1989 FORD FIESTA oil capacity

2A
1595Ford Fiesta Remake
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . Four-cylinder, in-line overhead valve
Engine code:1.0 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TLB
1.1 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUE or GUD
1.1 litre CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6A
1.3 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JBC
1.3 litre CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6B
Capacity: 1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 999 cc
1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1118 cc
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1297 cc
Bore:
1.0 and 1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 mm
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 73.96 mm
Stroke:
1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 67.40 mm
1.1 and 1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.48 mm
Compression ratio:
Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9.5:1
CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8:1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1-2-4-3 (No 1 cylinder at timing chain end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Valves
Valve clearance (cold): Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . 0.20 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 0.30 mm
Chapter 2 Part A:
HCS engine in-car repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Compression test - description and interpretation . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head rocker cover - removal and refitting . . . . . . . . . . . . . . 4
Cylinder head rocker gear - removal, inspection and refitting . . . . . 6
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . .See
“Weekly Checks”
Engine/transmission mountings - inspection and renewal . . . . . . . . 15 Flywheel - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 16
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 13
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing chain cover - removal and refitting . . . . . . . . . . . . . . . . . . . . 9
Timing chain, sprockets and tensioner - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 10
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . 5
2A•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
procarmanuals.com
http://vnx.su

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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2B
1595Ford Fiesta Remake
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . Four-cylinder, in-line overhead camshaft
Engine code:1.4 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. FUF or FUG
CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6E
1.4 litre PTE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . F4A
1.6 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. LUH
EFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LJC or LJD
Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . LHA
Capacity:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392 cc
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1596 cc
Bore:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.24 mm
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 79.96 mm
Stroke:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.30 mm
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 79.52 mm
Compression ratio:
1.4 litre CVH carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1
1.4 litre CVH CFi fuel injection engine . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1
1.4 litre PTE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9.5:1
1.6 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 9.5:1
EFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75:1
Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 8.0:1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Chapter 2 Part B:
CVH and PTE engine in-car repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Camshaft oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft, rocker arms and tappets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 11
Compression test - description and interpretation . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head rocker cover - removal and refitting . . . . . . . . . . . . . . 4
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . .See
“Weekly Checks”
Engine/transmission mountings - renewal . . . . . . . . . . . . . . . . . . . . 17 Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 18
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 15
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . . 8
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Timing belt tensioner and sprockets - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearances - general information . . . . . . . . . . . . . . . . . . . . . . . 5
2B•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
procarmanuals.com
http://vnx.su

Cylinder head
Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . 22.235 to 22.265 mm
Camshaft
Camshaft bearing journal diameter:Bearing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 44.75 mm
Bearing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.00 mm
Bearing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.25 mm
Bearing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.50 mm
Bearing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.75 mm
Camshaft bearing journal-to-cylinder head running clearance . . . . . . . 0.033 to 0.058 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.05 to 0.13 mm
Camshaft thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.99 to 5.01 mm
Lubrication
Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants, fluids and tyre pressures”
Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . See “Lubricants, fluids and tyre pressures”
Oil pressure:
Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 1.0 bar
At 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 2.8 bars
Oil pump clearances: Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 0.060 to 0.190 mm
Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.18 mm
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 0.014 to 0.100 mm
Torque wrench settingsNm lbf ft
Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 9 7
Oil pump pick-up to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil pump pick-up to pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil cooler threaded sleeve to cylinder block . . . . . . . . . . . . . . . . . . . . . 5742
Rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9 7
Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
8764
Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 3022
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 5037
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 108 80
Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 118
Camshaft toothed belt sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5742
Timing belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 1813
Rocker studs in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2015
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 2720
Rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 7 5
Timing belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9 7
Sump: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Engine mountings (CVH engines):
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
Engine mountings (PTE engines):
Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5037
Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 6447
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Note: Refer to Part D of this Chapter for remaining torque wrench settings.
2B•2 CVH and PTE engine in-car repair procedures
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2C
1595Ford Fiesta Remake
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . Four-cylinder, in-line, double overhead camshafts
Engine code:1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . L1G
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . RDB or RQC
Capacity:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1597 cc
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1796 cc
Bore:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 76.0 mm
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 80.6 mm
Stroke - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 88.0 mm
Compression ratio: 1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 10.3:1
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 10.0:1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Cylinder head
Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . 28.395 to 28.425 mm
Camshafts and hydraulic tappets
Camshaft bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.960 to 25.980 mm
Camshaft bearing journal-to-cylinder head running clearance . . . . . . . 0.020 to 0.070 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.080 to 0.220 mm
Lubrication
Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants, fluids and tyre pressures”
Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . See “Lubricants, fluids and tyre pressures”
Oil pressure: Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 1.3 to 2.5 bar
At 4000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 3.7 to 5.5 bars
Oil pump clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . Not specified
Chapter 2 Part C:
Zetec engine in-car repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshafts and hydraulic tappets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 11
Compression test - description and interpretation . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head cover - removal and refitting . . . . . . . . . . . . . . . . . . . 4
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . “Weekly Checks”Engine/transmission mountings - inspection and renewal . . . . . . . . 16
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 17
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Oil pump - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . . 8
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Timing belt tensioner and sprockets - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearances - general information . . . . . . . . . . . . . . . . . . . . . . . 5
2C•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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1595 Ford Fiesta Remake
The jack supplied with the vehicle tool kit
should only be used for changing the
roadwheels - see “Wheel changing” at the
front of this manual. When jacking up the
vehicle to carry out repair or maintenance
tasks, a pillar or trolley type jack of suitable
lifting capacity must be used, supplemented
with axle stands positioned only beneath the
appropriate points under the vehicle (see
illustration) . Note that the vehicle must never
be jacked up at the rear under the axle beam. The maximum kerb weight of the vehicle must
not be exceeded when jacking and supporting
the vehicle. Do not under any circumstances
jack up the rear of the vehicle under the rear axle.
Never work under, around or near a raised
vehicle unless it is adequately supported in at
least two places with axle stands.
The radio/cassette unit fitted as standard or
optional equipment may be equipped with a
built-in security code, to deter thieves. If the
power source to the unit is cut, the anti-theft
system will activate. Even if the power source
is immediately reconnected, the radio/
cassette unit will not function until the correct security code has been entered. Therefore,
if you do not know the correct security
code for the radio/cassette unit do not
disconnect either of the battery terminals, or
remove the radio/cassette unit from the
vehicle. To enter the correct security code, follow the instructions provided with the
radio/cassette player or vehicle handbook.
If an incorrect code is entered, the unit will
become locked, and cannot be operated.
If this happens, or if the security code is lost
or forgotten, seek the advice of your Ford
dealer.
Jacking and vehicle supportREF•5
REF
Radio/cassette unit anti-theft system - precaution
Underside view of the vehicle showing the jacking point locations
A Jacking points for trolley jack (always use a suitable block
of wood to protect the
vehicle body)
B Axle stand positions
C Jacking points for owner jack and wheel-free hoist
Buying spare parts
Spare parts are available from many
sources, including maker’s appointed
garages, accessory shops, and motor factors.
To be sure of obtaining the correct parts, it
will sometimes be necessary to quote the
vehicle identification number. If possible, it
can also be useful to take the old parts along
for positive identification. Items such as
starter motors and alternators may be
available under a service exchange scheme -
any parts returned should always be clean.
Our advice regarding spare part sources is
as follows.
Officially-appointed garages
This is the best source of parts which are
peculiar to your car, and which are not
otherwise generally available (eg badges,
interior trim, certain body panels, etc). It is
also the only place at which you should buy
parts if the vehicle is still under warranty.
Accessory shops
These are very good places to buy materials and components needed for the
maintenance of your car (oil, air and fuel
filters, spark plugs, light bulbs, drivebelts, oils
and greases, brake pads, touch-up paint, etc).
Components of this nature sold by a
reputable shop are of the same standard as
those used by the car manufacturer.
Besides components, these shops also sell
tools and general accessories, usually have
convenient opening hours, charge lower
prices, and can often be found not far from
home. Some accessory shops have parts
counters where the components needed for
almost any repair job can be purchased or
ordered.
Motor factors
Good factors will stock all the more
important components which wear out
comparatively quickly, and can sometimes
supply individual components needed for the
overhaul of a larger assembly (eg brake seals
and hydraulic parts, bearing shells, pistons,
valves, alternator brushes). They may also
handle work such as cylinder block reboring,
crankshaft regrinding and balancing, etc.
Tyre and exhaust specialists
These outlets may be independent, or
members of a local or national chain. They
frequently offer competitive prices when
compared with a main dealer or local garage,
but it will pay to obtain several quotes before
making a decision. When researching prices,
also ask what “extras” may be added - for
instance, fitting a new valve and balancing the
wheel are both commonly charged on top of
the price of a new tyre.
Other sources
Beware of parts or materials obtained from
market stalls, car boot sales or similar outlets.
Such items are not invariably sub-standard,
but there is little chance of compensation if
they do prove unsatisfactory. In the case of
safety-critical components such as brake
pads, there is the risk not only of financial loss
but also of an accident causing injury or
death. Second-hand components or assemblies
obtained from a car breaker can be a good
buy in some circumstances, but this sort of
purchase is best made by the experienced
DIY mechanic.
Buying spare parts
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