1984-1995 Ford Fiesta Workshop Service Repair Manual

1 Chapter 1 Routine maintenance and servicing Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Air cleaner temperature control check . . . . . . . . . . . . . . . . . . . . . . . .29 Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Battery electrolyte level check . . . . . . . . . . . . . . .see “Weekly checks” Battery terminal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Brake hydraulic fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Brake hydraulic system seal and hose renewal . . . . . . . . . . . . . . . . .32 Brake pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Choke adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Contact breaker point renewal and distributor lubrication - OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Crankcase ventilation system check . . . . . . . . . . . . . . . . . . . . . . . . .28 Emission control filter element renewal - CVH engines . . . . . . . . . . .30 Engine coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Engine idle speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Engine valve clearance check - OHV engines . . . . . . . . . . . . . . . . . .18 Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks” Front and rear brake pad/shoe check . . . . . . . . . . . . . . . . . . . . . . . . .4 Front wheel alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Handbrake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . . .14 HT lead, distributor cap and ignition circuit check . . . . . . . . . . . . . . .13 Ignition timing and contact breaker gap (dwell angle) check - OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Mixture adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Roadwheel security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Spark plug check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Steering and suspension security check . . . . . . . . . . . . . . . . . . . . . .24 Throttle damper operation check . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Timing belt renewal - CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . .34 Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks” Underbody inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks” 1•1 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 5 4 3 2 1 Servicing Specifications Lubricants and fluids See end of “Weekly checks” Capacities Engine oil With filter: 1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints) 1.3,1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 litres (6.2 Imp pints) Without filter: 1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 litres (4.8 Imp pints) 1.3, 1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints) Cooling system (including heater) 1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 litres (9.7 Imp pints) 1.3 and 1.4 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 litres (11.1 Imp pints) 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 litres (14.1 Imp pints) Fuel tank All models - pre 1985, except XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 litres (7.5 gallons) XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 litres (8.4 gallons) All models - 1985 on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 litres (8.8 gallons) Gearbox 4-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 litres (4.9 Imp pints) 5-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 litres (5.5 Imp pints)

1•2 Servicing Specifications Engine Oil filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104 Valve clearances (only OHV applicable): Inlet: At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in) Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 mm (0.008 to 0.010 in) Exhaust: At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 mm (0.023 in) Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 to 0.61 mm (0.022 to 0.024 in) Cooling system Drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.16 in) total deflection at the midpoint of the belt’s longest run Fuel system Air filter element type: 1.0 and 1.1 (OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W153 1.3 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W127 1.4 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W179 1.6 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W201 Ignition system Spark plugs: Make and type: Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RS9YCC or RS9YC Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC Electrode gap: RS9YCC and RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in) RS9YC and RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in) Note: The spark plug gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other type are to be fitted, refer to their manufacturer’s recommendations. Contact breaker points gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.50 mm (0.016 to 0.020 in) Dwell (mechanical ignition): Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48° to 52° Variation (from idle to 2000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4° maximum Overlap (lobe-to-lobe variation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° maximum Timing (initial): 1.0 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° BTDC 1.1 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC Ignition HT lead set: Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 k ohms maximum per lead Type: Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 8 boxed set Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 9 boxed set Brakes Front brake pad friction material minimum thickness . . . . . . . . . . . . . . 1.5 mm (0.059 in) Rear brake shoe friction material minimum thickness . . . . . . . . . . . . . . 1.0 mm (0.04 in) Tyres Tyre sizes: Note: Manufacturers often modify tyre sizes and pressure recommendations. The following is intended as a guide only. Refer to your vehicle handbook or a Ford dealer for the latest recommendations. XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185/60 HR 13 Other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 SR 13, 155/70 SR 13 or 165/65 SR 13 Tyre pressures: See end of “Weekly checks” Torque wrench settings Nm lbf ft Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Radiator coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.1 Gearbox oil filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20 Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 74 Spark plugs: OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 20 10 to 15 CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20 Brake caliper piston housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17

The maintenance intervals in this manual are provided with the assumption that you will be carrying out the work yourself. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys, more frequent maintenance intervals are recommended. When the vehicle is new, it should be serviced by a factory-authorised dealer service department, in order to preserve the factory warranty. Maintenance schedule 1•3 1 Every 250 miles (400 km) or weekly m Refer to “Weekly checks” Every 6000 miles (10 000 km) or 6 months - whichever comes sooner m Renew engine oil and filter (Section 3) m Check brake pads or shoes for wear (front and rear) (Section 4) m Check operation of brake fluid level warning indicator (Section 4) m Inspect engine bay and underside of vehicle for fluid leaks or other signs of damage (Section 5) m Check function and condition of seat belts (Section 6) m Check condition and security of exhaust system (Section 7) m Check tightness of wheel nuts (Section 8) m Check choke adjustment (Section 9) m Check idle speed (Section 10) m Check mixture adjustment (Section 11) m Check spark plugs (Section 12) m Check HT leads, distributor cap and ignition circuit (Section 13) m Check operation of latches, check straps and locks; lubricate if necessary (Section 14) m Check ignition timing and contact breaker gap (dwell angle) (OHV engines) (Section 15) m Check operation of throttle damper (where applicable) (Section 16) Every 12 000 miles (20 000 km) or 12 months - whichever comes sooner (continued) m Renew spark plugs (Section 21) m Check gearbox oil level (Section 22) m Renew distributor contact breaker points and lubricate distributor - OHV engines (Section 23) m Check security and condition of steering and suspension components, gaiters and boots (Section 24) m Inspect underbody and panels for corrosion or other damage (Section 25) m Inspect brake pipes and hoses (Section 26) m Road test (Section 27) m Check crankcase ventilation system (Section 28) Every 24 000 miles (40 000 km) or 2 years - whichever comes sooner m Check air cleaner temperature control (Section 29) m Renew emission control filter element - CVH engines (Section 30) m Renew air cleaner element (Section 31) Every 36 000 miles (60 000 km) or 3 years - whichever comes sooner m Renew brake hydraulic system seals and hoses if necessary (Section 32) m Renew brake hydraulic fluid (Section 33) m Renew timing belt - CVH engines (Section 34) m Check front wheel alignment (Section 35) Every 12 000 miles (20 000 km) or 12 months - whichever comes sooner m Check tightness of battery terminals, clean and neutralise corrosion (Section 17) m Check engine valve clearances - OHV engines (Section 18) m Check handbrake mechanism (Section 19) m Check condition and tension of auxiliary drivebelt (Section 20) Every 2 years, regardless of mileage m Renew coolant (Section 36)

1•4 Maintenance - component location Engine compartment - OHV 1 Coolant expansion tank 2 Engine oil dipstick 3 Oil filter 4 Ignition coil 5 Brake fluid reservoir 6 Battery 7 Cooling fan 8 Oil filler cap 9 Carburettor (air cleaner removed) 10 Alternator 11 Washer reservoir Engine compartment - CVH 1 Coolant expansion tank 2 Engine oil dipstick 3 Carburettor (air cleaner removed) 4 Fuel pump 5 Distributor 6 Ignition coil 7 Windscreen wiper motor 8 Ignition amplifier module 9 Battery 10 Brake fluid reservoir 11 Cooling fan 12 Oil filler cap 13 Washer reservoir

Maintenance - component location 1•5 1 Underside view of car at rear 1 Rear silencer 2 Brake secondary cable 3 Fuel tank 4 Suspension coil spring 5 Shock absorber lower mounting 6 Panhard rod 7 Anti-roll bar (certain models only) 8 Towing eye 9 Axle beam 10 Exhaust system mounting 11 Handbrake adjustment check plunger 12 Suspension trailing arm 13 Brake pressure control valve Underside view of car at front - CVH 1 Suspension arm 2 Driveshaft 3 Tie-bar 4 Alternator 5 Sump 6 Exhaust 7 Starter motor 8 Engine/gearbox bearer 9 Gearbox 10 Disc brake caliper 11 Gearchange rod and stabilizer rod

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1984-1995 Ford Fiesta Workshop Service Repair Manual

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