Ford Fiesta (1989-1995). Manual - part 9

8 Fit a new oil filter into position on
the oil pump body, as described in Chap-
ter 1.
9 Lower the vehicle to the ground, and top-
up the engine oil as described in “Weekly
Checks”.

13 Oil pump - dismantling,

inspection and reassembly

Dismantling

1 To inspect the oil pump components for
excessive wear, undo the retaining bolts and
remove the cover plate from the pump body.
Remove the O-ring seal from the cover face
(see illustration).
2 Wipe the exterior of the pump housing
clean housing.

Inspection

3 Noting their orientation, extract and clean
the rotors and the inner body of the pump
housing. Inspect them for signs of severe
scoring or excessive wear, which if evident
will necessitate renewal of the complete
pump.
4 Using feeler gauges, check the clearances
between the pump body and the outer rotor,
the inner-to-outer rotor clearance, and the
amount of rotor endfloat (see illustrations).

5 Check the drivegear for signs of excessive
wear or damage.
6 If the clearances measured are outside the
specified maximum clearances and/or the
drivegear is in poor condition, the complete
pump unit must be renewed.

Reassembly

7 Refit the rotors into the pump (in their
original orientation), lubricate the rotors and
the new O-ring seal with clean engine oil, and
refit the cover. Tighten the retaining bolts to
the specified torque wrench setting.

14 Crankshaft oil seals -

renewal

Front oil seal

1 Remove the crankshaft pulley as described
in Section 8.
2 Using a suitable claw tool, extract the oil
seal from the timing chain cover, but take care
not to damage the seal housing. As it is
removed, note the fitted orientation of the seal
in the cover.
3 Clean the oil seal housing in the timing
chain cover. Lubricate the sealing lips of the
new seal and the crankshaft stub with clean
engine oil.
4 Locate the new seal into position so that it

is squarely located on the crankshaft stub and
in the housing, and is correctly orientated.
Drift it into position using a large socket,
another suitable tool, or the old seal, until the
new seal is flush with the edge of the timing
chain cover.
5 Lightly lubricate the rubbing surface of the
crankshaft pulley, then refit the pulley as
described in Section 8.

Rear oil seal

6 Remove the flywheel as described in
Section 16.
7 Using a suitable claw tool, lever the seal
from the rear seal housing (taking care not to
damage the housing). As it is removed, note
the fitted orientation of the seal.
8 Clean the seal housing, the crankshaft
rear flange face and the flywheel mating
surface.
9 One of two possible methods may be used
to insert the new oil seal, depending on the
tools available.
10 If Ford service tool No 21-011 is available,
lubricate the crankshaft flange and the oil seal
inner lip with clean engine oil. Position the
seal onto the service tool (ensuring correct
orientation), then press the seal into its
housing.
11 If the service tool is not available, remove
the engine sump (Section 11), then unscrew
the Torx-head bolts retaining the rear seal
housing in position, and remove the
seal housing from the rear face of the cylinder
block. New gaskets will be required for both
the seal housing and the sump when refitting.
Clean the seal housing seat and the mating
surfaces of the sump and the crankcase. To fit
the seal squarely into its housing without
damaging either component, place a flat
block of wood across the seal, then carefully
tap the seal into position in the housing (see
illustration). Do not allow the seal to tilt as it
is being fitted. Lubricate the crankshaft flange
and the oil seal inner lip with clean engine oil,
then with a new gasket located on the seal
housing/crankcase face, fit the housing into
position. Take care not damage the seal lips
as it is passed over the crankshaft rear flange

HCS engine in-car repair procedures 2A•9

13.4b Checking the inner rotor-to-outer

rotor clearance

13.4a Checking the outer body-to-rotor

clearance

13.1 Extract the O-ring from the groove in

the oil pump

14.11a Positioning the crankshaft rear oil

seal in its housing

13.4c Checking the rotor endfloat

1595Ford Fiesta Remake

(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

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 mounting

retaining nut and washer from the

suspension strut cup retaining plate

15.8 Unscrew and remove the engine

mounting side bolt (arrowed) from under

the wheel arch

14.11b Fitting the rear oil seal housing

with a new gasket in position on the rear

face of the cylinder block

1595Ford Fiesta Remake

rear, and lower the transmission bearer from
the vehicle. Note plate fitment, as applicable,
for reassembly.
14 Unscrew 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

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

1595Ford Fiesta Remake

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 settings

lbf ft

Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pump pick-up to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pump pick-up to pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cooler threaded sleeve to cylinder block . . . . . . . . . . . . . . . . . . . . .

Rear oil seal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cylinder head bolts:

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

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

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

Angle-tighten a further 90º

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle-tighten a further 90º

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

108

Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft toothed belt sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Rocker studs in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sump:

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

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

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nut to body (by suspension strut) . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1595Ford Fiesta Remake

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