Ford Fiesta (1989-1995). Instruction - part 29

tachometer and an exhaust gas analyser (CO
meter) will be required.
1 Check that the idle speed and mixture
settings are as specified (as described in
Chapter 1). These must be correct before
checking/adjusting the fast-idle speed.
2 Switch the engine off, then remove the air
cleaner as described in Section 2.
3 With the engine at its normal operating
temperature and a tachometer connected in
accordance with its manufacturer’s
instructions, hold the throttle linkage partly
open, then close the choke plate until the fast-
idle adjusting screw aligns with the third
(middle) step on the fast-idle cam (see
illustration). Release the throttle linkage so
that the fast-idle speed adjusting screw rests
on the cam. Release the choke plate. The
linkage will hold it in the fast-idle speed
setting position, as long as the accelerator
pedal is not depressed.
4 Without touching the accelerator pedal,
start the engine and record the fast-idle speed
achieved. If adjustment is required, turn the
fast-idle speed adjusting screw until the
specified fast-idle speed is obtained.
5 When the throttle linkage is opened, the
choke plate should return to its fully-open
position. If this does not happen, either the

engine is not at its normal operating
temperature, or the automatic choke
mechanism is faulty.
6 Switch off the engine and disconnect the
tachometer. Refit the air cleaner.

32 Needle valve and float (Weber

TLD carburettor) - removal,
refitting and adjustment

4

1 Refer to Section 20 and proceed as
described, noting the following difference.
2 In paragraph 4, ignore the instruction to
detach the choke cable (an automatic choke
is fitted to the TLD type carburettor). Instead,
clamp the coolant supply and return hoses
which lead to the automatic choke unit to
minimise coolant loss, then ensure that the
cooling system is not pressurised (see
Chapter 1). Identify then detach both of the
coolant hoses at the automatic choke
housing. Catch any coolant spillage in a
suitable container. 

Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the

engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
3 On completion, reconnect the hoses to the
automatic choke unit, and remove the clamps
from the hoses. Check and top-up the coolant
level on completion (see “Weekly Checks” and
Chapter 1).

33 Automatic choke (Weber

TLD carburettor) - adjustment

3

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 coolant hoses to the choke
unit as described in paragraph 2 of the
previous Section.
4 Note the position of the choke coil housing
alignment marks, then undo the three
retaining screws and withdraw the automatic
choke bi-metal coil housing (see illustration).
5 Remove the inner heat shield (see
illustration). To check and adjust the choke
vacuum pull-down, secure the choke plate
lever in the closed position by fitting a rubber
band, open the throttle to allow the choke
plate to fully close, then release the throttle.
6 Using a screwdriver, push the operating
arm to the right against its spring, and
measure the clearance between the lower
edge of the choke plate and the venturi using
a twist drill or other suitable gauge rod (see
illustration). Where the clearance is outside
that specified, remove the plug from the
diaphragm housing, and turn the adjusting
screw (now exposed) in the required direction.
7 Fit a new diaphragm housing plug and
remove the rubber band.
8 Refit the heat shield so that its slotted hole
engages over the choke housing peg.
9 Refit the bi-metal coil housing by first
connecting the bi-metal spring to the choke
lever (ensuring correct engagement), locate
the housing and hand-tighten the three
retaining screws. Rotate the housing to align
the index line on the housing with the dot
mark on the choke main body, then retighten
the retaining screws.
10 Reconnect the coolant hoses with
reference to paragraph 3 in the previous
Section.
11 Refit the air cleaner as described in
Section 2.

4A•16 Fuel system – carburettor engines

33.6  Choke plate pull-down adjustment

(Weber TLD carburettor)

A Twist drill

C Adjusting screw

B Diaphragm held fully open

33.5  Automatic choke internal heatshield

(Weber TLD carburettor)

33.4  Automatic choke housing alignment

(Weber TLD carburettor)

A Dot punch mark
B Choke housing alignment mark

1595Ford Fiesta Remake

31.3  Fast-idle speed adjustment 

(Weber TLD carburettor) (Housing cut

away for illustration clarity)

A Fast-idle cam
B Fast-idle speed adjusting screw on third

step of cam

34 Automatic choke (Weber

TLD carburettor) - removal,
inspection and refitting

4

Note: Refer to the warning note in Section 1
before proceeding. A new carburettor upper
body gasket will be required when
reassembling. On completion, a tachometer
will be required to check the fast-idle speed
adjustment.

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 To prevent excess coolant loss, clamp the
coolant supply and return hoses to the
automatic choke unit, and ensure that the
cooling system is not pressurised (see
Chapter 1). Identify then detach both of the
coolant hoses at the automatic choke
housing. Catch any coolant spillage in a
suitable container. 

Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the

engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
4 Detach the fuel pipe and the anti-dieseling
solenoid wiring connector. Any crimped type
hose clips must be replaced with a screw
clamp type clips during reassembly.
5 Unscrew and remove the retaining screws

(two conventional, and four Torx type), then lift
the carburettor upper body clear and remove it.
6 Note the position of the choke housing
alignment marks, then undo the three retaining
screws and remove the choke bi-metal coil
unit. Remove the internal heat shield.
7 To remove the automatic choke unit, undo
the three retaining screws and detach the
choke link from the operating lever (see
illustration).
8 Undo the three retaining screws to remove
the vacuum diaphragm unit.
9 If dismantling the choke mechanism any
further, note the component fitment as an aid
to reassembly, but do not detach the choke
spindle.

Inspection

10 Clean and inspect all components for
wear, damage and/or distortion. Pay
particular attention to the condition of the
vacuum (pull-down) diaphragm and the choke
housing O-ring. Renew any items that are
defective (or suspect).

Refitting

11 Reassemble the automatic choke
mechanism, making references to the notes
taken during dismantling. Note that no
lubricants must be used (see illustration).
12 Refit the vacuum unit, making reference to
the notes taken during dismantling. Ensure
that the diaphragm is lying flat before
tightening the housing retaining screws.
13 Locate the O-ring (ensuring that it is
correctly seated), then reconnect the choke
link. Refit the automatic choke unit, and secure
with the retaining screws. Check and adjust
the choke vacuum pull-down as described 
in the previous Section (paragraphs 5 and 6).
14 Refit the inner heat shield, ensuring that
the location peg is securely engaged in its
notch.
15 Refit the automatic choke housing and the
bi-metal spring unit as described in the
previous Section (paragraph 9).
16 Refit the carburettor upper body, ensuring
that a new gasket is used and that the mating
surfaces are clean. Fit the retaining screws to
secure.
17 Reconnect the fuel hose to the carburettor,
using new screw type hose clips to secure it.
18 Reconnect the anti-dieseling solenoid
wiring connector.
19 Reconnect the coolant hoses to the
automatic choke unit, then check and if

necessary top-up the cooling system as
described in “Weekly Checks” and Chapter 1.
20 Reconnect the battery negative lead, then
check and adjust the fast-idle speed as
described in Section 31.
21 Refit the air cleaner (Section 2).

35 Carburettor (Weber TLD) -

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 Release any pressure remaining in the
cooling system (see Chapter 1), and then
detach the two coolant hoses from the
automatic choke unit. Catch any coolant
spillage in a suitable container. Identify each
hose for subsequent refitting, then plug their
ends or position them as high as possible to
prevent coolant leakage. 

Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the

engine is hot, as there is a very great risk of
scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first be
released. Cover the cap with a thick layer of
cloth, to avoid scalding, and slowly unscrew
the filler cap until a hissing sound can be
heard. When the hissing has stopped,
showing that pressure is released, slowly
unscrew the filler cap further until it can be
removed; if more hissing sounds are heard,
wait until they have stopped before
unscrewing the cap completely. At all times,
keep well away from the filler opening.
4 Disconnect the accelerator cable from the
linkage at the carburettor, as described in
Section 3.
5 Detach the anti-dieseling solenoid wiring
connector.
6 Detach the fuel feed hose at the carburettor.

Fuel system – carburettor engines  4A•17

34.11  Exploded view of the automatic choke linkage (Weber TLD carburettor)

34.7  Automatic choke assembly 

(Weber TLD carburettor)

A Pull-down diaphragm housing
B Securing screws

4A

1595Ford Fiesta Remake

A Operating link/fast-idle 

cam

B Fast-idle cam return spring
C Spindle sleeve
D Connecting rod and lever 

assembly

E Pull-down kink
F Actuating lever
G Automatic choke housing

As it is detached, plug the end of the hose to
prevent excessive fuel spillage and the ingress
of dirt. Where a crimped type hose clip is fitted,
cut it free, taking care not to damage the hose;
a new screw type clip will need to be obtained
to replace the crimped clip during reassembly.
7 Disconnect the relevant vacuum pipes from
the carburettor. As they are detached, label
them to ensure correct reassembly.
8 Unscrew and remove the four Torx-type
retaining screws, and carefully lift clear the
carburettor from the inlet manifold (see
illustration). Remove the gasket.

Refitting

9 Clean the carburettor and the inlet manifold
mating faces.
10 Refit the carburettor in the reverse order of
removal, ensuring that a new gasket is fitted.
11 If they are perished or were damaged
during removal, renew the fuel and/or vacuum
hoses.
12 Reconnect the automatic choke unit
hoses, and then check/top-up the cooling
system if required, as described in “Weekly
Checks” and Chapter 1.
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.

36 Carburettor (Weber TLD) -

dismantling, cleaning,
inspection and reassembly

4

Proceed as described in Section 24, but

refer to the appropriate illustrations for the
TLD carburettor (see illustrations). The
following should also be observed:

a) When refitting the idle mixture adjustment

screw, make the initial adjustment by
screwing it fully into position (without
overtightening it), then unscrewing it by
three full turns.

b) Refer to Section 32 to adjust the needle

valve and float.

c) When the carburettor is reassembled and

refitted, check and adjust the idle speed
and mixture settings as described in
Chapter 1.

37 Inlet manifold - 

removal and refitting

4

Note: Refer to the warning note in Section 1
before proceeding.

Removal

1 Drain the cooling system as described in
Chapter 1.
2 Remove the carburettor as described in the
relevant earlier Sections of this Chapter,
according to carburettor type.
3 Noting their locations, disconnect the
coolant, vacuum and breather hoses from the
manifold.
4 Disconnect the wiring multi-plugs from the
engine sensors at the inlet manifold.
Disconnect the radio earth lead at the inlet
manifold connector.
5 Undo the retaining bolts, and withdraw the
manifold from the cylinder head. Remove the
gasket.
6 With the manifold removed, clean all traces
of the old gasket from the mating surfaces of
the manifold and the cylinder head.

Refitting

7 Refitting is the reversal of removal. Use a
new gasket, and tighten the retaining bolts to
the specified torque. Refit the remainder of the
components with reference to the appropriate
Chapters of this instruction. On completion, 
refill the cooling system as described in
Chapter 1.

36.1c  Float level adjustment (Weber TLD

carburettor)

A Float level setting dimension
B Adjusting tag

36.1b  Jet arrangement in carburettor

upper body (Weber TLD carburettor)

A Primary air correction jet
B Secondary air correction jet
C Secondary main jet
D Primary main jet

4A•18 Fuel system – carburettor engines

36.1a  Exploded view of the carburettor (Weber TLD)

A Emulsion tubes
B Air correction jets
C Automatic choke 

assembly

D Choke pull-down

diaphragm

E Main jets
F Secondary barrel

diaphragm assembly

G Power valve diaphragm
H Accelerator pump

diaphragm

J Idle mixture adjusting

screw

K Fuel feed filter
L Needle valve assembly
M Anti-dieseling (fuel cut-off)

solenoid

35.8  General view of Weber TLD

carburettor

A Torx head screws securing carburettor to

inlet manifold

B Standard screws securing upper body to

main body

1595Ford Fiesta Remake

4B

1595Ford Fiesta Remake

General

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

Central Fuel injection (CFi)

Application  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 and 1.3 litre HCS engines and 1.4 litre CVH engines

Fuel grade

Fuel octane requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded

Fuel system data

Regulated fuel pressure - engine running at idle speed  . . . . . . . . . . . . .

1.0 ± 0.1 bars

Hold pressure - engine stopped after 1 minute  . . . . . . . . . . . . . . . . . . .

0.5 bars minimum

Torque wrench settings

Nm

lbf ft

CFi unit-to-inlet manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 to 15

9 to 11

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

16 to 20

12 to 15

Inlet air temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 to 25

15 to 18

Oxygen sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 to 70

37 to 52

Chapter 4 Part B:
Fuel system - central fuel injection engines

Accelerator cable - removal, refitting and adjustment  . . . . . . . . . . .

5

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

6

Air cleaner assembly and air inlet components - removal and 

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel cut-off switch - removal and refitting  . . . . . . . . . . . . . . . . . . . . 12
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel injection system - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injection system components - removal and refitting  . . . . . . . . 14
Fuel lines and fittings - general information  . . . . . . . . . . . . . . . . . . .

3

Fuel pump/fuel gauge sender unit - removal and refitting  . . . . . . . .

9

Fuel pump/fuel pressure - checking  . . . . . . . . . . . . . . . . . . . . . . . . .

7

Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

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

8

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  . . . . . . . . . . . . . . . . . . . . . . . .

1

Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 15
Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1

4B•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

5

4

3

2

1