Ford Fiesta (1989-1995). Instruction - part 7

2A

1595Ford Fiesta Remake

General

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

Four-cylinder, in-line overhead valve

Engine code:

1.0 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TLB

1.1 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GUE or GUD

1.1 litre CFi fuel injection models  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G6A

1.3 litre carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JBC

1.3 litre CFi fuel injection models  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J6B

Capacity:

1.0 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

999 cc

1.1 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1118 cc

1.3 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1297 cc

Bore:

1.0 and 1.1 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68.68 mm

1.3 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73.96 mm

Stroke:

1.0 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67.40 mm

1.1 and 1.3 litre models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.48 mm

Compression ratio:

Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5:1

CFi fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8:1

Firing order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2-4-3 (No 1 cylinder at timing chain end)

Direction of crankshaft rotation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise (seen from right-hand side of vehicle)

Valves

Valve clearance (cold):

Inlet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 mm

Exhaust  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 mm

Chapter 2 Part A:
HCS engine in-car repair procedures

Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . .See Chapter 1
Compression test - description and interpretation  . . . . . . . . . . . . . .

2

Crankshaft oil seals - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft pulley - removal and refitting  . . . . . . . . . . . . . . . . . . . . .

8

Cylinder head - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . .

7

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

4

Cylinder head rocker gear - removal, inspection and refitting  . . . . .

6

Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . .See “Weekly Checks”
Engine/transmission mountings - inspection and renewal  . . . . . . . . 15

Flywheel - removal, inspection and refitting  . . . . . . . . . . . . . . . . . . . 16
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 13
Oil pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing chain cover - removal and refitting  . . . . . . . . . . . . . . . . . . . .

9

Timing chain, sprockets and tensioner - removal, inspection 

and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

3

Valve clearances - checking and adjustment  . . . . . . . . . . . . . . . . . .

5

2A•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

Lubrication

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

See “Lubricants, fluids and tyre pressures”

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

See “Lubricants, fluids and tyre pressures”

Oil pressure:

At idle speed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.60 bars

At 2000 rpm  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.50 bars

Oil pump clearances:

Outer rotor-to-body  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.14 to 0.26 mm

Inner rotor-to-outer rotor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.051 to 0.127 mm

Rotor endfloat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025 to 0.06 mm

Torque wrench settings

Nm

lbf ft

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

5

4

Camshaft sprocket bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

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

115

85

Rocker shaft pedestal bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

32

Flywheel bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

49

Sump:

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

7

5

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

9

7

Stage 3 (with engine warm)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

7

Oil pressure switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

10

Cylinder head bolts (may be re-used once only):

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

30

22

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

Angle-tighten a further 90º

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

Angle-tighten a further 90º

Timing chain tensioner  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Timing chain cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

7

Crankshaft rear oil seal housing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

Rocker cover bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

4

Oil pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

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

9

7

Engine mountings:

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

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

2A•2 HCS engine in-car repair procedures

1595Ford Fiesta Remake

1

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 1.4 and 
1.6 litre CVH and PTE engines, and the 1.6
and 1.8 litre Zetec engines, will be found in
Parts B and C 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 engine is an overhead valve, water-

cooled, four cylinder in-line design,
designated HCS (High Compression Swirl).
The engine is mounted transversely at the
front of the vehicle together with the
transmission to form a combined power unit.

The crankshaft is supported in three or five

shell-type main bearings. The connecting rod
big-end bearings are also split shell-type, and
are attached to the pistons by interference-fit
gudgeon pins. Each piston is fitted with two
compression rings and one oil control ring.

The camshaft, which runs on bearings

within the cylinder block, is chain-driven from
the crankshaft, and operates the valves via
pushrods and rocker arms. The valves are
each closed by a single valve spring, and
operate in guides integral in the cylinder head.

The oil pump is mounted externally on the

crankcase, incorporates a full-flow oil filter,
and is driven by a skew gear on the camshaft.
On carburettor versions, the fuel pump is also
driven from the camshaft, via an eccentric
lobe.

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.

b)

Cylinder head rocker cover - removal
and refitting.

c)

Valve clearances - adjustment.

d)

Rocker shaft assembly - removal,
inspection and refitting.

e)

Cylinder head - removal and refitting

f)

Cylinder head and pistons -
decarbonising.

g)

Crankshaft pulley - removal and refitting.

h)

Crankshaft oil seals - renewal.

i)

Timing chain, sprockets and tensioner -
removal, inspection and refitting.

j)

Oil filter renewal.

k)

Oil pump - removal and refitting.

l)

Sump - removal and refitting.

m)

Flywheel - removal, inspection and
refitting.

n)

Engine/transmission mountings -
inspection and renewal.

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.

2

Compression test -
description and interpretation

2

1 When engine performance is down, or if
misfiring occurs which cannot be attributed to
the ignition or fuel systems, a compression
test can provide diagnostic clues as to the
engine’s condition. If the test is performed
regularly, it can give warning of trouble before
any other symptoms become apparent.
2 The engine must be fully warmed-up to
normal operating temperature, the oil level
must be correct and the battery must be fully
charged. The aid of an assistant will also be
required.
3 On fuel injection engines, refer to Chap-
ter 12 and remove the fuel pump fuse from the
fusebox. Now start the engine and allow it to
run until it stalls.
4 Disable the ignition system by
disconnecting the multi-plug from the DIS or
E-DIS ignition coil. Remove all the spark plugs
with reference to Chapter 1 if necessary.
5 Fit a compression tester to the No 1
cylinder spark plug hole - the type of tester
which screws into the plug thread is to be
preferred.
6 Arrange for an assistant to hold the
accelerator pedal fully depressed to the floor,
while at the same time cranking the engine
over for several seconds on the starter motor.
Observe the compression gauge reading. The
compression will build up fairly quickly in a
healthy engine. Low compression on the first
stroke, followed by gradually-increasing
pressure on successive strokes, indicates
worn piston rings. A low compression on the
first stroke which does not rise on successive
strokes, indicates leaking valves or a blown
head gasket (a cracked cylinder head could
also be the cause). Deposits on the underside
of the valve heads can also cause low
compression. Record the highest gauge
reading obtained, then repeat the procedure
for the remaining cylinders.
7 Due to the variety of testers available, and
the fluctuation in starter motor speed when
cranking the engine, different readings 
are often obtained when carrying out 
the compression test. For this reason, actual
compression pressure figures are not quoted
by Ford. However, the most important factor
is that the compression pressures are uniform
in all cylinders, and that is what this test is
mainly concerned with.
8 Add some engine oil (about three squirts
from a plunger type oil can) to each cylinder
through the spark plug holes, and then repeat
the test.

9 If the compression increases after the oil is
added, it is indicative that the piston rings are
definitely worn. If the compression does not
increase significantly, the leakage is occurring
at the valves or the head gasket. Leakage
past the valves may be caused by burned
valve seats and/or faces, or warped, cracked
or bent valves.
10 If two adjacent cylinders have equally low
compressions, it is most likely that the head
gasket has blown between them. The
appearance of coolant in the combustion
chambers or on the engine oil dipstick would
verify this condition.
11 If one cylinder is about 20 percent lower
than the other, and the engine has a slightly
rough idle, a worn lobe on the camshaft could
be the cause.
12 On completion of the checks, refit the
spark plugs and reconnect the HT leads and
the ignition coil plug. Refit the fuel pump fuse
to the fusebox.

3

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

2

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
at the end of the compression stroke for No 1
piston is used. On the HCS engine, No 1
cylinder is at the crankshaft pulley/timing
chain end of the engine. Proceed as follows.
2 Ensure that the ignition is switched off.
Disconnect the HT leads from the spark plugs,
then unscrew and remove the plugs as
described in Chapter 1.
3 Turn the engine over by hand (using a
spanner on the crankshaft pulley) to the point
where the timing mark on the crankshaft
pulley aligns with the TDC (0) mark or TDC
reference pointer on the timing cover (see
illustration). As the pulley mark nears the
timing mark, the No 1 piston is simultaneously
approaching the top of its cylinder. To ensure
that it is on its compression stroke, place a
finger over the No 1 cylinder plug hole, and

feel to ensure that air pressure exits from the
cylinder as the piston reaches the top of its
stroke.
4 A further check to ensure that the piston is
on its compression stroke can be made by
first removing the air cleaner (refer to the
relevant Part of Chapter 4), then unbolting and
removing the rocker cover, so that the
movement of the valves and rockers can be
observed.
5 With the TDC timing marks on the
crankshaft pulley and timing cover in
alignment, rock the crankshaft back and forth
a few degrees each side of this position, and
observe the action of the valves and rockers
for No 1 cylinder. When No 1 piston is at the
TDC firing position, the inlet and exhaust valve
of No 1 cylinder will be fully closed, but the
corresponding valves of No 4 cylinder will be
seen to rock open and closed.
6 If the inlet and exhaust valves of No 1
cylinder are seen to rock whilst those of 
No 4 cylinder are shut, the crankshaft will
need to be turned one full rotation to bring 
No 1 piston up to the top of its cylinder on the
compression stroke.
7 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 (in its
normal direction of rotation), 180º at a time,
and following the firing order (see
Specifications).

4

Cylinder head rocker cover -
removal and refitting

1

Removal

1 Where necessary for access, remove the air
cleaner as described in the relevant Part of
Chapter 4.
2 Detach the HT leads from the spark plugs.
Pull on the connector of each lead (not the
lead itself), and note the order of fitting.
3 Remove the engine oil filler cap and
breather hose (where fitted).
4 Unscrew the four retaining bolts, and lift the
rocker cover clear of the cylinder head.
Remove the gasket.

HCS engine in-car repair procedures  2A•3

3.3  Timing mark on the crankshaft pulley aligned with the TDC (0) mark on the timing

cover

2A

1595Ford Fiesta Remake

Refitting

5 Thoroughly clean the rocker cover, and
scrape away any traces of old gasket
remaining on the cover and cylinder head
mating surfaces.
6 Fit a new gasket to the rocker cover, then
refit the rocker cover (see illustrations).
Tighten the cover retaining bolts to the
specified torque wrench setting, in a diagonal
sequence.
7 Reconnect the HT leads, and refit the air
cleaner as described in Chapter 4.

5

Valve clearances - 
checking and adjustment

2

Note: The valve clearances must be checked
and adjusted only when the engine is cold.
1 The importance of having the valve
clearances correctly adjusted cannot be
overstressed, as they vitally affect the
performance of the engine. If the clearances
are too big, the engine will be noisy
(characteristic rattling or tapping noises) and
engine efficiency will be reduced, as the
valves open too late and close too early. A
more serious problem arises if the clearances
are too small, however. If this is the case, the
valves may not close fully when the engine is
hot, resulting in serious damage to the engine
(eg. burnt valve seats and/or cylinder head
warping/cracking). The clearances are
checked and adjusted as follows.
2 Set the engine to TDC for No 1 piston, as
described in Section 3.
3 Remove the rocker cover as described in
Section 4.
4 Starting from the thermostat end of the
cylinder head, the valves are numbered as
follows:

Valve No

Cylinder No

1 - Exhaust

1

2 - Inlet

1

3 - Exhaust

2

4 - Inlet

2

5 - Inlet

3

6 - Exhaust

3

7 - Inlet

4

8 - Exhaust

4

5 Adjust the valve clearances following the
sequence given in the following table. Turn
the crankshaft pulley 180º (half a turn) after
adjusting each pair of valve clearances.

Valves “rocking”

Valves to adjust

7 and 8

1 (exhaust), 2 (inlet)

5 and 6

3 (exhaust), 4 (inlet)

1 and 2

8 (exhaust), 7 (inlet) 

3 and 4

6 (exhaust), 5 (inlet)

6 The clearances for the inlet and exhaust
valves differ (refer to the Specifications). Use a
feeler gauge of the appropriate thickness to
check each clearance between the end of the
valve stem and the rocker arm (see
illustration). The gauge should be a firm
sliding fit between the valve and rocker arm.
Where adjustment is necessary, turn the
adjuster bolt as required with a ring spanner
to set the clearance to that specified. The
adjuster bolts are of stiff-thread type, and
require no locking nut.
7 On completion, refit the rocker cover as
described in Section 4.

6

Cylinder head rocker gear -
removal, inspection and
refitting

2

Removal

1 Remove the rocker cover as described in
Section 4.
2 Unscrew the four retaining bolts, and lift the
rocker gear assembly from the cylinder head.
As the assembly is withdrawn, ensure that the
pushrods remain seated in their positions in
the engine.

Inspection

3 To dismantle the rocker shaft assembly,
extract the split pin from one end of the shaft,
then withdraw the spring and plain washers
from the shaft.
4 Slide off the rocker arms, the support
pedestals and coil springs from the shaft, but

take care to keep them in their original order
of fitting (see illustration).
5 Clean the respective components, and
inspect them for signs of excessive wear or
damage. Check that the oil lubrication holes in
the shaft are clear.
6 Check the rocker shaft and arm pads which
bear on the valve stem end faces for wear and
scoring, and check each rocker arm on the
shaft for excessive wear. Renew any
components as necessary.

Refitting

7 Apply clean engine oil to the rocker shaft
prior to reassembling.

2A•4 HCS engine in-car repair procedures

6.4  Rocker shaft partially dismantled for

inspection

5.6  Adjusting the valve clearances

4.6b  Refitting the rocker cover

4.6a  Engage tags of rocker cover gasket

into the cut-outs in the cover

1595Ford Fiesta Remake

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

If the pushrods are to be removed,
keep them in the correct order of fitting
by labelling them 1 to 8, starting from
the thermostat end of the cylinder
head, or locate them in a card.