Servicing Specifications

Capacities
Engine oil
With filter:
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints)
1.3,1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 litres (6.2 Imp pints)
Without filter:
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 litres (4.8 Imp pints)
1.3, 1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints)
Cooling system (including heater)
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 litres (9.7 Imp pints)
1.3 and 1.4 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 litres (11.1 Imp pints)
1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 litres (14.1 Imp pints)
Fuel tank
All models - pre 1985, except XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 litres (7.5 gallons)
XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 litres (8.4 gallons)
All models - 1985 on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 litres (8.8 gallons)
Gearbox
4-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 litres (4.9 Imp pints)
5-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 litres (5.5 Imp pints)
Engine
Oil filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104
Valve clearances (only OHV applicable):
Inlet:
At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in)
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 mm (0.008 to 0.010 in)
Exhaust:
At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 mm (0.023 in)
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 to 0.61 mm (0.022 to 0.024 in)
Cooling system
Drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.16 in) total deflection at the midpoint of the belt’s longest run
Fuel system
Air filter element type:
1.0 and 1.1 (OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W153
1.3 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W127
1.4 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W179
1.6 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W201
Ignition system
Spark plugs:
Make and type:
Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RS9YCC or RS9YC
Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC
Electrode gap:
RS9YCC and RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in)
RS9YC and RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in)
Note: The spark plug gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other type are to
be fitted, refer to their manufacturer’s recommendations.
Contact breaker points gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.50 mm (0.016 to 0.020 in)
Dwell (mechanical ignition):
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48° to 52°
Variation (from idle to 2000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4° maximum
Overlap (lobe-to-lobe variation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° maximum
Timing (initial):
1.0 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° BTDC
1.1 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC
Ignition HT lead set:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 k ohms maximum per lead
Type:
Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 8 boxed set
Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 9 boxed set
Brakes
Front brake pad friction material minimum thickness . . . . . . . . . . . . . . 1.5 mm (0.059 in)
Rear brake shoe friction material minimum thickness . . . . . . . . . . . . . . 1.0 mm (0.04 in)
Tyres
Tyre sizes:
Note: Manufacturers often modify tyre sizes and pressure recommendations. The following is intended as a guide only. Refer to your vehicle
handbook or a Ford dealer for the latest recommendations.
XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185/60 HR 13
Other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 SR 13, 155/70 SR 13 or 165/65 SR 13
Tyre pressures: See end of “Weekly checks”
Torque wrench settings                                                                         Nm             lbf ft
Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25                 18
Radiator coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5             1.1
Gearbox oil filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27                 20
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100             74
Spark plugs:
OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 20     10 to 15
CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27             20
Brake caliper piston housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23                 17

The maintenance intervals in this manual are provided with the assumption that you will be carrying out the work yourself. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle.

If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys, more frequent maintenance intervals are recommended.

When the vehicle is new, it should be serviced by a factory-authorised dealer service department, in order to preserve the factory warranty.