Haynes Automotive Service Summaries Manual 1859604757, 9781859604755

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AUTOMOTIVE

SERVICE SUMMARIES MANUAL

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Automotive Summaries

Service

by James Robertson and lan Barnes The Haynes Manual for Service Schedules, servicing specifications, capacities and component locations

(3475-320)

Sparkford: Haynes, c1998

ABCDE FGHIJ KLMNO PQRST

© Haynes Publishing 1998

1859604757

Printed by J H Haynes & Co Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes Publishing

A book in the Haynes Service and Repair Manual Series

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system,

Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA

ISBN 1 85960 475 7

Editions Haynes S.A. Tour Aurore - La Défense 2, 18 Place des Reflets, 92975 PARIS LA DEFENSE Cedex, France

British Library Cataloguing in Publication Data A catalogue record for.this book is available from the British Library.

Haynes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, Sweden

without permission in writing from the copyright holder.

SERVICE SCHEDULES The schedules given in this book are based on the vehicle manufacturers’ recommendations. Note however that these recommendations are subject to change, sometimes retrospectively. Vehicles which are subject to intensive use (taxi work, full-time towing, operation on unmade roads or in climatic extremes, etc) should be serviced more frequently - typically twice as often as vehicles in normal use. Consult the appropriate manufacturer if in doubt. Timing belt renewal intervals vary widely and sometimes apparently arbitrarily. Given the damage which can result if a timing belt breaks in service, we strongly recommend erring on the side of caution and observing a shorter renewal interval when this is suggested in the schedules.

ACKNOWLEDGEMENTS Thanks are due to Champion Spark Plug who provided spark plug and glow plug information. Thanks are also due to the people at Sparkford who helped in the production of this techbook, especially: Jeremy Churchill, Mark Coombs, Spencer Drayton, Andy Legg, Matthew Minter and Steve Rendle.

This manual is not a direct reproduction of the vehicle manufacturers’ data, and its publication should not be taken as implying any technical approval by the vehicle manufacturers or importers. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by errors in, or omissions from, the information given.

2

CONTENTS Page

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General repair procedures

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Toolssand working facilities

© 525-4 sons: wotceey

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BMW-1 CIT-1

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oe vencites

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REN-1 ROV-1 VAU-1

VOL-1 VOV-1

CONTENTS BMW 320, 320i, 323i & 325i

3- & 5-Series (3-Series - 1983 to

3-Series - 1991 to 1995

(6-cylinder) - 1977 to 1987

1991, 5-Series - 1981 to 1993)

§_(4-cyl), 1991 to 1996 (6-cy))

Service schedule Servicing specifications Capacities

Service schedule Servicing specifications Capacities

BMW-5 BMW-6 BMW-7

Service schedule Servicing specifications Capacities

Component locations

BMW-8

Component locations

Component locations

BMW-1 BMW-2 BMW-3 BMW-3

AX petrol and diesel -

Xantia petrol - 1993 to 1995

1987 to 1994

BMW-9 BMW-10 BMW-11 BMW-11

ZX petrol - 1991 to 1994

Service schedule

CIT-13

Service schedule

CIT-18

Service schedule

CIT-1

Servicing specifications

CIT-14

Servicing specifications

CIT-19

Servicing specifications Capacities

CIT-2 CIT-3

Capacities Component locations

CIT-14 CIT-15

Capacities Component locations

CIT-20 CIT-20

Sour perme oeaticls

CIT-3

_Xantia diesel - 1993 to 1995

—-_ZX diesel - 1991 to 1993

BX petrol - 1983 to Sept 1994

service schedule

CIT-16 _ Service schedule

CIT-23

Service schedule Servicing specifications Capacities Component locations

Capacities Servicing specifications Component locations

CIT-16 CIT-17 CIT-17

CIT-24 CIT-25 CIT-25

CIT-5 CIT-6 CIT-7 CIT-8

Servicing specifications Capacities ~ Component locations

BX diesel - 1983 to Sept 1994 Service schedule Servicing specifications Capacities Component locations

CIT-10 CIT-11 CIT-11 CIT-12

Punto petrol - 1994 to 1996

Uno petrol - 1983 to 1995

Service schedule Capacities

Panda - 1981 to 1995 FIA-1 FIA-1

Service schedule Servicing specifications

FIA-5 FIA-6

Service schedule Servicing specifications

FIA-10 FIA-12

Servicing specifications Component locations

FIA-3 FIA-4

Capacities Component locations

FIA-6

Capacities

FIA-13

FIA-7

Component locations

FIA-13

Punto diesel - 1994 to 1996 Service schedule Servicing specifications Capacities Component locations

FIA-8 FIA-9 FIA-9 FIA-9

MM 4

CONTENTS FORD Fiesta petrol - 1983 to 1989

Escort petrol - 1980 to 1990

Service schedule

FOR-1

Service schedule

FOR-19

-

Servicing specifications

FOR-2

Servicing specifications

FOR-20

Service schedule

Capacities

FOR-3

Capacities

FOR-21

Component locations

FOR-4

Component locations

FOR-22

Fiesta petrol - 1989 to 1995 — Orion petrol - 1983 to 1990

Sierra & Sapphire 4-cyl petrol 1982 to 1993

_ Servicing specifications

FOR-36

FOR-37

Capacities

FOR-38

Saibligs ek sls

erry

Service schedule

FOR-5

Service schedule

For-24

Mondeo petrol - 1993 to 1996

Servicing specifications Capacities Component locations

FOR-6 FOR-7 FOR-8

Servicing specifications Capacities Component locations

FOR-25 FOR-26 FOR-26

Service schedule Servicing specifications Capacities

FOR-42 FOR-43 FOR-43

ll

ee

Fiesta petrol - 1995 to 1997

Escort & Orion petrol -

Service schedule Servicing specifications Capacities

1990 to 1997 FoR-10 FOR-11 — Service schedule FOR-11 — Servicing specifications

Component locations

FOR-12

aN oat

Mondeo diesel - 1993 to 1996 FOR-45 FOR-27 _ Service schedule FOR-46 FOR-28 __ Servicing specifications

Capacities

FOR-29

Capacities

FOR-46

Fiesta diesel - 1984 to 1995

Component locations

FOR-29

Component locations

FOR-47

Service schedule

FoR-13

Escort & Orion diesel -

Servicing specifications Capacities Component locations

FOR-14 FOR-14 FOR-15

Fiesta diesel - 1995 to 1997

Service schedule Servicing specifications Capacities Component locations

FOR-16 FOR-17 FOR-17 FOR-18

Micra - 1983 to Jan 1993 Service schedule Servicing specifications Capacities Component locations

NIS-1 NIS-3 NIS-3 NIS-4

Granada & Scorpio petrol -

1990 to 1997 — Service schedule — Servicing specifications

FOR-33

1985 to 1994 _— Service schedule

FOR-48

FOR-34

_ Servicing specifications

FOR-49

' Capacities Component locations

FOR-34 FOR-35

Capacities Component locations

FOR-50 FOR-50

Sunny - Oct 1986 to Mar 1991 Service schedule Servicing specifications Capacities Component locations

NIS-8 NIS-9 NIS-10 NIS-10

Bluebird - March 1986 to 1990 Service schedule Servicing specifications Capacities Component locations

NIS-13 NIS-14 NIS-15 NIS-16

Micra - 1993 to 1996 Service schedule Servicing specifications Capacities Component locations

NIS-5 NIS-6 NIS-6 NIS-7

See ‘Vauxhall’

oO

CONTENTS PEUGEOT 106 petrol and diesel 1991 to June 1996 Service schedule Servicing specifications Capacities Component locations

PEU-1 PEU-2 PEU-3 PEU-3

205 petrol - 1983 to 1995 Service schedule Servicing specifications Capacities Component locations

PEU-5 PEU-6 PEU-7 PEU-7

205 diesel - 1983 to 1995 Service schedule Servicing specifications Capacities Component locations

PEU-9 PEU-10 PEU-10 PEU-11

19 petrol - 1989 to Service schedule Servicing specifications Capacities Component locations

309 diesel - 1986 to 1993

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

PEU-12 PEU-13 PEU-13 PEU-14

REN-1 REN-2 REN-3 REN-3

1994 REN-5 REN-6 REN-7 REN-7

405 petrol - 1988 to 1996

Service schedule Servicing specifications Capacities Component locations

Service schedule Capacities Servicing specifications Component locations

PEU-15 PEU-16 PEU-16 PEU-17

PEU-24 PEU-25 PEU-26 PEU-27

309 petrol - 1986 to 1993

405 diesel - 1988 to 1996

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

PEU-18 PEU-18 PEU-20 PEU-20

Service schedule Servicing specifications Capacities Component locations

REN-14 REN-15 REN-16 REN-16

Clio petrol - 1991 to 1993 Service schedule Servicing specifications Capacities Component locations

REN-18 REN-19 REN-20 REN-20

19 diesel - 1989 to 1995

Clio diesel - 1991 to 1996

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

REN-11 REN-12 REN-12 REN-13

PEU-22 PEU-23 PEU-23 PEU-23

306 diesel - 1993 to 1995

21 petrol - 1986 to 1994

5 petrol - 1985 to 1996 Service schedule Servicing specifications Capacities Component locations

306 petrol - 1993 to 1995

REN-22 REN-23 REN-23 REN-24

PEU-29 PEU-30 PEU-30 PEU-31

Megane petrol (1.4 & 1.6 litre) - 1996 to 1997 Service schedule Servicing specifications Capacities Component locations

REN-25 REN-26 REN-26 REN-27

Mégane diesel - 1996 to 1997 Service schedule Servicing specifications Capacities Component locations

REN-28 REN-29 REN-29 REN-30

CONTENTS ROVER Mini - 1969 to 1996 Service schedule Servicing specifications Capacities Component locations

ROV-1 ROV-2 ROV-3 ROV-4

Metro - 1980 to 1990 Service schedule Servicing specifications Capacities Component locations

ROV-5 ROV-6 ROV-8 ROV-8

Metro, 111 & 114 1990 to 1996 Service schedule Servicing specifications Capacities Component locations

ROV-9 ROV-10 ROV-10 ROV-11

Maestro 1.3 & 1.6 petrol 1983 to 1995 Service schedule Servicing specifications Capacities Component locations

ROV-13 ROV-15 ROV-16 ROV-17

Montego 1.3 & 1.6 petrol 1984 to 1994

214 & 414 petrol 1990 to 1995

Service schedule Capacities Servicing specifications Component locations

Service schedule Capacities Servicing specifications Component locations

ROV-18 ROV-19 ROV-20 ROV-21

Montego 2.0 petrol 1984 to 1994 Service schedule Servicing specifications Capacities Component locations

216 & 416 petrol 1989 to 1992 ROV-22 ROV-23 ROV-24 ROV-25

Maestro and Montego diesel 1986 to 1993 Service schedule Servicing specifications Capacities Component locations

ROV-26 ROV-27 ROV-27 ROV-28

213 & 216 - 1984 to 1989 Service schedule Capacities Servicing specifications Component locations

ROV-32 ROV-33 ROV-33 ROV-34

Service schedule Capacities Servicing specifications Component locations

ROV-35 ROV-36 ROV-36 ROV-37

820, 825 & 827 petrol 1986 to 1995 Service schedule Capacities Servicing specifications Component locations

ROV-38 ROV-39 ROV-40 ROV-41

ROV-29 ROV-30 ROV-30 ROV-31

Nova petrol - 1983 to 1993

Cavalier petrol - 1981 to 1988

Vectra petrol - 1995 to 1998

Service schedule Capacities Servicing specifications Component locations

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

VAU-1 VAU-1 VAU-2 VAU-3

VAU-17 VAU-19 VAU-20 VAU-20

VAU-34 VAU-35 VAU-35 VAU-36

Corsa petrol - 1993 to 1997

Cavalier petrol - 1988 to 1995

Vectra diesel - 1995 to 1998

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

VAU-5 VAU-6 VAU-7 VAU-8

Astra & Belmont petrol - 1984 to 1991 Service schedule Servicing specifications Capacities Component locations

VAU-9 VAU-10 VAU-11 VAU-11

Astra petrol - 1991 to 1996 Service schedule Servicing specifications Capacities Component locations

VAU-22 VAU-23 VAU-24 VAU-24

VAU-37 VAU-38 VAU-38 VAU-39

diesel engine - 1982 to 1996

Carlton & Senator - 1986 to 1994

Service schedule Servicing specifications Capacities Component locations

Service schedule Servicing specifications Capacities Component locations

Nova, Corsa, Astra & Cavalier VAU-27 VAU-29 VAU-29 VAU-30

VAU-40 VAU-41 VAU-42 VAU-43

VAU-13 VAU-14 VAU-15 VAU-15 ~s

CONTENTS VOLKSWAGEN Polo petrol - 1982 to 1990 Service schedule

Golf & Jetta petrol -

Golf & Vento petrol -

VOL-1

1 984

to 1 992

VOL-7

Service schedule

VOL-12

VOL-9

Servicing specifications

VOL-13

Servicing specifications

VOL-2

Service schedule

Capacities

VOL-3

Servicing specifications

Component locations

VOL-3

Polo petrol - 1990 to 1994

1 992

to 1 996

Capacities

VOL-10

Capacities

VOL-14

Component locations

VOL-11

Component locations

VOL-15

Service schedule

VOL-4

Golf & Vento diesel -

Servicing specifications Capacities Component locations

VOL-5 VOL-5 VOL-6

1992 to 1996 Service schedule Servicing specifications

VOL-16 VOL-17

Capacities Component locations

VOL-17 VOL-18

VOLVO 300 Series - 1976 to 1991

400 Series (1721 cc & 1794 cc)

Service schedule

VOV-1

=

Servicing specifications

VOV-2

Service schedule

Capacities

VOV-3

Servicing specifications

VOV-7

Component locations

VOV-4

Capacities

VOV-8

Component locations

VOV-8

1987 to' 1992 VOV-6

CONVERSION FACTORS Length (distance) Inches (in) Feet (ft) Miles

Millimetres (mm)

x 0.0394 =

Metres (m) Kilometres (km)

x 3.281 x 0.621

Cubic centimetres (cc; cm’) Litres (I) Litres (l)

h, 9.8

Capacities Engine oil (including filter)

PUSGL TANIM Stereo cosas on soe hee Ge

aE SEMA-INIIO CNIOUIO.. 0 o.oo ola oc nares webb par She 4.95 litres SEMIS CUIOQINO rea 37 sels ha hate Sie a! c aisistale eiats4.84 litres

Manual transmission

MR

TTIILONYY Soin oo. has

do

at

eee eats 7.2 litres

ac

aes

47 litres

Non =tUmMbOenGiNiGiet.. crcslec tv ctpe nccres RAINE cite eth ethene 2.37 litres WU eHIGINe Farrat Pe rerisees ee eels Pea Tae viol «eee 1.98 litres

Power-assisted steering

...................... 0.65 litres

Turbo diesel 1 2 3 4 5 6 7 8 9

10 11 12 13

Engine oil filler cap Engine oil dipstick Oil filter Brake/clutch fluid reservoir Air cleaner cover Power steering pump Coolant expansion tank Windscreen washer fluid reservoir Front suspension strut upper mounting Fuel filter/neater housing Fuel injection pump Battery Power steering fluid reservoir

FIA-9

FIAT OS NE

SIE IE E a E A

TE IIE EL EEOU SSE

Uno 1983 to 1995 ASR

IT

a

TS EE NS OPSOS ON OTE

Servicing schedule - models up to June 1991 Every 6000 miles (10 000 km)— orsix months, whichever comes= first

Every 12 000 miles (20 000 km) or I

Check drivebelt tension [] Check carburettor idle speed and mixture adjustments

_

a

-] Check contact points and dwell angle (mechanical

7. ‘Check handbrake 4 avel | Check headlamp beam alignment

= ea pean csialaren

breaker distributors)

g Check suspension bushes for wear

|] Check tyre tread wear

[_] Check disc pads for wear

Every 12 000 miles (20000 km) or

Every 24 000 miles (40 000 km)

12 months, whichever comes first :

or two years, whichever comes net

(] Check and adjust valve clearances |

O Renew coolant anti-freeze ae

_] Renew aircleaner element

'

___{J

[_] Check exhaust system for corrosion -

[|] Renew contact breaker points cae adjust ‘dwell

angle (mechanical breaker distributors)

.

[| Check and adjust ignition timing [_] Renew spark plugs

[_] Check clutch adjustment

Renew transmission oil

[J Renew brake hydraulic fluid —

a

a Check for underbody corrosion and clean out door

ANG St GBI gies

’

Every 36 000 miles (60 000 km)

Check transmission oil level _ Check driveshaft and steering rack gaiters for ae

o three years, whichever eS

Check rear brake shoe linings for wear

. Renew the time bett- 1116 and 1299/1301 cc

FIA-10

——

first

|

Uno - 1983 to 1995

FIAT

Servicing schedule - models from June 1991

Every 4500 miles (7500 km) or — 6 months (whichever comes first) Note: Frequent oil and filter changes are good for the engine. We _recommend changing the oil at the mileage specified here, or at least twice a year if the mileage covered is less.

‘Renew the engine oil and oil filterfnor

ib

models)

Every 6000 miles (10 000 km) or 12 months (whichever comes first) L_} Renew the engine oil and oil filter (turbo models)

Every 9000 miles (15 000 km) or 12 months (whichever comes first) Check the tyre pressures and their condition (including the spare) 4 Where a pad wear warning light is fitted, check its operation Check the front brake disc pads for excessive wear L]| Check the underbody condition (fuel and brakes pipes, exhaust system, hoses, bushes and gaiters)

Check the condition and tension of drivebelts

IL jl Check the engine idle speed and CO emissions | Check the EGR system (If fitted) Check fluid levels (coolant, brake fluid and windscreen washer) Renew spark plugs (1372 cc turbo models)

Check the HT leads and connections Check the condition of all coolant, fuel and hydraulic hoses and connections

Every 18 000 miles (80 000 km) or 24 months (whichever comes first)

Every 18 000 miles (80 000 km) or 24 months (whichever comes first) (continued)

|_| Check and tighten (if necessary), inlet anc exhaust manifolds Check the clutch adjustment (cable operated _ models) Renew the fuel filter (where applicable) Renew the air cleaner element LII Renew the spark plugs and check the HT leads and connections (all models) Where applicable, have the ignition and injection systems checked (special equipment needed) Renew coolant Renew brake fluid

Every 28 000 miles (45 000 km) or 36 months (whichever comes first) In addition to the items listed for 9000 mile (15 000 km) or 12 months service

Check Lambda (oxygen) sensors operation (special equipment needed) Check fuel evaporation system (where fitted) Check the transmission oil level Check the condition crankcase ventilation system

Every 37 000 miles (60 000 km) or 48 months (whichever comes first) In addition to the items listed for 18 000 mile (30 000 km) or 24 months service

|__| Check the condition of the rear brake shoe linings Renew timing belt (Note: The manufacturer recommends that the timing belt is changed every 65 000 miles (100 000 km). However, we strongly advise that this belt is replaced sooner, as extensive damage may occu, if the belt fails under certain driving conditions)

In addition to the items listed for 9000 mile (15 000 km) or 12 months service

Check the rear brake disc pads for wear (where applicable) Check/adjust the valve clearances

—

Every 74 500 miles (120 000 km) |_] Renew the manual transmission oil

FIA-11

_

FIAT

Uno - 1983 to 1995

Servicing specifications Engine Valve clearances:

Inlet

Exhaust

0.15 mm

0.20 mm

0.40 mm

0.50 mm

0.25 to 0.35 mm 0.35 to 0.45 mm

0.35 to 0.45 mm 0.45 to 0.55 mm

Up to June 1991:

COGS Ge [NS Seajecatcva 5. deocot onosekCueMeeOOndeh o=d.ncuino stubs cae to ae Ae GiSCranMalt SOMCCEMOIMES. cus.cya sve wrs-ores chetevsiors erecers ama wes From June 1991: OOO nduilOSiccks. #5 85.8 849. Mak rhe w SRS ee he ZOO malSOMA CCLAMO ISI 2 CO ccm ais cueteuacse, eueieinioecthn ore)ae aarchars

Cooling system Antifreeze mixture: 28% antifreeze ....... CERT e WAC AE A aS Meade tre BSOSGTANTIKCSZE wees cietay conse es tahsew aaahoupoinceher eee Pons Areycjpay at ame preteen. Note: Refer to antifreeze manufacturer for latest recommendations.

Protection down to -15°C Protection down to -30°C

Fuel system

Idle speed

CO % at idle

Modelsite tos stime lOO ters crates eens, cttings eundsuereyale caus Shaye, s2apsesusig sie Models from June 1991: Carburettor models: GOSICOR. ia.c5 aeeneeeton hae nae eats Rete ASOT, MIGS ABE: Fae: Sate dae

800 to 850 rpm

3.5 max

750 750 800 800 800

1.0 to 2.0% 1.0to2.0% 0.5 to 1.5% 1.0 to 2.0% 0.5 to 1.5%

CEN Clot ratieanEa tO meee Gace? iatrcichtnat eae CeCe a ooeo hs See TOSCO Reet slr eiey. Goes. Sieeedox Sims Su SE da ieahees . i. 1116 cc (95 RON unleaded engine) ...........2.0. cece eeee TB OM1 29 OT SONECC acne aegis ded heed cuncepetiee ane cideismgeyine ee Fuel injection models: SOO/TTMOGICC reece ee eens She nM nce ee eee eee Rare Ttceee Ss ABOMCETUFDOMOR ci. ee sos wie eyed cecetuctalievh ce ot Re eter tel ones HSA 2ACC NC ine veetere apsne eiSuniel Gecinemcic SRaRRORa eshoa ER EE tea ao

NSKZ COWS

coco cosa beboponcdvovedho ders eer ouone ade

to to to to to

800 800 850 900 900

rpm rpm rpm rpm rpm

850 + 50 rpm 850 + 50 rpm 850 + 50 rpm

0 to 0.35% 0.5 to 1.5%

825 + 25 rom

1.2 to 1.8%

Ignition timing Models up to June 1991: SOSICCIENGING | eee ee ie Fete ed Ok ben ate hs ae Ree TANGandASO1Ceengines sels vex hens es ale sen Oe dress = eae Models from June 1991: At idle with vacuum hose disconnected and plugged: Marelli SE101A and Ducellier 525473A ................0005. Marelli SE100EX, SE100CX and SE100NX ...............005. Marelli: SEq Oi Gite snnticsig. 2% sat arcuate eee ei ac. sae et respons he Marelli SETMOOSX expecta ets an sant roeenns epmesarsan espe are cee pr ReNea TSIAZACLC (2 aed i ten ane ca ahrSle elt len Soca yy otSa a 1301 turbovie/1S72 tUnDO lei Seteenerea tra eiictere tls oe RI teal cures

10° BTDC 3° BTDC Not available 2 to 6° BTDC 8 to 12° BTDC

Spark plugs

Type

Gap

ModelsiuiptoduinenlOO dvs a scr ors sae 2)teas eRe ee teen oeieweRenemerecre Models from June 1991: OOS MOSSE Ged299/ 1SOMCCL ne nee tee tate anh mee nia each SZC CUO Miteeta sarang cctnepeasrenaia..c/c susgttbn, Sache aaebocease aucke on etme iees AS ONRLULOONSasteteane cctase at xh ates ahaa Rees Eatmreae eases. USIZAUMD ONS eeees eeicbatts) Shea. Pauses, RaceaaeS ACAPELLA OIE Rate

Champion RN9YCC

0.8 mm

Champion Champion Champion Champion

0.8 mm 0.8mm 0.8 mm 0.9mm

5° BTDC at idle 10° BTDC at idle

2° BIDC

RC9YCC RN9YCC RC7YCC RC7BYC4

Braking system Mimimum pad lining friction material thickness .................0-

1.5mm

Mimimum shoe lining friction material thickness

1.5mm

TLVVCM

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

ES SUN CS gece dace sets. now's daisies ee neal

Refer to vehicle manufacturer’s tyre specification plate

Torque wrench settings Gearboxoilttillerand/dram plug: ....:..5.ceacauis snes ae ehoaideues « SpaliclUGS mercer meeercant So fas yoy 2 2 cece ere rnin ee ee ROagWhEGRDOIS aie ieaenraceen cit!sions.cpigs a araceuseeuesoeese canteen meaemeutatieaee =

FIA-12

46 25 86

34 18 63

Uno - 1983 to 1995

FIAT

Capacities Models up to June 1991 Engine oil (with filter change):

903 ce engine st ALR. AGEN

QUC.. 5...

Bice

ry,

eee

MAGlandwSOMeclengines vce .f...... 2 wees oe an eee: Cooling system: 903:cc enginécaseae: bist seclegi\.d..... GRR, eee nee ee 1116i:cciengine erin besticols .8....i-. . a See ee SOA CC ONGINGE he ea MES oe Layee fo ee eee @olitank: 270s. pean seve hin apieatiniorst > ao oa OM ee nas oeuad Cee mriaecneae UPANISMISSION. cooks layer ees meena Pade oie «fl eo ee RT oc eee as

3.42 litre 4.10

litre

4.6 litre 6.0 litre 6.2 litre 42.0 litre 2.40 litre

Models from June 1991 Engine oil (with filter change): 903999 andi 108:CCk, ts. ecco le wes,. eeReoe Rui aed dens DANG 1299/1380 Wand W372 CCe. we cise eiepeies tie open eee

3.8 litres 4.1 litres

Cooling system: SOSFOSS andi 108:cCs. Fe tare ran ae cuit fciann tee ee oe 1116 and 1299/1301 cc, non-catalyst 13872 ccie ...............

lsn2-ccile:withicatalysti tea. ccr cutee ai can tere eriaas pie

epae eee

6.5 litres

ABSOPCCAUMDOHO® din icsis ane aor tei aie eiraieshis cL ea ae eee Co en 1372) CCLUNDONE® .cSiv acs cletae chien! 2 Dakss ee ae: canes ee Fuel tank: NBZZiOC tUIDO 1Oio es ance tees aie mane oc oS Re CRE eae ee Allfothnen mOdeIS |crcsctigss ita. ctene «asco WetTas RR se eI os sae Transmission: MSOC LUTOONG mists soc tuys oreo MURA ve Beer att eens Ore eeeEeae ag eee TOL COMUMDONG mc ereateiee cis ic, ene» Kus sb dees tere neconutkancteaidey ee ceawchee

6.9 litres 7.7 litres

ALOTOMOMOIMOS

cians canveke: «,= «Spence « tea ten

Maer

4.6 litres 6.2 litres

lakitudetna o odete aieeoiePe tsi ercts

50 litres 42 litres 2.9 litres 2.0 litres

2.4 litres

55S model (air cleaner removed for clarity)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Strut upper mounting Washer fluid reservoir Brake fluid reservoir Ignition coil Throttle cable Carburettor Battery Timing belt cover Distributor Oil filler cap Radiator electric cooling fan Radiator Coolant expansion tank Front mounting Clutch operating cable

FIA-13

FIAT

Uno - 1983 to 1995 999 cc FIRE engined model (air cleaner removed for clarity)

1 2 3 4 5 6 7 8 Q 10 11 12 13 14 15

Wiper motor cover Suspension strut turret Brake hydraulic fluid reservoir Carburettor Washer fluid reservoir Right-hand engine mounting Fuel pump Ignition distributor Ignition coil Headlamp Oil filler cap Battery Radiator cooling fan Coolant filler/expansion tank Radiator

1301 cc Turbo ie engined model 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

FIA-14

Alternator air cooling intake Washer fluid reservoir cap Suspension strut turret Secondary fuel filter Fuel supply hose Coolant expansion tank Brake fluid reservoir cap Ignition system ECU Inlet manifold Excessive pressure switch Air cleaner Timing belt cover Fuel pressure regulator Airflow meter Throttle position switch Air intake duct Air intake to throttle valve housing Engine oil filler cap Radiator cooling fan Headlamp dim-dip transformer Intercooler air duct Ignition distributor Headlamp Main idle speed adjusting screw Base setting idle speed screw

FIAT

Uno - 1983 to 1995

1372 cc ie engined model 1 2 3 4 5 6 7

Engine oil level dipstick Timing belt cover Engine mounting (right-hand) Clutch master cylinder fluid reservoir Fuel supply and return hoses Injection unit Inlet manifold

8 Washer reservoir 9 Brake master cylinder and fluid reservoir 10 Injection system fuse/relay block 11 Suspension strut turret 12 Ignition coil 13 Ignition system ECU

14 15 16 17 18

Battery Coolant filter expansion tank Ignition distributor Radiator cooling fan Engine oil filler cap 19 Starter motor 20 Oil filter

FIA-15

i Ane ' BSeTE

si3to eri‘Oreen ridiui)

FORD ELLE

ESR

TRI

TD

We

aSA

Fiesta petrol 1983 to Feb 1989

saa eoherare

Every 6000 miles (10 000 km) or 6 months -whichever comes sooner Renew engine oil and filter Check brake Pace or Sines for wear (front and OC _ rear) Check operation of brakefluid level warning indicator Inspect engine bay and underside of vehicle for OO fluid leaks or other signs of damage

Check function and condition of seat belts

roCheck

condition and security of exhaust

system

Check tightness of wheel nuts Check choke adjustment

II }!

Every 12 000 miles (20 000 km) or 12 months -whichever comes3 sooner

(continued)

Renew spark plugs Check gearbox oil level : Renew distributor contact breaker points and lubricate distributor -OHV engines_ @ Check security and condition of steering and | suspension components, gaiters and boots Inspect underbody and panels for corrosion. oO. other damage Inspect brake pipes and hoses Road test

Check crankcase ventilation system

Check idle speed

Check mixture adjustment Check spark plugs Check HT leads, distributer cap ¢ and ignition circuit | Check operation of latches, check straps and locks; lubricate if necessary LI Check ignition timing and contact breaker gap (dwell angle) (OHV engines) L] Check operation of throttle damper (where applicable)

-

Every 12 000 miles (20 000 km) or 12 months - whichever comes sooner Check tightness of battery terminals, clean and neutralise corrosion (| Check engine valve clearances - OHV engines

| | Check handbrake mechanism Check condition and tension of auxiliary drivebelt

|

Every 24 000 miles (40 000 km) or 2 years - whichever comes sooner |] Check air cleaner temperature control |_| Renew emission control filter element- A engines [| Renew air cleaner element

Every 36 000 miles (60 000 km) or 3 years - whichever comes sooner Renew brake hydraulic system seals and hoses if necessary [_}] Renew brake hydraulic fluid Renew timing belt - CVH engines Check front wheel alignment

Every 2 years, regardless of mileage co

|_| Renew coolant

FOR-1

FORD

Fiesta petrol - 1983 to Feb 1989

Servicing specifications Engine Valve clearances Inlet: At operating @ellch sae Exhaust: At operating COLA ra

(only OHV applicable): temperature et ee

en

Ie

eee

SoA

Enea

temperature

sett cbetastes Gs) cue ict, cyennd We

Rese sch euskal Sader ata cmb oe

0.22 mm 0.20 to 0.25 mm 0.59 mm 0.56 to 0.61 mm

Cooling system Antifreeze 35% 50%

Water 65% 50%

Fuel system

Idle speed

CO mixture

OMitrenDromlOCO)h ee. 2 nM eee eRe Re ck ee cee eee eee NAOMI LOSG-ON) ies srcemty itt easowe's Wists Sec wee tees s WETNESS AS That Nalpole hee HAELARE Steete lror: he eR Cee EPR ERM Nee NES ernie enonAen

800 775 750 750 775 750

Antifreeze mixtures: PROtECHOMGOWNMO 2 On G eons cocks a se oe woke ohm enters ore PKOleCtiOnrGOWOitO-40°C sangre age RI ns alstiane ca suerearal asa\leels

TEA tO yeecbeeegie ds Me Meh potheneuc. ave hate snes oR EL ode woke NoRte ee atehe onder « MAGHIIKe (KEN SS Mie tetacecsus ta eraelaae crccsier aces oe wreie tours ahem A OHitrel(TOS/-Onies cetera Aci se eset epnue tle tbat. melee iteldehe a deiats f+

rpm to 825 to 850 to 850 to 825 to 850

rpm rpm rpm rpm rpm

1.25% 1.0 to 1.3% 1.0 to 2.0% 1.25 to 1.75% 1.0 to 1.5% 1.25 to 1.75%

Ignition system Spark plugs: Mechanicalisystermijccvae ElectronieisyStenn:. Electrode gap:

o c.:. 245 « sels | soa ccs sustecren tyes oes 1.4 litre CVH (CFi fuel injection) and PTE engine ................ 1.6 litre CVH (carburettor) engines: WithiChampioniRG AV CC sees 9 ccsyps.sncc-c sos 7honamieceaneaeel ears With: Cham piomiAG7y. Gavorweete esatcwcayeterscn tsfeo! ea ltuseat ety eee cexPaerets 1.6 litre CVH (EFi fuel injection) engines: NonetunbommoGelsy wis.) ocean 0a btaukeiers Mur mat sie Niecame ne TUDO IMOGESISH saree tetsnea tsSiete Mitetsrsds cucee eek wie's oteketens. uecraxar sRegehe AkGrandi:Silitre ZetecienGineS. 7s . chica cherictichetna Sess oes ne ats Ignition timing:

Champion RS9YCC or RS9YC Champion RC7YCC or RC7YC Champion RC7YCC4 or RC7YC4 Champion C61YC Champion RE7YCC 1.0 mm 0.8 mm 1.0 mm 0.8 mm 0.7 mm 1.0 mm 0.7 mm 1.3 mm

1.4 and 1.6 litre carburettor models with distributor:

For use with 4-star leaded petrol (97 RON) ...............4-. For use with unleaded petrol (95 or 98 RON) ................. 1.4 litre CFi fuel injection models with distributor (pre-Sept 1990)... AllLOtherimodelsy.cct commie csten tok & Ghelcper ope tastey mean Te arene

12° BTDC at idle speed (vacuum pipe disconnected and plugged) 8° BTDC at idle speed (vacuum pipe disconnected and plugged) 10° BTDC at idle speed (set using STAR test equipment) Totally controlled by ignition module or EEC IV engine management module * Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to their manufacturer’s recommendations.

Braking system Minimum front brake pad lining thickness ...................00-. Minimum rear brake shoe lining thickness ..............0-+ eee eee

FOR-6

1.5mm 1.0 mm

FORD

Fiesta petrol - Feb 1989 to Oct 1995 Tyres pressures (cold) 135 R 13-S: Normal loading (up to three persons) ...............----+--eees Fully laden (over three persons) ..........-. eee eee eee eee eee 145 R 13-S: Normal loading (up to three persons) ..........-...0-e eee ee eee Fully laden (over three persons) .......... 20 eee ee eee eee eee 145 R 13 78R (Courier models): Normal loading (driver plus 170 kg load) ...................04. Fully-laden (over normal load, up to maximum - see VIN plate) ..... 155/70 R 13-S: Normal loading (up to three persons) ...........200e eee eee eeee Fully laden (over three persons) .......... 2... ecece eee ee ee ees 165/65 R 13-S: Normal loading (up to three persons) ...........00 eee cece eee Eullydadendoventhree persons) ins .cc a+ amen eras ons wits 6m oe 165/65 R 13-H: Normal loading (up to three persons) .............00 eee eee Fully-laden (over three perSOns) ...... 0. 0c eee ee eee tee 165/70 R 13 79T (Courier models): Normal loading (driver plus 170 kg load) ............-00-20eeeFully-laden (over normal load, up to maximum - see VIN plate)..... 175/60 R 13, 175/60 R 13-H: Normal loading (up to three persons) ...........ee eee eee eeee Fully-laden (over three perSONS) ....... 2.0. e cece eee e eee eens 185/55 R 14 79H: Normal loading (up to three persons) ......... 0.02 eee eee renee Eully-ladent(over three persons) 42. 2. cisa1. cre cuaeuelncle spe re w+ ella te 185/55 R 14 78V: Normal loading (up to three persons) ............0 cee eeee eee Fully-laden (over three persons) ......... 6:0 cee eee eee eee ee 185/60 R 13 80H: Normal loading (up to three persons) .........-. eee eee eee eee Fully laden (over three persons) ...............eeeeeeeee renee

Front

Rear

2.1 bar (30 psi) 2.3 bar (33 psi)

2.0 bar (29 psi) 2.8 bar (40 psi)

1.8 bar (26 psi) 2.3 bar (33 psi)

1.8 bar (26 psi) 2.8 bar (40 psi)

2.3 bar (33 psi)

2.5 bar (36 psi)

2.3 bar (33 psi)

2.8 bar (40 psi)

2.0 bar (29 psi) 2.3 bar (33 psi)

2.8 bar (40 psi)

1.8 bar (26 psi) 2.3 bar (33 psi)

1.8 bar (26 psi) 2.8 bar (40 psi)

2.0 bar (29 psi) 2.3 bar (33 psi)

2.0 bar (29 psi) 2.8 bar (40 psi)

2.3 bar (33 psi) 2.3 bar (33 psi)

2.5 bar (36 psi)

1.8 bar (26 psi) 2.3 bar (33 psi)

1.8 bar (26 psi) 2.8 bar (40 psi)

2.0 bar (29 psi) 2.3 bar (33 psi)

2.0 bar (29 psi) 2.8 bar (40 psi)

2.0 bar (29 psi)

2.1 bar (30 psi)

1.8 bar (26 psi) 2.3 bar (33 psi)

2.0 bar (29 psi) 2.1 bar (30 psi)

1.8 bar (26 psi) 2.3 bar (33 psi)

1.8 bar (26 psi)

2.8 bar (40 psi)

Note: For sustained high speeds above 100 mph (160 km/h), increased pressures are necessary. Consult the driver’s handbook supplied with the vehicle. Pressures apply only to original-equipment tyres, and may vary if other makes or type is fitted; check with the tyre manufacturer or supplier for correct pressures if necessary.

Ibf ft 18 15

Torque wrench settings EMGinetoilscrain’ Plugs cease lsc aay le wooo oie ys oer y Wlelcfn Geta alee et Manual transmission filler/level plug... 2.0.22... eee eee eee eee Spark plugs: FIG SLOMOIMeS rates eee ere tte haape oievaperoseletia obey abelpeas tat tn ayeeeessiage CV and PINEXeMGiMeS aietetas eee etacy aio ee ace lea shete elpol ttel= etiameuoyeroNe ZETEC CNGINCS —aieyars avai Spats tele eaSbobs Go wcerata) olcdiete olimclince.«0 ue.OB oa ROAGWHEEIAUTS 2. see telte hs CM Wad ween e tym a ole avolonnteifeiayatsdoletiayécs con

71 to 100

52 to 74

Capacities Engine oil At oil and filter change: EGS) Cine flte 6-4 Ge oie emule cicraec cndice osoadte = yeaa oio.o corpse oye cc GCVblandiPIMEONGINES |. see aeiS sh wn) ee ibhe star. eveneeel = cle ereriens tarsi

ZELOCONGINES Pareces atrte serchs allyWit oneS wilelfelehries queer piageuege adslsleloln= pisces cievenshteeseslr FS SienGineSeamatar GVH andiPMECNnGineS .2. estes sete se) Ue acs nayrreeeie oye sieueiren onan see ZOLEC CNOIMES ciejcrarcliecs ecotavacys, ays ers 0)e/a o's.0 Minviena elebealayerats eee aie chem

Etrelitan cae

ere

Manual transmiSSION

Re

ok cei

ate ee ee nee

7.1 litres 7.6 litres 7.0 litres 42.0 litres

eneewe eee cee ccc 0000 ...2...0...c

3.1 litres

eee eee .....................0-00

3.5 litres

Automatic transmission

a

FOR-7

FORD

Fiesta petrol - Feb 1989 to Oct 1995 1.1 litre HCS Engine oil filler cap Engine oil level dipstick Cooling system expansion tank Brake fluid reservoir Windscreen/tailgate washer fluid aARWN— reservoir cap Battery Vehicle identification plate Thermostat housing Radiator cooling fan thermal switch multi-plug Alternator Starter motor solenoid CTX automatic transmission fluid level dipstick 13 Exhaust heatshield/airbox

14 15

16 Tk 18 i 20 Za 22 23

Brake pressure control valves

Top of suspension strut mounting assembly Carburettor Fuel feed hose Anti-dieselling (fuel-cut off) solenoid connection Throttle kicker Throttle kicker control solenoid Ignition module Heater blower motor cover Windscreen wiper motor mounting bracket

1.4 litre CVH CFi Engine oil filler cap Engine oil level dipstick Cooling system expansion tank Brake fluid reservoir — akwWNh Windscreen/tailgate washer fluid reservoir cap Battery Vehicle identification plate Thermostat housing ©O ONO Pre-heat tube 10 Timing belt cover 11 Distributor 12 Fuel filter 13 Heater blower motor cover 14 Windscreen wiper motor mounting bracket 15 Jack and wheelbrace retaining bolt 16 Top of suspension strut mounting assembly il EEC IV engine management module cover 18 CFi unit 19 Fuel injector 20 Fuel pressure regulator 21 Throttle plate control motor 22 Carbon canister 23 Manifold absolute pressure sensor 24 Ignition module

FOR-8

FORD

Fiesta petrol - Feb 1989 to Oct 1995

1.6 litre CVH EFi 1 2 3 4 5

Engine oil filler cap Engine oil level dipstick Cooling system expansion tank Brake fluid reservoir Windscreen/tailgate washer fluid

reservoir cap Battery Vehicle identification plate Thermostat housing Timing belt cover Top of suspension strut mounting assembly 11 Windscreen wiper motor mounting bracket 12 Jack and wheelbrace retaining bolt 13 Distributorless (E-DIS) ignition coil

6 7 8 9 10

14 15 16 17 18 19 20 21 22 23

24 25

Fuel filter Air cleaner Air inlet duct Idle speed control valve Fuel pressure regulator Throttle housing Upper section of inlet manifold Intake air temperature sensor Fuel trap EEC IV engine management module cover Manifold absolute pressure sensor Ignition module

1.8 litre Zetec SEFi

Hitt

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21 22

23 24 25

Engine oil filler cap Engine oil level dipstick Cooling system expansion tank Braking system fluid reservoir Windscreen/tailgate washer fluid reservoir cap Battery VIN plate Thermostat housing Timing belt cover Top of suspension strut mounting assembly Windscreen wiper motor mounting bracket Jack and wheelbrace retaining bolt Distributorless (E-DIS) ignition coil Fuel filter Air cleaner Air inlet duct Idle speed control valve Fuel pressure regulator Throttle housing Inlet manifold Throttle position sensor Fuel system pressure release/test point EEC IV engine management module cover Mass air flow sensor Ignition module

FOR-9

FORD Fiesta petrol Oct 1995 to 1997

Servicing schedule Every 40000 miles Renew the spark. Plugs -models w engine

Zetec-S

Every 60 000 miles — =—sese Renew the fuel filter h Zetec Renew the timing belt -models \with engine Note: Although ‘the ponnel interval for ee belt ren wal is 100 000 miles, it is strongly recommended that the timing renewal interval is reduced on vehicles which are subject

intensive use. The actual belt renewal interval is therefore very ML _up to the individual owner, but bear in mind that severe engin € | damage will result if the belt breaks

Every 100 000 miles” Adjust the valve clearances - models withZee engine

Every 100 000 miles or 10 years, | whichever comes sooner Renew the timing belt-models with Zetec-SE engine Note: This is the interval recommended by For but we recommend that belt is changed more frequently, at 60 000 ie ~ see above:

Every 3 years, regardless of mileage __] Renew the brake fluid—

sheck he crankcase ventilation system - models with Endura-E engine (Section 19) Check the oil filler cap -models with Endura-E ~engine (Section 20) — LJ] Check the manual transmission oil level (Section 21) eS]

FOR-10

Every 4 years, regardless of mileage. Renew the coolant and check the condition of the expansion tank pressure cap 8

FORD

Fiesta petrol - Oct 1995 to 1997

Servicing specifications Engine Valve clearances (cold): Leake Iics Sirolile ALS ruck ste ne ner RTRONG wo ZACC-SE ENGST ete ne

Inlet

RBC ee

A MEM Ee ee OREO eee ee ee

0.20 mm 0.17 to 0.23 mm

Exhaust 0.30 mm 0.27 to 0.833 mm

Cooling system Antifreeze mixture: SOD GaN tife OZ encase cesrenpter eran ar5 Tare a aN RON TRESS ee ap SS OraMtheeZzOm pee eae, Perm cyeee rN PRIS oul ao Salat akonees Note: Refer to antifreeze manufacturer for latest recommendations.

Protection down to -37°C Protection down to -45°C

Ignition system Spark plugs: ENGUrace eliGimGm: mex cements Maistre . . U. inintiniide «Ak wala noe ACC LOEB et tae Ae MERE ee a Spay ahhMean « Mtn ateantantorl ahs ag Runeeeae ss

Type

Gap*

Champion RS9YCC Champion RE7YCC

0.8 mm

1.0 mm *The spark plug gap quoted is that recommended by Champion for their specified plug listed above. If spark plugs of any other type are to be fitted, refer to their manufacturer’s recommendations.

Brakes Front brake pad friction material minimum thickness Rear brake shoe friction material minimum thickness

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

Tyre pressures (cold)

Rear

Normal load (up to 3 people):

155/70 R 13 tyres: MatchbackimodelSetwrs ter sists sccelem wieteis e speretwams eager. c/s Mani (petrolengine) models gfacans fore swe stds w nle ce ee earnest 165/70 R 13 tyres: Hatchback models: 1.25 litre and 1.4 litre Zetec-SE petrol engine models: Manualtransmissioniimodels:.-.'..... . hc as stunts ce aes Automatic transmission models ...............2000000s 1.3 Endura-E petrol engine models ................20..... 1.8 Endura-DE diesel engine models .................0055 Van (diesel engine) models .......... 0.0.0 ccece eee eee eee Courierand:GombiimOdelss. «cerita saree «la waisie cer OMe.sles mais G5) SOMALI ALVIS tae. cpavaxc MEINE ete o Taerenisyjodel Siete cree MUSAREE MO.aye Sauer Full load (more than 3 people): All except Van, Courier and Combi models with 165/70 R 13 tyres . . Van, Courier and Combi models with 165/70 R13 tyres ..........

2.4 bar (35 psi) 2.1 bar (31 psi)

1.8 bar (26 psi) 1.8 bar (26 psi)

2.1 bar (31 psi) 2.2 bar (32 psi)

1.8 bar (26 psi)

2.3 bar (34 psi)

2.8 bar (41 psi) 2.8 bar (41 psi)

Torque wrench settings

Nm

Ibf ft

Spark plugs: Endtra=S'engiie ger -acieeni mttnttnsre isco srs alsin me asararemntecere = IZELOC- OEE ease nie eevee ns eee a oiwe wiricee eoANUBABNS wiseage,anasonl Manual transmission filler/level plug... ......... 00200 ceee ee ee eee PAULOMALICLANSIMISSIOMCLAIN OIG) sera cgcvens cpa mw sive clare eee eo) areies cen OACWNeC Ut samen ema Pie win reir aklere aieydivin cone a a lwahalns oie

ay, 15 35 33 85

13 11 26 25 63

2.2 bar (32 psi) 2.4 bar (35 psi)

2.1 bar (31 psi) 2.0 bar (29 psi) 2.2 bar (32 psi) 2.5 bar (37 psi)

1.8 1.8 1.8 1.8

bar bar bar bar

(26 (26 (26 (26

psi) psi) psi) psi)

1.8 bar (26 psi) 1.8 bar (26 psi)

Capacities Fuel: tanker

Engine oil Including oil filter: Endura-E engine Zetec-SE engine Excluding oil filter: Endura-E engine Zetec-SE engine

(approximate) (approximate)

...............-0005 .........,.+2.+208s

3.25 litres 4.0 litres

(approximate) (approximate)

............-..+005...............0008.

2.75 litres 3.5 litres

Oise Soe