Index Ford Ford Fiesta - service and repair manual 1989-1995 year

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Ford Fiesta (1989-1995). Manual - part 1

Lubricants and fluids

Refer to end of “Weekly Checks”

Capacities

Engine oil

At oil and filter change:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.25 litres

CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.50 litres

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25 litres

Difference between dipstick minimum and maximum level notches . . .

0.5 to 1.0 litre

Cooling system

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 litres

CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 litres

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 litres

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42.0 litres

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 litres

Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 litres

Engine

Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise (seen from right-hand side of vehicle)

Oil filter:

HCS, CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C104

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C148

Cooling system

Coolant protection at standard 40% antifreeze/water mixture ratio:

Slush point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-25ºC (-13ºF)

Solidifying point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-30ºC (-22ºF)

Coolant specific gravity at standard 40% antifreeze/water
mixture ratio and 15ºC/59ºF - with no other additives in coolant . . . . .

1.061

Fuel system

Idle speed*:

1.0, 1.1 and 1.3 litre HCS (carburettor) engines . . . . . . . . . . . . . . . . .

750 ± 50 rpm (cooling fan running)

1.4 and 1.6 litre CVH (carburettor) engines:

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 ± 50 rpm (cooling fan running)

CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 ± 50 rpm (cooling fan running)

1.6 litre CVH (EFi fuel injection) engines:

Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 ± 50 rpm

Base idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

750 ± 50 rpm

Idle mixture CO content*:

1.0, 1.1 and 1.3 litre HCS (carburettor) engines . . . . . . . . . . . . . . . . .

1.0 ± 0.5%

1.4 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.25%

1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.5%

1.6 litre CVH (fuel injection) engines:

Non turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 ± 0.25%

Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.25%

*Note: The idle speed and mixture CO content is only adjustable on the engines shown above. On all other engines, it is controlled by the engine
management system, and cannot be checked or adjusted without specialised test equipment.
Air filter element:

1.0, 1.1 and 1.3 litre HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W153

1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W226

1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W226

1.6 litre CVH (fuel injection) engines . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion U557

1.6 and 1.8 litre Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion U612

Fuel filter:

HCS, CVH (fuel injection) and PTE engines:

Without quick-release fuel line fittings . . . . . . . . . . . . . . . . . . . . . .

Champion L204

With quick-release fuel line fittings . . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L218

1•2

Servicing Specifications

1595Ford Fiesta Remake

Ignition system

Firing order:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2-4-3 (No 1 cylinder at timing chain end of engine)

All other engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2 (No 1 cylinder at timing belt end of engine)

Spark plugs*:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RS9YCC or RS9YC

1.4 and 1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . .

Champion RC7YCC or RC7YC

1.6 litre CVH (EFi fuel injection) and PTE engines

Non-turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC7YCC4 or RC7YC4

Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C61YC

1.6 and 1.8 litre Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RE7YCC

Electrode gap*:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

1.4 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

1.4 litre CVH (CFi fuel injection) and PTE engine . . . . . . . . . . . . . . . .

1.0 mm

1.6 litre CVH (carburettor) engines:

With Champion RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

With Champion RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.7 mm

1.6 litre CVH (EFi fuel injection) engines:

Non-turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.7 mm

1.6 and 1.8 litre Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 mm

Spark plug (HT) leads:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-28

1.4 and 1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . .

Champion LS-14

1.4 litre CVH (CFi fuel injection) and PTE engines . . . . . . . . . . . . . . .

Champion LS-14

1.6 litre CVH (EFi fuel injection) engines . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-26

1.6 and 1.8 litre Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

Maximum resistance per lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 000 ohms

* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to their
manufacturer’s recommendations.

Braking system

Minimum front brake pad lining thickness . . . . . . . . . . . . . . . . . . . . . . .

1.5 mm

Minimum rear brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Tyres

Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Weekly Checks”

Wiper blades

Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-4803

Tailgate/rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-4103

Torque wrench settings

lbf ft

Auxiliary drivebelt cover fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary drivebelt adjustment:

Adjusting bolt (sliding arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Central (locking) bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pinion (adjuster) nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tensioner pulley centre bolt (HCS engines) . . . . . . . . . . . . . . . . . . . .

Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual transmission filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark plugs:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 to 100

52 to 74

Servicing Specifications

1•3

1595Ford Fiesta Remake

The maintenance schedule for these

vehicles, based on the manufacturer’s
recommendations, is as described below -
note that the schedule starts from the
vehicle’s date of registration. These are the
minimum maintenance intervals recommen-
ded by the factory for Fiestas driven daily, but
subjected only to “normal” use. If you wish to
keep your vehicle in peak condition at all
times, you may wish to perform some of these
procedures even more often. Because
frequent maintenance enhances the
efficiency, performance and resale value of
your vehicle, we encourage you to do so. If
your usage is not “normal”, shorter intervals

are also recommended - the most important
examples of these are noted in the schedule.
These shorter intervals apply particularly if
you drive in dusty areas, tow a caravan or
trailer, sit with the engine idling or drive at low
speeds for extended periods (ie, in heavy
traffic), or drive for short distances (less
than four miles) in below-freezing
temperatures.

When your vehicle is new, it should be

serviced by a Ford dealer service department
to protect the factory warranty. In many
cases, the initial maintenance check is done
at no cost to the owner. Note that this first
free service (carried out by the selling dealer

1500 miles or 3 months after delivery),
although an important check for a new
vehicle, is not part of the regular maintenance
schedule, and is therefore not mentioned
here.

It should be noted that for the 1992 model

year, for all models except RS Turbo, the
service time/mileage intervals were
extended by the manufacturer to the periods
shown in this schedule. Although these
intervals can be applied retrospectively,
owners of earlier vehicles may notice a
discrepancy between this schedule and the
one shown in the Service Guide supplied
with the vehicle.

1•4

Maintenance schedule

1595Ford Fiesta Remake

Every 250 miles (400 km) or weekly

Refer to “Weekly Checks”.

Every 5000 miles (8000 km) or
6 months, whichever occurs first

Note: Frequent oil and filter changes are good for the engine. We
recommend changing the oil at the mileage specified here, or at least
twice a year if the mileage covered is less.

Renew the engine oil and filter (Section 3).

Every 10 000 miles (16 000 km) or
12 months, whichever occurs first

Carry out all operations listed above, plus the following:

Check the auxiliary drivebelt (Section 4).

Check under the bonnet for fluid leaks and hose condition

(Section 5).

Check the condition of all engine compartment wiring (Sec-

tion 6).

Check the valve clearance adjustment - HCS engines only

(Section 7).

Check the manual transmission oil level (Section 8).

Check the engine idle speed and mixture - HCS and CVH

engines only, where possible (Section 9).

Check the steering, suspension and roadwheels (Section 10).

Check the driveshaft rubber gaiters and CV joints (Section 11).

Check the exhaust system (Section 12).

Check the underbody, and all fuel/brake lines (Section 13).

Check the brake system (Section 14).

Check the security of all roadwheel nuts (Section 15).

Check the doors, tailgate and bonnet, and lubricate their hinges

and locks (Section 16).

Check the seat belts (Section 17).

Check the condition of the bodywork, paint and exterior trim

(Section 18).

Road test (Section 19).

Check the automatic transmission fluid level (Section 20).

Every 20 000 miles (32 000 km) or
two years, whichever occurs first

Carry out all operations listed above, plus the following:

Renew the spark plugs and check the condition of the HT leads

- all engines except Zetec (Section 21).

Clean the idle speed control valve (Weber type) - CVH EFi

engines only (Section 22).

Every 30 000 miles (48 000 km) or
three years, whichever occurs first

Carry out all operations listed above, plus the following:

Renew the coolant (Section 23).

Renew the air cleaner filter element and check the air cleaner

temperature control system - carburettor engines only (Sec-

tion 24).

Check the emission control systems (Section 25).

Renew the spark plugs and check the condition of the HT leads

- Zetec engines (Section 21).

Renew the automatic transmission fluid (Section 26).

Check the handbrake adjustment (Section 27).

Check the front wheel alignment (Section 28).

Note: If the vehicle is used regularly in dusty or polluted conditions,
the air cleaner filter element should be renewed at more frequent
intervals.

Every 40 000 miles

Renew the timing belt - CVH and PTE engines only (Section 29).

Every 60 000 miles

Renew the timing belt - Zetec engines only (Section 29).

Renew the fuel filter (Section 30).

Every three years
(regardless of mileage)

Renew the brake fluid (Section 31).

1•6

Maintenance – component location

1.6 litre (XR2i) CVH EFi fuel injection engine

1595Ford Fiesta Remake

1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Brake fluid reservoir
5 Windscreen/tailgate washer fluid reservoir

cap

6 Battery
7 Vehicle identification plate
8 Thermostat housing
9 Timing belt cover
10 Top of suspension strut mounting

assembly

11 Windscreen wiper motor mounting bracket
12 Jack and wheelbrace retaining bolt
13 Distributorless (E-DIS) ignition coil
14 Fuel filter
15 Air cleaner
16 Air inlet duct
17 Idle speed control valve
18 Fuel pressure regulator
19 Throttle housing
20 Upper section of inlet manifold
21 Intake air temperature sensor
22 Fuel trap
23 EEC IV engine management module cover
24 Manifold absolute pressure sensor
25 Ignition module

1.8 litre (XR2i) Zetec SEFi fuel injection engine

1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Braking system fluid reservoir
5 Windscreen/tailgate washer fluid reservoir

cap

6 Battery
7 VIN plate
8 Thermostat housing
9 Timing belt cover
10 Top of suspension strut mounting

assembly

11 Windscreen wiper motor mounting bracket
12 Jack and wheelbrace retaining bolt
13 Distributorless (E-DIS) ignition coil
14 Fuel filter
15 Air cleaner
16 Air inlet duct
17 Idle speed control valve
18 Fuel pressure regulator
19 Throttle housing
20 Inlet manifold
21 Throttle position sensor
22 Fuel system pressure release/test point
23 EEC IV engine management module cover
24 Mass air flow sensor
25 Ignition module

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