitting, then plug their
ends or position them as high as possible to
prevent coolant leakage. Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the
engine is hot, as there is a very great risk of
scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first be
released. Cover the cap with a thick layer of
cloth, to avoid scalding, and slowly unscrew
the filler cap until a hissing sound can be
heard. When the hissing has stopped,
showing that pressure is released, slowly
unscrew the filler cap further until it can be
removed; if more hissing sounds are heard,
wait until they have stopped before
unscrewing the cap completely. At all times,
keep well away from the filler opening.
4 Disconnect the accelerator cable from the
linkage at the carburettor, as described in
Section 3.
5 Detach the anti-dieseling solenoid wiring
connector.
6 Detach the fuel feed hose at the carburettor.
Fuel system – carburettor engines 4A•17
34.11 Exploded view of the automatic choke linkage (Weber TLD carburet\
tor)
34.7 Automatic choke assembly
(Weber TLD carburettor)
A Pull-down diaphragm housing
B Securing screws
4A
1595Ford Fiesta Remake
A Operating link/fast-idle cam
B Fast-idle cam return spring
C Spindle sleeve
D Connecting rod and lever assembly
E Pull-down kink
F Actuating lever
G Automatic choke housing
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As it is detached, plug the end of the hose to
prevent excessive fuel spillage and the ingress
of dirt. Where a crimped type hose clip is fitted,
cut it free, taking care not to damage the hose;
a new screw type clip will need to be obtained
to replace the crimped clip during reassembly.
7Disconnect the relevant vacuum pipes from
the carburettor. As they are detached, label
them to ensure correct reassembly.
8 Unscrew and remove the four Torx-type
retaining screws, and carefully lift clear the
carburettor from the inlet manifold (see
illustration) . Remove the gasket.
Refitting
9Clean the carburettor and the inlet manifold
mating faces.
10 Refit the carburettor in the reverse order of
removal, ensuring that a new gasket is fitted.
11 If they are perished or were damaged
during removal, renew the fuel and/or vacuum
hoses.
12 Reconnect the automatic choke unit
hoses, and then check/top-up the cooling
system if required, as described in “Weekly
Checks” and Chapter 1.
13 When the battery is reconnected, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.
36 Carburettor (Weber TLD) -
dismantling, cleaning,
inspection and reassembly
4
Proceed as described in Section 24, but
refer to the appropriate illustrations for the
TLD carburettor (see illustrations) . The
following should also be observed: a) When refitting the idle mixture adjustment
screw, make the initial adjustment by
screwing it fully into position (without
overtightening it), then unscrewing it by
three full turns.
b) Refer to Section 32 to adjust the needle
valve and float.
c) When the carburettor is reassembled and refitted, check and adjust the idle speed
and mixture settings as described in
Chapter 1.
37 Inlet manifold -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding.
Removal
1 Drain the cooling system as described in
Chapter 1.
2 Remove the carburettor as described in the
relevant earlier Sections of this Chapter,
according to carburettor type.
3 Noting their locations, disconnect the
coolant, vacuum and breather hoses from the
manifold.
4 Disconnect the wiring multi-plugs from the
engine sensors at the inlet manifold.
Disconnect the radio earth lead at the inlet
manifold connector.
5 Undo the retaining bolts, and withdraw the
manifold from the cylinder head. Remove the
gasket.
6 With the manifold removed, clean all traces
of the old gasket from the mating surfaces of
the manifold and the cylinder head.
Refitting
7 Refitting is the reversal of removal. Use a
new gasket, and tighten the retaining bolts to
the specified torque. Refit the remainder of the
components with reference to the appropriate
Chapters of this manual. On completion,
refill the cooling system as described in
Chapter 1.
36.1c Float level adjustment (Weber TLD carburettor)
A Float level setting dimension
B Adjusting tag
36.1b Jet arrangement in carburettor upper body (Weber TLD carburettor)
A Primary air correction jet
B Secondary air correction jet
C Secondary main jet
D Primary main jet
4A•18 Fuel system – carburettor engines
36.1a Exploded view of the carburettor (Weber TLD)
A Emulsion tubes
B Air correction jets
C Automatic choke assembly
D Choke pull-down
diaphragm E Main jets
F Secondary barrel
diaphragm assembly
G Power valve diaphragm
H Accelerator pump
diaphragm J Idle mixture adjusting
screw
K Fuel feed filter
L Needle valve assembly
M Anti-dieseling (fuel cut-off) solenoid
35.8 General view of Weber TLD carburettor
A Torx head screws securing carburettor to inlet manifold
B Standard screws securing upper body to main body
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