Haynes Ford Diesel Engine Owners Workshop Manual 1850105111, 9781850105114

Citation preview

ze) Ie

ae

DIESEL ENGINE 1984 to 1989.1.6 & 1.8 litre Front-wheel-drive applications

fia

“S

Th

*

2

:

-

4 ,

(oo

wi

seg

oe

ee

ng

seg

'

oe ver

ee

ee =

is

| RESERVE

STOCK

}

Ford Diesel Engine Owners Workshop Mianual Matthew

Minter

Models covered This manual covers the Ford 1608 cc (1.6 litre) and 1753 cc (1.8 litre) Diesel engines used in the Ford Fiesta, Ford Escort and Ford Orion ‘

(1172-10R3)

AScoE

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes Publications, Inc 861

Lawrence

Drive

Beeie oli

anit ut 9552

Acknowledgements Thanks are due to Douglas Seaton Ltd, of Yeovil, for the loan of the cars used in the preparation of this manual. Certain illustrations are the copyright of the Ford Motor Company, and are used with their permission. Duckhams Oils provided lubrication data. Thanks are also due to Sykes-Pickavant who supplied some of the workshop tools, and to all those people at Sparkford who helped in the production of the manual.

1.

A

“6004 36 267 pew

© Haynes Publishing Group 1990 A book in the Haynes Owners Workshop

0)

QDek~

INV

|> ly -Ey 10. Manual

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

Series

Nr Yeovil

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, without permission in writing from the copyright holder.

ISBN 1 85010 511 1 British Library Cataloguing in Publication Data Minter, Matthew, 7952Ford diesel engine owners workshop manual. 1. Cars. Maintenance & repair |. Title Il. Series

629.28722 ISBN 1-85010-511-1

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or ommisions from, the information given.

Contents Page

Acknowledgements

2

About this manual

5

Introduction to the Ford 1.6 and 1.8 Diesel engines

5

General dimensions, weights and capacities

6

Buying spare parts

7

General repair procedures Tools and working facilities

Conversion factors

11

12

—

Safety first!

13

Routine maintenance

Recommended Fault diagnosis

16

lubricants and fluids ;

|

Chapter 1 Engine (a/so see Chapter 8 page

20

141)

Chapter 2 Cooling system (a/so see Chapter 8, page

17

81

1417)

Chapter 3 Fuel and exhaust systems (a/so see Chapter 8, page

96

1417)

Chapter 4 Clutch, transmission and driveshafts (a/so see Chapter 8 page

141)

115

Chapter 5 Braking system

117

Chapter 6 Suspension and steering

119

Chapter 7 Electrical system (also see Chapter 8, page 147)

121

Chapter 8 Supplement:

Index

Revisions and information

on later models

141

19

No

Front three-quarter view of Ford 1.6 Diesel engine. Camshaft drivebelt cover has been removed Camshaft sprocket Inlet manifold Engine oil filler cap Lifting eye Coolant hose connections (coolant pump inlet) /njector (one of four) ND AR®WYs Injection pipes

Crankcase ventilation hose Fuel pipes Engine oil dipstick Temperature gauge sender Vacuum pump Thermostat elbow Radiator fan switch

Flywheel

716 17 718 19

Cold start device Fuel injection pump Alternator Alternator/water pump drivebelt 20 Crankshaft pulley 21 Injection pump sprocket

22 Water pump pulley 23 Mounting bracket 24 Coolant hose connection (heater) 25 Camshaft drivebelt 26 Camshaft drivebelt tensioner 27 Coolant hose connection (bleed)

About this manual Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work. Unlike most Haynes manuals, which cover a particular vehicle in different trim levels and engine sizes, this book covers one engine and its associated equipment as fitted to a range of vehicles. Items which are common to Diesel and petrol models — eg bodywork, transmission and running gear — are not covered in this book.

/ts arrangement The manual is divided into eight Chapters, each covering a logical sub-division of the engine and its systems. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the

Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed anti-clockwise, and tightened by turning clockwise.

by turning

Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Introduction to the Ford 1.6 & 1.8 Diesel engines This engine, the smallest Diesel in Ford's range, has been available since 1984. It is fitted to the front wheel drive passenger vehicles and light vans — Fiesta, Escort and Orion. Like the equivalent petrol engines it is mounted transversely. The engine is a completely new design, unlike those offered by some other manufacturers which are simply ‘conversions’ of existing petrol engines. On paper the outputs of the 1.6 and 1.8 Diesel engines fall between those of Ford’s 1.1 and 1.3 petrol engines. On the road it is no slouch, only a certain amount of clatter at idle betraying its presence to the driver. It is almost impossible to stall, and satisfactory progress can be made in heavy traffic using the first two gears without touching the throttle. The Diesel’s fuel economy benefits are well known; to these can be added longer engine life, and (at present) a higher resale value, than petrol-engined equivalents.

Routine limited for purchase or to work on

maintenance tasks are few and easily carried out. Access is some repair operations. Certain jobs will require the construction of special tools; this apart, the engine is easy and displays many thoughtful design features.

The fuel injection equipment is made by Bosch. It is not user-serviceable, but provided that the specified fuel system maintenance is carried out, it should not give any trouble. Compared with a spark ignition system, the Diesel equipment is virtually maintenancefree. Outside the engine bay, the vehicles to which this engine is fitted are much the same in Diesel and petrol versions. For complete coverage of a particular vehicle, the appropriate manual for petrolengined vehicles will be needed as well.

General dimensions, weights and capacities Dimensions

(typical)

Overall length: Fiesta] 6i sem got. wracmeccemr rue ciate ener eee eo ee RleStagl Cutest meer Gree aera, ae ee wt ee ee ESCONt(HatchbaGk)mrateme bce ks ae te Ae ok eee Escorty(ESfate) Re acces eee fost. ns cena ea eee ESCOrpi (Nain) Rents cae teeter ce,cote tnd ol Me RR one OVlON Reece aereriets, weds tA: Oe eee ee Overall width (including mirrors): BleSta stIAG) sereepee ot hace. cen ek otal na haery on He tert et hess sees EAE: Riestaate8 #(exclUdimasmitrors)a cues ise ee nies oc eee ee Escorts (allimodels) A epenmnnnetn sail ace. De iy Le Be, a, ee SION: te emcee rs ie a ATI Nae By I Lt ea

Overall height:

Fiesta leO mrnratsr.t, eee Fiesta 120%, cette ee

teh tow, cet een eae

ie oe Mle a Peat. Ce

te ee oe

Le

Escort Match back) Be x ict ce Oe totes lo cet e. Ste demcm, Slee kl ESGOrhe{ ESCSte) oe sate, fac eee rate a prea’ ge a eal Papen ae Escort (Van) beet oe aks cite Sa ee ee i de th OTT te2 citi,A Oe. cae one eects Mg el) Oe Ot

3.647 3.791 3.970 4.034 4.219 4.194

m m to to m m

(11 ft (12 ft 4.056 4.128 (13 ft (13 ft

11.6 in) 5.4 in) m (13 ft 0.3 in to 13 ft 3.7 in) m (13 ft 2.8 in to 13 ft 6.5 in) 10.1 in) 9.1 in)

1.709 1.605 1.844 1.844

to m m m

1.725 m (5 ft 3.2 (6 ft 0.6 (6 ft 0.6

(5 ft 7.3 in to 5 ft 7.9 in) in) in) in)

1.334 1.389 1.402 1.400 1.568 1.407

m m m m m m

(4 ft 4.5 (4 ft 6.7 (4 ft 7.2 (4 ft 7.1 (5 ft 1.7 (4 ft 7.4

in) in) in) in) in) in)

Weights (typical) Kerb weights (approx): hlestaglGs(except Van) 2m giiec teen. eat ncgivacinr eo ee as. Fiesta 116 "(Vani Nitesee sata Pee bet as sy. Pea el tad eh Fiestas| -Bi(excepa ah) eens eieenn.im.ceR tI RipestayiicO- CUG0Y) setten eee a rhea! i: Side orcec ih leRitecz dese.

ESCOnt (EState)”

..:.. | 9piltevel chack/wp up - 27 ae valve clakegnnes che. ncthue * ecttmarayvetenn condition check

=

Bor

|

oni

a

Pet mg

«194

wat 219 fAaxirman treet

ee

1108, 18

(02

1] Px

ng iting ak modem

wit

Qbt

~oih n

; )

vn aa

rer

4)

Ea

“ani

cr

srountbeeeal "pieopm tersne

ee aTaGe ment - patentee~ sean wd ianeoeul

_ terrae eo) modele hgh

pnivease bre '

EscorvOniom: trom. 87

CY laa

oO.

erry! Saneor renova and oelonlry sara - 28

Cit Fittne

ext /

ee anno

wea opeegt