Content .. 11 12 13 14 ..

Ford Fiesta (1989-1995). Instruction - part 13

1595Ford Fiesta Remake

General

Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-cylinder, in-line, double overhead camshafts

Engine code:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L1G

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RDB or RQC

Capacity:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1597 cc

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1796 cc

Bore:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76.0 mm

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80.6 mm

Stroke - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88.0 mm

Compression ratio:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3:1

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0:1

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)

Cylinder head

Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . .

28.395 to 28.425 mm

Camshafts and hydraulic tappets

Camshaft bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25.960 to 25.980 mm

Camshaft bearing journal-to-cylinder head running clearance . . . . . . .

0.020 to 0.070 mm

Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.080 to 0.220 mm

Lubrication

Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Lubricants, fluids and tyre pressures”

Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Lubricants, fluids and tyre pressures”

Oil pressure:

Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 to 2.5 bar

At 4000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 to 5.5 bars

Oil pump clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not specified

Chapter 2 Part C:
Zetec engine in-car repair procedures

Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshafts and hydraulic tappets - removal, inspection

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Compression test - description and interpretation . . . . . . . . . . . . . .

Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . .

Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head cover - removal and refitting . . . . . . . . . . . . . . . . . . .

Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . .“Weekly Checks”

Engine/transmission mountings - inspection and renewal . . . . . . . . 16
Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 17
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pump - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . .

Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . .

Timing belt tensioner and sprockets - removal, inspection

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . .

Valve clearances - general information . . . . . . . . . . . . . . . . . . . . . . .

2C•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

Torque wrench settings

lbf ft

Cylinder head cover bolts:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft sprocket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft bearing cap bolts:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head bolts:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle-tighten a further 105º

Timing belt cover fasteners:

Upper-to-middle (outer) cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

Cover-to-cylinder head or block bolts . . . . . . . . . . . . . . . . . . . . . . . .

Cover studs-to-cylinder head or block . . . . . . . . . . . . . . . . . . . . . . . .

Timing belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing belt tensioner backplate locating peg . . . . . . . . . . . . . . . . . . . . .

Timing belt tensioner spring retaining pin . . . . . . . . . . . . . . . . . . . . . . .

Timing belt guide pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary drivebelt idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front engine lifting eye bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust manifold heat shield bolts:

Shield-to-cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield/dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield/coolant pipe-to-manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

Oil pump-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pick-up pipe-to-pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil baffle/pump pick-up pipe nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil filter adapter-to-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pressure warning light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant pipe-to-sump bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

Crankshaft left-hand oil seal carrier bolts . . . . . . . . . . . . . . . . . . . . . . . .

Engine mountings:

Engine front right-hand mounting:

Alternator mounting bracket-to-cylinder block bolts . . . . . . . . . . .

41 to 58

30 to 43

Mounting bracket-to-alternator mounting bracket bolts . . . . . . . .

Not available

Mounting through-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

Outer bracket-to-mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

58 to 79

43 to 58

Inner bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 to 79

43 to 58

Outer bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 to 79

43 to 58

Engine rear right-hand mounting: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bracket-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 to 104

56 to 77

Mounting-to-(cylinder block) bracket bolts . . . . . . . . . . . . . . . . . . .

71 to 98

52 to 72

Mounting-to-body bolt and nut . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Transmission mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refer to Chapter 7A or 7B

Note: Refer to Part D of this Chapter for remaining torque wrench settings.

2C•2 Zetec engine in-car repair procedures

1595Ford Fiesta Remake

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 engines, and the 1.4 and 1.6 litre CVH
and PTE engines, will be found in Parts A
and B 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 Zetec engine, (formerly Zeta), is of

sixteen-valve, double overhead camshaft

(DOHC), four-cylinder, in-line type, mounted
transversely at the front of the vehicle, with
the transmission on its left-hand end.

Apart from the plastic timing belt covers

and the cast-iron cylinder block/crankcase, all
major engine castings are of aluminium alloy.

The crankshaft runs in five main bearings,

the centre main bearing’s upper half
incorporating thrustwashers to control
crankshaft endfloat. The connecting rods
rotate on horizontally-split bearing shells at
their big-ends. The pistons are attached to the
connecting rods by gudgeon pins which are
an interference fit in the connecting rod small-
end eyes. The aluminium alloy pistons are

fitted with three piston rings: two
compression rings and an oil control ring.
After manufacture, the cylinder bores and
piston skirts are measured and classified into
three grades, which must be carefully
matched together, to ensure the correct
piston/cylinder clearance; no oversizes are
available to permit reboring.

The inlet and exhaust valves are each

closed by coil springs; they operate in guides
which are shrink-fitted into the cylinder head,
as are the valve seat inserts.

Both camshafts are driven by the same

toothed timing belt, each operating eight
valves via self-adjusting hydraulic tappets,
thus eliminating the need for routine checking
and adjustment of the valve clearances. Each
camshaft rotates in five bearings that are line-
bored directly in the cylinder head and the
(bolted-on) bearing caps; this means that the
bearing caps are not available separately from
the cylinder head, and must not be
interchanged with caps from another engine.

The water pump is bolted to the right-hand

end of the cylinder block, inboard of the
timing belt, and is driven with the power
steering pump and alternator by a flat
“polyvee”-type auxiliary drivebelt from the
crankshaft pulley.

When working on this engine, note that

Torx-type (both male and female heads) and
hexagon socket (Allen head) fasteners are
widely used; a good selection of bits, with the
necessary adapters, will be required, so that
these can be unscrewed without damage and,
on reassembly, tightened to the torque
wrench settings specified.

Lubrication is by means of an eccentric-

rotor trochoidal pump, which is mounted on
the crankshaft right-hand end, and draws oil
through a strainer located in the sump. The
pump forces oil through an externally-
mounted full-flow cartridge-type filter - on
some versions of the engine, an oil cooler is
fitted to the oil filter mounting, so that clean oil
entering the engine’s galleries is cooled by the
main engine cooling system.

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.

Cylinder head cover - removal and
refitting.

Timing belt covers - removal and refitting.

Timing belt - renewal.

Timing belt tensioner and sprockets -
removal and refitting.

Camshaft oil seals - renewal.

Camshafts and hydraulic tappets -
removal and refitting.

Cylinder head - removal and refitting.

Cylinder head and pistons -
decarbonising.

Sump - removal and refitting.

Crankshaft oil seals - renewal.

Oil pump - removal and refitting.

m) Flywheel/driveplate - removal and

refitting.

Engine/transmission 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.

Compression test -
description and interpretation

Refer to Section 2 in Part A of this Chapter.

Top Dead Centre (TDC) for
No 1 piston - locating

1 Top 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 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the right-hand roadwheel.
4 Remove the auxiliary drivebelt cover (see
Chapter 1) to expose the crankshaft pulley
and timing marks.
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).

6 Note the two pairs of notches in the inner
and outer rims of the crankshaft pulley. In the
normal direction of crankshaft rotation the first
pair of notches are irrelevant to the vehicles
covered in this instruction, while the second pair
indicate TDC when aligned with the rear edge
of the raised mark on the sump. Rotate the
crankshaft clockwise until the second pair of
notches align with the edge of the sump mark;
use a straight edge extended out from the
sump if greater accuracy is required (see
illustrations).
7 Nos 1 and 4 cylinders are now at TDC, one
of them on the compression stroke. Remove
the oil filler cap; if No 4 cylinder exhaust cam
lobe is pointing to the rear of the vehicle and
slightly downwards, it is No 1 cylinder that is
correctly positioned. If the lobe is pointing
horizontally forwards, rotate the crankshaft
one full turn (360º) clockwise until the pulley
notches align again, and the lobe is pointing
to the rear and slightly down. No 1 cylinder
will then be at TDC on the compression
stroke.
8 Once No 1 cylinder has been positioned at
TDC on the compression stroke, TDC for any
of the other cylinders can then be located by
rotating the crankshaft clockwise 180º at a
time and following the firing order (see
Specifications).
9 With the engine set at No 1 piston on TDC
compression, refit the drivebelt cover and the
roadwheel, then lower the vehicle and refit the
spark plugs.

Cylinder head cover -
removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air inlet components as
necessary for access as described in the
Chapter 4D.
3 Disconnect the accelerator cable from the
throttle linkage as described in Chapter 4D.
4 On models equipped with power steering,
release the high pressure fluid pipe from the

Zetec engine in-car repair procedures 2C•3

3.6b . . . use a straight edge extended out

from the sump (arrowed) if greater

accuracy is required

3.6a Do not use crankshaft pulley’s first

pair of notches “A” - align second pair of

notches “B” with raised rib on sump “C” . . .

1595Ford Fiesta Remake

Turning the engine will be
easier if the spark plugs are
removed first - see Chapter 1.

clamp brackets and disconnect the pipe joint
union over the top of the cylinder head cover.
Place absorbent rags beneath the union as it
is disconnected to soak up escaping fluid and
plug the open unions to prevent dirt entry and
further fluid loss. Move the pipe(s) clear just
sufficiently to allow removal of the cylinder
head cover.
5 Remove the timing belt upper cover (see
Section 7).
6 Disconnect the crankcase breather hose
from the cylinder head cover union (see
illustration).
7 Unplug the HT leads from the spark plugs
and withdraw them, unclipping the leads from
the cover.
8 Working progressively, unscrew the
cylinder head cover retaining bolts, noting the
spacer sleeve and rubber seal at each, then
withdraw the cover (see illustration).
9 Discard the cover gasket; this must be
renewed whenever it is disturbed. Check that
the sealing faces are undamaged, and that the
rubber seal at each retaining bolt is
serviceable; renew any worn or damaged
seals.

Refitting

10 On refitting, clean the cover and cylinder
head gasket faces carefully, then fit a new
gasket to the cover, ensuring that it locates
correctly in the cover grooves (see illustration).
11 Refit the cover to the cylinder head, then
insert the rubber seal and spacer sleeve at
each bolt location (see illustration). Start all

bolts finger-tight, ensuring that the gasket
remains seated in its groove.
12 Working in a diagonal sequence from the
centre outwards, and in two stages (see
Specifications), tighten the cover bolts to the
specified torque wrench setting.
13 Refit the HT leads, clipping them into
place so that they are correctly routed; each is
numbered, and can also be identified by the
numbering on its respective coil terminal.
14 Reconnect the crankcase breather hose,
and refit the timing belt upper cover.
Reconnect and adjust the accelerator cable,
then refit the air inlet components (see
Chapter 4B).
15 On models with power steering,
reconnect the high pressure fluid pipe then
bleed the system as described in Chapter 10.

Valve clearances -
general information

Refer to Section 5 in Part B of this Chapter.

Crankshaft pulley -
removal and refitting

Removal

1 Remove the auxiliary drivebelt - either
remove the drivebelt completely, or just

secure it clear of the crankshaft pulley,
depending on the work to be carried out (see
Chapter 1).
2 If necessary, rotate the crankshaft until the
timing marks align (see Section 3).
3 The crankshaft must now be locked to
prevent its rotation while the pulley bolt is
unscrewed. To do this, remove the starter
motor (Chapter 5A) and lock the starter ring
gear teeth using a suitable screwdriver.
4 It should now just be possible to reach
between the crankshaft pulley and the body
side member to undo and remove the pulley
bolt and withdraw the pulley. However, if
additional working clearance is needed,
proceed as follows.
5 If not already done, chock the rear wheels
then jack up the front of the car and support it
on axle stands (see “Jacking and Vehicle
Support”). Remove the front right-hand
roadwheel.
6 Support the weight of the
engine/transmission using a trolley jack, with
a wooden spacer to prevent damage to the
sump.
7 From above, unscrew the three bolts
securing the engine’s front right-hand (Y-
shaped) mounting bracket to the alternator
mounting bracket. Unfasten the engine’s rear
right-hand mounting from the body by
unscrewing first the single nut (and washer)
immediately to the rear of the timing belt
cover, then the bolt in the wheel arch
8 With the engine’s right-hand mountings
unfastened from the body, lower the
engine/transmission on the jack until a socket
spanner can be fitted to the crankshaft pulley
bolt.
9 With the starter ring gear teeth locked,
unscrew the crankshaft pulley bolt and
withdraw the pulley (see illustration).

Refitting

10 Refitting is the reverse of the removal
procedure; ensure that the pulley’s keyway is
aligned with the crankshaft’s locating key, and
tighten the pulley bolt to the specified torque
wrench setting. If the engine mountings were
disturbed, use the jack to adjust the height of
the engine/transmission until the bolts (and
nut, with washer) can be refitted and screwed

2C•4 Zetec engine in-car repair procedures

6.9 Unscrew pulley bolt to release

crankshaft pulley

4.11 Ensure rubber seal is fitted to each

cover bolt spacer, as shown

4.10 Ensure gasket is located correctly in

cover groove

4.8 Removing cylinder head cover

1595Ford Fiesta Remake

4.6 Disconnecting crankcase breather

hose from cylinder head cover union

Content .. 11 12 13 14 ..