Ford Fiesta (1989-1995). Instruction - part 28

the seal washer is removed together with the
valve (see illustration).
5 Undo the three screws securing the choke
mechanism, and detach it (see illustration).
6 Unscrew and remove the two air correction
jets from the underside of the upper body.
Note the size and location of each, to ensure
correct refitting.
7 Invert the upper body so that the emulsion
tubes can fall out of their apertures (above the
air correction jets). Remove the emulsion
tubes from their locations, again having noted
the size and location of each.
8 Unscrew and remove the main jets, again
having noted their fitted positions.
9 Dismantle the carburettor lower (main) body
as follows.
10 Prise free the accelerator pump discharge
tube, but take care not to damage it or the
carburettor body (see illustration).
11 Undo the four screws securing the
accelerator pump; remove the cover, followed
by the diaphragm and return spring (see
illustrations). The valve should come out on
the end of the return spring. Check that the
valve is complete and with its O-ring seal
(where applicable).
12 Undo the three retaining screws, and
remove the power valve unit. Remove the
cover and return spring, followed by the
diaphragm.
13 Where fitted, undo the retaining screws
and remove the throttle kicker unit from the
lower (main) body.

4A•12 Fuel system – carburettor engines

24.11c  . . . and the return spring and valve

assembly

24.11b  . . . followed by its diaphragm . . .

24.11a  Remove the accelerator pump

cover . . .

24.10  Carefully prising out the accelerator

pump discharge tube assembly

24.5  Undo the three screws securing the

choke mechanism (arrowed)

24.4  Withdrawing the anti-dieseling (fuel

cut-off) solenoid

1595Ford Fiesta Remake

24.2  Exploded view of the carburettor (Weber TLDM)

A Anti-dieseling (fuel cut-

off) solenoid

B Emulsion tubes
C Air-correction jets
D Choke pull-down

diaphragm assembly

E Instruction choke linkage
F Needle valve
G Float
H Fast-idle adjusting screw
J Idle speed adjusting

screw

K Idle mixture adjusting

screw

L Throttle plates
M Power valve assembly
N Accelerator pump

assembly

P Throttle kicker (if fitted)
Q Upper body gasket
R Main jets

14 Prise free and remove the tamperproof
seal, then unscrew and remove the idle
mixture adjustment screw.
15 Undo the retaining screws, and remove
the throttle housing from the carburettor main
body.

Cleaning and inspection

16 Wash the carburettor components,
drillings and passages with clean petrol, then
blow them dry using a low-pressure air line. A
high-pressure air line must not be applied to
the accelerator pump discharge assembly or
the pump supply valve, as they each contain a
rubber Vernay valve, and these can easily be
damaged under high pressure. Never use a
piece of wire for cleaning purposes.
17 Examine all of the carburettor
components for signs of damage or wear,
paying particular attention to the diaphragms,
throttle spindle and plates, needle valve and
mixture screw; the power valve jet is adjacent
to the primary main jet. Renew all
diaphragms, sealing washers and gaskets as
a matter of course.

Reassembly

18 Refit the throttle housing to the
carburettor main body (fitting a new gasket),
and secure with its retaining screws.
19 Refit the idle mixture adjustment screw.
Make an initial adjustment by screwing it fully
in (but do not overtighten or screw it onto its
seat), then unscrew it two full turns.
20 Where fitted, reassemble the throttle
kicker, ensuring that its diaphragm lies flat,
and that the relative position of the operating
link to the kicker cover is correct.
21 Fit the power valve, ensuring that its
diaphragm lies flat and the vacuum 
gallery aligns with the diaphragm and
housing.
22 Refit the accelerator pump. Take care not
damage the valve as it is inserted, and check
that the O-ring seal is correctly located on the
end of the valve. Check that the valve is not
trapped by the spring.
23 Refit the accelerator pump discharge jet.
Take care not to damage the valve and/or the
O-ring seal, and ensure that they are correctly
located.
24 Commence reassembly of the upper body
by inserting the emulsion tubes and the air
correction jets into their respective ports (as
noted during removal).
25 Screw the anti-dieseling solenoid into
position. Ensure that the aluminium washer is
fitted, and take care not to overtighten the
valve.
26 Refit the needle valve and the float, and
adjust the float setting as described in Sec-
tion 20.
27 Refit the choke control mechanism, and
secure with its three retaining screws.
28 Locate a new gasket onto the mating
face, then refit the carburettor upper body to
the main body. As they are reassembled, take
care not to snag the float on the carburettor

main body. Fit and tighten the retaining
screws to secure.
29 On completion, refit the carburettor as
described in Section 23. Where applicable,
check and adjust the throttle kicker setting
(Section 21) after adjusting the idle speed and
mixture settings.

25 Carburettor (Weber DFTM) -

description

The carburettor operates in essentially the

same manner as TLDM instrument described
in Section 18, but the following features
should be noted.

A throttle kicker is fitted to both instruction

transmission, and CTX automatic trans-
mission models, the operation of the unit is
described in Section 18.

The secondary venturi (barrel) is vacuum-

operated on instruction transmission models. On
CTX automatic transmission equipped models
it is operated sequentially.

A bleed back solenoid (if fitted) is used to

control the amount of fuel being delivered to
the venturi by the action of the accelerator
pump.

Idle speed and mixture adjustment

procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.

26 Carburettor (Weber DFTM) -

fast-idle speed adjustment

4

Refer to the procedure contained in Sec-

tion 19, but note the following points:

a) When removing the air cleaner, do not

disconnect the vacuum supply or
crankcase ventilation hoses; the air
cleaner should be positioned clear of the
carburettor assembly.

b) The fast-idle adjusting screw is located 

on the side of the linkage (see
illustration).

27 Throttle kicker unit (Weber

DFTM carburettor) - removal,
refitting and adjustment

4

Refer to the procedure contained in Sec-

tion 21.

28 Carburettor (Weber DFTM) -

removal and refitting

4

Note: Refer to the warning note in Section 1
before proceeding. New gaskets will be
required on refitting, and a tachometer and an
exhaust gas analyser will be required on
completion.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Disconnect the choke cable from the
carburettor (Section 6).
4 Carefully prise out the accelerator link
retaining clip, remove both securing bolts,
then detach the cable and bracket assembly.
Position the cable and bracket assembly clear
of the carburettor.
5 Disconnect the fuel feed hose at the
carburettor, and plug its end to avoid spillage
and prevent dirt ingress. If a crimped type
hose clip is fitted, cut this free taking care not
to damage the hose.
6 Disconnect all relevant vacuum pipes from
the carburettor, having labelled them for
subsequent refitting.
7 Disconnect the electrical lead from the anti-
dieseling (fuel cut-off) solenoid, and the bleed
back solenoid (if fitted).
8 Remove the four nuts securing the
carburettor to the inlet manifold, then
withdraw it from the vehicle.

Refitting

9 Clean the carburettor and manifold gasket
mating faces.
10 Refit in the reverse order of removal. Fit a
new gasket, and tighten the retaining screws
securely. Ensure that the fuel supply 
hose connection to the carburettor is 
securely fitted, using a new screw type
retaining clip.
11 Reconnect the choke cable, and adjust it
as described in Section 6.
12 Refer to Section 2 and refit the air 
cleaner.
13 When the battery is reconnected, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.

Fuel system – carburettor engines  4A•13

26.1  Instruction choke fast-idle adjustment.

Inset shows fast-idle adjusting screw

(Weber DFTM carburettor)

4A

1595Ford Fiesta Remake

29 Carburettor (Weber DFTM) -

dismantling, cleaning,
inspection and reassembly

4

Note: Refer to the warning note in Section 1
before proceeding. Check parts avail-
ability before dismantling. If possible, obtain
an overhaul kit containing all the relevant
gaskets, seals, etc, required for reassembly
prior to dismantling the carburettor.

Dismantling

1 With the carburettor removed from the

vehicle, prepare a clean, flat work surface
prior to commencing dismantling. The
following procedures may be used for partial
or complete dismantling, as required.
2 Clean the exterior of the carburettor and
detach all vacuum pipes (where applicable),
having noted their fitted location for correct
subsequent reassembly.
3 Remove the six screws securing the
carburettor upper body, and detach it.
Discard the gasket (see illustration).
4 Dismantle the carburettor upper body as
described in the following paragraphs.
5 Remove the three screws securing the

choke pull-down diaphragm and detach it
(see illustration).
6 Unscrew the brass nut adjacent to the fuel
feed connection, and remove the fuel feed
filter.
7 Tap out the float retaining pin, then detach
the float and needle valve.
8 Unscrew and remove the needle valve
housing.
9 Dismantle the carburettor main body as
described in the following paragraphs.
10 Remove the main and idle jets, having
noted the size and fitted location of each one
to ensure correct subsequent reassembly.
Note that the main jets are a combined
assembly incorporating air correction jets and
emulsion tubes. Carefully prise out the
accelerator pump discharge tube.
11 Detach the throttle kicker and its
mounting bracket assembly.
12 Remove the anti-dieseling (fuel cut-off)
solenoid.
13 Remove the four screws securing the
accelerator pump assembly, and dismantle
the assembly noting the fitment of its
components 

(see illustration).

14 Disconnect the secondary barrel
diaphragm operating rod by pulling the lower
section of rod downwards and twisting to
release it from its retaining socket. Remove its
four cover retaining screws and dismantle the
assembly (see illustration).
15 Undo the three screws securing the
power valve assembly and remove its
diaphragm 

(see illustration).

4A•14 Fuel system – carburettor engines

29.15  Exploded view of the power valve

assembly (Weber DFTM carburettor)

A  Vacuum gallery      B  Diaphragm

29.14  Exploded view of the secondary

barrel diaphragm assembly

A Diaphragm

C Operating rod

B Return spring

29.13  Accelerator pump renewal 

(Weber DFTM carburettor)

A  Diaphragm      B  Housing (cover)

29.5  Choke pull-down assembly (A) and
fuel feed filter housing (B) (Weber DFTM

carburettor)

29.3  Exploded view of the carburettor (Weber DFTM)

A Instruction choke assembly
B Choke vacuum pull-down
C Secondary idle jet
D Secondary barrel

diaphragm assembly

E Idle speed adjusting 

screw

F Idle mixture adjusting

screw

G Accelerator pump

assembly

H Throttle kicker
J Power valve diaphragm
K Float

L Primary main jet combined

assembly

M Primary idle jet
N Needle valve
P Fuel feed filter
Q Secondary main jet

combined assembly

1595Ford Fiesta Remake

16 Prise out the tamperproof seal covering
the fuel mixture screw, then undo and remove
the mixture screw.

Cleaning and inspection

17 Wash the carburettor components,
drillings and passages with clean petrol, then
blow them dry using a low-pressure air line. A
high-pressure air line must not be applied to
the accelerator pump discharge assembly or
the pump supply valve, as they each contain a
rubber Vernay valve, and these can easily be
damaged under high pressure. Never use a
piece of wire for cleaning purposes.
18 Examine all of the carburettor
components for signs of damage or wear,
paying particular attention to the diaphragms,
throttle spindle and plates, needle valve and
mixture screw; the power valve jet is adjacent
to the primary main jet. Renew all
diaphragms, sealing washers and gaskets as
a matter of course.

Reassembly

19 Refit the fuel mixture screw by fully
winding the screw in, then unwinding three
turns to give an approximate setting.
20 Refit the power valve assembly ensuring
that the diaphragm lies flat, and that the
vacuum gallery lines up correctly with the
diaphragm and housing.
21 Reassemble the secondary barrel
diaphragm into its housing, ensuring that 
the diaphragm lies flat and that the vacuum
gallery lines up with the diaphragm and
housing. Also, to assist with installation, do
not reconnect its operating rod until the cover
has been secured.
22 Refit the throttle kicker mounting bracket.
23 Refit the anti-dieseling (fuel cut-off)
solenoid, using a new sealing washer.
24 Refit the accelerator pump assembly,
ensuring that the diaphragm lies flat and is not
kinked.
25 Reassemble the throttle kicker, ensuring
that the diaphragm lies flat and that the

relative position of the diaphragm operating
link to the throttle kicker cover is correct. Fully
attach the throttle kicker assembly.
26 Refit the main and idle jets, making
reference to the notes taken during
dismantling to ensure correct fitted locations.
27 Reassemble the carburettor upper body
as described in the following paragraphs.
28 Refit the needle valve housing (using a
new washer if applicable).
29 Refit the needle valve and float assembly,
having ensured that the float tag locates
below the spring clip on the needle valve.
Insert the float retaining pin to secure.
30 Adjust the float level as follows. Ensuring
that a new gasket is fitted to the carburettor
upper body, hold the upper body in the
vertical position; the needle valve must be
shut off. Measure the distance shown (see
illustration), and adjust by bending the float
tag if the measurement is outside the
specification. Recheck the float level
adjustment after bending the float tag, as
necessary.
31 Refit the choke pull-down diaphragm,
ensuring that the diaphragm lies flat and that
the vacuum gallery lines up correctly with the
diaphragm and housing (see illustration).
32 Adjust the choke pull-down as follows.
Fully close the choke, then instructionly push the
diaphragm operating rod up to its stop;
measure the distance between the
downdraught side of the choke plate and the
venturi, using a gauge rod or the shank of a
twist drill bit (of known size). If the
measurement is outside specification, remove
the tamperproof seal from the housing, and
adjust the now revealed adjustment screw
accordingly. Fit a new tamperproof seal after
successful adjustment.
33 Refit the fuel feed filter, and secure with
its brass nut and sealing washer.
34 Refit the carburettor upper body to the
carburettor main body, ensuring that its new
gasket seats correctly and that the float does
not foul during assembly. Insert and tighten
the securing screws.

35 Reconnect any vacuum pipes removed
during dismantling (where applicable).
36 On completion, refit the carburettor as
described in Section 28. Where applicable,
check and adjust the throttle kicker setting
(Section 27) after adjusting the idle speed and
mixture settings.

30 Carburettor (Weber TLD) -

description

This carburettor incorporates many of the

features of the TLDM type described in
Section 18. The main differences are that a
throttle kicker is not used, the secondary
venturi (barrel) is vacuum-operated, and that a
coolant-heated automatic choke control
system is fitted.

The choke system is fully automatic. When

the engine is cold, the bi-metal spring which
controls the position of the choke plate is fully
wound up, and holds the plate closed. As the
engine warms up, the bi-metal spring is
heated by the coolant and begins to unwind,
thereby progressively opening the choke
plate. A vacuum-operated pull-down
mechanism controls the choke plate under
certain operating conditions, and an internal
fast-idle system is incorporated.

Idle speed and mixture adjustment

procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.

31 Carburettor (Weber TLD) -

fast-idle speed adjustment

4

Note:  Before carrying out any carburettor
adjustments, ensure that the spark plug gaps
are set as specified, and that all electrical and
vacuum connections are secure. To carry out
checks and adjustments, an accurate

Fuel system – carburettor engines  4A•15

29.31  Exploded view of the choke pull-down assembly (Weber DFTM carburettor)

A  Housing       B  Diaphragm

29.30  Float level adjustment (Weber DFTM

carburettor)

A Float level setting dimension
B Adjusting tag

4A

1595Ford Fiesta Remake