Ford Fiesta (1989-1995). Instruction - part 25

motor and resistor assembly (see
illustration).
18 Undo the two nuts securing the assembly
to the bulkhead and remove it from the
vehicle.
19 Detach the heater fan cover, having
released its two retaining clips.
20 Release the heater fan motor retaining
strap from underneath, using a flat-bladed
screwdriver, and remove it. Remove the
resistor assembly and/or heater fan motor, as
required (see illustrations).
21 Refitting is a reversal of the removal

procedure, ensuring that the heater fan motor
wires are routed under the retaining strap, but
are not pinched by it.

Heater matrix

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
22 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
23 Drain the cooling system (see Chapter 1).
24 Release the hose clips and disconnect the
two heater hoses from their dual heater matrix
connector on the bulkhead, at the rear of the
engine compartment. Plug the hoses to
prevent excessive coolant loss, collecting
spillage and any remaining coolant from the
heater matrix in a suitable container.
25 Undo the screws securing the heater

matrix connector to the bulkhead, and detach
its cover plate and gasket (see illustration).
26 Where fitted, remove the centre console
as described in Chapter 11.
27 Unclip and detach the footwell vent from
the base of the heater casing (see
illustration).
28 Unclip the lower cover from the heater
casing and remove the heater matrix, being
careful to avoid any residual coolant spillage
in the passenger compartment (see
illustrations).
29 Refitting is a reversal of the removal
procedure. On completion, refill the cooling
system as described in Chapter 1.

Heater casing assembly

30 Remove the facia, as described in
Chapter 11.
31 Remove the heater matrix, as described
previously in this Section.
32 Disconnect the heater control cables from
the heater casing assembly as described
previously in this Section.
33 Disconnect the side outlet vent ducting
from the heater casing. The side outlet ducts
can be removed by undoing the screws
securing them to the bulkhead, as required.
34 Undo the two heater casing securing nuts
and remove the casing from the vehicle (see
illustration).
35 Refitting is a reversal of the removal
procedure, with reference to the applicable
Chapters and Sections of this instruction.

Cooling, heating and ventilation systems 3•9

11.20b Removing the heater fan motor

11.20a Releasing the heater fan motor

retaining strap from the underside of the

assembly

11.17 Disconnecting the wiring from the

heater fan motor and resistor assembly

(arrowed)

11.34 Heater casing securing nuts

(arrowed)

11.28b Withdrawing the heater matrix

11.27 Removing the footwell vent from the

base of the heater casing

11.25 Exploded view of the heater matrix

connections

A Cover plate
B Gasket
C Heater matrix

connector pipe

D Hose clips
E Heater hoses
F Screw

11.28a Unclipping the lower heater casing

cover

1595Ford Fiesta Remake

1595Ford Fiesta Remake

General

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear-mounted fuel tank, mechanical fuel pump, single Weber
carburettor

Carburettor

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single or twin choke, downdraught

Application:

1.0 litre HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (1V) TLM

1.1 litre HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (2V) TLDM

1.3 HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (2V) TLDM

1.4 litre CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (2V) DFTM

1.6 litre CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (2V) TLD

Fuel grade

Fuel octane requirement:

Engines without catalytic converter* . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded or 97 RON leaded

Engines with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded (leaded fuel must not be used)

*Refer to dealer for latest recommendations

Chapter 4 Part A:
Fuel system - carburettor engines

Accelerator cable (CTX automatic transmission models) -

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator cable (instruction transmission models) - removal, refitting

and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . .

Accelerator pump diaphragm (Weber TLM carburettor) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Automatic choke (Weber TLD carburettor) - adjustment . . . . . . . . . 33
Automatic choke (Weber TLD carburettor) - removal, inspection

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Carburettor (Weber DFTM) - description . . . . . . . . . . . . . . . . . . . . . 25
Carburettor (Weber DFTM) - dismantling, cleaning, inspection

and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Carburettor (Weber DFTM) - fast-idle speed adjustment  . . . . . . . . . 26
Carburettor (Weber DFTM) - removal and refitting  . . . . . . . . . . . . . . 28
Carburettor (Weber TLD) - description  . . . . . . . . . . . . . . . . . . . . . . . 30
Carburettor (Weber TLD) - dismantling, cleaning, inspection

and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Carburettor (Weber TLD) - fast-idle speed adjustment . . . . . . . . . . . 31
Carburettor (Weber TLD) - removal and refitting . . . . . . . . . . . . . . . . 35
Carburettor (Weber TLDM) - description . . . . . . . . . . . . . . . . . . . . . . 18
Carburettor (Weber TLDM) - dismantling, cleaning, inspection and

reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Carburettor (Weber TLDM) - fast-idle speed adjustment  . . . . . . . . . 19
Carburettor (Weber TLDM) - removal and refitting  . . . . . . . . . . . . . . 23
Carburettor (Weber TLM) - description  . . . . . . . . . . . . . . . . . . . . . . . 12

Carburettor (Weber TLM) - dismantling, cleaning, inspection and

reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Carburettor (Weber TLM) - fast-idle speed adjustment  . . . . . . . . . . 13
Carburettor (Weber TLM) - removal and refitting  . . . . . . . . . . . . . . . 15
Choke cable - removal, refitting and adjustment  . . . . . . . . . . . . . . .

Fuel gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . .

Fuel pump - testing, removal and refitting . . . . . . . . . . . . . . . . . . . .

Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . .

Fuel tank filler pipe - removal and refitting  . . . . . . . . . . . . . . . . . . . . 11
Fuel tank ventilation tube - removal and refitting  . . . . . . . . . . . . . . . 10
General fuel system checks  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . .

Idle speed and mixture check and adjustment . . . . . . . .See Chapter 1
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 37
Needle valve and float (Weber TLD carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 32

Needle valve and float (Weber TLDM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 20

Needle valve and float (Weber TLM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 14

Throttle kicker control solenoid (Weber TLDM carburettor) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Throttle kicker unit (Weber DFTM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 27

Throttle kicker unit (Weber TLDM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 21

Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . . .See Chapter 1

4A•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

Fuel pump

Delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.24 to 0.38 bars

Carburettor data

Weber (1V) TLM carburettor - 1.0 litre HCS engines

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3400 ± 100 rpm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26.0 ± 1.0 mm

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220

Weber (2V) TLDM carburettor - 1.1 litre HCS engines

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fast-idle speed:

Instruction transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2800 rpm

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

2600 rpm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.0 ± 1.0 mm

Throttle kicker speed:

Instruction transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1250 to 1350 rpm

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

1050 to 1150 rpm

Primary

Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 mm

28 mm

Main jet:

Instruction transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

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

112

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F113

F75

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195

155

Weber (2V) TLDM carburettor - 1.3 litre HCS engines

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500 rpm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.0 ± 1.0 mm

Throttle kicker speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1900 ± 100 rpm

Primary

Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 mm

20 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F113

F75

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

130

Weber (2V) DFTM carburettor - 1.4 litre CVH engines

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2800 ± 100 rpm

Choke pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 to 3.2 mm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 ± 0.5 mm

Throttle kicker speed:

Instruction transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1300 ± 50 rpm

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

1100 ± 50 rpm (in Neutral)

Primary

Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 mm

23 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

125

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210

155

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F22

F60

Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber (2V) TLD carburettor - 1.6 litre CVH engines

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1800 ± 50 rpm (on third step of fast-idle cam)

Choke pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 ± 0.5 mm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.0 ± 0.5 mm

Primary

Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

127

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F105

F71

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

125

Torque wrench settings

lbf ft

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 to 20

12 to 15

Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 to 20

12 to 15

4A•2 Fuel system – carburettor engines

1595Ford Fiesta Remake

General information and
precautions

General information

The fuel system on all models with

carburettor induction comprises a rear-
mounted fuel tank, a mechanical diaphragm
fuel pump, a carburettor and an air cleaner.

The fuel tank is mounted at the rear, under

the floorpan behind the rear seats. The tank
has a “ventilation-to-atmosphere system”
through a combined roll-over/anti-trickle fill
valve assembly, located in the left-hand rear
wheel arch. A filler neck sensing pipe, integral
with the fuel tank filler pipe, will shut off the
petrol pump filler gun when the predetermined
maximum level of fuel is reached in the tank,
so preventing spillage and wastage. A
conventional fuel level sender unit is mounted
in the top face of the fuel tank.

One of two fuel pump types will be fitted,

depending on the engine type. On HCS
engines, the fuel pump is operated by a
pivoting rocker arm; one end rests on an
eccentric lobe on the engine camshaft, and
the other end is attached to the fuel pump
diaphragm. The pump fitted to the CVH
engine is operated by a separate pushrod,
one end rests on an eccentric lobe on the
engine camshaft, and the other rests on the
pump actuating rod which operates the
diaphragm. Both types of mechanical pump
incorporate a nylon mesh filter, and are of
sealed type (they cannot be serviced or
overhauled).

Four different types of Weber carburettor

are featured in the range, further details being
given in later Sections of this Chapter.

The air cleaner incorporates a “waxstat”

controlled air inlet, supplying either hot air
from a shroud mounted around the exhaust
manifold, or cool air from a duct in the front of
the vehicle.

Precautions

Warning: Petrol is extremely
flammable - great care must be
taken when working on any part

of the fuel system. Do not smoke or allow
any naked flames or uncovered light bulbs
near the work area. Note that gas powered
domestic appliances with pilot flames,
such as heaters, boilers and tumble
dryers, also present a fire hazard - bear
this in mind if you are working in an area
where such appliances are present.
Always keep a suitable fire extinguisher
close to the work area and familiarise
yourself with its operation before starting
work. Wear eye protection when working
on fuel systems and wash off any fuel spilt
on bare skin immediately with soap and
water. Note that fuel vapour is just as
dangerous as liquid fuel; a vessel that has
just been emptied of liquid fuel will still
contain vapour and can be potentially
explosive. Petrol is a highly dangerous and
volatile liquid, and the precautions
necessary when handling it cannot be
overstressed.

Many of the operations described in this

Chapter involve the disconnection of fuel
lines, which may cause an amount of fuel
spillage. Before commencing work, refer
to the above Warning and the information
in “Safety first” at the beginning of this
instruction.

When working with fuel system

components, pay particular attention to
cleanliness - dirt entering the fuel system
may cause blockages which will lead to
poor running.

Certain adjustment points in the fuel system

are protected by tamperproof caps, plugs or
seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty.

Carburettors are delicate instruments, and

care must be taken not to disturb any
components unnecessarily. Before attempting
work on a carburettor, ensure that the relevant
spares are available; it should be noted that a

complete strip down of a carburettor is
unlikely to cure a fault which is not
immediately obvious, without introducing new
problems. If persistent problems occur, it is
recommended that the services of a Ford
dealer or a carburettor specialist are sought.
Most dealers will be able to provide
carburettor rejetting and servicing facilities.
Where necessary, it may be possible to
purchase a reconditioned carburettor.

Air cleaner -
removal and refitting

Note: Air cleaner element renewal and air
cleaner temperature control system checks
are described in Chapter 1.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 On CVH engine models, pull free and
release the accelerator cable from the locating
clip on the side of the air cleaner.
3 Undo the two (HCS engine) or three (CVH
engine) retaining screws, and partially lift the
air cleaner from the carburettor so that the
hose and wiring connections to the underside
of the air cleaner body are accessible (see
illustration).
4 Note their connections and routings, then
detach the wiring multi-plug and hoses from
the underside of the air cleaner (see
illustrations). On CVH engines, also
disconnect the vacuum hose from the inlet
manifold.
5 Lift the air cleaner from the carburettor.
6 If required, the inlet air temperature sensor
can be unscrewed and removed from the
base of the air cleaner (where fitted).

Refitting

7 Refit in the reverse order of removal. Renew
any hoses that are perished or cracked, and
ensure that all fittings are securely and
correctly reconnected.

Fuel system – carburettor engines 4A•3

2.4b Disconnecting the intake air

temperature sensor multi-plug

(CVH engine shown)

2.4a Disconnecting the oil separator/

crankcase ventilation hose from the air

cleaner (CVH engine shown)

2.3 Undoing the air cleaner retaining

screws (HCS engine shown)

1595Ford Fiesta Remake

Content .. 23 24 25 26 ..