manual transmission FORD FIESTA 1989 Service User Guide

the specified type of fluid. It is essential that
no dirt is introduced into the transmission
during this operation.
7Depending on the extent to which the fluid
was allowed to drain, it is possible that the
amount of fluid required when filling the
transmission may be more than the specified
amount (see “Lubricants, fluids and tyre
pressures” ). However, due to fluid remaining in
the system, it is more likely that less than the
specified amount will be required. Add about
half the specified amount, then run the engine
up to its normal operating temperature and
check the level on the dipstick. When the level
approaches the maximum mark, proceed as
detailed in Section 20 to check the level and
complete the final topping-up as described.
27 Handbrake adjustment
3
1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Fully
release the handbrake.
2 Check that the handbrake cables are
correctly routed and secured by the retaining
clips at the appropriate points under the vehicle.
3 The handbrake is checked for adjustment
by measuring the amount of movement
possible in the handbrake adjuster plungers.
These are located on the inside face of each
rear brake backplate (see illustration) . Thetotal movement of the two plungers combined
should be between 0.5 and 2.0 mm. If the
movement measured is outside of this
tolerance, the handbrake is in need of
adjustment. Adjustment is made altering the
position of the in-line cable adjuster sleeve.
4
When adjustment to the handbrake is
necessary, a new adjustment sleeve locking
pin will be required, and this must therefore
be obtained before making the adjustment.
5 To adjust the handbrake, first ensure that it
is fully released, then firmly apply the
footbrake a few times to ensure that the rear
brake adjustment is taken up by the automatic
adjusters. Extract the locking pin from
the adjuster sleeve (see illustration), then
turn the sleeve to set the combined move-
ment of the plungers within the tolerance range specified (0.5 to 2.0 mm). Turn the
locking nut by hand as tight as is possible
(two clicks) against the adjustment sleeve.
Now grip the locknut with a suitable wrench,
and turn it a further two clicks (maximum).
6
Secure the adjustment by inserting the new
lock pin.
7 Check that the operation of the handbrake
is satisfactory, then lower the vehicle to the
ground, apply the handbrake and remove the
chocks from the front wheels.
28 Front wheel alignment check
4
Refer to Chapter 10, Section 29.
Every 30 000 miles or three years1•25
27.5 Handbrake cable adjuster locking
pin (A), locknut (B) and adjuster sleeve (C)27.3 Handbrake adjustment plunger
located on the inside face of each rear brake backplate
1
1595Ford Fiesta Remake
Every 40 000 miles
29 Timing belt renewal
4
Refer to Chapter 2, Part B or C as
applicable.
Every 60 000 miles
30 Fuel filter renewal
1
Warning: Petrol is extremely
flammable, so extra precautions
must be taken when working on
any part of the fuel system. Do
not smoke, or allow open flames or bare
light bulbs, near the work area. Also, do
not work in a garage if a natural gas-type appliance with a pilot light is present.
While performing any work on the fuel system, wear safety glasses, and have a
suitable (Class B) fire extinguisher on
hand. If you spill any fuel on your skin,
rinse it off immediately with soap and
water.
1
On fuel injection engines, an in-line fuel
filter is provided in the fuel pump outlet line.
The filter is located in the engine compartment
either below and behind the battery, or on the
left-hand side of the engine compartment
bulkhead. The renewal procedure is the same
for both locations. The filter performs a vital
role in keeping dirt and other foreign matter
out of the fuel system, and so must be renewed at regular intervals, or whenever you
have reason to suspect that it may be
clogged. It is always unpleasant working
under a vehicle - pressure-washing or hosing
clean the underbody in the filter’s vicinity will
make working conditions more tolerable, and
will reduce the risk of getting dirt into the fuel
system.
2
Depressurise the fuel system as described
in the relevant Part of Chapter 4.
3 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1), then position
a suitable container beneath the fuel filter to
catch escaping fuel. Have a rag handy to soak
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2A
1595Ford Fiesta Remake
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . Four-cylinder, in-line overhead valve
Engine code:1.0 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TLB
1.1 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUE or GUD
1.1 litre CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . G6A
1.3 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JBC
1.3 litre CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . J6B
Capacity: 1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 999 cc
1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1118 cc
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1297 cc
Bore:
1.0 and 1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 mm
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 73.96 mm
Stroke:
1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 67.40 mm
1.1 and 1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.48 mm
Compression ratio:
Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9.5:1
CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8:1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1-2-4-3 (No 1 cylinder at timing chain end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Valves
Valve clearance (cold): Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . 0.20 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 0.30 mm
Chapter 2 Part A:
HCS engine in-car repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Compression test - description and interpretation . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head rocker cover - removal and refitting . . . . . . . . . . . . . . 4
Cylinder head rocker gear - removal, inspection and refitting . . . . . 6
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . .See
“Weekly Checks”
Engine/transmission mountings - inspection and renewal . . . . . . . . 15 Flywheel - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 16
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 13
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing chain cover - removal and refitting . . . . . . . . . . . . . . . . . . . . 9
Timing chain, sprockets and tensioner - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 10
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . 5
2A•1
Specifications 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
54321
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Lubrication
Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants, fluids and tyre pressures”
Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . See “Lubricants, fluids and tyre pressures”
Oil pressure: At idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 0.60 barsAt 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 1.50 bars
Oil pump clearances: Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 0.14 to 0.26 mm
Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 to 0.127 mm
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 0.025 to 0.06 mm
Torque wrench settingsNm lbf ft
Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 1813
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 115 85
Rocker shaft pedestal bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4332
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 6749
Sump: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 9 7
Stage 3 (with engine warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 1410
Cylinder head bolts (may be re-used once only): Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 3022
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Timing chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 8 6
Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 9 7
Crankshaft rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1813
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 5 4
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . 1813
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 9 7
Engine mountings: Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 72 40 to 53
Rubber insulator to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 to 95 52 to 70
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Note: Refer to Part D of this Chapter for remaining torque wrench settings.
2A•2 HCS engine in-car repair procedures
1595Ford Fiesta Remake
1 General information
How to use this Chapter
This Part of Chapter 2 is devoted to repair
procedures possible while the engine is still
installed in the vehicle, and includes only the
Specifications relevant to those procedures.
Similar information concerning the 1.4 and
1.6 litre CVH and PTE engines, and the 1.6
and 1.8 litre Zetec engines, will be found in
Parts B and C of this Chapter respectively.
Since these procedures are based on the
assumption that the engine is installed in the
vehicle, if the engine has been removed from
the vehicle and mounted on a stand, some
of the preliminary dismantling steps outlined
will not apply. Information concerning engine/transmission
removal and refitting, and engine overhaul, can
be found in Part D of this Chapter, which also
includes the Specifications relevant to those
procedures.
Engine description
The engine is an overhead valve, water-
cooled, four cylinder in-line design,
designated HCS (High Compression Swirl).
The engine is mounted transversely at the
front of the vehicle together with the
transmission to form a combined power unit. The crankshaft is supported in three or five
shell-type main bearings. The connecting rod
big-end bearings are also split shell-type, and
are attached to the pistons by interference-fit
gudgeon pins. Each piston is fitted with two
compression rings and one oil control ring. The camshaft, which runs on bearings
within the cylinder block, is chain-driven from
the crankshaft, and operates the valves via
pushrods and rocker arms. The valves are
each closed by a single valve spring, and
operate in guides integral in the cylinder head. The oil pump is mounted externally on the
crankcase, incorporates a full-flow oil filter,
and is driven by a skew gear on the camshaft.
On carburettor versions, the fuel pump is also
driven from the camshaft, via an eccentric
lobe.
Repair operations possible with
the engine in the car
The following work can be carried out with
the engine in the car:
a) Compression pressure - testing.
b) Cylinder head rocker cover - removal
and refitting.
c) Valve clearances - adjustment.
d) Rocker shaft assembly - removal,
inspection and refitting.
e) Cylinder head - removal and refitting
f) Cylinder head and pistons - decarbonising.
g) Crankshaft pulley - removal and refitting.
h) Crankshaft oil seals - renewal.
i) Timing chain, sprockets and tensioner -
removal, inspection and refitting.
j) Oil filter renewal.
k) Oil pump - removal and refitting.
l) Sump - removal and refitting.
m) Flywheel - removal, inspection and
refitting.
n) Engine/transmission mountings -
inspection and renewal.
Note: It is possible to remove the pistons and
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(see illustration). Centralise the seal on the
shaft, then insert and tighten the housing
retaining bolts to the specified torque setting.
Refit the sump with reference to Section 11.
12 Check that the crankshaft rear flange
and the flywheel mating faces are clean, then
refit the flywheel as described in Section 16.
15 Engine/transmission mountings - inspection and
renewal
2
Inspection
1 The engine/transmission mountings seldom
require attention, but broken or deteriorated
mountings should be renewed immediately, or
the added strain placed on the driveline
components may cause damage or wear.
2 During the check, the engine/transmission
must be raised slightly, to remove its weight
from the mountings.
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Position
a jack under the sump, with a large block of
wood between the jack head and the sump,
then carefully raise the engine/transmission
just enough to take the weight off the
mountings.
4 Check the mountings to see if the rubber is
cracked, hardened or separated from the metal components. Sometimes, the rubber
will split right down the centre.
5
Check for relative movement between each
mounting’s brackets and the
engine/transmission or body (use a large
screwdriver or lever to attempt to move the
mountings). If movement is noted, lower the
engine and check-tighten the mounting
fasteners.
Renewal
6 The engine mountings can be removed if
the weight of the engine/transmission is
supported by one of the following alternative
methods.
7 Either support the weight of the assembly
from underneath using a jack and a suitable
piece of wood between the jack saddle and
the sump or transmission (to prevent
damage), or from above by attaching a hoist
to the engine. A third method is to use a
suitable support bar with end pieces which
will engage in the water channel each side of
the bonnet lid aperture. Using an adjustable hook and chain connected to the engine, the
weight of the engine and transmission can
then be taken from the mountings.
Engine right-hand mounting
8
Unscrew and remove the mounting side
bolt from under the right-hand wheel arch
(see illustration) .
9 Unscrew and remove the mounting
retaining nut and washer from the suspension
strut cup retaining plate (see illustration).
10 Undo the three bolts securing the
mounting unit to the cylinder block. The
mounting unit and bracket can then be
lowered from the engine (see illustration).
11 Unbolt and remove the mounting from its
support bracket.
Transmission bearer and mountings
12 Unscrew and remove the two nuts
securing the mountings (front and rear) to the
transmission bearer (see illustration).
13 Support the transmission bearer, then
undo and remove the four retaining bolts from
the floorpan, two at the front and two at the
2A•10 HCS engine in-car repair procedures
15.12 Exploded view of the transmission bearer mountings
15.10 Undo the three bolts securing the
mounting assembly to the cylinder block
and withdraw the mounting
15.9 Unscrew and remove the mountingretaining nut and washer from the
suspension strut cup retaining plate15.8 Unscrew and remove the engine
mounting side bolt (arrowed) from under the wheel arch14.11b Fitting the rear oil seal housing
with a new gasket in position on the rear face of the cylinder block
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rear, and lower the transmission bearer from
the vehicle. Note plate fitment, as applicable,
for reassembly.
14Unscrew the single nut securing each
mounting and its retainer to the transmission
support bracket, and remove. The
transmission support brackets are fixed
externally to the transmission casing and do
not need to be removed for this operation.
All mountings
15 Refitting of all mountings is a reversal of
removal. Make sure that the original sequence
of assembly of washers and plates is
maintained.
16 Do not fully tighten any mounting bolts
until they are all located. As the mounting
bolts and nuts are tightened, check that the
mounting rubbers do not twist.
16 Flywheel - removal, inspection
and refitting
3
Refitting
1 Remove the transmission as described in
Chapter 7A, then remove the clutch as
described in Chapter 6. 2
Unscrew the six retaining bolts, and remove
the flywheel from the rear end flange of the
crankshaft - take care not to drop the
flywheel, as it is heavy. A tool similar to that
shown in illustration 16.5 can be fitted to
prevent the flywheel/crankshaft from rotating
as the bolts are removed. If on removal, the
retaining bolts are found to be in poor
condition (stretched threads, etc) they must
be renewed.
Inspection
3 Inspect the starter ring gear on the flywheel
for any broken or excessively-worn teeth. If
evident, the ring gear must be renewed; this is
a task best entrusted to a Ford dealer or a
competent garage. Alternatively, obtain a
complete new flywheel.
4 The clutch friction surface on the flywheel
must be carefully inspected for grooving or
hairline cracks (caused by overheating). If
these conditions are evident, it may be
possible to have the flywheel surface-ground
to renovate it, providing that the balance is
not upset. Regrinding is a task for an
automotive engineer. If surface-grinding is not
possible, the flywheel must be renewed.
Refitting
5 Check that the mating faces of the flywheel and the crankshaft are clean before refitting.
Lubricate the threads of the retaining bolts
with engine oil before they are screwed into
position. Locate the flywheel onto the
crankshaft, and insert the bolts. Hand-tighten
them initially, then tighten them in a
progressive sequence to the specified torque
wrench setting
(see illustration) .
6 Refit the clutch as described in Chapter 6
and the transmission as described in Chap-
ter 7A.
HCS engine in-car repair procedures 2A•11
16.5 Tightening the flywheel retaining bolts to the specified torque
Note the “peg” tool (arrowed) locking the ring gear teeth to prevent the flywheel/crankshaft from rotating
2A
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2B
1595Ford Fiesta Remake
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . Four-cylinder, in-line overhead camshaft
Engine code:1.4 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. FUF or FUG
CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6E
1.4 litre PTE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . F4A
1.6 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. LUH
EFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LJC or LJD
Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . LHA
Capacity:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392 cc
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1596 cc
Bore:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.24 mm
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 79.96 mm
Stroke:
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.30 mm
1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 79.52 mm
Compression ratio:
1.4 litre CVH carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1
1.4 litre CVH CFi fuel injection engine . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1
1.4 litre PTE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9.5:1
1.6 litre CVH engine: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 9.5:1
EFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75:1
Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 8.0:1
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Chapter 2 Part B:
CVH and PTE engine in-car repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Camshaft oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft, rocker arms and tappets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 11
Compression test - description and interpretation . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head rocker cover - removal and refitting . . . . . . . . . . . . . . 4
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . .See
“Weekly Checks”
Engine/transmission mountings - renewal . . . . . . . . . . . . . . . . . . . . 17 Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 18
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 15
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . . 8
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Timing belt tensioner and sprockets - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearances - general information . . . . . . . . . . . . . . . . . . . . . . . 5
2B•1
Specifications 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
54321
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Cylinder head
Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . 22.235 to 22.265 mm
Camshaft
Camshaft bearing journal diameter:Bearing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 44.75 mm
Bearing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.00 mm
Bearing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.25 mm
Bearing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.50 mm
Bearing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.75 mm
Camshaft bearing journal-to-cylinder head running clearance . . . . . . . 0.033 to 0.058 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.05 to 0.13 mm
Camshaft thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.99 to 5.01 mm
Lubrication
Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants, fluids and tyre pressures”
Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . See “Lubricants, fluids and tyre pressures”
Oil pressure:
Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 1.0 bar
At 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 2.8 bars
Oil pump clearances: Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 0.060 to 0.190 mm
Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.18 mm
Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 0.014 to 0.100 mm
Torque wrench settingsNm lbf ft
Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 9 7
Oil pump pick-up to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil pump pick-up to pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Oil cooler threaded sleeve to cylinder block . . . . . . . . . . . . . . . . . . . . . 5742
Rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 9 7
Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
8764
Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 3022
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 5037
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 108 80
Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 118
Camshaft toothed belt sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5742
Timing belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 1813
Rocker studs in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2015
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 2720
Rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 7 5
Timing belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9 7
Sump: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 7 5
Engine mountings (CVH engines):
Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 72 40 to 53
Rubber insulator to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 to 95 52 to 70
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Engine mountings (PTE engines):
Engine mounting (right-hand):Bolt to body (in wheel arch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5037
Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . . 6447
Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 7A or 7B
Note: Refer to Part D of this Chapter for remaining torque wrench settings.
2B•2 CVH and PTE engine in-car repair procedures
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1 General information
How to use this Chapter
This Part of Chapter 2 is devoted to repair
procedures possible while the engine is still
installed in the vehicle, and includes only the
Specifications relevant to those procedures.
Similar information concerning the 1.3 litre
HCS engine, and the 1.6 and 1.8 litre Zetec
engines, will be found in Parts A and C of this
Chapter respectively. Since these procedures
are based on the assumption that the engine
is installed in the vehicle, if the engine has
been removed from the vehicle and mounted
on a stand, some of the preliminary
dismantling steps outlined will not apply.
Information concerning engine/transmission
removal and refitting, and engine overhaul, can
be found in Part D of this Chapter, which also
includes the Specifications relevant to those
procedures.
Engine description
The engine is a four-cylinder, in-line
overhead camshaft type, designated CVH
(Compound Valve angle, Hemispherical
combustion chamber) or PTE (Pent roof, high
Torque, low Emission). The PTE engine was
introduced for 1994 and, apart from
modifications to the cylinder head, camshaft
and intake system, is virtually identical to the
CVH engine it replaces. The engine is
mounted transversely at the front of the
vehicle together with the transmission to form
a combined power unit. The crankshaft is supported in five split-
shell type main bearings within the cast-iron
crankcase. The connecting rod big-end
bearings are split-shell type, and the pistons
are attached by interference-fit gudgeon pins.
Each piston has two compression rings and
one oil control ring.
The cylinder head is of light alloy
construction, and supports the camshaft in five
bearings. Camshaft drive is by a toothed
composite rubber timing belt, which is driven by
a sprocket on the front end of the crankshaft.
The timing belt also drives the water pump,
which is mounted below the cylinder head. Hydraulic cam followers (tappets) operate the
rocker arms and valves. The tappets are
operated by pressurised engine oil. When a
valve closes, the oil passes through a port in the
body of the cam follower, through four grooves
in the plunger and into the cylinder feed
chamber. From the chamber, the oil flows to a
ball-type non-return valve and into the pressure
chamber. The tension of the coil spring causes
the plunger to press against the valve, and so
eliminates any free play. As the cam lifts the
follower, the oil pressure in the pressure
chamber is increased, and the non-return valve
closes off the port feed chamber. This in turn
provides a rigid link between the cam follower,
the cylinder and the plunger. These then rise as a unit to open the valve. The cam follower-to-
cylinder clearance allows the specified quantity
of oil to pass from the pressure chamber, oil only
being allowed past the cylinder bore when the
pressure is high during the moment of the valve
opening. When the valve closes, the escape of
oil will produce a small clearance, and no
pressure will exist in the pressure chamber. The
feed chamber oil then flows through the non-
return valve and into the pressure chamber, so
that the cam follower cylinder can be raised by
the pressure of the coil spring, eliminating free
play until the valve is operated again.
As wear occurs between the rocker arm
and the valve stem, the quantity of oil that
flows into the pressure chamber will be
slightly more than the quantity lost during the
expansion cycle of the cam follower.
Conversely, when the cam follower is
compressed by the expansion of the valve, a
slightly smaller quantity of oil will flow into the
pressure chamber than was lost. A rotor-type oil pump is mounted on the
timing cover end of the engine, and is driven
by a gear on the front end of the crankshaft. A
full-flow type oil filter is fitted, and is mounted
on the side of the crankcase.
Repair operations possible with
the engine in the car
The following work can be carried out with
the engine in the car:
a) Compression pressure - testing.
b) Rocker cover - removal and refitting.
c) Timing belt - removal, refitting and
adjustment.
d) Camshaft oil seal - renewal.
e) Camshaft - removal and refitting.
f) Cylinder head - removal and refitting.
g) Cylinder head and pistons - decarbonising.
h) Crankshaft pulley - removal and refitting.
i) Crankshaft oil seals - renewal.
j) Oil filter renewal.
k) Sump - removal and refitting.
l) Flywheel - removal, inspection and refitting.
m) Mountings - removal and refitting.
Note: It is possible to remove the pistons and
connecting rods (after removing the cylinder
head and sump) without removing the engine.
However, this is not recommended. Work of
this nature is more easily and thoroughly
completed with the engine on the bench, as
described in Chapter 2D.
2 Compression test -
description and interpretation
2
Refer to Section 2 in Part A of this Chap-
ter.
3 Top Dead Centre (TDC) for
No 1 piston - locating
2
1Top dead centre (TDC) is the highest point
of the cylinder that each piston reaches as the
crankshaft turns. Each piston reaches its TDC
position at the end of its compression stroke,
and then again at the end of its exhaust
stroke. For the purpose of engine timing, TDC
on the compression stroke for No 1 piston is
used. No 1 cylinder is at the timing belt end of
the engine. Proceed as follows.
2 Remove the upper timing belt cover as
described in Section 7.
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
4 Undo the retaining bolts, and remove the
cover from the underside of the crankshaft
pulley.
5 Fit a spanner onto the crankshaft pulley bolt,
and turn the crankshaft in its normal direction
of rotation (clockwise, viewed from the pulley
end) to the point where the crankshaft pulley
timing notch is aligned with the TDC (0) timing
mark on the timing belt cover.
6 Although the crankshaft is now in top dead
centre alignment, with piston Nos 1 and 4 at
the top of their stroke, the No 1 piston may
not be on its compression stroke. To confirm
that it is, check that the timing pointer on the
camshaft sprocket is exactly aligned with the
TDC mark on the front face of the cylinder
head (see illustrations) . If the pointer is not
aligned, turn the crankshaft pulley one further
CVH and PTE engine in-car repair procedures 2B•3
3.6b Camshaft sprocket timing mark
aligned with the TDC mark on the front
face of the cylinder head3.6a Crankshaft pulley notch (arrowed)aligned with the TDC (0) mark on the
timing belt cover
2B
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Turning the engine will be
easier if the spark plugs are
removed first - see Chapter 1.
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9Align the pump gear flats with those on the
crankshaft, then fit the oil pump. Check that
the sump mating faces of the oil pump and
the base of the crankcase are flush each side,
then tighten the retaining bolts to the
specified torque setting. Remove the
protective guide (see illustrations) .
10 Refit the oil pick-up tube to the oil pump,
using a new gasket and tighten to the
specified torque.
11 Slide the thrustwasher onto the front end
of the crankshaft, then insert the Woodruff key
into position in the groove in the crankshaft.
The key must be located with its flat edge
parallel with the line of the crankshaft, to
ensure that the crankshaft sprocket slides
fully into position as it is being refitted.
12 Refit the sump, crankshaft sprocket, the
timing belt, timing belt cover and drivebelt
pulley (as described in the appropriate earlier
Sections of this Chapter). Refit and adjust the
drivebelt as described in Chapter 1.
13 On completion, lower the vehicle and
reconnect the battery negative terminal.
15 Oil pump - dismantling,
inspection and reassembly
3
Dismantling
1 The oil pump fitted is a low-friction rotor-
type, driven from the front end of the
crankshaft. Where a high-mileage engine is being reconditioned, it is recommended that a
new oil pump is fitted.
2
To inspect the rotor assembly, first remove
the pump from the engine (Section 14), then
undo the retaining screws and remove the
cover plate (see illustration) . Remove the O-
ring seal.
Inspection
3 Clean the rotors and the inside of the pump
housing, then visually inspect the various
components for signs of excessive wear and
scoring. Check the pump components for
wear using feeler gauges in the same manner
as that described in Part A of this Chapter,
Section 13. Refer to the Specifications at the
start of this Chapter for specific details.
Reassembly
4 When reassembling the pump, ensure that
the inner (driving) and outer (driven) rotors are
located with the corresponding indented
matchmarks facing the same way (see
illustration) .
16Crankshaft oil seals -
renewal
4
Front oil seal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Chock the rear wheels then jack up the front of the car and support it on axle stands
(see
“Jacking and Vehicle Support” ).
3 Remove the auxiliary drivebelt as described
in Chapter 1.
4 Remove the crankshaft pulley (Section 6),
the timing belt covers (Section 7), the timing
belt (Section 8) and crankshaft sprocket,
Woodruff key and thrustwasher (Section 9).
5 The oil seal is now accessible for removal
from the front face of the oil pump housing
(see illustration) . To withdraw the seal, a
hooked tool will be required; if available, use
Ford special tool No 21-096. Take care not to
damage the oil pump housing during removal.
As it is removed, note the fitted orientation of
the seal in its housing.
6 Clean the oil pump housing and the
crankshaft stub, then lubricate the lips of the
new seal and the crankshaft front stub with
clean engine oil.
7 The oil seal should be drawn into position
using the Ford special tool No 21-093A.
Failing this, use a tube of suitable diameter,
with the crankshaft pulley bolt and washers.
Do not hammer the seal into position. To
protect the seal lips as it is fitted onto the
crankshaft, cut a thin sheet of plastic to suit
and furl it round the front of the crankshaft,
over the journal shoulder.
8 When the seal is fully fitted, remove the
special tool (or fabricated tool) and withdraw
the plastic protector. Check that the
crankshaft is still at the TDC position and refit
the Woodruff key, thrustwasher and sprocket.
Refit and tension the timing belt, then refit the
timing belt cover and crankshaft pulley as
described in the appropriate Sections earlier
in this Chapter.
9 Refit and adjust the auxiliary drivebelt as
described in Chapter 1.
10 On completion, lower the vehicle and
reconnect the battery.
Rear oil seal
11 With the engine or transmission removed
from the vehicle for access, remove the clutch
as described in Chapter 6.
12 Remove the flywheel/driveplate as
described in Section 18.
13 If available, use Ford tool No 21-151 or a
suitable clawed tool to extract the seal from
2B•12 CVH and PTE engine in-car repair procedures
16.5 Crankshaft front oil seal - seen from
below (arrowed)15.4 Inner and outer rotor matchmarks (arrowed)15.2 Oil pump cover plate retainingscrews (arrowed)
14.9b With the oil pump refitted, removethe protective guide (arrowed)14.9a Refit the oil pump
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its housing. If the seal housing is removed
from the rear face of the engine, the seal can
be removed as described in paragraph 18. As
it is removed, note the direction of fitting, and
take care not to damage the seal housing as
the seal is extracted.
14Clean the seal housing, the crankshaft
rear flange face, and the flywheel/driveplate
mating surfaces.
15 One of two possible methods may be
used to insert the new oil seal, depending on
the tools available.
16 If Ford special service tool No 21-095 is
available, lubricate the seal lips of the seal and
its running face on the crankshaft with clean
engine oil. Position the seal (correctly
orientated) into the special tool, then draw the
seal into the housing using two
flywheel/driveplate securing bolts so that the
seal is against the stop.
17 If the correct Ford service tool is not
available, it will be necessary to remove the oil
seal carrier housing. To do this, first remove
the sump as described in Section 13, then
unscrew the seal housing retaining bolts and
remove the housing from the rear face of the
crankcase.
18 Drive the old seal from the housing by
carefully tapping it from its aperture using a
suitable punch as shown (see illustration). As
it is removed, note the direction of fitting, and
take care not to damage the seal housing as
the seal is extracted.
19 New gaskets will be required for the seal
housing and sump during reassembly. Clean
the mating faces of the seal housing, the
crankcase and sump. Insert the new seal
squarely into its housing. To avoid damaging
the seal or the housing, place a flat piece of
wood across the face of the seal, and
carefully tap or draw the seal into place. Do
not allow the seal to tilt in the housing as it is
being fitted.
20 Lubricate the running surface on the
crankshaft and the oil seal lip with clean
engine oil. Locate a new gasket onto the rear
face of the crankcase, and refit the oil seal
housing and seal. To avoid damaging the lips
of the seal as it is passed over the end of the
crankshaft, cut a thin sheet of plastic to suit
and furl it round the rear flange of the crankshaft so that it protrudes, and press the
seal over it. With the seal in position, withdraw
the plastic protector. Centralise the seal on the
shaft, check that the housing-to-sump flange
faces are flush to the sump face on the base of
the crankcase, then insert and tighten the
housing retaining bolts to the specified torque.
21
Refit the sump with reference to Sec-
tion 13.
22 Refit the flywheel/driveplate as described
in Section 18.
23 Refit the clutch as described in Chapter 6.
24 Refit the engine or transmission, as
applicable.
17 Engine/transmission mountings - renewal
2
1The removal and refitting method for the
transmission bearer and mountings is as
described for HCS engines in Part A, Sec-
tion 15. On XR2i models, it will be necessary
to remove the front suspension crossmember
first (refer to Chapter 10). 2
The engine right-hand mounting is
significantly different to that fitted to HCS
engines, in that it is a two-piece bracket, and
its removal and refitting procedure is detailed
below.
3 First of all support the engine/transmission
assembly as described in Part A, Section 15,
then unscrew and remove the two nuts
securing the two halves of the mounting
bracket assembly.
4 Unscrew and remove the three bolts
securing the engine bracket section to the
cylinder block (see illustration) .
5 Unscrew and remove the mounting
retaining nut and washer from their location
near the suspension strut.
6 Unscrew and remove the mounting side
bolt from under the right-hand wheel arch.
7 Refitting is a reversal of the removal
procedure. Make sure when refitting
engine/transmission mountings, that any
washers and plates removed during the
dismantling process are refitted in their
original sequence. Do not fully tighten any
mounting bolts until they are all located. As
the mounting bolts and nuts are tightened,
check that the mounting rubbers do not twist.
CVH and PTE engine in-car repair procedures 2B•13
17.4 Exploded view of the right-hand engine mounting16.18 Rear oil seal removal
2B
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