Ford New Fiesta: 1983-85 Autobook

224 Pages·160.646 MB·English

by  Bloomsbury Publishing Plc

OWNERS WORKSHOP MANUAL
NEW FIESTA
Ford New Fiesta 1.0 Dash, Popular,
Popular Plus, L; 1.1 Dash, Popular Plus, L,
Ghia; 1.3L, Ghia; 1.6 XR2; 1.6 Diesel
Popular Plus, L
1983-85
OWM948
Gag -assa
, FC<2-
EAST SUSSEX COUNTY LIBRARY
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Digitized by the Internet Archive
in 2022 with funding from
Kahle/Austin Foundation
https://archive.org/details/fordnewfiesta1980000unse
FORD NEW FIESTA
1983—85 Autobook
By the Autobooks Team
of Writers and Illustrators
Ford New Fiesta 1.0 Dash, Popular,
Popular Plus, L 1983-85
Ford New Fiesta 1.1 Dash, Popular Plus,
L, Ghia 1983-85
Ford New Fiesta 1.3 L, Ghia 1984-85
Ford New Fiesta 1.6 XR2 1984-85
Ford New Fiesta 1.6 Diesel Popular Plus,
L 1984-85
TX Autobooks
ZV A & C Black • London
The Autobook
series of
Workshop Manuals
is the
largest in the world
and covers
the majority of
British and Continental
motor cars
as well as the
majority of
Japanese and
Australian models
Whilst every care has been taken
to ensure correctness
of information
it is obviously not possible to
guarantee complete freedom
from errors or omissions
or to accept liability
arising from
such errors or omissions
EAST SUSSEX
v. ! w i ' 671^
j I Gas assaa for
i ^C>i52. i “731
ISBN 0 7136 2514 7 ; u “ , , ' ~~~,,‘
COUNTY LIBRARY
First Edition 1985 L——■— ---------------------------------------------•
© A & C Black (Publishers) Ltd. 1985
All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without the
prior permission of A & C Black (Publishers) Ltd.
948
Printed in Great Britain by G. Beard and Son Ltd. A
Contents
Anglo American Glossary Page 6
Introduction Page 7
Chapter 1 The Pushrod Operated OHV Engine Page 9
1 : 1 Description 1 : 7 Removing and refitting the 1 : 12 Pistons and connecting rods
1 : 2 Maintenance cylinder head 1 : 13 The flywheel
1 : 3 Valve clearance adjustment 1 : 8 Servicing the head and valve 1 : 14 Crankshaft oil seals
1 : 4 The oil filter gear 1 : 15 Crankshaft and main bearings
1 : 5 Removing and refitting the 1 : 9 Camshaft and timing gear 1 : 16 The cylinder block
engine 1 : 10 Sump removal and refitment 1 : 17 Mountings
1 : 6 Dismantling and reassembling 1 : 11 The oil pump 1 : 18 Faultdiagnosis
the engine
Chapter 2 The CVH Overhead Camshaft Engine Page 21
2 : 1 Description 2 : 6 Removing and refitting 2 : 12 The oil pump
2 : 2 Maintenance thecylinderhead 2 : 13 Pistons and connecting rods
2 : 3 The oil filter 2 : 7 Servicing the head and 2 : 14 The flywheel
2 : 4 Removing and refitting the valve gear 2 : 15 Crankshaft oil seals
engine 2 : 8 Hydraulic tappets 2 : 16 Crankshaft and main bearings
2 : 5 Dismantling and reassembling 2 : 9 Camshaft and camshaft drive 2 : 17 The cylinder block
the engine 2 : 10 The cooling system pump 2 : 18 Mountings
2 : 11 Sump removal and refitment 2 : 19 Faultdiagnosis
Chapters The Diesel Engine Page 37
3 : 1 Description 3 : 8 Removing and refitting the 3 : 14 The injection pump drive
3 : 2 Maintenance sump and the oil intake and timing casing
3 : 3 The oil filter 3 : 9 The pistons and connecting 3 : 15 The oil pump
3 : 4 Valve clearance adjustment rods 3 : 16 The crankshaftand main
3 : 5 Removing and refitting the 3 : 10 Removing and refitting the bearings
cylinder head engine 3 : 17 The cylinder block
3 : 6 The camshaft and tappets 3 : 11 The flywheel 3 : 18 Reassembling the engine
3 : 7 Servicing the cylinder head 3 : 12 Dismantling the engine 3 : 19 The mountings
3 : 13 The camshaft drive 3 : 20 Faultdiagnosis
Chapter 4 The Fuel System Page 51
4 : 1 Description 4 : 5 Fuel pump (carburetter 4 : 9 Weber twin venturi
4 : 2 Maintenance models) carburetter
4 : 3 Air cleaner 4 : 6 Carburetter controls 4 : 10 Diesel fuel injection system
4 : 4 Fuel tank and gauge sender 4 : 7 Ford single venturi 4 : 11 Exhaust system
unit carburetter 4 : 12 Faultdiagnosis
4 : 8 Ford variable venturi
carburetter
Chapters The Ignition System Page 71
5 : 1 Description 5 : 5 The contact breaker type 5 : 8 Spark sustain system
5 : 2 Maintenance distributor 5 : 9 Timing the ignition
5 : 3 Ignition faults 5 : 6 The breakerless type 5 : 10 Sparking plugs
5 : 4 The coil distributor 5 : 11 Faultdiagnosis
5 : 7 Ignition amplifier module
Chapter6 The Cooling System Page 83
6 : 1 Description 6 : 5 The diesel engine coolant 6 : 8 The cooling fan
6 : 2 Maintenance pump 6 : 9 Frost precautions
6 : 3 The OHV engine coolant pump 6 : 6 The thermostat 6 : 10 Fault diagnosis
6:4 The CVH engine coolant pump 6 : 7 The radiatorand degas tank
Chapter? The Clutch Page 91
7 : 1 Description 7 : 3 Clutch release mechanism 7:6 Refitting the clutch
7 : 2 Maintenance 7 : 4 Removing the clutch 7 : 7 Fault diagnosis
7 : 5 Servicing the clutch
Chapters The Transmission Page 95
8 : 1 Description 8 : 5 4-speed transmission 8 : 7 5-speed transmission
8 : 2 Maintenance dismantling dismantling
8 : 3 The gearchange linkage 8 : 6 4-speed transmission 8 : 8 5-speed transmission
8:4 Transmission removal and reassembly reassembly
refitment 8 : 9 Fault diagnosis
Chapter 9 The Drive Shafts, Front Suspension and Hubs Page 111
9 : 1 Description 9 : 4 Drive shafts 9 : 7 Suspension units
9 : 2 Maintenance 9 : 5 Lower arms 9 : 8 Camberand caster angles
9:3 Hubs 9 : 6 Tie bars 9 : 9 Fault diagnosis
Chapter 10 The Rear Suspension and Hubs Page 119
10 : 1 Description 10 : 4 Stabiliser bar and connecting 10 : 7 Dampers
10 : 2 Maintenance links 10 : 8 Springs and bump stops
10 : 3 Hubs 10 : 5 Panhard rod 10 : 9 Axle
10 : 6 Lower arms 10 : 10 Fault diagnosis
Chapter 11 The Steering Gear Page 123
11:1 Description 11 : 4 Bellows renewal 11 : 7 Steering unit overhaul
11:2 Maintenance 11 : 5 Tie rods 11:8 Steering column
11:3 Tie rod end renewal 11 : 6 Steering unit removal and 11 : 9 Wheel alignment
refitment 11 : 10 Fault diagnosis
Chapter 12 The Braking System Page 129
12 : 1 Description 12 : 5 The pressure proportioning 12 : 8 Bleeding the hydraulic
12 : 2 Maintenance valves system
12:3 The front brakes 12 : 6 The hydraulic system 12 : 9 The handbrake
12 : 4 The rear brakes 12 : 7 The servo unit 12 : 10 Faultdiagnosis
Chapter 13 The Electrical Equipment Page 141
13 : 1 Description 13 : 5 The alternator and drive 13 : 9 Instruments and warning
13:2 The battery 13 : 6 The headlamps and lighting lights
13:3 Fuses, relaysand flasher circuits 13 : 10 Switches
unit 13 : 7 Wipers and washers 13 : 11 Sender units
13 : 4 The starter motor 13 : 8 Horn 13 : 12 Faultdiagnosis
Chapter 14 The Bodywork Page 159
14:1 Bodywork finish 14 : 6 The tailgate 14 : 11 Seat belts
14:2 Raising and supporting the 14 : 7 Door trim 14 : 12 The facia crash pad
vehicle 14 : 8 Doors and door components 14 : 13 The heater and ventilation
14 : 3 The bumpers and spoilers 14 : 9 Door window glass system
14:4 Thefrontgrille 14 : 10 The windscreen, backlight 14 : 14 Towing
14:5 The bonnet and fixed quarterlight glass
Appendix Page 171
Metric Conversion Tables Page 172
Technical Data Page 173
Wiring Diagrams Page 189
Maintenance Summary Page 205
Hints on Maintenance and Overhaul Page 209
Glossary of Terms Page 211
Index Page 213
The Autobook, having been written and published in
England, is produced using all English phrases, terms,
spellings and component descriptions. Some of these
do, of course, differ from those in general use in
America and, therefore, in order to simplify the
identification of components, the following glossary
is provided.
Glossary
English American English American
Aerial Antenna Layshaft (of gearbox) Countershaft
Accelerator Gas pedal Leading shoe (of brake) Primary shoe
Alternator Generator Locks Latches
Anti-roll bar Stabiliserorsway bar Motorway Freeway, turnpike, etc
Battery Energizer Number plate License plate
Bodywork Sheet metal Paraffin Kerosene
Bonnet (engine cover) Hood Petrol Gasoline
Boot lid Trunk lid Petrol tank Gastank
Boot (luggage Trunk 'Pinking' 'Pinging'
compartment) Propeller shaft Driveshaft
Bottom gear 1st gear Quarter light Quarterwindow
Bulkhead Firewall Retread Recap
Cam follower or tappet Valve lifter ortappet Reverse Back-up
Carburetter Carburetor Rocker cover Valve cover
Catch Latch Roof rack Car-top carrier
Choke/venturi Barrel Saloon Sedan
Circlip Snap-ring Seized Frozen
Clearance Lash Side indicator lights Side marker lights
Crownwheel Ring gear (of differential) Side light Parking light
Disc (brake) Rotor/disk Silencer Muffler
Drop arm Pitman arm Spanner Wrench
Drop head coupe Convertible Sill panel (beneath doors) Rocker panel
Dynamo Generator (DC) Split cotter (for valve Lock (for valve spring
Earth (electrical) Ground spring cap) retainer)
Engineer's blue Prussian blue Split pin Cotter pin
Estate car Station wagon Steering arm Spindlearm
Exhaust manifold Header Sump Oil pan
Fast back (Coupe) Hardtop Tab washer Tang; lock
Fault finding/diagnosis Trouble shooting Tailgate Liftgate
Float chamber Float bowl Tappet Valve lifter
Free-play Lash Thrust bearing Throw-out bearing
Freewheel Coast Top gear High
Gudgeon pin Piston pin or wrist pin Trackrod (of steering) Tie-rod (or connecting rod)
Gearchange Shift Trailing shoe (of brake) Secondary shoe
Gearbox Transmission Transmission Whole drive line
Halfshaft Axleshaft Tyre Tire
Handbrake Parking brake Van Panel wagon/van
Hood Soft top Vice Vise
Hotspot Heat riser Wheel nut Lug nut
Indicator Turn signal Windscreen Windshield
Interiorlight Dome lamp Wing/mudguard Fender
6 NEW FIESTA —