Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing Chapter 1 Routine maintenance and servicing
1595Ford Fiesta Remake2C•16 Zetec engine in-car repair procedures4 Check the mountings to see if the rubber iscracked, hardened or separated from themetal components. Sometimes, the rubberwill split right down the centre.5 Check for relative movement between eachmounting’s brackets and the engine/transmission or body (use a large screwdriveror lever to attempt to move the mountings). Ifmovement is noted, lower the engine andcheck-tighten the mounting fasteners.Renewal6 The engine mountings can be removed ifthe weight of the engine/transmission issupported by one of the following alternativemethods.7 Either support the weight of the assemblyfrom underneath using a jack and a suitablepiece of wood between the jack saddle andthe sump or transmission (to preventdamage), or from above by attaching a hoistto the engine. A third method is to use asuitable support bar with end pieces whichwill engage in the water channel each side ofthe bonnet lid aperture. Using an adjustablehook and chain connected to the engine, theweight of the engine and transmission canthen be taken from the mountings.Engine front right-hand mounting8 This mounting consists of a two-piecebracket bolted to the inner wing panel,connected by the bonded-rubber mountingitself to a (Y-shaped) bracket, bolted (via thealternator mounting bracket) to the cylinderblock (see illustration).9 Unscrew the three bolts securing the frontright-hand mounting bracket to the alternatormounting bracket.10 Unscrew the bolts securing the mountingbracket to the inner wing panel and chassisrail and withdraw the mounting assembly.16.8 Engine front right-handmountingEngine rear right-hand mounting11 This mounting consists of the bondedrubbermounting secured to the inner wingpanel by a (horizontal) bolt, accessible fromwithin the wheel arch, and a (vertical) stud, theretaining nut of which is accessible from theengine compartment. The mounting is boltedto a bracket, which is in turn bolted to thecylinder block.12 Unbolt the mounting from the body byunscrewing first the single nut (and washer)immediately to the rear of the timing beltcover, then the bolt in the wheel arch.13 Unbolt the mounting from the cylinderblock bracket and withdraw the mountingassembly.Transmission bearer and mountings14 On XR2i models, remove the frontsuspension crossmember as described inChapter 10.15 Unscrew and remove the two nutssecuring the mountings (front and rear) to thetransmission bearer16 Support the transmission bearer, thenundo and remove the four retaining bolts fromthe floorpan, two at the front and two at therear, and lower the transmission bearer fromthe vehicle. Note plate fitment, as applicable,for reassembly.17 To remove the mountings from thetransmission, unscrew the upper bolt andlower stud (front mounting) or the three nuts(rear mounting) and withdraw the relevantmounting and bracket assembly from thetransmission.All mountings18 Refitting of all mountings is a reversal ofremoval. Make sure that the original sequenceof assembly of washers and plates ismaintained.19 Do not fully tighten any mounting boltsuntil they are all located. As the mountingbolts and nuts are tightened, check that themounting rubbers do not twist.17 Flywheel/driveplate -removal, inspection and3refittingRemoval1 Remove the transmission (see the relevantPart of Chapter 7).2 Where appropriate, remove the clutch(Chapter 6).3 Use a centre-punch or paint to makealignment marks on the flywheel/driveplateand crankshaft, to ensure correct alignmentduring refitting.4 Prevent the flywheel/driveplate from turningby locking the ring gear teeth, or by bolting astrap between the flywheel/driveplate and thecylinder block/crankcase. Slacken the boltsevenly until all are free.5 Remove each bolt in turn, and ensure thatnew replacements are obtained forreassembly; these bolts are subjected tosevere stresses, and so must be renewed,regardless of their apparent condition,whenever they are disturbed.6 Noting the reinforcing plate (automatictransmission models only), withdraw theflywheel/driveplate; do not drop it - it is veryheavy.Inspection7 Clean the flywheel/driveplate to removegrease and oil. Inspect the surface for cracks,rivet grooves, burned areas and score marks.Light scoring can be removed with emerycloth. Check for cracked and broken ring gearteeth. Lay the flywheel/driveplate on a flatsurface, and use a straight edge to check forwarpage.8 Clean and inspect the mating surfaces ofthe flywheel/driveplate and the crankshaft. Ifthe crankshaft left-hand seal is leaking, renewit (see Section 15) before refitting theflywheel/driveplate.9 While the flywheel/driveplate is removed,clean carefully its inboard (right-hand) face,particularly the recesses which serve as thereference points for the crankshaft speed/position sensor. Clean the sensor’s tip, andcheck that the sensor is securely fastened.Refitting10 On refitting, ensure that the engine/transmission adapter plate is in place (wherenecessary), then fit the flywheel/driveplate tothe crankshaft so that all bolt holes align - itwill fit only one way - check this using themarks made on removal. Do not forget thereinforcing plate (automatic transmissionmodels).11 Lock the flywheel/driveplate by themethod used on dismantling. Working in adiagonal sequence to tighten them evenly,and increasing to the final amount in two orthree stages, tighten the new bolts to thespecified torque wrench setting.12 The remainder of reassembly is thereverse of the removal procedure, referring tothe relevant text for details where required.
2D•1Chapter 2 Part D:Engine removal and overhaul proceduresContentsCamshaft and tappets - removal, inspection and refitting(HCS engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Crankshaft - refitting and main bearing running clearancecheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . 12Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . 13Cylinder head - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cylinder head - reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cylinder head and valve components - cleaning and inspection . . . 8Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 19Engine - removal and refitting (HCS engines) . . . . . . . . . . . . . . . . . . 3Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . 6Degrees of difficultyEasy, suitable fornovice with littleexperienceHCS engines1SpecificationsFairly easy, suitablefor beginner withsome experienceCylinder headMaximum permissible gasket surface distortion (measured overfull length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mmValve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45ºValve 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.2Fairly difficult,suitable for competentDIY mechanicEngine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . 15Engine/transmission removal - preparation and precautions . . . . . . 2Engine/transmission - removal and refitting (CVH andPTE engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine/transmission - removal and refitting (Zetec engines) . . . . . . 5General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Main and big-end bearings - inspection . . . . . . . . . . . . . . . . . . . . . . 14Piston/connecting rod assemblies - refitting and big-endbearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . 18Piston/connecting rod assemblies - removal and inspection . . . . . . 11Piston rings - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Difficult, suitable forexperienced DIYmechanic4Very difficult,suitable for expert DIYor professional52DValves - general Inlet ExhaustValve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.7 to 104.4 mm 104.2 to 104.7 mmValve head diameter:1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.90 to 33.10 mm 28.90 to 29.10 mm1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.40 to 34.60 mm 28.90 to 29.10 mmValve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm 7.0 mmValve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.069 0.046 to 0.095Cylinder blockCylinder bore diameter:1.0 and 1.1 litre engines:Standard class 1 (or A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 to 68.69 mmStandard class 2 (or B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.69 to 68.70 mmStandard class 3 (or C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.70 to 68.71 mmOversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.20 to 69.21 mmOversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.70 to 69.71 mm1.3 litre engines:Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.94 to 73.95 mmStandard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.50 to 73.96 mmStandard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.96 to 73.97 mmOversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.50 to 74.51 mmOversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.00 to 75.01 mm1595Ford Fiesta Remake
- Page 18 and 19: 1595Ford Fiesta Remake1•18 Every
- Page 20 and 21: 1595Ford Fiesta Remake1•20 Every
- Page 22 and 23: 1595Ford Fiesta Remake1•22 Every
- Page 24 and 25: 1595Ford Fiesta Remake1•24 Every
- Page 26 and 27: 1595Ford Fiesta Remake1•26 Every
- Page 28 and 29: 1595Ford Fiesta Remake2A•2 HCS en
- Page 30 and 31: 1595Ford Fiesta Remake2A•4 HCS en
- Page 32 and 33: 1595Ford Fiesta Remake2A•6 HCS en
- Page 34 and 35: 1595Ford Fiesta Remake2A•8 HCS en
- Page 36 and 37: 1595Ford Fiesta Remake2A•10 HCS e
- Page 38 and 39: 1595Ford Fiesta Remake2A•12 HCS e
- Page 40 and 41: 1595Ford Fiesta Remake2B•2 CVH an
- Page 42 and 43: 1595Ford Fiesta Remake2B•4 CVH an
- Page 44 and 45: 1595Ford Fiesta Remake2B•6 CVH an
- Page 46: 1595Ford Fiesta Remake2B•8 CVH an
- Page 49 and 50: CVH and PTE engine in-car repair pr
- Page 51 and 52: CVH and PTE engine in-car repair pr
- Page 53 and 54: 2C•1Chapter 2 Part C:Zetec engine
- Page 55 and 56: Zetec engine in-car repair procedur
- Page 57 and 58: Zetec engine in-car repair procedur
- Page 59 and 60: Zetec engine in-car repair procedur
- Page 61 and 62: Zetec engine in-car repair procedur
- Page 63 and 64: Zetec engine in-car repair procedur
- Page 65 and 66: Zetec engine in-car repair procedur
- Page 67: Zetec engine in-car repair procedur
- Page 71 and 72: Engine removal and overhaul procedu
- Page 73 and 74: Engine removal and overhaul procedu
- Page 75 and 76: Engine removal and overhaul procedu
- Page 77 and 78: Engine removal and overhaul procedu
- Page 79 and 80: Engine removal and overhaul procedu
- Page 81 and 82: Engine removal and overhaul procedu
- Page 83 and 84: Engine removal and overhaul procedu
- Page 85 and 86: Engine removal and overhaul procedu
- Page 87 and 88: Engine removal and overhaul procedu
- Page 89 and 90: Engine removal and overhaul procedu
- Page 91 and 92: Engine removal and overhaul procedu
- Page 93 and 94: Engine removal and overhaul procedu
- Page 95 and 96: 3•1Chapter 3Cooling, heating and
- Page 97 and 98: Cooling, heating and ventilation sy
- Page 99 and 100: Cooling, heating and ventilation sy
- Page 101 and 102: Cooling, heating and ventilation sy
- Page 103 and 104: Cooling, heating and ventilation sy
- Page 105 and 106: 4A•1Chapter 4 Part A:Fuel system
- Page 107 and 108: Fuel system - carburettor engines 4
- Page 109 and 110: Fuel system - carburettor engines 4
- Page 111 and 112: Fuel system - carburettor engines 4
- Page 113 and 114: Fuel system - carburettor engines 4
- Page 115 and 116: Fuel system - carburettor engines 4
- Page 117 and 118: Fuel system - carburettor engines 4
2D•1<strong>Chapter</strong> 2 Part D:Engine removal <strong>and</strong> overhaul proceduresContentsCamshaft <strong>and</strong> tappets - removal, inspection <strong>and</strong> refitting(HCS engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Crankshaft - refitting <strong>and</strong> main bearing running clearancecheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Crankshaft - removal <strong>and</strong> inspection . . . . . . . . . . . . . . . . . . . . . . . . 12Cylinder block/crankcase - cleaning <strong>and</strong> inspection . . . . . . . . . . . . 13Cylinder head - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cylinder head - reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cylinder head <strong>and</strong> valve components - cleaning <strong>and</strong> inspection . . . 8Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 19Engine - removal <strong>and</strong> refitting (HCS engines) . . . . . . . . . . . . . . . . . . 3Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . 6Degrees of difficultyEasy, suitable fornovice with littleexperienceHCS engines1SpecificationsFairly easy, suitablefor beginner withsome experienceCylinder headMaximum permissible gasket surface distortion (measured overfull length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mmValve seat angle (inlet <strong>and</strong> exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45ºValve seat width (inlet <strong>and</strong> exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 to 1.75 mm**The inlet <strong>and</strong> exhaust valves have special inserts which cannot be recut using conventional tools.2Fairly difficult,suitable for competentDIY mechanicEngine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . 15Engine/transmission removal - preparation <strong>and</strong> precautions . . . . . . 2Engine/transmission - removal <strong>and</strong> refitting (CVH <strong>and</strong>PTE engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine/transmission - removal <strong>and</strong> refitting (Zetec engines) . . . . . . 5General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Main <strong>and</strong> big-end bearings - inspection . . . . . . . . . . . . . . . . . . . . . . 14Piston/connecting rod assemblies - refitting <strong>and</strong> big-endbearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . 18Piston/connecting rod assemblies - removal <strong>and</strong> inspection . . . . . . 11Piston rings - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Difficult, suitable forexperienced DIYmechanic4Very difficult,suitable for expert DIYor professional52DValves - general Inlet ExhaustValve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.7 to 104.4 mm 104.2 to 104.7 mmValve head diameter:1.0 <strong>and</strong> 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.90 to 33.10 mm 28.90 to 29.10 mm1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.40 to 34.60 mm 28.90 to 29.10 mmValve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm 7.0 mmValve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.069 0.046 to 0.095Cylinder blockCylinder bore diameter:1.0 <strong>and</strong> 1.1 litre engines:St<strong>and</strong>ard class 1 (or A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 to 68.69 mmSt<strong>and</strong>ard class 2 (or B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.69 to 68.70 mmSt<strong>and</strong>ard class 3 (or C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.70 to 68.71 mmOversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.20 to 69.21 mmOversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.70 to 69.71 mm1.3 litre engines:St<strong>and</strong>ard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.94 to 73.95 mmSt<strong>and</strong>ard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.50 to 73.96 mmSt<strong>and</strong>ard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.96 to 73.97 mmOversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.50 to 74.51 mmOversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.00 to 75.01 mm1595Ford Fiesta Remake