Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake2D•4 Engine removal and overhaul proceduresPistons and piston ringsPiston diameter (production):1.4 litre engine:Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 litre carburettor engine and turbocharged engine:Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 litre EFi (non-turbo) fuel injection engine:Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.190 to 77.200 mm77.200 to 77.210 mm77.210 to 77.220 mm77.220 to 77.230 mm77.480 to 77.490 mm77.490 to 77.500 mm77.500 to 77.510 mm79.910 to 79.920 mm79.920 to 79.930 mm79.930 to 79.940 mm79.940 to 79.950 mm80.200 to 80.210 mm80.210 to 80.220 mm80.220 to 80.230 mm79.915 to 79.925 mm79.925 to 79.935 mm79.935 to 79.945 mm79.945 to 79.955 mm80.205 to 80.215 mm80.215 to 80.225 mmOversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.225 to 80.235 mmPiston-to-cylinder bore clearance:1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.040 mm1.6 litre carburettor engine and turbocharged engine . . . . . . . . . . . . 0.020 to 0.040 mm1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . . . 0.015 to 0.035 mmPiston ring end gaps - installed:Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.50 mmOil control rings:1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 1.40 mm1.6 litre carburettor engine and turbocharged engine . . . . . . . . . . 0.40 to 1.40 mm1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . 0.25 to 0.40 mmGudgeon pinsLength:1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.000 to 63.800 mm1.6 litre carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.200 to 67.000 mm1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . . . 63.000 to 63.800 mm1.6 litre turbocharged engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.600 to 64.400 mmDiameter:White colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Red colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interference fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankshaft and bearingsMain bearing journal diameter:Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.622 to 20.625 mm20.625 to 20.628 mm20.628 to 20.631 mm20.631 to 20.634 mm0.005 to 0.011 mm0.013 to 0.045 mm57.98 to 58.00 mm0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.73 to 57.75 mm0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.48 to 57.50 mm0.75 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.23 to 57.25 mmMain bearing journal-to-shell running clearance . . . . . . . . . . . . . . . . . . 0.011 to 0.058 mmCrankpin (big-end) bearing journal diameter:Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.89 to 47.91 mm0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.64 to 47.66 mm0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.39 to 47.41 mm0.75 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.14 to 47.16 mm1.00 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.89 to 46.91 mmCrankpin (big-end) bearing journal-to-shell running clearance . . . . . . .Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thrustwasher thickness:Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 to 0.060 mm0.09 to 0.30 mm2.301 to 2.351 mm2.491 to 2.541 mm
Engine removal and overhaul procedures 2D•5Torque wrench settings Nm lbf ftMain bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 70Crankpin (big-end) bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 24Engine-to-transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30Note: Refer to Part B of this Chapter for remaining torque wrench settings.Zetec enginesCylinder headMaximum permissible gasket surface distortion . . . . . . . . . . . . . . . . . . 0.10 mmValve seat included angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90ºValve guide bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.060 to 6.091 mmValves - general Inlet ExhaustValve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.870 to 97.330 mm 96.470 to 96.930 mmValve head diameter:1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 mm 24.5 mm1.8 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm 28.0 mmValve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.028 to 6.043 mm 6.010 to 6.025 mmValve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 to 0.064 mm 0.035 to 0.081 mmCylinder blockCylinder bore diameter:1.6 litre engine:Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8 litre engine:Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pistons and piston ringsPiston diameter1.6 litre engine:Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8 litre engine:Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oversizes - all engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston-to-cylinder bore clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston ring end gaps - installed:76.000 to 76.010 mm76.010 to 76.020 mm76.020 to 76.030 mm80.600 to 80.610 mm80.610 to 80.620 mm80.620 to 80.630 mm75.975 to 75.985 mm75.985 to 75.995 mm75.995 to 76.005 mm80.570 to 80.580 mm80.580 to 80.590 mm80.590 to 80.600 mmNone availableNot specifiedCompression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.50 mmOil control ring:1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 1.00 mm1.8 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.38 to 1.14 mmGudgeon pinDiameter:White colour code/piston crown marked “A” . . . . . . . . . . . . . . . . . . .Red colour code/piston crown marked “B” . . . . . . . . . . . . . . . . . . . .Blue colour code/piston crown marked “C” . . . . . . . . . . . . . . . . . . . .Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interference fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankshaft and bearingsMain bearing journal standard diameter . . . . . . . . . . . . . . . . . . . . . . . . .Main bearing journal-to-shell running clearance . . . . . . . . . . . . . . . . . .Main bearing shell undersizes available . . . . . . . . . . . . . . . . . . . . . . . . .Crankpin (big-end) bearing journal standard diameter . . . . . . . . . . . . . .Crankpin (big-end) bearing journal-to-shell running clearance . . . . . . .Big-end bearing shell undersizes available . . . . . . . . . . . . . . . . . . . . . .Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.622 to 20.625 mm20.625 to 20.628 mm20.628 to 20.631 mm0.010 to 0.016 mm0.011 to 0.042 mm57.980 to 58.000 mm0.011 to 0.058 mm0.02 mm, 0.25 mm46.890 to 46.910 mm0.016 to 0.070 mm0.02 mm, 0.25 mm0.090 to 0.310 mm2D1595Ford Fiesta Remake
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1•1Chapter 1Routine maintenance a
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1595Ford Fiesta Remake1•4 Mainten
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1595Ford Fiesta Remake1•10 Every
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Page 28 and 29: 1595Ford Fiesta Remake2A•2 HCS en
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Page 38 and 39: 1595Ford Fiesta Remake2A•12 HCS e
Page 40 and 41: 1595Ford Fiesta Remake2B•2 CVH an
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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 69 and 70: 2D•1Chapter 2 Part D:Engine remov
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Page 95 and 96: 3•1Chapter 3Cooling, heating and
Page 97 and 98: 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
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4B•1Chapter 4 Part B:Fuel system
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Fuel system - central fuel injectio
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4C•1Chapter 4 Part C:Fuel system
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Fuel system - electronic fuel injec
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4D•1Chapter 4 Part D: Fuel system
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Fuel system - sequential electronic
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4E•1Chapter 4 Part E:Exhaust and
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Exhaust and emission control system
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5A•1Chapter 5 Part A:Starting and
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Starting and charging systems 5A•
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5B•1Chapter 5 Part B:Ignition sys
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Ignition system 5B•3flux can pass
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Ignition system 5B•55.3 Disconnec
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Ignition system 5B•79.3 Distribut
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9•1Chapter 9Braking systemContent
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Braking system 9•34 Withdraw the
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Braking system 9•56.3 Depress and
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Braking system 9•78.3 Compress th
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Braking system 9•911.6 Servo moun
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Braking system 9•11Bleeding - usi
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Braking system 9•1318.4 Handbrake
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Braking system 9•1524.6 Belt-brea
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Braking system 9•17cylinder reser
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10•1Chapter 10Suspension and stee
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Suspension and steering 10•31 Gen
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Suspension and steering 10•52.17
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Suspension and steering 10•7A Sus
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Suspension and steering 10•99.6 P
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Suspension and steering 10•11posi
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Suspension and steering 10•1319.1
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Suspension and steering 10•15that
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Suspension and steering 10•17Refi
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11•1Chapter 11Bodywork and fittin
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Bodywork and fittings 11•3almost
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Bodywork and fittings 11•57.3b Bo
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Bodywork and fittings 11•715.2 Ra
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Bodywork and fittings 11•918.2 Mi
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Bodywork and fittings 11•1121.5 D
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Bodywork and fittings 11•1327.3 T
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Bodywork and fittings 11•1531.20
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Bodywork and fittings 11•17to avo
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Bodywork and fittings 11•1942.1 A
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Bodywork and fittings 11•2146.12
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12•1Chapter 12Body electrical sys
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Body electrical systems 12•3Bulbs
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Body electrical systems 12•53.1a
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Body electrical systems 12•750 Un
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Body electrical systems 12•96.13
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Body electrical systems 12•1727 A
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Wiring diagrams 12•1912Notes, int
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Wiring diagrams 12•21Diagram 1a:
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Wiring diagrams 12•23Diagram 1c:
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Wiring diagrams 12•25Diagram 1e:
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Wiring diagrams 12•27Diagram 2a:
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1595Ford Fiesta RemakeDiagram 3: An
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1595Ford Fiesta RemakeDiagram 3b: A
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Wiring diagrams 12•33Diagram 4: I
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REF•2 Conversion factorsWeightsKe
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REF•4 General repair proceduresWh
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REF•6 Conversion FactorsLength (d
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REF•8 Tools and working facilitie
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REF•10 MOT test checksThis is a g
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REF•12 MOT test checksExhaust sys
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REF•14 Fault findingEngine Engine
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REF•16 Fault findingEngine (conti
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REF•18 Fault findingAutomatic tra
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REF•20 Fault findingElectrical sy
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REF•22 Glossary of technical term
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REF•28 IndexFault finding - clutc
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Left blank formanual listingpages15
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Preserving Our Motoring HeritageJoh
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Chapter 1 Routine maintenance and servicing

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