Ford Festiva. Manual — part 29

2. Remove main bearing cap bolts. Remove cap and lower bearing insert. Use bearing remover or fabricated cotter key to remove upper

bearing insert. Insert bearing remover in journal lubrication hole. Rotate crankshaft in normal direction of operation only. Repeat
procedure for remaining main bearings.

3. Check bearings for abnormal wear. Check crankshaft for grooves, scratches and pitting. Using Plastigage method, check clearance of

main bearing-to-crankshaft. Always keep at least 2 bearings and caps tight during clearance check. See, at end of article,

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

table under ENGINE SPECIFICATIONS.

4. Lubricate and install new bearings in cap and block. Match bearing tangs with notch in cap and block. Position cap in its proper

location and position. Install cap bolts and tighten to specification. See

TORQUE SPECIFICATIONS

table at end of article. Repeat

procedure for remaining main bearings.

CRANKSHAFT END PLAY

Check crankshaft end play with dial indicator. End play should be .0031-.0111" (.08-.282 mm). Service limit is .012" (.30 mm). If end play is
not within specification, replace thrust bearings as necessary.

CYLINDER BLOCK

1. Using straightedge and feeler gauge, check entire cylinder head surface of cylinder block. Ensure warpage does not exceed .006" (.15

mm). If warpage exceeds specification, cylinder block surface can be machined a maximum of .008" (.20 mm).

2. Replace cylinder block if it needs to be machined more than .008" (.20 mm). Check cylinder bore for wear, out-of-round, taper and

piston fit. See

CYLINDER BORE SPECIFICATIONS

table. Oversize pistons are available in .010" and .020" (.25 mm and .50 mm).

CYLINDER BORE SPECIFICATIONS

LUBRICATION

ENGINE OILING SYSTEM

Oiling system is force-feed type and uses a full-flow oil filter. Oil is retrieved from oil pan by oil pump pick-up tube and distributed to oil
filter. Oil is then filtered and routed throughout engine.

Crankcase Capacity

1.3 L crankcase capacity is 3.2 qts. (3.0 L) without filter change and 3.6 qts. (3.4 L) with filter change. For 1.6 L vehicles, capacity is 3.2 qts
(3.2 L) without filter and 3.72 qts. (3.5 L) with filter.

Normal Oil Pressure (Hot)

Normal oil pressure is 50-64 psi (3.5-4.5 kg/cm

2

) at 3000 RPM.

Pressure Regulator Valve

Pressure regulator valve is located in oil pump body and is nonadjustable.

OIL PUMP

Removal

Remove oil pan, pick-up tube and screen, timing belt and crankshaft sprocket. Remove front engine cover bolts and remove front cover.
Remove bolts retaining pump cover to back side of front cover housing.

2) Remove pump cover and inner and outer gears. Pry out front seal from front cover. Remove cotter pin. Remove pressure regulator retainer,
spring and valve.

OIL PUMP SPECIFICATIONS

or replacement.

Application

In. (mm)

Cylinder Diameter

Standard Bore

1.3L

2.7953-2.7960 (71.000-71.019)

1.6L

3.0709-3.0716 (78.000-78.019)

Maximum Bore

1.3L

2.8020 (71.17)

1.6L

3.0905-3.0913 (78.500-78.519)

Maximum Out-Of-Round & Taper

.0007 (.019)

Piston-To-Bore Clearance

.006 (.15)

Application

In. (mm)

Inner Gear-To-Outer Gear

1.3L

.008 (.20)

1.6L

.0008-.0063 (.02-.16)

Outer Gear-To-Housing

1.3L

.009 (.22)

1.6L

.0035-.0071 (.09-.18)

End Play

1.3L

.006 (.14)

Installation

1. Install pressure regulator valve, spring, retainer and new cotter pin. Press a new seal in front cover housing. Install outer and inner gears

in housing. Install pump cover. Coat bolts with Loctite and tighten to specification. See

TORQUE SPECIFICATIONS

table at end of

article.

2. Install new gasket and install front cover housing. Install new gasket and install pick-up tube and screen. Tighten all bolts/nuts to

specification. To complete installation, reverse removal procedure.

ENGINE COOLING

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

1.6L

.0012-.0043 (.03-.11)

NOTE:

Refer to

WATER PUMP

under REMOVAL & INSTALLATION in this article.

Application

Ft. Lbs. (N.m)

"A" Arm Front Bolt

72-86 (97-117)

A/C Compressor Bolt

29-40 (39-54)

Camshaft Sprocket Bolt

36-45 (49-61)

Connecting Rod Nut

Step 1

11-13 (15-18)

Step 2

1.3L

22-25 (30-34)

1.6L

35-38 (47-52)

Crankshaft Pulley Bolts

9-13 (12-17)

Crankshaft Sprocket Bolt

80-87 (108-118)

Crossmember-To-Body Bolt

1.3L

47-66 (64-89)

1.6L

27-37 (35-50)

Cylinder Head Bolt

Step 1

35-40 (48-54)

Step 2

56-60 (76-81)

Exhaust Manifold-To-Cylinder Head

1.3L

12-17 (16-23)

1.6L

29-42 (39-57)

Exhaust Pipe-To-Manifold

29-42 (39-57)

Exhaust Pipe-To-Support Bracket

32-45 (43-61)

Flywheel Bolt

71-76 (96-103)

Front Cover Housing Bolt (1.3L)

14-19 (19-26)

Front Engine Mount Nut

32-38 (43-52)

Heater Tube

32-45 (43-61)

Intake Manifold-To-Cylinder Head

1.3L

14-20 (19-27)

1.6L

47-66 (64-89)

Main Bearing Cap Bolts

40-44 (54-59)

O2 Sensor

27-33 (37-45)

Oil Pump Cover Bolt (1.6L)

14-18 (19-25)

P/S Pump Bracket (Nut & Bolt)

35-49 (47-66)

P/S Adjusting Nut

27-38 (37-52)

P/S Pivot Bolt

23-34 (31-46)

Pulse Air Tube Nut

23-34 (31-46)

Rear Engine Mount Nut

1.3L

21-34 (28-46)

1.6L

47-66 (64-89)

Rocker Arm Shaft Bolts

16-21 (22-28)

Side Engine Mount Nuts

1.3L

29-40 (39-54)

1.6L
RH

49-67 (67-91)

LH

33-48 (45-65)

Spark Plug

11-17 (15-23)

Thermostat Housing Bolt

14-22 (19-30)

Timing Belt Tensioner Adjusting Bolt

14-19 (19-26)

Turbo Oil Supply Tube

Engine Block Side

12-18 (16-24)

Banjo Side

(1)

106-159 (12-18)

Turbo-To-Manifold

29-42 (39-57)

Water Outlet Bolt

14-22 (19-30)

Water Pump Pulley Bolts (1.3L)

36-45 (49-61)

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

Water Pump-To-Block

14-19 (19-26)

Wheels

66-89 (90-120)

INCH Lbs. (N.m)

Camshaft Bearing Cap Bolt

97-124 (11-14)

Camshaft Cover

71-97 (8-11)

Camshaft Thrust Plate Bolt

71-106 (8-12)

Front Cover Housing Bolt (1.6L)

71-97 (8-11)

Oil Pan Bolt

1.3L

71-80 (8-9)

1.6L

71-97 (8-11)

Oil Pressure Sender

106-159 (12-18)

Oil Pump Cover Bolt (1.3L)

89-133 (10-15)

Pickup Tube-To-Oil Pump Bolt

71-97 (8-11)

Radiator Fan Bracket

71-97 (8-11)

Rear Engine Plate Bolt

71-97 (8-11)

Temperature Sender

44-89 (5-10)

Timing Belt Cover Bolt

71-97 (8-11)

Valve Cover Bolt

44-79 (5-9)

Water Pump Pulley Bolts (1.6L)

71-97 (8-11)

(1)

This specification is INCH Lbs.

Application

Specification

Displacement

1.3L

80.8 Cu. In. (1.3L)

1.6L

97.4 Cu. In. (1.6L)

Bore

1.3L

2.80" (71.0 mm)

1.6L

3.07" (78 mm)

Stroke (1.3L & 1.6L)

3.29" (83.6 mm)

Compression Ratio

1.3L

9.7:1

1.6L

N/A

Fuel System

PFI

HP@RPM

1.3L

58 @ 5000

1.6L

(Non-Turbo)

100 @ 5750

(Turbo)

132 @ 6000

Torque Ft. Lbs.@RPM

1.3L

73 @ 3000

1.6L

(Non-Turbo)

95 @ 5500

(Turbo)

136 @ 3000

Application

In. (mm)

Crankshaft

End Play

.0031-.0111 (.080-.282)

Runout (Maximum)

.002 (.05)

Main Bearings

Journal Diameter

1.9661-1.9668 (49.938-

49.956)

Journal Out-Of-Round

.002 (.05)

Journal Taper

.002 (.05)

Oil Clearance

.0009-.0017 (.024-.042)

Connecting Rod Bearings

Journal Diameter

1.3L

1.5724-1.5731 (39.939-

39.957)

1.6L

1.7693-1.7699 (44.940-

44.956)

Journal Out-Of-Round

.002 (.05)

Journal Taper

.002 (.05)

CONNECTING RODS

CONNECTING RODS

PISTONS, PINS & RINGS

PISTONS PINS & RINGS

CYLINDER BLOCK

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

Oil Clearance

.0011-.0027 (.028-.068)

Application

In. (mm)

Bore Diameter

Pin Bore

1.3L

.7854-.7859 (19.948-19.961)

1.6L

.7875-.7880 (20.003-20.014)

Crankpin Bore

1.8897-1.8904 (48.000-48.016)

Center-To-Center Length

5.230-5.234 (132.85-132.95)

Maximum Bend & Twist

(1)

1.3L

.0016 (.04)

1.6L

.0078 (.198)

Side Play

.012 (.30)

(1)

Per 3.94" (100 mm) of length.

Application

In. (mm)

Piston

Clearance (Max.)

.006 (.15)

Diameter

1.3L

2.793-2.794 (70.954-70.974)

1.6L

3.0690-3.0698 (77.954-77.974)

Pins

Outside Diameter

1.3L

.7864-.7866 (19.974-19.980)

1.6L

.7869-.7871 (19.987-19.993)

Inside Diameter

.524 (13.309)

Pin-To-Piston Fit

1.3L

.0003-.0005 (.0076-.0127)

1.6L

.0004-.0012 (.0100-.0260)

Rod Fit

(1)

0-.0012 (0-.030)

Rings

No. 1

End Gap

.006-.012 (.15-.30)

Side Clearance

.001-.003 (.03-.07)

No. 2

End Gap

.006-.012 (.15-.30)

Side Clearance

.001-.003 (.03-.07)

No. 3 (Oil)

End Gap

.008-.028 (.20-.70)

Side Clearance

1.3L

.039 (1.0)

1.6L

.001-.003 (.03-.07)

(1)

This is a negative clearance (interference fit).

Application

In. (mm)

Cylinder Bore

Standard Diameter

1.3L

2.7953-2.7961 (71.00-

71.02)

1.6L

3.0709-3.0716

(78.000-78.019)

Maximum Taper

.0007 (.018)

Maximum Out-Of-Round

.0007 (.018)

Maximum Deck Warpage

.006 (.15)

Application

In. (mm)

Intake Valves

Face Angle

45°