1989 FORD FIESTA inner rod

1
1595Ford Fiesta Remake
Chapter 1
Routine maintenance and servicing
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 20
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . 26
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 4
Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . 18
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 14
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 31
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 23
Door, tailgate and bonnet check and lubrication . . . . . . . . . . . . . . . 16
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 11
Emission control system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front wheel alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 30Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Idle speed and mixture check and adjustment . . . . . . . . . . . . . . . . 9
Idle speed control valve cleaning and maintenance . . . . . . . . . . . . . 22
Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 1
Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 8
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 19
Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 17
Spark plug renewal and HT component check . . . . . . . . . . . . . . . . . 21
Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 10
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 29
Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 13
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 5
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1•1
Contents
Easy,
suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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lubricant, together with dirt and water entry,
resulting in rapid deterioration of the balljoints
or steering gear.
3Check the power-assisted steering fluid
hoses (where fitted) for chafing or
deterioration, and the pipe and hose unions
for fluid leaks. Also check for signs of fluid
leakage under pressure from the steering gear
rubber gaiters, which would indicate failed
fluid seals within the steering gear.
4 Grasp the roadwheel at the 12 o’clock and
6 o’clock positions, and try to rock it. Very
slight free play may be felt, but if the
movement is appreciable, further investigation
is necessary to determine the source.
Continue rocking the wheel while an assistant
depresses the footbrake. If the movement is
now eliminated or significantly reduced, it is
likely that the hub bearings are at fault. If the
free play is still evident with the footbrake
depressed, then there is wear in the
suspension joints or mountings.
5 Now grasp the wheel at the 9 o’clock and 3
o’clock positions, and try to rock it as before.
Any movement felt now may again be caused
by wear in the hub bearings or the steering
track rod balljoints. If the outer track rod end
balljoint is worn, the visual movement will be
obvious. If the inner joint is suspect, it can be
felt by placing a hand over the rack-and-
pinion rubber gaiter, and gripping the track
rod. If the wheel is now rocked, movement will
be felt at the inner joint if wear has taken
place.
6 Using a large screwdriver or flat bar, check
for wear in the suspension mounting bushes
by levering between the relevant suspension
component and its attachment point. Some
movement is to be expected, as the
mountings are made of rubber, but excessive
wear should be obvious. Also check the
condition of any visible rubber bushes,
looking for splits, cracks or contamination of
the rubber.
7 With the vehicle standing on its wheels,
have an assistant turn the steering wheel
back-and-forth, about an eighth of a turn each
way. There should be very little, if any, lost
movement between the steering wheel and
roadwheels. If this is not the case, closely
observe the joints and mountings previously described, but in addition, check the steering
column universal joints for wear, and also
check the rack-and-pinion steering gear itself.
Rear suspension check
8
Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Remove
the rear roadwheels.
9 Check the rear hub bearings for wear, using
the method described for the front hub
bearings (paragraph 4).
10 Using a large screwdriver or flat bar,
check for wear in the suspension mounting
bushes by levering between the relevant
suspension component and its attachment
point. Some movement is to be expected, as
the mountings are made of rubber, but
excessive wear should be obvious. Check the
condition of the shock absorbers and their
bushes/mountings. On Van models, check the
leaves of the leaf springs for signs of cracking,
distortion, or other damage.
Roadwheel check and balancing
11 Periodically remove the roadwheels, and
clean any dirt or mud from the inside and
outside surfaces. Examine the wheel rims for
signs of rusting, corrosion or other damage.
Light alloy wheels are easily damaged by
“kerbing” whilst parking, and similarly, steel
wheels may become dented or buckled.
Renewal of the wheel is very often the only
course of remedial action possible.
12 The balance of each wheel and tyre
assembly should be maintained, not only to
avoid excessive tyre wear, but also to avoid
wear in the steering and suspension
components. Wheel imbalance is normally
signified by vibration through the vehicle’s
bodyshell, although in many cases it is
particularly noticeable through the steering
wheel. Conversely, it should be noted that
wear or damage in suspension or steering
components may cause excessive tyre wear.
Out-of-round or out-of-true tyres, damaged
wheels and wheel bearing wear/
maladjustment also fall into this category.
Balancing will not usually cure vibration
caused by such wear.
13 Wheel balancing may be carried out with
the wheel either on or off the vehicle. If balanced on the vehicle, ensure that the
wheel-to-hub relationship is marked in some
way prior to subsequent wheel removal, so
that it may be refitted in its original position.
11 Driveshaft rubber gaiter and
CV joint check
1
1The driveshaft rubber gaiters are very
important, because they prevent dirt, water
and foreign material from entering and
damaging the constant velocity (CV) joints.
External contamination can cause the gaiter
material to deteriorate prematurely, so it’s a
good idea to wash the gaiters with soap and
water occasionally.
2 With the vehicle raised and securely
supported on axle stands, turn the steering
onto full-lock, then slowly rotate each front
wheel in turn. Inspect the condition of the
outer constant velocity (CV) joint rubber
gaiters, squeezing the gaiters to open out the
folds. Check for signs of cracking, splits, or
deterioration of the rubber, which may allow
the escape of grease, and lead to the ingress
of water and grit into the joint (see
illustration) . Also check the security and
condition of the retaining clips. Repeat these
checks on the inner CV joints. If any damage
or deterioration is found, the gaiters should be
renewed as described in Chapter 8.
3 At the same time, check the general
condition of the outer CV joints themselves,
by first holding the driveshaft and attempting
to rotate the wheels. Any appreciable
movement in the CV joint indicates wear in the
joint, wear in the driveshaft splines, or a loose
driveshaft retaining nut. Repeat this check on
the inner joints, by holding the inner joint yoke
and attempting to rotate the driveshaft.
12 Exhaust system check
1
1 With the engine cold (at least three hours
after the vehicle has been driven), check the
complete exhaust system, from its starting
1•16Every 10 000 miles or 12 months
11.2 Check the driveshaft gaiters by hand for cracks and/or leaking grease10.2c Check the condition of the steering rack gaiters10.2b Check the condition of the lowerarm balljoint dust cover (arrowed)
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point at the engine to the end of the tailpipe.
Ideally, this should be done on a hoist, where
unrestricted access is available; if a hoist is
not available, raise and support the vehicle on
axle stands.
2Check the pipes and connections for
evidence of leaks, severe corrosion, or
damage. Make sure that all brackets and
rubber mountings are in good condition, and
tight; if any of the mountings are to be
renewed, ensure that the replacements are of
the correct type (see illustration) . Leakage at
any of the joints or in other parts of the system
will usually show up as a black sooty stain in
the vicinity of the leak. Note: Exhaust sealants
should not be used on any part of the exhaust
system upstream of the catalytic converter -
even if the sealant does not contain additives
harmful to the converter, pieces of it may
break off and foul the element, causing local
overheating.
3 At the same time, inspect the underside of
the body for holes, corrosion, open seams,
etc, which may allow exhaust gases to enter
the passenger compartment. Seal all body
openings with silicone or body putty.
4 Rattles and other noises can often be
traced to the exhaust system, especially the
rubber mountings. Try to move the system,
silencer(s) and catalytic converter. If any
components can touch the body or
suspension parts, secure the exhaust system
with new mountings.
5 Check the running condition of the engine
by inspecting inside the end of the tailpipe;
the exhaust deposits here are an indication
of the engine’s state of tune. The inside of the
tailpipe should be dry, and should vary in
colour from dark grey to light grey/brown; if it
is black and sooty, or coated with white
deposits, the engine is in need of a thorough
fuel system inspection.
13 Underbody and fuel/brake line check
1
1With the vehicle raised and supported on
axle stands or over an inspection pit,
thoroughly inspect the underbody and wheel
arches for signs of damage and corrosion. In
particular, examine the bottom of the side
sills, and any concealed areas where mud can
collect. Where corrosion and rust is evident,
press and tap firmly on the panel with a
screwdriver, and check for any serious
corrosion which would necessitate repairs. If
the panel is not seriously corroded, clean
away the rust, and apply a new coating of
underseal. Refer to Chapter 11 for more
details of body repairs.
2 At the same time, inspect the PVC-coated
lower body panels for stone damage and
general condition.
3 Inspect all of the fuel and brake lines on the
underbody for damage, rust, corrosion and
leakage. Also make sure that they are correctly supported in their clips. Where
applicable, check the PVC coating on the
lines for damage.
14 Brake check
2
Note:
For detailed photographs of the brake
system, refer to Chapter 9.
1 The work described in this Section should
be carried out at the specified intervals, or
whenever a defect is suspected in the braking
system. Any of the following symptoms could
indicate a potential brake system defect:
a) The vehicle pulls to one side when the brake pedal is depressed.
b) The brakes make scraping or dragging
noises when applied.
c) Brake pedal travel is excessive.
d) The brake fluid requires repeated topping-
up.
2 A thorough inspection should be made to
confirm the thickness of the linings, as
follows.
Front brakes
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
4 For better access to the brake calipers,
remove the wheels.
5 Look through the inspection window in the
caliper, and check that the thickness of the
friction lining material on each of the pads is
not less than the recommended minimum
thickness given in the Specifications. Note:
Bear in mind that the lining material is normally
bonded to a metal backing plate.
6 If it is difficult to determine the exact
thickness of the pad linings, or if you are at all
concerned about the condition of the pads,
then remove them from the calipers for further
inspection (refer to Chapter 9).
7 Check the remaining brake caliper in the
same way.
8 If any one of the brake pads has worn down to, or below, the specified limit,
all fourpads
must be renewed as a set.
9 Measure the thickness of the discs with a
micrometer, if available, to make sure that they
still have service life remaining. If any disc is
thinner than the specified minimum thickness,
renew it (refer to Chapter 9). In any case,
check the general condition of the discs. Look
for excessive scoring and discolouration
caused by overheating. If these conditions
exist, remove the relevant disc and have it
resurfaced or renewed (refer to Chapter 9).
10 Before refitting the wheels and lowering
the car, check all brake lines and hoses (refer
to Chapter 9). In particular, check the flexible
hoses in the vicinity of the calipers, where
they are subjected to most movement. Bend
them between the fingers (but do not actually
bend them double, or the casing may be
damaged) and check that this does not reveal
previously-hidden cracks, cuts or splits.
Rear brakes
11 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
12 For better access, remove the rear
wheels.
13 To check the brake shoe lining thickness
without removing the brake drums, prise the
rubber plugs from the backplates, and use an
electric torch and mirror to inspect the linings
of the leading brake shoes. Check that the
thickness of the lining material on the brake
shoes is not less than the recommendation
given in the Specifications.
14 If it is difficult to determine the exact
thickness of the brake shoe linings, or if you
are at all concerned about the condition of the
shoes, then remove the rear drums for a more
comprehensive inspection (refer to Chap-
ter 9).
15 With the drum removed, check the shoe
return and hold-down springs for correct
installation, and check the wheel cylinders for
leakage of brake fluid. Check the friction
surface of the brake drums for scoring and
discoloration. If excessive, the drum should
be resurfaced or renewed.
16 Before refitting the wheels, check all
brake lines and hoses (refer to Chapter 9). On
completion, apply the handbrake and check
that the rear wheels are locked. The
handbrake also requires periodic adjustment,
and if its travel seems excessive, refer to
Section 27.
15 Roadwheel nut tightness check
1
1Apply the handbrake.
2 Remove the wheel covers, using the flat
end of the wheelbrace supplied in the tool kit
(on some models it will be necessary to
unscrew the retaining bolts with a special
key).
Every 10 000 miles or 12 months1•17
12.2 Ensure that the exhaust system
rubber mountings replacements are of the correct type - their colour is a good guide. Those nearest to the catalytic converterare more heat-resistant than the others
1
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3Check that the roadwheel nuts are tightened
to the specified torque wrench setting.
4 Refit the wheel covers.
16 Door, tailgate and bonnet
check and lubrication
1
1Check that the doors and tailgate/boot lid
close securely. Check that the bonnet safety
catch operates correctly. Check the operation
of the door check straps.
2 Lubricate the hinges, door check straps,
the striker plates and the bonnet catch
sparingly with a little oil or grease.
17 Seat belt check
1
1 Check the seat belts for satisfactory
operation and condition. Inspect the webbing
for fraying and cuts. Check that they retract
smoothly and without binding into their reels.
2 Check that the seat belt mounting bolts are
tight, and if necessary tighten them to the
specified torque wrench settings as given in
Chapter 11.
18 Bodywork, paint and exterior trim check
1
1The best time to carry out this check is after
the car has been washed so that any surface
blemish or scratch will be clearly evident and
not hidden by a film of dirt.
2 Starting at one front corner check the
paintwork all around the car, looking for minor
scratches or more serious dents. Check all
the trim and make sure that it is securely
attached over its entire length.
3 Check the security of all door locks, door
mirrors, badges, bumpers, front grille and
wheel trim. Anything found loose, or in need of
further attention should be done with reference
to the relevant Chapters of this manual.
4 Rectify any problems noticed with the
paintwork or body panels as described in
Chapter 11.
19 Road test
1
Check the operation and
performance of the braking
system
1 Make sure that the vehicle does not pull to
one side when braking, and that the wheels
do not lock prematurely when braking hard.
2 Check that there is no vibration through the
steering when braking. 3
Check that the handbrake operates
correctly, without excessive movement of the
lever, and that it holds the vehicle stationary
on a slope.
4 Test the operation of the brake servo unit
as follows. With the engine switched off,
depress the footbrake four or five times to
exhaust the vacuum, then hold the pedal
depressed. Start the engine, and there should
be a noticeable “give” in the brake pedal as
vacuum builds up. Allow the engine to run for
at least two minutes, and then switch it off. If
the brake pedal is depressed again, it should
be possible to detect a hiss from the servo as
the pedal is depressed. After about four or five
applications, no further hissing should be
heard, and the pedal should feel considerably
firmer.
Steering and suspension
5 Check for any abnormalities in the steering,
suspension, handling or road “feel”.
6 Drive the vehicle, and check that there are
no unusual vibrations or noises.
7 Check that the steering feels positive, with
no excessive sloppiness or roughness, and
check for any suspension noises when
cornering and driving over bumps.
Drivetrain
8 Check the performance of the engine,
transmission and driveshafts.
9 Check that the engine starts correctly, both
when cold and when hot.
10 Listen for any unusual noises from the
engine and transmission.
11 Make sure that the engine runs smoothly
when idling, and that there is no hesitation
when accelerating.
12 On manual transmission models, check
that all gears can be engaged smoothly
without noise, and that the gear lever action is
not abnormally vague or “notchy”.
13 On automatic transmission models, make
sure that the drive seems smooth without
jerks or engine speed “flare-ups”. Check that
all the gear positions can be selected with the
vehicle at rest. If any problems are found, they
should be referred to a Ford dealer.
14 Listen for a metallic clicking sound from
the front of the vehicle, as the vehicle is driven
slowly in a circle with the steering on full-lock.
Carry out this check in both directions. If a
clicking noise is heard, this indicates wear in a
driveshaft joint, in which case renew the joint
if necessary.
Clutch
15 Check that the clutch pedal moves
smoothly and easily through its full travel, and
that the clutch itself functions correctly, with
no trace of slip or drag. If the movement is
uneven or stiff in places, check that the cable
is routed correctly, with no sharp turns.
16 Inspect both ends of the clutch inner
cable, both at the transmission end and inside
the car, for signs of wear and fraying.
Instruments and electrical
equipment
17 Check the operation of all instruments
and electrical equipment.
18 Make sure that all instruments read
correctly, and switch on all electrical equipment
in turn, to check that it functions properly.
20 Automatic transmission fluid level check
1
1The level of the automatic transmission fluid
should be carefully maintained. Low fluid level
can lead to slipping or loss of drive, while
overfilling can cause foaming, loss of fluid and
transmission damage.
2 The transmission fluid level should only be
checked when the transmission is hot (at its
normal operating temperature). If the vehicle
has just been driven over 10 miles (15 miles in
a cold climate), and the fluid temperature is 60
to 70ºC, the transmission is hot.
Caution: If the vehicle has just been driven
for a long time at high speed or in city
traffic in hot weather, or if it has been
pulling a trailer, an accurate fluid level
reading cannot be obtained. In these
circumstances, allow the fluid to cool
down for about 30 minutes.
3 Park the vehicle on level ground, apply the
handbrake, and start the engine. While the
engine is idling, depress the brake pedal and
move the selector lever through all the gear
positions three times, beginning and ending in
“P”.
4 Allow the engine to idle for one minute, then
(with the engine still idling) remove the
dipstick from its tube. Note the condition and
colour of the fluid on the dipstick.
5 Wipe the fluid from the dipstick with a clean
rag, and re-insert it into the filler tube until the
cap seats.
6 Pull the dipstick out again, and note the
fluid level. The level should be between
the “MIN” and “MAX” marks. If the level is
on the “MIN” mark, stop the engine, and add
the specified automatic transmission fluid
through the dipstick tube, using a clean funnel
if necessary. It is important not to introduce
dirt into the transmission when topping-up.
7 Add the fluid a little at a time, and keep
checking the level as previously described
until it is correct. The difference between the
“MIN” and “MAX” marks on the dipstick is
approximately 0.4 litres.
8 The need for regular topping-up of the
transmission fluid indicates a leak, which
should be found and rectified without delay.
9 The condition of the fluid should also be
checked along with the level. If the fluid on the
dipstick is black or a dark reddish-brown
colour, or if it has a burned smell, the fluid
should be changed. If you are in doubt about
the condition of the fluid, purchase some new
fluid, and compare the two for colour and smell.
1•18Every 10 000 miles or 12 months
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Lubrication
Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants, fluids and tyre pressures”
Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . See “Lubricants, fluids and tyre pressures”
Oil pressure: At idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 0.60 barsAt 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 1.50 bars
Oil pump clearances: Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 0.14 to 0.26 mm
Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 to 0.127 mm
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 0.025 to 0.06 mm
Torque wrench settingsNm lbf ft
Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 1813
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 115 85
Rocker shaft pedestal bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4332
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 6749
Sump: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 9 7
Stage 3 (with engine warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 1410
Cylinder head bolts (may be re-used once only): Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 3022
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Timing chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 8 6
Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 9 7
Crankshaft rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1813
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 5 4
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . 1813
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 9 7
Engine mountings: Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 72 40 to 53
Rubber insulator to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 to 95 52 to 70
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Note: Refer to Part D of this Chapter for remaining torque wrench settings.
2A•2 HCS engine in-car repair procedures
1595Ford Fiesta Remake
1 General information
How to use this Chapter
This Part of Chapter 2 is devoted to repair
procedures possible while the engine is still
installed in the vehicle, and includes only the
Specifications relevant to those procedures.
Similar information concerning the 1.4 and
1.6 litre CVH and PTE engines, and the 1.6
and 1.8 litre Zetec engines, will be found in
Parts B and C of this Chapter respectively.
Since these procedures are based on the
assumption that the engine is installed in the
vehicle, if the engine has been removed from
the vehicle and mounted on a stand, some
of the preliminary dismantling steps outlined
will not apply. Information concerning engine/transmission
removal and refitting, and engine overhaul, can
be found in Part D of this Chapter, which also
includes the Specifications relevant to those
procedures.
Engine description
The engine is an overhead valve, water-
cooled, four cylinder in-line design,
designated HCS (High Compression Swirl).
The engine is mounted transversely at the
front of the vehicle together with the
transmission to form a combined power unit. The crankshaft is supported in three or five
shell-type main bearings. The connecting rod
big-end bearings are also split shell-type, and
are attached to the pistons by interference-fit
gudgeon pins. Each piston is fitted with two
compression rings and one oil control ring. The camshaft, which runs on bearings
within the cylinder block, is chain-driven from
the crankshaft, and operates the valves via
pushrods and rocker arms. The valves are
each closed by a single valve spring, and
operate in guides integral in the cylinder head. The oil pump is mounted externally on the
crankcase, incorporates a full-flow oil filter,
and is driven by a skew gear on the camshaft.
On carburettor versions, the fuel pump is also
driven from the camshaft, via an eccentric
lobe.
Repair operations possible with
the engine in the car
The following work can be carried out with
the engine in the car:
a) Compression pressure - testing.
b) Cylinder head rocker cover - removal
and refitting.
c) Valve clearances - adjustment.
d) Rocker shaft assembly - removal,
inspection and refitting.
e) Cylinder head - removal and refitting
f) Cylinder head and pistons - decarbonising.
g) Crankshaft pulley - removal and refitting.
h) Crankshaft oil seals - renewal.
i) Timing chain, sprockets and tensioner -
removal, inspection and refitting.
j) Oil filter renewal.
k) Oil pump - removal and refitting.
l) Sump - removal and refitting.
m) Flywheel - removal, inspection and
refitting.
n) Engine/transmission mountings -
inspection and renewal.
Note: It is possible to remove the pistons and
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Torque wrench settingsNmlbf ft
Cylinder head cover bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 2 1.5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Camshaft sprocket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
6850
Camshaft bearing cap bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 9 7
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 1914
Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 2418
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 4533
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 105º
Timing belt cover fasteners: Upper-to-middle (outer) cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3
Cover-to-cylinder head or block bolts . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Cover studs-to-cylinder head or block . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Timing belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
3828
Timing belt tensioner backplate locating peg . . . . . . . . . . . . . . . . . . . . . 9 7
Timing belt tensioner spring retaining pin . . . . . . . . . . . . . . . . . . . . . . . 9 7
Timing belt guide pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3828
Water pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 9 7
Auxiliary drivebelt idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4735
Front engine lifting eye bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1612
Exhaust manifold heat shield bolts: Shield-to-cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Shield/dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 9 7
Shield/coolant pipe-to-manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2317
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 115 85
Oil pump-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Oil pick-up pipe-to-pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Oil baffle/pump pick-up pipe nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914
Oil filter adapter-to-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
2216
Oil pressure warning light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720
Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 2015
Coolant pipe-to-sump bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
110 81
Crankshaft left-hand oil seal carrier bolts . . . . . . . . . . . . . . . . . . . . . . . . 2216
Engine mountings: Engine front right-hand mounting:Alternator mounting bracket-to-cylinder block bolts . . . . . . . . . . . 41 to 58 30 to 43
Mounting bracket-to-alternator mounting bracket bolts . . . . . . . . Not available Not available
Mounting through-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not available Not available
Outer bracket-to-mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 58 to 79 43 to 58
Inner bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 to 79 43 to 58
Outer bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 to 79 43 to 58
Engine rear right-hand mounting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 to 104 56 to 77
Mounting-to-(cylinder block) bracket bolts . . . . . . . . . . . . . . . . . . . 71 to 98 52 to 72
Mounting-to-body bolt and nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 to 138 75 to 102
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Note: Refer to Part D of this Chapter for remaining torque wrench settings.
2C•2 Zetec engine in-car repair procedures
1595Ford Fiesta Remake
1 General information
How to use this Chapter
This Part of Chapter 2 is devoted to repair
procedures possible while the engine is still
installed in the vehicle, and includes only the
Specifications relevant to those procedures.
Similar information concerning the 1.3 litre
HCS engines, and the 1.4 and 1.6 litre CVH
and PTE engines, will be found in Parts A
and B of this Chapter respectively. Since these procedures are based on the
assumption that the engine is installed in the
vehicle, if the engine has been removed from
the vehicle and mounted on a stand, some
of the preliminary dismantling steps outlined
will not apply.
Information concerning engine/transmission
removal and refitting, and engine overhaul, can
be found in Part D of this Chapter, which also
includes the Specifications relevant to those
procedures.
Engine description
The Zetec engine, (formerly Zeta), is of
sixteen-valve, double overhead camshaft (DOHC), four-cylinder, in-line type, mounted
transversely at the front of the vehicle, with
the transmission on its left-hand end.
Apart from the plastic timing belt covers
and the cast-iron cylinder block/crankcase, all
major engine castings are of aluminium alloy. The crankshaft runs in five main bearings,
the centre main bearing’s upper half
incorporating thrustwashers to control
crankshaft endfloat. The connecting rods
rotate on horizontally-split bearing shells at
their big-ends. The pistons are attached to the
connecting rods by gudgeon pins which are
an interference fit in the connecting rod small-
end eyes. The aluminium alloy pistons are
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fitted with three piston rings: two
compression rings and an oil control ring.
After manufacture, the cylinder bores and
piston skirts are measured and classified into
three grades, which must be carefully
matched together, to ensure the correct
piston/cylinder clearance; no oversizes are
available to permit reboring.The inlet and exhaust valves are each
closed by coil springs; they operate in guides
which are shrink-fitted into the cylinder head,
as are the valve seat inserts. Both camshafts are driven by the same
toothed timing belt, each operating eight
valves via self-adjusting hydraulic tappets,
thus eliminating the need for routine checking
and adjustment of the valve clearances. Each
camshaft rotates in five bearings that are line-
bored directly in the cylinder head and the
(bolted-on) bearing caps; this means that the
bearing caps are not available separately from
the cylinder head, and must not be
interchanged with caps from another engine. The water pump is bolted to the right-hand
end of the cylinder block, inboard of the
timing belt, and is driven with the power
steering pump and alternator by a flat
“polyvee”-type auxiliary drivebelt from the
crankshaft pulley.
When working on this engine, note that
Torx-type (both male and female heads) and
hexagon socket (Allen head) fasteners are
widely used; a good selection of bits, with the
necessary adapters, will be required, so that
these can be unscrewed without damage and,
on reassembly, tightened to the torque
wrench settings specified. Lubrication is by means of an eccentric-
rotor trochoidal pump, which is mounted on
the crankshaft right-hand end, and draws oil
through a strainer located in the sump. The
pump forces oil through an externally-
mounted full-flow cartridge-type filter - on
some versions of the engine, an oil cooler is
fitted to the oil filter mounting, so that clean oil
entering the engine’s galleries is cooled by the
main engine cooling system.
Repair operations possible with
the engine in the car
The following work can be carried out with
the engine in the car:
a) Compression pressure - testing.
b) Cylinder head cover - removal and
refitting.
c) Timing belt covers - removal and refitting.
d) Timing belt - renewal.
e) Timing belt tensioner and sprockets - removal and refitting.
f) Camshaft oil seals - renewal.
g) Camshafts and hydraulic tappets - removal and refitting.
h) Cylinder head - removal and refitting.
i) Cylinder head and pistons - decarbonising.
j) Sump - removal and refitting.
k) Crankshaft oil seals - renewal.
l) Oil pump - removal and refitting. m)
Flywheel/driveplate - removal and
refitting.
n) Engine/transmission mountings - removal and refitting.
Note: It is possible to remove the pistons and
connecting rods (after removing the cylinder
head and sump) without removing the engine.
However, this is not recommended. Work of
this nature is more easily and thoroughly
completed with the engine on the bench, as
described in Chapter 2D.
2 Compression test -
description and interpretation
2
Refer to Section 2 in Part A of this Chapter.
3 Top Dead Centre (TDC) for No 1 piston - locating
2
1Top dead centre (TDC) is the highest point
of the cylinder that each piston reaches as the
crankshaft turns. Each piston reaches its TDC
position at the end of its compression stroke,
and then again at the end of its exhaust
stroke. For the purpose of engine timing, TDC
on the compression stroke for No 1 piston is
used. No 1 cylinder is at the timing belt end of
the engine. Proceed as follows.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Remove
the right-hand roadwheel.
4 Remove the auxiliary drivebelt cover (see
Chapter 1) to expose the crankshaft pulley
and timing marks.
5 Fit a spanner onto the crankshaft pulley
bolt, and turn the crankshaft in its normal
direction of rotation (clockwise, viewed from
the pulley end). 6
Note the two pairs of notches in the inner
and outer rims of the crankshaft pulley. In the
normal direction of crankshaft rotation the first
pair of notches are irrelevant to the vehicles
covered in this manual, while the second pair
indicate TDC when aligned with the rear edge
of the raised mark on the sump. Rotate the
crankshaft clockwise until the second pair of
notches align with the edge of the sump mark;
use a straight edge extended out from the
sump if greater accuracy is required (see
illustrations) .
7 Nos 1 and 4 cylinders are now at TDC, one
of them on the compression stroke. Remove
the oil filler cap; if No 4 cylinder exhaust cam
lobe is pointing to the rear of the vehicle and
slightly downwards, it is No 1 cylinder that is
correctly positioned. If the lobe is pointing
horizontally forwards, rotate the crankshaft
one full turn (360º) clockwise until the pulley
notches align again, and the lobe is pointing
to the rear and slightly down. No 1 cylinder
will then be at TDC on the compression
stroke.
8 Once No 1 cylinder has been positioned at
TDC on the compression stroke, TDC for any
of the other cylinders can then be located by
rotating the crankshaft clockwise 180º at a
time and following the firing order (see
Specifications).
9 With the engine set at No 1 piston on TDC
compression, refit the drivebelt cover and the
roadwheel, then lower the vehicle and refit the
spark plugs.
4 Cylinder head cover -
removal and refitting
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air inlet components as
necessary for access as described in the
Chapter 4D.
3 Disconnect the accelerator cable from the
throttle linkage as described in Chapter 4D.
4 On models equipped with power steering,
release the high pressure fluid pipe from the
Zetec engine in-car repair procedures 2C•3
3.6b . . . use a straight edge extended out from the sump (arrowed) if greater
accuracy is required3.6a Do not use crankshaft pulley’s first
pair of notches “A” - align second pair of
notches “B” with raised rib on sump “C” . . .
2C
1595Ford Fiesta Remake
Turning the engine will be
easier if the spark plugs are
removed first - see Chapter 1.
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2D
1595Ford Fiesta Remake
HCS engines
Cylinder head
Maximum permissible gasket surface distortion (measured over
full length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 0.15 mm
Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º
Valve seat width (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 to 1.75 mm*
*The inlet and exhaust valves have special inserts which cannot be recut\
using conventional tools.
Valves - generalInletExhaust
Valve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 103.7 to 104.4 mm 104.2 to 104.7 mm
Valve head diameter: 1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.90 to 33.10 mm 28.90 to 29.10 mm
1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 34.40 to 34.60 mm 28.90 to 29.10 mm
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 7.0 mm 7.0 mm
Valve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.069 0.046 to 0.095
Cylinder block
Cylinder bore diameter: 1.0 and 1.1 litre engines:
Standard class 1 (or A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 to 68.69 mm
Standard class 2 (or B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.69 to 68.70 mm
Standard class 3 (or C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.70 to 68.71 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.20 to 69.21 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.70 to 69.71 mm
1.3 litre engines:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.94 to 73.95 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.50 to 73.96 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.96 to 73.97 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 74.50 to 74.51 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 75.00 to 75.01 mm
Chapter 2 Part D:
Engine removal and overhaul procedures
Camshaft and tappets - removal, inspection and refitting (HCS engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 10
Crankshaft - refitting and main bearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 17
Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . 13
Cylinder head - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head - reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head and valve components - cleaning and inspection . . . 8
Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - removal and refitting (HCS engines) . . . . . . . . . . . . . . . . . . 3
Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . 6 Engine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . 15
Engine/transmission removal - preparation and precautions . . . . . . 2
Engine/transmission - removal and refitting (CVH and
PTE engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 4
Engine/transmission - removal and refitting (Zetec engines) . . . . . . 5
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Main and big-end bearings - inspection . . . . . . . . . . . . . . . . . . . . . . 14
Piston/connecting rod assemblies - refitting and big-end
bearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston/connecting rod assemblies - removal and inspection . . . . . . 11
Piston rings - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
16
2D•1
Specifications Contents
Easy, suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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