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Factory Workshop Manual
Ford
Fiesta 1996 08.1995-02.2002
(08.1995-02.2002)
Anonymous
1st January 2018
Make
Model
Engine and year
This manual was submitted by
Date
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Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > About This Manual
Introduction This manual has been written in a format that is designed to meet the needs of
technicians worldwide. The objective is to use common formats and include similar content in each
manual. This manual provides general descriptions for accomplishing diagnosis and testing,
service and repair work with tested, effective techniques. Following them will help assure reliability.
Special Tools The special tool(s) table provided at the beginning of each procedure shows all
special tools required to carry out a repair. Where possible, illustrations are provided to assist in
identifying the special tool required. Important Safety Instructions Appropriate service methods and
correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well
as the personal safety of the individual carrying out the work. This manual cannot possibly
anticipate all such variations and provide advice or cautions as to each. Anyone who departs from
the instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or components. Warnings,
Cautions and Notes in This Manual As you read through this manual, you will come across
WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a
series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step,
it is placed at the beginning of the specific step (after the step number). How to Use This Manual
This manual covers diagnosis and testing, service and repair procedures. This manual is structured
into groups and sections, with specific system sections collected together under their relevant
group. A group covers a specific portion of the vehicle. The manual is divided into five groups,
General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group
is the first number of a section number. Pages at the start of the manual list all sections available.
Each section has a contents list detailing Specifications, Description and Operation, Diagnosis and
Testing, In Vehicle Repairs, Disassembly and Assembly, Removal and Installation. If components
need to be removed or disassembled in sequence, the sequence will be identified numerically in a
graphic and the corresponding text will be numbered accordingly. All left and right-hand references
to the vehicle are taken from a position sitting in the driver seat looking forward. All left and
right-hand references to the engine are taken from a position at the flywheel looking towards the
front camshaft pulley. Where appropriate, instructions will be given for the use of the diagnostic
tool. Overview Procedures Overview procedures contain an exploded view illustration(s). The
numbered sequence within the illustration(s) indicate the order to be followed when
removing/disassembling or when installing/assembling a component. Additional information,
symbol(s) or a torque figure, may also be shown alongside the component. There are ten symbols
used to give additional information when removing/disassembling or when installing/assembling a
component. Inspection and Verification Visual Inspection Charts, Symptom Charts and other
information charts (such as diagnostic routines) or supplement test procedures with technical
specifications will navigate the user to a specific test procedure. Symptom Chart The symptom
chart indicates symptoms, sources and actions to address a condition. Pinpoint Tests For electrical
systems, pinpoint test steps are used to identify the source of a concern in a logical, step-by-step
manner. pinpoint tests have two columns: CONDITIONS and DETAILS/RESULTS/ACTIONS. The
CONDITIONS column is used exclusively for graphics and icons (with or without captions) and the
DETAILS/RESULTS/ACTIONS column provides direction to another test step or specific corrective
actions. The boxed numbers indicate the order in which the described action is to be performed.
Component Tests A component test is used when a component is tested in multiple pinpoint tests,
or if a procedure is too complicated to be formatted within a single page of the pinpoint test.
Graphics Test graphics show the measurement or test to be performed in a test step. A
representative tester graphic is used for voltmeters and ohmmeters. If multiple measurements are
made in a single graphic, the test leads are drawn with a solid line until the test lead splits to
indicate the multiple measurements, at which point dashed lines are used. Breakout box-type
testers are represented by a double circle test pin. Test pins are labeled with the pin number.
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Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it
in use and with its tool number shown. Torque settings will be given at the relevant point in the
procedure.
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Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Health and Safety Precautions
Introduction Many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health. This subsection lists, alphabetically, some of these
hazardous operations and the materials and equipment associated with them. Precautions
necessary to avoid these hazards are identified. The list is not exhaustive and all operations and
procedures, and the handling of materials, should be carried out with health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier
should be consulted. Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric
acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and
clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing
accidents. Display Eye Hazard sign. Air Bags See also Fire, Chemical Materials. Highly flammable,
explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering
wheel and passenger side of the instrument panel. The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is
Sodium Azide. This material is hermetically sealed in the module and is completely consumed
during deployment. No attempt should be made to open an air bag inflator as this will lead to the
risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage. After normal deployment, gloves and safety goggles must be
worn during the handling process. Deployed air bags should be disposed of in a plastic bag in
accordance with local regulations at an approved chemical waste site. Following any direct contact
with gas generant. Air Bags - Do's Air Bags - Do Nots Air Conditioning Refrigerant See also
Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking
policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed.
Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact
with the skin or eyes, immediately rinse the affected areas with water. Eyes should also be rinsed
with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY. Air Conditioning Refrigerant - Do Nots Adhesives and Sealers See also Fire,
Chemical Materials. Highly flammable, flammable, combustible – observe No Smoking policy.
Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be
observed, for example disposable paper covering benches; should be dispensed from applicators
where possible; containers, including secondary containers, should be labeled appropriately.
Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions. Water-based
Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small
amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and
adequate ventilation provided during use. Hot Melt Adhesives In the solid state, they are safe. In
the molten state they may cause burns and health hazards may arise from the inhalation of toxic
fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal
cut-out and adequate extraction. Resin-based Adhesives/Sealers, for example Epoxide and
Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or
toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can
result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin.
Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing
or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be
avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues)
MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad
and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well
ventilated areas as vapors can cause irritation to the nose and eyes. For two-pack systems see
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Resin-based and Isocyanate Adhesives/Sealers. Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives. Individuals suffering from asthma or respiratory allergies should
not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating
to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous
system including drowsiness. In extreme cases, loss of consciousness may result. Long term
exposure to vapor concentrations may result in adverse health effects. Prolonged contact with the
skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage. Any spraying should
preferably be carried out in exhaust ventilated booths, removing vapors and spray droplets from the
breathing zone. Wear appropriate gloves, eye and respiratory protection. Antifreeze See also Fire,
Solvents. For example isopropanol, ethylene glycol, methanol. Highly flammable, flammable,
combustible. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these
vapors. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling or industrial water system that is connected or
linked to general, food preparation or drinking water supplies. Asbestos See also Warning Symbols
on Vehicles at the end of this subsection. Breathing asbestos dust may cause lung damage or, in
some cases, cancer. Used in brake and clutch linings, transmission brake bands and gaskets. The
use of drum cleaning units, vacuum cleaning or damp wiping is preferred. Asbestos dust waste
should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or
drilling is attempted on materials containing asbestos the item should be dampened and only hand
tools or low speed power tools used. Battery Acids See also Acids and Alkalis. Gases released
during charging are explosive. Never use naked flames or allow sparks near charging or recently
charged batteries. Make sure there is adequate ventilation. Brake and Clutch Linings and Pads
See Asbestos. Brake Fluids (Polyalkylene Glycols) See also Fire. Splashes to the skin and eyes
are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation vapor hazards do not
arise at ambient temperatures because of the very low vapor pressure. Brazing See Welding.
Chemical Materials See also Legal Aspects. Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should
always be used with caution and stored and handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts. The effects of
excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life expectancy. Chemical Materials - Do's
Chemical Materials - Do Nots Chlorofluorocarbons (CFC) There is concern in the scientific
community that CFCs and Halons are depleting the upper ozone layer which filters out harmful
ultraviolet radiation. Decreased filtration of ultraviolet radiation may result in increases in skin
cancer, cataracts and immune system suppression in humans, as well as decreased productivity of
crops and aquatic systems. CFCs are used primarily as refrigerants in vehicle air conditioning
systems and as aerosol propellants. Halons are used as fire extinguishants. Clutch Fluids See
Brake fluids. Clutch Linings and Pads See Asbestos. Corrosion Protection Materials See also
Solvents, Fire. Highly flammable, flammable – observe No Smoking policy. These materials are
varied and the manufacturers instructions must be followed. They may contain solvents, resins or
petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces. Cutting See Welding. Dewaxing See
Solvents and Fuels (Kerosene). Dusts Powder, dusts or clouds may be irritant, harmful or toxic.
Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation is inadequate. Fine dusts of combustible
material can present an explosion hazard. Avoid explosive limits and sources of ignition. Electric
Shock Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition. Make sure that electrical equipment is maintained in good condition
and frequently tested. Faulty equipment should be labeled and preferably removed from the
workstation. Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked
or otherwise damaged. Make sure that electrical equipment and flexes do not come into contact
with water. Make sure that electrical equipment is protected by the correct rated fuse. Never
misuse electrical equipment and never use equipment that is in any way faulty. The results could
be fatal. Make sure that the cables of mobile electrical equipment cannot get trapped and
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damaged, such as in a vehicle hoist. Make sure that the designated electrical workers are trained
in basic First Aid. In cases of electrocution: Engine Oils See Lubricants and Grease. Exhaust
Fumes These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only
under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Gasoline (petrol) engine There may not be adequate warning of odor or of irritation before toxic or
harmful effects arise. These may be immediate or delayed. Diesel engine Soot, discomfort and
irritation usually give adequate warning of hazardous fume concentrations. Fibre Insulation See
also Dusts. Used in noise and sound insulation. The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and not a chemical effect. Precautions should be
taken to avoid excessive skin contact through careful organization of work practices and the use of
gloves. Fire See also Welding, Foams, Legal Aspects. Many of the materials found on or
associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if
burnt. Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes. Make sure, before using electrical or
welding equipment, that there is no fire hazard present. Have a suitable fire extinguisher available
when using welding or heating equipment. First Aid Apart from meeting any legal requirements it is
desirable for someone in the workshop to be trained in First Aid procedures. Splashes in the eye
should be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed
with soap and water. In case of cold burns, from alternative fuels, place affected area in cool to
cold water. Individuals affected by inhalation of gases and fumes should be removed to fresh air
immediately. If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container or label. Do not induce vomiting unless this
action is indicated on the label. Fluoroelastomer See Viton. Foams - Polyurethane See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning. Follow
manufacturers instructions. Unreacted components are irritating and may be harmful to the skin
and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma,
bronchial medical problems, or histories of allergic diseases should not work in or near uncured
materials. The components, vapors or spray mists can cause direct irritation, sensitivity reactions
and may be toxic or harmful. Vapors and spray mists must not be inhaled. These materials must be
applied with adequate ventilation and respiratory protection. Do not remove the respirator
immediately after spraying; wait until the vapors/mists have cleared. Burning of the uncured
components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames
or the use of electrical equipment during foaming operations and until vapors/mists have cleared
should not be allowed. Any heat cutting of cured foams or partially cured foams should be
conducted with extraction ventilation. See also the vehicle Body Repair Manual. Freon See Air
Conditioning Refrigerant. Fuels See also, Fire, Legal Aspects, Chemicals and Solvents. Avoid skin
contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol) Highly flammable - observe No Smoking policy. Swallowing can result in mouth
and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs,
through vomiting, is a very serious hazard. Gasoline dries the skin and can cause irritation and
dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor
gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the
concentration of gasoline vapors must be kept very low. High concentrations will cause eye, nose
and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high
concentrations will result in rapid loss of consciousness. Make sure there is adequate ventilation
when handling and using gasoline. Great care must be taken to avoid the serious consequences of
inhalation in the event of vapor build up arising from spillages in confined spaces. Special
precautions apply to cleaning and maintenance operations on gasoline storage tanks. Gasoline
should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid. Gas-oil
(Diesel Fuel) Combustible. Gross or prolonged skin contact with high boiling point gas oils may
also cause serious skin disorders including skin cancer. Kerosene (Paraffin) Used also as heating
fuel, solvent and cleaning agent. Flammable - observe No Smoking policy. Irritation of the mouth
and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration
into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes
in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to
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harmful vapors. Exposure to mists and vapors from kerosene at elevated temperature should be
avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is
adequate ventilation. Alternative Fuel Highly flammable. Observe ``NO SMOKING" signs. Make
sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be
taken to avoid the serious consequences of inhalation in the event of vapor build up in confined
spaces. Inhalation in high concentrations may cause dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result in loss of consciousness. Contact with liquefied
petroleum gas (LPG) or compressed natural gas (CNG) to the skin may cause cold burns and frost
bite. Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves
should be worn during removal and installation of LPG/CNG fuel system components. LPG/CNG
fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or
even death. If a leak is detected, under no circumstances attempt to seal the leak by tightening the
union/connection until the fuel in the system or component is depressurized. Once tightened the
system should be checked for integrity following the specified procedures. If the fuel tank is to be
removed for service or repair the fuel must be evacuated using dedicated equipment and following
the specified procedures. Gas Cylinders See also Fire. Gases such as oxygen, acetylene, argon
and propane are normally stored in cylinders at pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders to avoid mechanical damage to them or to the
valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings. Cylinders should be stored in well-ventilated enclosures, and protected from ice and
snow, or direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in
close proximity to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders
and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving
gas cylinders. Gases See Gas Cylinders. Gaskets (Fluoroelastomer) See Viton. General Workshop
Tools and Equipment It is essential that all tools and equipment are maintained in good condition
and that the correct safety equipment is used where required. Never use tools or equipment for any
purpose other than that for which they were designed. Never overload equipment such as hoists,
jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always
immediately apparent and may result in a fatal failure the next time that the equipment is used. Do
not use damaged or defective tools or equipment, particularly high-speed equipment such as
grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious
injury. Wear suitable eye protection when using grinding, chiseling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment. Make sure there is adequate ventilation to
control dusts, mists and fumes. High Pressure Air, Lubrication and Oil Test Equipment See also
Lubricants and Greases. Always keep high-pressure equipment in good condition, and regularly
maintained, particularly at joints and unions. Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious
injury. Halon See CFCs. Legal Aspects There are many laws and regulations relating to health and
safety in the use and disposal of materials and equipment in a workshop. For a safe working
environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and
local authorities. Lubricants and Greases Avoid all prolonged and repeated contact with mineral
oils. All lubricants and greases may be irritating to the eyes and skin. Transmission Fluids Safety
instructions Certain Transmission and Power Steering fluids supplied to Ford may contain additives
which have the potential to cause skin disease (dermatitis) to exposed persons. The dermatitis may
be irritant or allergic in nature. Risks are higher where prolonged or repeated skin contact with a
fluid may occur. These fluids are used for vehicle initial fill and service purposes. This sub-section
is to: Control measures Workplace risk assessments made under national chemical control
regulations should identify operations involving the fluids as potentially hazardous and specify
workplace control and worker awareness measures. In such circumstances, the relevant Material
Safety Datasheet (see the details specified below) which specifies hazards and control measures
in detail should be made available for guidance. Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin contact. Work practices should be organised so as
to minimise the potential for skin contact. This may include the use of drip trays, absorbents,
correct fluid handling equipment (funnels etc), and workplace housekeeping measures such as the
cleaning of contaminated surfaces. Personnel engaged in operations where skin contact could
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occur (such as fluid draining or filling) should wear impervious gloves made from nitrile rubber,
certified to a chemical protection standard, e.g. Europe Standard EN374. This glove type is widely
available from reputable suppliers of gloves for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the inside they
should be replaced. Eye protection with safety glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products may offer some supplementary protection, but
such barrier creams should not be used in place of protective clothing. If accidental skin contact
occurs with the fluids, wash the area thoroughly with soap or skin cleanser and water. Accidental
eye contact should be dealt with as per normal first aid practices, by flushing the eyes with an eye
wash or clean cool water for 10 minutes, after which medical attention should be obtained. Remove
and launder clothing which becomes contaminated with the fluids. Do not place rags contaminated
with fluid in clothing pockets. Wash thoroughly after completing operations where skin exposure
may have occurred. It is important that personnel do not smoke, eat or drink whilst handling the
fluids or affected transmissions. These measures are designed to limit the risk from accidental
ingestion. Label any decanted fluid properly/use an equivalent label to that on original product
containers. Clean up any spills promptly using an inert absorbent and wash down contaminated
surfaces with detergent and water. Dispose of any waste fluids safely as hazardous waste. Safety
Data Sheets Safety Data Sheets, which detail specific material handling instructions and
precautions are available from the respective national sales company, and via internet
www.msds.ford.com. Used Engine Oil Prolonged and repeated contact with mineral oil will result in
the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition,
used engine oil contains potentially harmful contaminants, which may cause skin cancer. Adequate
means of skin protection and washing facilities must be provided. Do not employ used engine oils
as lubricants or for any application where appreciable skin contact is likely to occur. Environmental
Precautions Burning used engine oil in small space heaters or boilers can be recommended only
for units of approved design. If in doubt check with the appropriate local authority and manufacturer
of approved appliances. Dispose of used oil and used oil filters through authorized waste disposal
contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt,
contact the relevant local authority for advice on disposal facilities. It is illegal to pour used oil on to
the ground, down sewers or drains, or into watercourses. Noise Some operations may produce
high noise levels, which could, in time, damage hearing. In these cases, suitable ear protection
must be worn. Noise Insulation Materials See Foams, Fibre Insulation. O-Rings (Fluoroelastomer)
See Viton. Paints See also Solvents, Chemical Materials. Highly flammable, flammable - observe
No Smoking policy One Pack Can contain harmful or toxic pigments, driers and other components
as well as solvents. Spraying should be carried out only with adequate ventilation. Two Pack Can
also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers
instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and
Sealers under Adhesives and Sealers. Spraying should preferably be carried out in exhausted
ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in
booths should wear appropriate respiratory protection. Those doing small-scale repair work in the
open workshop should wear air-fed respirators. Pressurized Equipment See High Pressure Air,
Lubrication and Oil Test Equipment. Solder Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be
produced. Some fumes may be produced by the application of any flame to surfaces coated with
grease, and inhalation of these should be avoided. Removal of excess solder should be
undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects
if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected
and removed promptly to prevent general air contamination by lead. High standards of personal
hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Solvents See also Chemical Materials, Fuels (Kerosene), Fire. For example acetone, white spirit,
toluene, xylene, trichloroethane. Used in cleaning and dewaxing materials, paints, plastics, resins
and thinners. Some may be highly flammable or flammable. Skin contact will degrease the skin and
may result in irritation and dermatitis following repeated or prolonged contact. Some can be
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absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe
irritation and could lead to loss of vision. Brief exposure of high concentrations of vapors or mists
will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower
concentrations of vapors or mists, for which there might not be adequate warning indications, can
cause more serious toxic or harmful effects. Aspiration into the lungs, for example through
vomiting, is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and
clothing. Wear protective gloves, goggles and clothing if necessary. Make sure there is good
ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly
sealed. Do not use in confined spaces. When spraying materials containing solvents, for example
paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the
absence of adequate general ventilation. Do not apply heat or flame except under specific and
detailed manufacturers instructions. Sound Insulation See Fibre Insulation, Foams. Suspended
Loads There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load, for example a suspended engine. Always make sure that
lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the
job, in good condition and regularly maintained. Transmission Brake Bands See Asbestos.
Underseal See Corrosion Protection. Viton In common with many other manufacturers vehicles,
some components have O-rings, seals or gaskets, which contain a material known as `Viton'. Viton
is a fluoroelastomer, that is a synthetic rubber type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel and Tecmoflon. When used under design
conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400°C, the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact,
into the general body system. O-rings, seals or gaskets which have been exposed to very high
temperatures will appear charred or as a black sticky substance. DO NOT; under any
circumstances touch them or the attached components. Enquiries should be made to determine
whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If
they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious, as the material may
be Viton or any fluoroelastomer. If Viton or any other fluoroelastomers have been used, the
affected area should be decontaminated before the commencement of work. Disposable heavy
duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralize the acid before disposing of the
decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be
discarded carefully and safely. Welding See also Fire, Electric Shock, Gas Cylinders. Welding
processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding. Resistance
Welding This process may cause particles of molten metal to be emitted at a high velocity, and the
eyes and skin must be protected. Arc Welding This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin burns to the operator and to other persons nearby.
Gas-shielded welding processes are particularly hazardous in this respect. Personal protection
must be worn, and screens used to shield other people. CONTACT LENS WEARERS ARE
ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc
spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This
may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and
appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes
and gases from the metals being welded, the rods and from any applied coatings or contamination
on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable
welding work is anticipated. In extreme cases or confined spaces where adequate ventilation
cannot be provided, air-fed respirators may be necessary. Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to
prevent leakage of these gases, with consequent risk of fire and explosion. The process will
produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye
protection should be used, but the ultra-violet emission is much less than that from arc welding,
and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and
Page 10
gases may be produced from coatings on the work, particularly during cutting away of damaged
body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be
produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of
fumes and expert advice may be required. SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE
ANY WELDING OR CUTTING TAKES PLACE ON VESSELS, WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles Decals showing warning symbols will be found on various vehicle
components. These decals must not be removed. The warnings are for the attention of
owners/operators and persons carrying out service or repair operations on the vehicle. The most
commonly found decals are reproduced below together with an explanation of the warnings. White
Spirit See Solvents.
Page 11
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-01 Identification
Codes > Description and Operation > Identification Codes
The vehicle identification plate is located in the engine compartment on the front body
crossmember. The codes stamped on the plate during production enable precise details of the
vehicle build specification to be established. The Vehicle Identification Number (VIN) may also be
checked through the windshield. Vehicle Identification Number VIN Position 1, 2 and 3 — World
Manufacturer Identifier VIN Position 4 and 10 — Body Type VIN Positions 5 and 6 — Constant X
VIN Position 7 — Product Source Company VIN Position 8 — Assembly Plant VIN Position 9 —
Model Range VIN Position 11 — Year of Manufacture VIN Position 12 — Month of Manufacture up to 2000 Month of Manufacture - 2000 Onwards VIN Position 13 to 17 — Five Digit Number
Vehicle serial number Vehicle Certification Label (typical) or VIN Plate Item 1 to 6: Vehicle
Certification Label Item 7: Smoke Value (Diesel only) Item 8 and 9: Variants Item 10: Emission
Level Codes Item 11: Body Color Codes For vehicles built in continental plants, the second digit of
the paint code denotes the original model year of that colours introduction. For vehicles built in UK
plants, the second digit of the paint code denotes the current model year. Item 12: Interior Trim
Codes Item 13: Transaxle Final Drive Ratio Item 14: Transaxle Codes Item 15: Engine Codes Item
16: Hand of Drive
Page 12
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Diagnosis and Testing > General Procedures > Front Toe Adjustment
Check Adjustment
Page 13
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Bearing
Adapter for 204-158 (Thrust Pad) 204-158-01 (14-038-01) Collet for 205-295 204-158 (14-038)
Remover, Bearing (Main Tool) 205-295 (15-050A) Installer, Rear Hub Oil Seal 205-075 (15-036)
Installer/Aligner, Crankshaft Rear Oil Seal 303-171-03 (21-102-03) Installer, Front Wheel Bearing
204-160 (14-040) Installer, Front Hub Oil Seal 204-256 (14-046) Removal Installation
Page 14
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm
Removal Installation
Page 15
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Stabilizer Bar
Alignment Pins, Subframe 205-316 (15-097A) Removal Installation
Page 16
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Knuckle
Separator, Ball Joint 211-020 (13-006) Adaptor for 204-158 204-158-01 (14-038-01) Lever, Wheel
Knuckle 204-159 (14-039) Installer, Halfshaft 204-161 (14-041) Removal Installation
Page 17
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm Ball Joint
Removal Installation
Page 18
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Strut and Spring Assembly
Lever, Wheel Knuckle 204-159 (14-039) Removal Installation
Page 19
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Strut and Spring
Assembly
Compressor, Coil Spring 204-167 (14-042) Adapters for 204-157 204-167-01 (14-042-01)
Disassembly Assembly
Page 20
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Beam Axle
Removal Installation
Page 21
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Trailing Arm Bushing
Remover/Installer, Pivot Bushing 205-342 (15-110) Adaptor for 205-342 205-342-01 (15-110-01)
Adaptor for 205-342 205-342-02 (15-110-02) Removal Installation
Page 22
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Spindle
Removal Installation
Page 23
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Strut and Spring Assembly
Removal Installation
Page 24
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Bearing
Installer, Front Hub Oil Seal 204-066 (14-018) Installer, Wheel Hub Bearing Cone and Oil Seal
205-101 (15-051) Remover, Oil Seal 303-112 (21-051) Removal Installation
Page 25
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Strut and Spring
Assembly
Compressor, Coil Spring 204-167 (14-042) Adapters for 204-167 307-278 (15-111) Disassembly
Assembly
Page 26
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02B Rear Suspension - Courier >
Description and Operation > Rear Suspension
The Courier has a rear axle assembly design that is unlike any rear axle assembly that has ever
been used on the Fiesta range. The Courier rear axle assembly consists of two trailing arms
connected by a V-shaped section beam, two rear axle carriers, two stabiliser and two torsion bars
fixed at the centre by a connecting link. The axle carriers are secured to the body by four bolts. The
axle assembly is also supported by two shock absorbers.
Page 27
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02B Rear Suspension - Courier >
Description and Operation > Diagnosis and Testing > Removal and Installation > Axle
Removal Installation
Page 28
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02B Rear Suspension - Courier >
Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Stabilizer Bar
Slide Hammer 205-047 (15-011) Adaptor for 205-047 205-011-03 (15-011-03) Alignment Fixture,
Rear Suspension 205-305 (15-087) Removal Installation
Page 29
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02B Rear Suspension - Courier >
Description and Operation > Diagnosis and Testing > Removal and Installation > Wheel Hub
Removal Installation
Page 30
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft LH
Installer, drive halfshaft 204-161 (14-041) Remover, drive halfshaft 308-256 (16-089) Removal
Installation
Page 31
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft RH
Installer, drive halfshaft 204-161 (14-041) Boot clamp tightening tool 204-169 (14-044) Removal
Installation
Page 32
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Inner Constant Velocity (CV) Joint Boot
Boot clamp tightening tool 14-044 Removal Installation
Page 33
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Halfshaft LH
Boot clamp tightening tool 204-169 (14-044) Disassembly Assembly
Page 34
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Halfshaft RH
Boot clamp tightening tool 204-169 (14-044) Separating tool 205-310 (15-091) Bridge, drive pinion
bearing remover 205-311 (15-092) Disassembly Assembly
Page 35
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02A Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Drum
Removal Installation
Page 36
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02A Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Shoes
Removal Installation
Page 37
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02A Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Wheel Cylinder
Removal Installation
Page 38
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02A Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Backing Plate
Removal Installation
Page 39
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02B Drum Brake - Courier >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Shoes - Courier
Removal Installation
Page 40
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Pads
Brake piston retracting tool 12-014 Removal Installation
Page 41
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Parking Brake Cable Adjustment
Adjustment
Page 42
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Control
Removal Installation
Page 43
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Warning Indicator Switch
Removal Installation
Page 44
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation Courier > Description and Operation > Diagnosis and Testing > Removal and Installation > Cable and Conduit
Removal Installation
Page 45
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Pedal
Removal Installation
Page 46
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Vacuum Pump
Removal Installation
Page 47
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Hydraulic Control Unit (HCU)
Removal Installation
Page 48
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor
Removal Installation
Page 49
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Speed Sensor
Removal Installation
Page 50
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Speed Sensor Ring
Adaptor, Thrust Pad, Wheel Hub 204-158-01 (14-038-01) Remover, Bearing 205-310 (15-091)
Remove/Installer, Crankshaft Bearing 303-433 (21-185) Removal Installation
Page 51
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor Ring
Remove/Installer, Crankshaft Bearing 303-433 (21-185) Removal Installation
Page 52
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > Steering System
Principles of Operations The steering wheel rotational movement is transferred to the steering gear
through the steering column shaft. The steering gear converts this rotational movement, through
the action of the rack and pinion gear into lateral movement. This movement in turn is transferred
to the wheel knuckle through the tie-rods and tie-rod ends. Hydraulic fluid under pressure is
supplied to the steering gear by the power steering pump. As the steering wheel is rotated, the
hydraulic fluid is allowed to pass through the steering gear valve to one side of a double-acting
piston, dependent on which direction the steering wheel is rotated. The fluid moves the piston,
which forms part of the steering gear, giving power assistance to the effort required to turn the front
road wheels. Variants fitted with the 1.8L DI engine and air-conditioning have an Electro-hydraulic
power steering pump fitted. The pump is controlled by the EEC V Powertrain Control Module
(PCM) and starts to work as soon as the engine is running. Inspection and Verification Visual
Inspection Chart Symptom Chart Symptom Chart PINPOINT TEST A : THE
ELECTRO-HYDRAULIC POWER STEERING PUMP IS INOPERATIVE Component Tests Steering
Linkage Inspect the steering gear boots for cuts, deterioration, twisting or distortion. make sure the
boots are secure. Install new boots or clamps as necessary.
Page 53
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing
Page 54
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - Vehicles Built Up To:
02-2000 1.8L Duratorq-TDDi (Lynx) Diesel
Page 55
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - Vehicles Built From:
02-2000 1.8L Duratorq-TDDi (Lynx) Diesel, Vehicles With: Air Conditioning
Page 56
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-01 Manual Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear
Separator, ball joint 13-006 Removal Installation
Page 57
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - Vehicles Built From: 01-1999
1.3L Endura-E (HCS), Vehicles Without: Air Conditioning
Expander, Teflon seal 13-015 Remover, power steering pump pulley 13-022 Installer, camshaft
pulley 21-192 Removal Installation
Page 58
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - Vehicles Built From: 02-2000
1.8L Diesel, Vehicles With: Air Conditioning
Removal Installation
Page 59
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Pinion Seal
Adaptor for 16-042A-01 16-042A Remover, oil seal 21-143 Remover, oil seal 21-151 Removal
Installation
Page 60
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear
Separator, ball joint 211-020 (13-006) Expander, Teflon seal 211-188 (13-015) Alignment pins,
subframe 205-316 (15-097A) Socket, hydraulic line union 211-268A (13-026A) Removal Installation
Page 61
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Fluid Cooler
Removal Installation
Page 62
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 1.4L-1.6L
Socket, Hydraulic Line Union Nut 211-269 (13-027) Socket, Hydraulic Line Union Nut 211-268A
(13-026A) Expander, Teflon Seal 211-188 (13-015) Removal Installation
Page 63
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear to Fluid Cooler Return Hose
Socket, Hydraulic Line Union Nut 211-268A (13-026A) Expander, Teflon Seal 211-188 (13-015)
Removal Installation
Page 64
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Tie Rod End
Separator, ball joint 13-006 Removal Installation
Page 65
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Boot
Removal Installation
Page 66
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Removal and Installation > Steering Wheel
Removal Installation
Page 67
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Description and Operation > Diagnosis and Testing > Steering Column Switches
Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE IGNITION SWITCH IS INOPERATIVE PINPOINT TEST B : NO POWER
IN ACC PINPOINT TEST C : NO POWER IN RUN PINPOINT TEST D : NO POWER IN START
PINPOINT TEST E : THE MULTIFUNCTION SWITCH/HAZARD WARNING SWITCH DOES NOT
OPERATE CORRECTLY
Page 68
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Column Multifunction Switch
Removal Installation
Page 69
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Diameter
Page 70
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Clearance
Page 71
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft End Play
1. End play = maximum value minus minimum value
Page 72
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Surface Inspection
Page 73
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft End Play
Page 74
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Lobe Lift
Page 75
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Diameter
Page 76
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft Main Bearing Journal Diameter
Page 77
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring End Gap
Page 78
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin to Bore Diameter
Page 79
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin Diameter
Page 80
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Inspection
Page 81
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring-to-Groove Clearance
Page 82
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Connecting Rod Large End Bore
Page 83
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Head Distortion
Page 84
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Stem Diameter
Page 85
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Seat Inspection
Page 86
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Flywheel Inspection
Page 87
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > Engine
General The basic engine for the Fiesta is the Endura-E engine. This familiar 1,3 liter engine has
been revised and is now available in two versions with 37 kW (50 PS) and 44 kW (60 PS). The 37
kW variant will only be available in Germany and Austria. The main changes to the previous model
include sequential, electronically controlled multiport fuel injection, a new aluminium oil pan and a
thermoplastic intake manifold. From '99 1/2 MY the mass air flow (MAF) and the intake air
temperature (IAT) sensor are no longer installed. The new temperature/manifold absolute pressure
(T-MAP) sensor will be integral with the intake manifold. Cylinder Block Thread repairs to the
cylinder block are permitted provided that Helicoil thread inserts are used. The remaining material
thickness must be at least 3,2 mm for diameters up to 9,5 mm and at least 4,8 mm for larger
diameters. Water plugs must not be removed. Crankshaft The crankshaft runs on five bearings.
The bearing caps are numbered at the factory and should be refitted accordingly during installation.
The first main bearing has a seat for the tensioning arm of the chain tensioner. The crankshaft and
the main bearing caps have colored marks which indicate their size. With the bearing caps these
marks are on the bearing caps themselves, and on the crankshaft the colored marks are on the
crank webs. Cylinder Head The cast iron cylinder head is positioned on the cylinder block with two
sleeves, and fastened with ten bolts. The cylinder head mating face is allowed to show distortion of
0,25 mm over the whole length. Thread repairs are permitted provided that Helicoil thread inserts
are used. Cylinder Head Gasket The cylinder head gasket is made of aramide fiber with filler and
must be renewed every time it is removed. The gasket is steel-coated for protection around the oil
pressure bore and the cylinder bore. Pistons The pistons are made of an aluminium-silicone alloy,
and have three piston rings: Barrel faced plane ring (top) Napier ring (middle) Oil scraper ring
(bottom) Piston rings can be renewed separately, without reworking the cylinder liners. On
installation, the piston ring gaps must be distributed around the circumference and spaced at least
90 degrees apart. The arrows on the piston crown point forwards. Oil Pan On installation, the
tightening sequence for the bolts must be observed. Renew the gasket of the aluminium oil pan if
Page 88
there is any visible damage to it. Sealer should be applied to the cylinder block when installing the
oil pan. Thread repairs on the oil pan are permitted provided Helicoil thread inserts are used. Intake
Manifold The intake manifold is made of thermoplastic. This design has two advantages: it reduces
weight and conducts less heat than the die-cast version. The use of plastic also improves the flow
characteristics, reduces the tendency to condensation at cold start and improves the response of
the engine during a warm start. Valve Train The valve timing is controlled by the crankshaft via a
single roller chain to the low lying camshaft. The camshaft transmits the timing actions to the valves
via tappets, push rods and a rocker shaft. Thermostat The gasket of the thermostat housing must
be renewed every time the thermostat housing is fitted.
Page 89
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > Valve Clearance
Page 90
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Intake Manifold
Removal Installation
Page 91
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Crankshaft Front Seal
Installer, timing cover oil seal 303-091 (21-046) Remover, crankshaft oil seal 303-293 (21-143)
Removal Installation
Page 92
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Crankshaft Rear Seal
Adapter for 303-172 303-171-01 (21-102-01) Adapter for 303-172 303-171-02 (21-102-02A)
Adapters for 303-171-02 303-171-04 (21-102-04) Installer/aligner, crankshaft rear oil seal 303-172
(21-102) Remover, crankshaft rear oil seal 303-336 (21-151) Immobilizing tool, flywheel 303-393
(21-168) Aligner, clutch disk 308-204 (16-067)
Page 93
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Valve Seals
Replacer, valve stem seals 303-037 (21-007 A) Compressor, valve spring 303-060 (21-024)
Adapter for 303-060 303-060-01 (21-024-01) Adapter for 303-060 303-060-05 (21-024-05) Installer,
valve collets 303-362 (21-156) Adapter, air supply (cylinder head) 303-363 (21-157) Pliers, valve
stem oil seal 303-390 (21-165) Removal Installation
Page 94
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Cylinder Head
Angle gauge 303-174 (21-540) Removal Installation
Page 95
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Removal > Engine
Separator, ball joint 211-020 (13-006) Engine lifting bracket 303-122 (21-068A) Remover/installer,
coolant hose clip 303-397 (24-003) Remover, drive halfshaft 308-237 (16-087) Remover, drive
halfshaft 308-256 (16-089) Removal
Page 96
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Removal > Disassembly > Engine
Immobilizing tool, flywheel 303-393 (21-168) Assembly stand 303-435 (21-187) Mounting frame for
303-435 303-435-02 (21-050 A) Disassembly
Page 97
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > General Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Assembly > Engine
Installer, timing cover oil seal 303-091 (21-046) Adapter for 303-172 303-171-01 (21-102-01)
Adapter for 303-172 303-171-02 (21-102-02A) Adapters for 303-171-02 303-171-04 (21-102-04)
Installer/aligner, crankshaft rear oil seal 303-172 (21-102) Angle gauge 303-174 (21-540)
Immobilizing tool, flywheel 303-393 (21-168) Assembly stand 303-435 (21-187) Mounting frame for
303-435 303-435-02 (21-050A) Aligner, clutch disc 308-204 (16-067) Assembly 1. Coat the spark
plug threads with lubricant .
Page 98
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 1.25L-1.4L Zetec-SE
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > Valve Clearance
Compressor, valve clearance adjustment 303-563 (21218) Remover/installer, valve adjusting shim
303-563-01 (21801) Spark plug connector pliers 303-622 (21226) Adjust
Page 99
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 1.25L-1.4L Zetec-SE
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Crankshaft
Front Seal
Remover, crankshaft oil seal 303-293 (21143) Installer, crankshaft oil seal 303-395 (21171)
Removal Installation
Page 100
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 1.25L-1.4L Zetec-SE
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Valve Seals
Installer, valve stem oil seals 303-037 (21007A) Compressor, valve spring 303-361 (21155)
Adapter for 303 - 361 303-361-04 (2115504) Adapter for 303 - 361 303-361-05 (2115505) Installer,
valve collets 303-362 (21156) Connector, air supply (cylinder head) 303-363 (21157) Pliers, valve
stem seals 303-508 (21211) Removal Installation
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