Chapter 1 Routine maintenance and servicing

11.07.2015 Views
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

Page 1: 1•1Chapter 1Routine maintenance a

Page 4 and 5: 1595Ford Fiesta Remake1•4 Mainten



Page 10 and 11: 1595Ford Fiesta Remake1•10 Every









Page 28 and 29: 1595Ford Fiesta Remake2A•2 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 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 69 and 70: 2D•1Chapter 2 Part D:Engine remov

Page 71: Engine removal and overhaul procedu

Page 75 and 76: Engine removal and overhaul procedu










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








Page 123 and 124: 4B•1Chapter 4 Part B:Fuel system

Page 125 and 126: Fuel system - central fuel injectio




Page 133 and 134: 4C•1Chapter 4 Part C:Fuel system

Page 135 and 136: Fuel system - electronic fuel injec




Page 143 and 144: 4D•1Chapter 4 Part D: Fuel system

Page 145 and 146: Fuel system - sequential electronic



Page 151 and 152: 4E•1Chapter 4 Part E:Exhaust and

Page 153 and 154: Exhaust and emission control system



Page 159 and 160: 5A•1Chapter 5 Part A:Starting and

Page 161 and 162: Starting and charging systems 5A•



Page 167 and 168: 5B•1Chapter 5 Part B:Ignition sys

Page 169 and 170: Ignition system 5B•3flux can pass

Page 171 and 172: Ignition system 5B•55.3 Disconnec

Page 173 and 174: Ignition system 5B•79.3 Distribut

Page 175 and 176: 9•1Chapter 9Braking systemContent

Page 177 and 178: Braking system 9•34 Withdraw the

Page 179 and 180: Braking system 9•56.3 Depress and

Page 181 and 182: Braking system 9•78.3 Compress th

Page 183 and 184: Braking system 9•911.6 Servo moun

Page 185 and 186: Braking system 9•11Bleeding - usi

Page 187 and 188: Braking system 9•1318.4 Handbrake

Page 189 and 190: Braking system 9•1524.6 Belt-brea

Page 191 and 192: Braking system 9•17cylinder reser

Page 193 and 194: 10•1Chapter 10Suspension and stee

Page 195 and 196: Suspension and steering 10•31 Gen

Page 197 and 198: Suspension and steering 10•52.17

Page 199 and 200: Suspension and steering 10•7A Sus

Page 201 and 202: Suspension and steering 10•99.6 P

Page 203 and 204: Suspension and steering 10•11posi

Page 205 and 206: Suspension and steering 10•1319.1

Page 207 and 208: Suspension and steering 10•15that

Page 209 and 210: Suspension and steering 10•17Refi

Page 211 and 212: 11•1Chapter 11Bodywork and fittin

Page 213 and 214: Bodywork and fittings 11•3almost

Page 215 and 216: Bodywork and fittings 11•57.3b Bo

Page 217 and 218: Bodywork and fittings 11•715.2 Ra

Page 219 and 220: Bodywork and fittings 11•918.2 Mi

Page 221 and 222: Bodywork and fittings 11•1121.5 D

Page 223 and 224: Bodywork and fittings 11•1327.3 T

Page 225 and 226: Bodywork and fittings 11•1531.20

Page 227 and 228: Bodywork and fittings 11•17to avo

Page 229 and 230: Bodywork and fittings 11•1942.1 A

Page 231 and 232: Bodywork and fittings 11•2146.12

Page 233 and 234: 12•1Chapter 12Body electrical sys

Page 235 and 236: Body electrical systems 12•3Bulbs

Page 237 and 238: Body electrical systems 12•53.1a

Page 239 and 240: Body electrical systems 12•750 Un

Page 241 and 242: Body electrical systems 12•96.13




Page 249 and 250: Body electrical systems 12•1727 A

Page 251 and 252: Wiring diagrams 12•1912Notes, int

Page 253 and 254: Wiring diagrams 12•21Diagram 1a:

Page 255 and 256: Wiring diagrams 12•23Diagram 1c:

Page 257 and 258: Wiring diagrams 12•25Diagram 1e:

Page 259 and 260: Wiring diagrams 12•27Diagram 2a:

Page 261 and 262: 1595Ford Fiesta RemakeDiagram 3: An

Page 263 and 264: 1595Ford Fiesta RemakeDiagram 3b: A

Page 265 and 266: Wiring diagrams 12•33Diagram 4: I

Page 267 and 268: REF•2 Conversion factorsWeightsKe

Page 269 and 270: REF•4 General repair proceduresWh

Page 271 and 272: REF•6 Conversion FactorsLength (d

Page 273 and 274: REF•8 Tools and working facilitie

Page 275 and 276: REF•10 MOT test checksThis is a g

Page 277 and 278: REF•12 MOT test checksExhaust sys

Page 279 and 280: REF•14 Fault findingEngine Engine

Page 281 and 282: REF•16 Fault findingEngine (conti

Page 283 and 284: REF•18 Fault findingAutomatic tra

Page 285 and 286: REF•20 Fault findingElectrical sy

Page 287 and 288: REF•22 Glossary of technical term



Page 293 and 294: REF•28 IndexFault finding - clutc

Page 295 and 296: Left blank formanual listingpages15

Page 297: Preserving Our Motoring HeritageJoh

refitting

disconnect

refit

retaining

removal

cylinder

bolts

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Chapter 1 Routine maintenance and servicing

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