Remove/install/overhaul Ford Festiva I

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt on procedure, a simple torque specification may be all that is furnished.

DISASSEMBLY

Note. Clean carburetor exterior before disassembly.

1. Mark and disconnect stepper motor vacuum hoses. Remove stepper motor hose routing clips. Disconnect wiring from brackets. Remove stepper motor. Remove canister purge solenoid valve. Remove choke breaker diaphragm. Remove fast idle cam breaker diaphragm mounting screws. Remove secondary throttle lock-out spring.
2. Remove linkage clip and fast idle cam breaker diaphragm. Remove fast idle cam linkage clip and disconnect linkage from cam lever. Remove 3 remaining air horn mounting screws and remove air horn from carburetor main body. Remove hinge pin and float from air horn assembly.
3. Remove air horn gasket. Remove fuel inlet needle valve, seat and filter. Remove power valve assembly. Remove choke cover rivets and remove choke cover. Remove choke breaker linkage clip and disconnect linkage from diaphragm. DO NOT lose small washer from end of linkage. Remove choke housing screws and housing. Remove choke breaker linkage and fast idle cam linkage as necessary.
4. Remove base idle adjusting screw and spring. Remove idle switch attaching bolt, switch, spring and washer. Remove slow fuel-cut solenoid valve and gasket. Remove venturi springs. Remove decel jet and filter. Remove accelerator pump discharge tube. Remove accelerator pump discharge check ball and spring.
5. Remove accelerator pump cover, diaphragm and spring. Remove sight glass bracket, sight glass and "O" ring. Remove primary and secondary main metering jet plugs and gaskets. Remove jets and gaskets. Note jet sizes and location for reassembly reference.
6. Remove throttle return spring. Remove secondary throttle diaphragm linkage clip. Remove secondary throttle diaphragm and gasket. Disassemble secondary diaphragm. Note locations and direction of routing clips and bracket for reassembly reference.
7. Remove throttle body attaching screws. Note location of hollow screw for reassembly reference. (Scheme 1) Separate main body from throttle body and insulator. Remove insulator and gaskets. Remove air/fuel mixture adjusting screw plug, screw, spring and screw cap from throttle body. If necessary, disassemble cams and levers from throttle shafts. Note position of cams and levers for reassembly reference.

Note. Always use a back-up wrench to prevent binding of throttle plates during disassembly and reassembly of throttle shafts.

Scheme 1

CLEANING

Note. Do not immerse synthetic parts, electrical components or diaphragm assemblies in carburetor cleaner.

Clean cast parts in carburetor cleaner. Clean jets, fuel passages and vacuum ports with compressed air. Do not use wire or drills. Clean remaining parts with solvent and a soft brush.

REASSEMBLY

To reassemble, reverse disassembly procedure. If removed, ensure throttle shaft levers and cams are installed properly. (Scheme 5) Ensure jets are installed in proper location. Set float level and float drop. Perform remaining adjustments as necessary. See ADJUSTMENTS.

ADJUSTMENTS

Note. For all on-vehicle adjustments not covered in this article, see appropriate ADJUSTMENTS article.

Float Level

Invert air horn assembly. Measure distance between air horn gasket and top edge of float. If distance is not to specification, adjust by bending tab on float hinge. See CARBURETOR ADJUSTMENT SPECIFICATIONS. (Scheme 2)

Scheme 2

Float Drop

Hold air horn upright with float hanging freely. Measure distance between air horn gasket and bottom edge of float. If float drop is not to specification, adjust by bending tab on float hinge. (Scheme 3) See CARBURETOR ADJUSTMENT SPECIFICATIONS.

Scheme 3

Scheme 4

Scheme 5

Choke Breaker

Set choke to closed position. Using a vacuum pump, apply 16 in. Hg to choke breaker diaphragm. Check choke valve-to-air horn clearance. Adjust clearance if not to specification by bending tab on lever. (Scheme 6) See CARBURETOR ADJUSTMENT SPECIFICATIONS.

Scheme 6

Choke Unloader

Open throttle fully while holding choke valve closed. Measure distance between upper edge of choke plate and air horn. Clearance should be.061-.081" (1.55-2.06 mm). Adjust clearance by bending choke unloader lever. (Scheme 7)

Scheme 7

Throttle Opening

Open throttle and position fast idle cam so throttle lever stops against third step when throttle is released. Measure clearance between primary throttle valve and throttle body. Clearance should be .009-.014" (.25-.36 mm). If clearance is not within specification, adjust clearance using fast idle speed adjusting screw.

Throttle Cable Free Play

Remove air cleaner assembly. Measure accelerator cable deflection at carburetor. Deflection should be .04-.12" (1.0-3.0 mm). If deflection is not to specification, loosen nuts attaching cable casing to routing bracket. Adjust nuts to obtain specified deflection. Tighten nuts to lock cable housing in position.

CARBURETOR ADJUSTMENT SPECIFICATIONS

Scheme 8

Scheme 9

FUEL RAILS (PFI)

Removal and installation is primarily an unbolt and bolt on procedure. Mark all components for reinstallation before removing. To release fuel pressure, see BASIC TESTING article.

Removal & Installation

If exhaust sensor is difficult to remove, use rust penetrant to avoid possible damage to exhaust threads. Apply anti-seize to sensor threads (if reusing old sensor). New sensor comes precoated with anti-seize. DO NOT remove anti-seize from sensor.

See also:
• ADJUSTMENTS
• CARBURETOR ADJUSTMENT SPECIFICATIONS