Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2A•2 HCS engine in-car repair proceduresLubricationEngine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pressure:At idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .At 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pump clearances:Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See “Lubricants, fluids and tyre pressures”See “Lubricants, fluids and tyre pressures”0.60 bars1.50 bars0.14 to 0.26 mm0.051 to 0.127 mm0.025 to 0.06 mmTorque wrench settings Nm lbf ftCamshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 85Rocker shaft pedestal bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 32Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 49Sump:Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7Stage 3 (with engine warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 10Cylinder head bolts (may be re-used once only):Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten a further 90ºStage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten a further 90ºTiming chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7Crankshaft rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7Engine mountings:Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43Bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 72 40 to 53Rubber insulator to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 to 95 52 to 70Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7BNote: Refer to Part D of this Chapter for remaining torque wrench settings.1 General informationHow to use this ChapterThis Part of Chapter 2 is devoted to repairprocedures possible while the engine is stillinstalled in the vehicle, and includes only theSpecifications relevant to those procedures.Similar information concerning the 1.4 and1.6 litre CVH and PTE engines, and the 1.6and 1.8 litre Zetec engines, will be found inParts B and C of this Chapter respectively.Since these procedures are based on theassumption that the engine is installed in thevehicle, if the engine has been removed fromthe vehicle and mounted on a stand, someof the preliminary dismantling steps outlinedwill not apply.Information concerning engine/transmissionremoval and refitting, and engine overhaul, canbe found in Part D of this Chapter, which alsoincludes the Specifications relevant to thoseprocedures.Engine descriptionThe engine is an overhead valve, watercooled,four cylinder in-line design,designated HCS (High Compression Swirl).The engine is mounted transversely at thefront of the vehicle together with thetransmission to form a combined power unit.The crankshaft is supported in three or fiveshell-type main bearings. The connecting rodbig-end bearings are also split shell-type, andare attached to the pistons by interference-fitgudgeon pins. Each piston is fitted with twocompression rings and one oil control ring.The camshaft, which runs on bearingswithin the cylinder block, is chain-driven fromthe crankshaft, and operates the valves viapushrods and rocker arms. The valves areeach closed by a single valve spring, andoperate in guides integral in the cylinder head.The oil pump is mounted externally on thecrankcase, incorporates a full-flow oil filter,and is driven by a skew gear on the camshaft.On carburettor versions, the fuel pump is alsodriven from the camshaft, via an eccentriclobe.Repair operations possible withthe engine in the carThe following work can be carried out withthe engine in the car:a) Compression pressure - testing.b) Cylinder head rocker cover - removaland refitting.c) Valve clearances - adjustment.d) Rocker shaft assembly - removal,inspection and refitting.e) Cylinder head - removal and refittingf) 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 andrefitting.n) Engine/transmission mountings -inspection and renewal.Note: It is possible to remove the pistons and