check engine FORD FIESTA 1989 Service Repair Manual

4 Air cleaner assembly and airinlet components -
removal and refitting
1
Note: Air cleaner element renewal and air
cleaner temperature control system checks
(where applicable) are described in Chapter 1.
Air cleaner assembly
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Undo the retaining bolts and partially lift the
air cleaner from the CFi unit, so that the hose
and wiring connections to the underside of
the air cleaner body are accessible.
3 Note their connections and routings, then
detach the wiring and hoses from the
underside of the air cleaner.
4 Lift the air cleaner clear from the CFi unit.
5 Refit in the reverse order of removal.
6 Renew any hoses that are perished or
cracked, and ensure that all fittings are
securely and correctly reconnected.
Air inlet components
7 The air cleaner inlet spout and related
components are removed with the air cleaner
assembly as described above.
5 Accelerator cable - removal,
refitting and adjustment
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Fold back the carpet and insulation in the
driver’s footwell to gain access to the
accelerator pedal.
3 Detach the accelerator cable from the
pedal.
4 Remove the air cleaner assembly as
described in Section 4.
5 Working at the throttle housing end of the
cable, pivot the throttle quadrant by hand to
release the tension from the cable, then
detach the inner cable nipple from the throttle
lever.
6 Detach the outer cable from the
adjuster/support bracket, then remove the
cable.
Refitting and adjustment
7 Refit in the reverse order of removal. When
the cable is reconnected at each end, have an
assistant depress the accelerator, and check
that the throttle fully opens and shuts without
binding. Ensure that there is a small amount of
slack in the inner cable when the throttle is
fully released. If adjustment is required,
release the outer cable retaining clip from the
cable at the adjustment/support bracket, slide
the cable through the adjuster grommet to the
point required, then refit the retaining clip to
secure it in the set position.
6 Accelerator pedal -
removal and refitting
1
Refer to Part A, Section 5.
7 Fuel pump/fuel pressure -
checking
3
Note: Refer to the warning note in Section 1
before proceeding.
Fuel pump operation check
1 Switch on the ignition, and listen for the fuel
pump (the sound of an electric motor running,
audible from beneath the rear seats). Assuming
there is sufficient fuel in the tank, the pump
should start and run for approximately one or
two seconds, then stop, each time the ignition
is switched on. Note:If the pump runs
continuously all the time the ignition is switched
on, the electronic control system is running in
the backup (or “limp-home”) mode referred to
by Ford as “Limited Operation Strategy” (LOS).
This almost certainly indicates a fault in the
EEC IV module itself, and the vehicle should
therefore be taken to a Ford dealer for a full test
of the complete system, using the correct
diagnostic equipment; do not waste time or risk
damaging the components by trying to test the
system without such facilities.
2 Listen for fuel return noises from the fuel
pressure regulator. It should be possible to
feel the fuel pulsing in the regulator and in the
feed hose from the fuel filter.
3 If the pump does not run at all, check the
fuse, relay and wiring (see Chapter 12). Check
also that the fuel cut-off switch has not been
activated and if so, reset it.
Fuel pressure check
4 A fuel pressure gauge will be required for this
check and should be connected in the fuel line
between the fuel filter and the CFi unit, in
accordance with the gauge maker’s instructions.
5 Start the engine and allow it to idle. Note
the gauge reading as soon as the pressure
stabilises, and compare it with the figures
given for regulated fuel pressure in the
Specifications . If the pressure is high, check
for a restricted fuel return line. If the pressure
is low, renew the fuel pressure regulator. 6
Switch off the engine, and check that after
one minute, the hold pressure has not fallen
below that specified. If it has, check the seals
on the fuel injector (see Section 14) and renew
them if they appear in any way suspect. If the
seals are okay, then the fuel pressure
regulator or CFi unit are suspect.
7 Carefully disconnect the fuel pressure
gauge, depressurising the system first as
described in Section 2.
8 Run the engine, and check that there are no
fuel leaks.
8 Fuel tank - removal,
inspection and refitting
3
Proceed as described in Part A, Section 8, but
before disconnecting the battery, relieve the
residual pressure in the fuel system (see Sec-
tion 2), and equalise tank pressure by removing
the fuel filler cap. Note also that it will be
necessary to release any additional ventilation
tubes from their retaining clips, and to reposition
or remove the underbody heat shields on certain
models for access to the tank retaining bolts.
9 Fuel pump/fuel gauge
sender unit - removal and
refitting
3
Note: Refer to the warning note in Section 1
before proceeding. Ford specify the use of their
service tool 23-026 (a large box spanner with
projecting teeth to engage the fuel pump/sender
unit retaining ring’s slots) for this task. While
alternatives are possible, in view of the difficulty
experienced in removing and refitting the
pump/sender unit, it is strongly advised that the
correct tool is obtained before starting work.
Removal
1 A combined fuel pump and fuel gauge
sender unit are located in the top face of the
fuel tank. The combined unit can only be
detached and withdrawn from the tank after
the tank is released and lowered from
under the vehicle. Refer to Section 8 and
remove the fuel tank, then proceed as follows.
2 With the fuel tank removed, the
pump/sender unit can be unscrewed using
the special tool (see illustration) .
3 Withdraw the unit upwards from the tank
(see illustration) , and detach the seal ring.
9.3 Fuel pump (A) and sender unit (B)
4B•4 Fuel system - central fuel injection engines
9.2 Ford Special tool engaged on the fuel
pump/sender unit
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The seal ring must be renewed whenever the
pump/sender unit is withdrawn from the tank.
Refitting
4Refit in the reverse order of removal. Lightly
coat the new unit seal ring with grease to ease
fitting, and ensure that the seal is not
distorted as the unit is fitted into position.
Insert the unit so that the lug of the unit is in
engagement with the slot in the tank aperture,
then turn the unit to lock and secure.
10 Fuel tank ventilation tube -
removal and refitting
3
Refer to Part A, Section 10, but note that on
models with evaporative emission control, the
ventilation tube connects to the combined
roll-over/anti-trickle-fill valve assembly but,
instead of venting to atmosphere, a further
tube runs the length of the vehicle to a carbon
canister in the front right-hand corner of the
engine compartment. Further information on the evaporative
emission control system is contained in Part E
of this Chapter.
11 Fuel tank filler pipe -
removal and refitting
3
Refer to Part A, Section 11.
12 Fuel cut-off switch -
removal and refitting
2
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the left-hand sill scuff plate as
described in Chapter 11, Section 42. 3
Undo the retaining screws and withdraw the
cut-off (inertia) switch and bracket assembly.
As it is withdrawn, disconnect the wiring multi-
plug from the switch (see illustrations).
4 The switch may be separated from the
bracket by removing the two securing screws.
Refitting
5 Reconnect the wiring multi-plug to the
switch, ensuring that it is felt to snap securely
into position.
6 Refit the switch to the bracket then relocate
the bracket, and refit the screw to secure it.
7 Reset the switch by pushing the top button
down, then refit the sill scuff plate.
8 Reconnect the battery and restart the
engine to ensure that the switch has reset.
13 Fuel injection system -
checking
3
Note: Refer to the warning note in Section 1
before proceeding. If a fault appears in the fuel injection
system, first ensure that all the system wiring
connectors are securely connected and free
of corrosion. Ensure that the fault is not due to
poor maintenance; ie, check that the air
cleaner filter element is clean, the spark plugs
are in good condition and correctly gapped,
the valve clearances are correctly adjusted
(where adjustable), the cylinder compression
pressures are correct, the ignition timing is
correct (where adjustable), and that the
engine breather hoses are clear and
undamaged, referring to Chapters 1, 2 and 5
for further information. If these checks fail to reveal the cause of
the problem, the vehicle should be taken to a
suitably-equipped Ford dealer for testing. A
wiring block connector is incorporated in the
engine management circuit, into which a
special electronic diagnostic tester can be
plugged. The tester will locate the fault quickly
and simply, alleviating the need to test all the system components individually, which is a
time-consuming operation that also carries a
risk of damaging the EEC IV engine
management module.
14 Fuel injection system
components -
removal and refitting
3
Note: Refer to the warning note in Section 1
before proceeding.
Fuel injector
1 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap.
Warning: This procedure will
merely relieve the increased
pressure necessary for the engine
to run - remember that fuel will
still be present in the system components,
and take precautions accordingly before
disconnecting any of them.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Refer to Section 4 and remove the air
cleaner.
4 Release the injector feed wiring multi-plug,
and detach it from the injector (pulling on the
plug - not the wire) (see illustration).
Fuel system - central fuel injection engines 4B•5
12.3b . . . and disconnect the multi-plug as it is withdrawn. Switch
to bracket retaining screws (arrowed)12.3a Remove the screw securing the inertia switch bracket . . .
14.4 Disconnect the multi-plug from the injector
4B
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5Bend over the locking tabs retaining the
injector screws, then undo and remove the
screws. Withdraw the injector retaining collar,
then carefully withdraw the injector from the
CFi unit (noting its orientation) followed by its
seals. Withdraw the seal from the retaining
collar (see illustrations) .
6 Refit in the reverse order of removal.
Always use new seals in the CFi unit and the
retaining collar, and lightly lubricate them with
clean engine oil prior to assembly. Take care
not to damage the seals as they are fitted and
as the injector is fitted, check that the location
peg engages correctly.
Fuel pressure regulator
7 Refer to paragraphs 14 to 22 in this Section
and remove the CFi unit from the vehicle.
8 Unscrew and remove the four regulator
retaining screws, and remove the regulator
(see illustration) . As they are removed, note
the fitting positions and the orientation of the
components. Do not(unless absolutely
necessary) attempt to prise out the plug or
adjust the screw in the centre of the housing
(if no plug is fitted), as this will alter the system
pressure.
9 Examine the components, and renew any
that are defective or suspect.
10 To refit, position the regulator on its side,
then insert the small spring, the valve,
diaphragm (ensuring that it seats correctly),
large spring, cup and then the regulator cover.
Insert and tighten the retaining screws, but take care not overtighten them, or the cover
will be distorted.
11
Carefully place the ball into position on
the spring cup, and ensure that it seats
correctly.
12 If removed, fit the central Allen type
adjuster screw, hand-tighten it and then
unscrew it (from the hand-tight position) three
full turns to make a provisional adjustment.
13 Refit the CFi unit in accordance with
paragraphs 23 to 25 in this Section, but note
that further checks for fuel leaks must be
made with the engine running. The fuel
system pressure must be checked by a Ford
dealer or other suitable specialist at the
earliest opportunity.CFi unit
14 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that
fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
15 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
16 Refer to Section 4 and remove the air
cleaner.
17 Position a suitable drain tray under the
coolant hose connections to the CFi unit. Ensure that the cooling system is not
pressurised (see Chapter 1), then detach the
hoses from the unit. Plug or clamp the hoses
to prevent further coolant spillage whilst the
hoses are detached.
Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the
engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
18 Disconnect the fuel return pipe from the
CFi unit.
19 Refer to Section 5 and disconnect the
accelerator cable from the CFi unit.
20 Disconnect the inlet air temperature
sensor, throttle plate control motor and
throttle position sensor wiring multi-plug
connectors.
4B•6 Fuel system - central fuel injection engines
14.8 Exploded view of the fuel pressure
regulator assembly14.5e Withdrawing the seal from theinjector retaining collar14.5d Injector seals in the CFi unit
14.5c Withdrawing the injector from the CFi unit14.5b Removing the injector retainingcollar14.5a Removing an injector retainingcollar securing bolt and its locktab
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21Disconnect the vacuum hose from the CFi
unit.
22 Unscrew and remove the four retaining
screws, and remove the CFi unit from the inlet
manifold (see illustration) . Remove the
gasket.
23 Clean the CFi unit and the inlet manifold
mating faces.
24 Refit in the reverse order of removal.
Tighten the retaining bolts to the specified
torque wrench setting. Check and top-up the
cooling system as required (see “Weekly
Checks” and Chapter 1).
25 When the CFi unit is refitted, turn the
ignition on and off at least five times to
pressurise the system, and check for leaks.
Throttle plate control motor
26 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
27 Refer to Section 4 and remove the air
cleaner.
28 Detach the wiring multi-plugs from the
throttle position sensor and the throttle plate
control motor, and release the retaining clips
on the bracket (see illustrations) .
29 Undo and remove the motor support
bracket screws, and remove the bracket
complete with the motor from the CFi unit
(see illustration) .
30 Undo the motor retaining screws and
remove it from the support bracket.
31 Refit in the reverse order of removal, but
note the following points: a) When refitting the motor and its support
bracket to the injector unit, the throttle
position sensor must locate on the
accelerator linkage, and the bracket must
align with the pegs.
b) On completion, the idle speed should be
checked by a Ford dealer or fuel injection
specialist who has the required
equipment to link up with the EEC IV
engine management module.
Fuel trap
32 A fuel trap is fitted to the manifold
absolute pressure sensor vacuum hose on
certain models.
33 To remove the fuel trap, disconnect the
vacuum hoses from the fuel trap and withdraw it.
34 Refit in the reverse order of removal. It is
important to ensure that the trap is correctly
orientated, with the “CARB” mark on one end face towards the inlet manifold, and the
“DIST” mark towards the MAP sensor
(see
illustration) .
EEC IV engine management
module
Note: The module is fragile. Take care not to
drop it, or subject it to any other kind of
impact. Do not subject it to extremes of
temperature, or allow it to get wet.
35 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
36 Unscrew and remove the two nuts
securing the module cover in the engine
compartment, then carefully draw the cover
away from its location. Unscrew the module
multi-plug retaining bolt and disconnect the
multi-plug from the module (see illustrations).
37 The aid of an assistant will be required at
this stage, to support and withdraw the
Fuel system - central fuel injection engines 4B•7
14.28b Disconnecting the throttle plate control motor multi-plug14.28a Release the throttle position
sensor multi-plug from its retaining clip and disconnect it14.22 CFi unit securing screws (arrowed)
14.36b Undoing the EEC IV engine
management module multi-plug retaining
bolt
14.34 Fuel trap vacuum connection markings14.29 Throttle-plate control motor andthrottle position sensor assembly
mounting bracket securing screws (arrowed)
14.36a Undoing the EEC IV engine
management module cover retaining nuts
(vehicle jack removed for clarity)
4B
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module from inside the passenger
compartment as its mounting bracket
retaining tags are compressed and released
from the engine compartment. Do not allow
the module to drop into the passenger
compartment as irreparable damage is likely
to result (see illustration) . The module may
be separated from its mounting bracket by
undoing the securing bolts.
38 Refitting is a reversal of the removal
procedure, ensuring that the module
mounting bracket retaining tags are felt to
snap into position
Crankshaft position sensor
39 Refer to Chapter 5B.
Coolant temperature sensor
40Refer to Chapter 3.
Inlet air temperature sensor
41Remove the air cleaner assembly as
described in Section 4.
42 Releasing its clip, unplug the sensor’s
electrical connector, then unscrew the sensor
from the CFi unit (see illustration).
43 Refitting is the reverse of the removal
procedure. Tighten the sensor to the specified
torque wrench setting; if it is overtightened, its
tapered thread may crack the resonator.
Throttle position sensor
44 Remove the air cleaner assembly as
described in Section 4.
45 Releasing its wire clip, unplug the
sensor’s wiring connector. Remove the
retaining screws, and withdraw the unit from
the throttle plate control motor bracket (see
illustration) . Do not force the sensor’s centre
to rotate past its normal operating sweep; the
unit will be seriously damaged.
46 Refitting is the reverse of the removal
procedure, ensuring that the sensor actuating
arm is correctly located.
Vehicle speed sensor
47 The sensor is mounted at the base of the
speedometer drive cable, and is removed with
the speedometer drive pinion. Refer to the
relevant Section of Chapter 7A or B, as
applicable.
Manifold absolute pressure
sensor
48 The sensor is located near the centre of
the engine compartment bulkhead.
49 Disconnect the wiring multi-plug, and
detach the vacuum hose from the base of the
sensor (see illustration) .
50 Undo the two retaining screws, and
withdraw the sensor from its location. 51
Refitting is the reverse of the removal
procedure.
Power steering pressure switch
52 Releasing its clip, unplug the switch’s
electrical connector, then unscrew the switch
from the power steering high pressure pipe.
Place a wad of rag underneath, to catch any
spilt fluid. If a sealing washer is fitted, renew it
if it is worn or damaged.
53 Refitting is the reverse of the removal
procedure; tighten the switch securely, then
top-up the fluid reservoir (see “Weekly
Checks” ) to replace any fluid lost from the
system, and bleed out any trapped air (see
Chapter 10).
Oxygen sensor
Note: The sensor is delicate, and will not work
if it is dropped or knocked, if its power supply
is disrupted, or if any cleaning materials are
used on it.
54 Release the sensor’s electrical connector
from its bracket and unplug it to disconnect
the sensor (see illustration) .
55 Raise and support the front of the vehicle
if required to remove the sensor from
underneath (“see Jacking and vehicle
support” ). Remove the sensor heat shield then
unscrew the sensor from the exhaust system
front downpipe; collect the sealing washer
(where fitted).
56 On refitting, clean the sealing washer
(where fitted) and renew it if it is damaged or
4B•8 Fuel system - central fuel injection engines
14.54 Oxygen sensor (A) (shown with its
heatshield removed), and its multi-plug (B)
14.49 Manifold absolute pressure sensor location
A Securing screws B Multi-plug C Vacuum hose\
Arrows indicate ignition module retaining screws
14.45 Throttle position sensor retainingscrews (arrowed) (shown with throttle plate control motor removed)14.42 Disconnecting the intake airtemperature sensor multi-plug
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4C
1595Ford Fiesta Remake
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . Electronic Fuel injection (EFi) with turbocharger on RS Turbo models
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1.6 litre CVH engines
Fuel grade
Fuel octane requirement:Engines without catalytic converter* . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON unleaded or 97 RON leaded
Engines with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON unleaded (leaded fuel must notbe used)
*Refer to dealer for latest recommendations
Fuel system data
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Fuel pump pressure - engine not running . . . . . . . . . . . . . . . . . . . . . . . 3.0 bars minimum
Regulated fuel pressure - engine running at idle speed . . . . . . . . . . . . . 2.3 to 2.5 bars
Hold pressure - engine stopped after two minutes . . . . . . . . . . . . . . . . Not less than 0.8 bars below regulated pressure
Turbocharger
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . . Garrett AiResearch T02
Boost pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 0.47 to 0.51 bars
Chapter 4 Part C:
Fuel system - electronic fuel injection engines
Accelerator cable - removal, refitting and adjustment . . . . . . . . . . . 5
Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Air cleaner assembly and air inlet components - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 4
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel cut-off switch - removal and refitting . . . . . . . . . . . . . . . . . . . . 12
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .See Chapter 1
Fuel injection system - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injection system components - removal and refitting . . . . . . . . 14
Fuel lines and fittings - general information . . . . . . . . . . . . . . . . . . . 3
Fuel pump/fuel gauge sender unit - removal and refitting . . . . . . . . 9
Fuel pump/fuel pressure - checking . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel system - depressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 8 Fuel tank filler pipe - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
Fuel tank ventilation tube - removal and refitting . . . . . . . . . . . . . . . 10
General fuel system checks . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Idle speed and mixture check and adjustment . . . . . . . .See Chapter 1
Idle speed control valve cleaning and maintenance . . . .See Chapter 1
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 15
Intercooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Turbocharger - general information and precautions . . . . . . . . . . . . 16
Turbocharger - removal, examination and refitting . . . . . . . . . . . . . . 20
Turbocharger boost control valve - removal and refitting . . . . . . . . . 18
Turbocharger boost pressure - checking and adjustment . . . . . . . . 19
Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See\
Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
4C•1
Specifications Contents
Easy,
suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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Engine temperature information is supplied
by the coolant temperature sensor. This
component is an NTC (Negative Temperature
Coefficient) thermistor - that is, a semi-
conductor whose electrical resistance
decreases as its temperature increases. It
provides the EEC IV module with a constantly-
varying (analogue) voltage signal, corre-
sponding to the temperature of the engine
coolant. This is used to refine the calculations
made by the module, when determining the
correct amount of fuel required to achieve the
ideal air/fuel mixture ratio. Inlet air temperature information is supplied
by the inlet air temperature sensor. This
component is also an NTC thermistor - see the
previous paragraph - providing the module with
a signal corresponding to the temperature of air
passing into the engine. This is used to refine
the calculations made by the module, when
determining the correct amount of fuel required
to achieve the ideal air/fuel mixture ratio. A throttle position sensor is mounted on the
end of the throttle valve spindle, to provide
the EEC IV module with a constantly-varying
(analogue) voltage signal corresponding to the
throttle opening. This allows the module to
register the driver’s input when determining
the amount of fuel required by the engine. Road speed is monitored by the vehicle
speed sensor. This component is a Hall-effect
generator, mounted on the transmission’s
speedometer drive. It supplies the module with a
series of pulses corresponding to the vehicle’s
road speed, enabling the module to control
features such as the fuel shut-off on overrun. A manifold absolute pressure sensor
measures inlet manifold vacuum, and supplies
this information to the EEC IV module for
calculation of engine load at any given throttle
position. Where power steering is fitted, a pressure-
operated switch is screwed into the power
steering system’s high-pressure pipe. The
switch sends a signal to the EEC IV module to
reduce engine speed should the power steering
fluid pressure become excessively high. On models with a catalytic converter, the
oxygen sensor in the exhaust system provides
the EEC IV module with constant feedback -
“closed-loop” control - which enables it to
adjust the mixture to provide the best possible
conditions for the catalytic converter to operate. On turbocharged engines, control of the
turbocharger boost pressure is also governed
by the EEC IV module, acting through the
boost control valve. This allows inlet manifold
depression to be applied to the turbocharger
wastegate control. The turbocharger consists of a turbine that
is driven by the exhaust gases, to suck air
through the air filter and to compress it into the
engine. An air-cooled intercooler, mounted
next to the radiator, cools the inlet air (heated
by its passage through the turbocharger); this
increases the density of the compressed
fuel/air mixture entering the engine, thus
improving the engine’s power output.Precautions
Warning: Petrol is extremely
flammable - great care must be
taken when working on any part
of the fuel system. Do not
smoke or allow any naked flames or
uncovered light bulbs near the work area.
Note that gas powered domestic
appliances with pilot flames, such as
heaters, boilers and tumble dryers, also
present a fire hazard - bear this in mind if
you are working in an area where such
appliances are present. Always keep a
suitable fire extinguisher close to the work
area and familiarise yourself with its
operation before starting work. Wear eye
protection when working on fuel systems
and wash off any fuel spilt on bare skin
immediately with soap and water. Note
that fuel vapour is just as dangerous as
liquid fuel; a vessel that has just been
emptied of liquid fuel will still contain
vapour and can be potentially explosive.
Petrol is a highly dangerous and volatile
liquid, and the precautions necessary
when handling it cannot be overstressed. Many of the operations described in this
Chapter involve the disconnection of fuel
lines, which may cause an amount of fuel
spillage. Before commencing work, refer
to the above Warning and the information
in “Safety first” at the beginning of this
manual. When working with fuel system
components, pay particular attention to
cleanliness - dirt entering the fuel system
may cause blockages which will lead to
poor running.
Note: Residual pressure will remain in the fuel
lines long after the vehicle was last used,
when disconnecting any fuel line, it will be
necessary to depressurise the fuel system as
described in Section 2 .
Note: Refer to Section 16 for specific
precautions relating to turbocharged engines.
2 Fuel system -
depressurisation
1
Refer to Part B, Section 2.
3 Fuel lines and fittings -
general information
Refer to Part B, Section 3.
4 Air cleaner assembly and air inlet components - removal
and refitting
1
Note: Air cleaner element renewal and air
cleaner temperature control system checks
(where applicable) are described in Chapter 1.
Air cleaner assembly
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 If the idle speed control valve is mounted
on the air cleaner, disconnect the multi-plug
and the air bypass hose from the valve.
3 Disconnect the flexible hose between the
air cleaner lid and the air inlet duct or
turbocharger air inlet.
4 Disconnect the crankcase breather hose
from the front of the air cleaner housing.
5 Unclip and remove the air cleaner lid, then
withdraw the element.
6 Remove the two bolts securing the forward
end of the air cleaner housing, free the
rearward end of the housing from its location
and carefully withdraw from the vehicle (see
illustration) .
7 Refitting is a reversal of the removal
procedure.
Air inlet components
8 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
9 If the idle speed control valve is mounted
on the air cleaner, disconnect the multi-plug
and the air bypass hose from the valve (see
illustration) .
10 Disconnect the HT leads from the spark
plugs, labelling them if necessary to avoid
confusion on refitting.
Fuel system - electronic fuel injection engines 4C•3
4.9 General view of the air inlet
components on non-Turbo models
A Air inlet duct
B Air inlet duct securing bolts
C Spark plug HT lead connectors
D Air cleaner lid
E Idle speed control valve multi-plug
F Air bypass hose
4.6 Air cleaner housing attachments A Bolts B Grommet
4C
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11On non-Turbo models, disconnect the
flexible hose between the air cleaner lid and
the air inlet duct.
12 On Turbo models, disconnect the idle
speed control valve air bypass hose from the
air inlet duct and the flexible hose between
the air inlet duct and intercooler (see
illustration) .
13 Undo the two retaining bolts, and remove
the air inlet duct from the rocker cover.
14 Refitting is the reverse of the removal
procedure.
5 Accelerator cable - removal,
refitting and adjustment
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air inlet components as
described in Section 4.
3 Fold back the carpet and insulation in the
driver’s footwell to gain access to the
accelerator pedal.
4 Detach the accelerator cable from the
pedal.
5 Working at the throttle housing end of the
cable, pivot the throttle quadrant by hand to
release the tension from the cable, then
detach the inner cable nipple from the throttle
lever (see illustration) .
6 Detach the outer cable from the
adjuster/support bracket, then remove the
cable.
Refitting and adjustment
7 Refit in the reverse order of removal. When
the cable is reconnected at each end, have an assistant depress the accelerator, and check
that the throttle fully opens and shuts without
binding. Ensure that there is a small amount of
slack in the inner cable when the throttle is
fully released. If adjustment is required,
release the outer cable retaining clip from the
cable at the adjustment/support bracket, slide
the cable through the adjuster grommet to the
point required, then refit the retaining clip to
secure it in the set position.
6 Accelerator pedal
-
removal and refitting
1
Refer to Part A, Section 5.
7 Fuel pump/fuel pressure -
checking
3
Note: Refer to the warning note in Section 1
before proceeding.
Fuel pump operation check
1 Switch on the ignition, and listen for the fuel
pump (the sound of an electric motor running,
audible from beneath the rear seats). Assuming
there is sufficient fuel in the tank, the pump
should start and run for approximately one or
two seconds, then stop, each time the ignition
is switched on. Note:If the pump runs
continuously all the time the ignition is switched
on, the electronic control system is running in
the backup (or “limp-home”) mode referred to
by Ford as “Limited Operation Strategy” (LOS).
This almost certainly indicates a fault in the
EEC IV module itself, and the vehicle should
therefore be taken to a Ford dealer for a full test of the complete system, using the correct
diagnostic equipment; do not waste time or risk
damaging the components by trying to test the
system without such facilities.
2
Listen for fuel return noises from the fuel
pressure regulator. It should be possible to
feel the fuel pulsing in the regulator and in the
feed hose from the fuel filter.
3 If the pump does not run at all, check the
fuse, relay and wiring (see Chapter 12). Check
also that the fuel cut-off switch has not been
activated and if so, reset it.
Fuel pressure check
4 A fuel pressure gauge will be required for
this check and should be connected in the
fuel line between the fuel filter and the fuel rail,
in accordance with the gauge maker’s
instructions.
5 Disconnect the wiring from the E-DIS
ignition coil and the fuel injectors.
6 Switch the ignition on and off twice, and
check that the pump pressure is as listed in
the Specifications .
7 If the pressure is not as specified, check the
fuel system for leaks or damage. If the system
appears okay, renew the fuel pump.
8 Reconnect the wiring to the ignition coil and
fuel injectors.
9 If the pump pressure was satisfactory, start
the engine and allow it to idle. Disconnect the
vacuum hose at the fuel pressure regulator,
and plug the hose. Note the gauge reading as
soon as the pressure stabilises, and compare
it with the figures given for regulated fuel
pressure in the Specifications.
10 If the regulated fuel pressure is not as
specified, remove the plug from the top of the
fuel pressure regulator, and using a suitable
Allen key, adjust the pressure regulator as
necessary.
11 Switch off the engine, and check that the
fuel pressure stays at the specified hold
pressure for two minutes after the engine is
turned off.
12 Carefully disconnect the fuel pressure
gauge, depressurising the system first as
described in Section 2. Reconnect the ignition
coil and fuel injector wiring.
13 Run the engine, and check that there are
no fuel leaks.
4C•4 Fuel system - electronic fuel injection engines
5.45 Accelerator cable retention
arrangement at the throttle linkage
4.12 Air intake, turbocharger and intercooler details on Turbo models
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1 Fresh air intake
2 Air cleaner lid
3 Turbocharger
4 Intercooler
5 Air inlet duct
6 Throttle housing
7 Inlet manifold
8 (Hitachi-built) idle
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8 Fuel tank- removal,
inspection and refitting
3
Proceed as described in Part A, Section 8,
but before disconnecting the battery, relieve
the residual pressure in the fuel system (see
Section 2), and equalise tank pressure by
removing the fuel filler cap.
9 Fuel pump/fuel gauge sender unit - removal and
refitting
3
Refer to Part B, Section 9.
10 Fuel tank ventilation tube -
removal and refitting
3
Refer to Part A, Section 10, but note that on
models with evaporative emission control, the
ventilation tube connects to the combined
roll-over/anti-trickle-fill valve assembly but,
instead of venting to atmosphere, a further
tube runs the length of the vehicle to a carbon
canister in the front right-hand corner of the
engine compartment.
Further information on the evaporative
emission control system is contained in Part E
of this Chapter.
11 Fuel tank filler pipe -
removal and refitting
3
Refer to Part A, Section 11.
12 Fuel cut-off switch -
removal and refitting
1
Refer to Part B, Section 12.
13 Fuel injection system -
checking
3
Refer to Part B, Section 13
14 Fuel injection system components - removal and
refitting
3
Note: Refer to the warning note in Section 1
before proceeding.
Fuel rail and injectors
Note: For simplicity, and to ensure that the
necessary absolute cleanliness on reassembly,
the following procedure describes the removal
of the fuel rail assembly, complete with the
injectors and pressure regulator, so that
the injectors can be serviced individually on a clean work surface. It is also possible to remove
and refit an individual injector, once the fuel
system has been depressurised and the battery
has been disconnected. If this approach is
followed, read through the complete
procedure, and work as described in the
relevant paragraphs, depending on the amount
of preliminary dismantling required. Be careful
not to allow any dirt to enter the system.
1
Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Warning: This procedure will
merely relieve the increased
pressure necessary for the engine
to run - remember that fuel will
still be present in the system components,
and take precautions accordingly before
disconnecting any of them.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Disconnect the HT lead connectors from the
spark plugs, and release the leads from their
locating grooves in the air inlet duct. Position
them out of the way. On Turbo models, undo the
two screws and remove the HT lead bracket.
4 Remove the air inlet components as
described in Section 4.
5 Unscrew the retaining nuts and the bolt,
and detach the accelerator cable support
bracket at the throttle housing.
6 Disconnect the wiring connector from the
throttle position sensor.
7 Unscrew the four retaining bolts, and
remove the throttle housing and its mating
face gasket (see illustration) .
8 Disconnect the wiring multi-plug from the
engine coolant temperature sensor and the
inlet air temperature sensor.
9 Disconnect the wiring multi-plugs from the
fuel injectors, then undo the two retaining
bolts and detach the wiring harness from the
fuel rail (see illustrations) .
10 Unscrew the fuel supply pipe at the fuel
rail. Plug the rail and pipe, to prevent further
fuel spillage and the possible ingress of dirt.
11 Disconnect the fuel return and vacuum
pipes from the pressure regulator, and catch
any fuel spillage in a clean cloth.
12 Unscrew the fuel rail securing bolts, and
carefully withdraw the rail (complete with
injectors) from the engine (see illustrations).
Fuel system - electronic fuel injection engines 4C•5
14.9b . . . unbolt the wiring harness . . .
14.9a Disconnect the wiring multi-plug
from each injector . . .14.7 Throttle housing retaining boltlocations (arrowed)
4C
1595Ford Fiesta Remake 14.12a Remove the fuel rail retaining
bolts . . .
14.9c . . . and remove the completeharness
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13Detach the fuel injectors from the fuel rail,
then remove the upper and lower seal from
each injector (see illustration) . All seals must
be renewed (even if only one injector is to be
renewed).
14 Prior to refitting the injectors, ensure that
all mating surfaces are perfectly clean.
Lubricate the new injector seals with clean
engine oil to ease their assembly to the
injectors.
15 Refitting is a reversal of the removal
procedure. Refer to the Specificationsat the
start of this Chapter for the tightening torques.
When refitting the fuel rail, ensure that the
injectors are correctly located. Ensure that the
mating surfaces of the throttle housing are
perfectly clean before assembling.
16 On completion, restart the engine and
check the various fuel connections for any
signs of leaks.
Fuel pressure regulator
17 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that
fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
18 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1). 19
Release the fuel return pipe securing clip,
and detach the pipe from the regulator.
20 Pull free the vacuum pipe from the
regulator connector (see illustration).
21 Unscrew the two retaining bolts and
remove the regulator. Remove the old sealing
ring for renewal.
22 Refit in the reverse order of removal.
Lubricate the new seal ring with clean engine oil
to ease assembly. When the regulator is refitted
and the fuel and vacuum lines are reconnected,
turn the ignition on and off five times (without
cranking the engine) and check for any sign of
fuel leaks before restarting the engine.
Idle speed control valve
Note: The idle speed control valve may be
mounted on the air cleaner, on the engine
compartment bulkhead, or on the side of the
inlet manifold according to valve make and
year of manufacture. Valves manufactured by
Weber are mounted on the air cleaner and
require periodic maintenance (see Chapter 1).
Bulkhead and inlet manifold mounted valves
are manufactured by Hitachi and are
maintenance free.
23 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
24 Disconnect the valve’s wiring multiplug
(see illustration) .
25 Where applicable disconnect the air
hose(s) from the valve.
26 Undo the two or four bolts (according to
type), and remove the valve from the air
cleaner, bulkhead or inlet manifold. 27
Refitting is a reversal of the removal
procedure. Ensure that the mating faces are
clean before reassembling.
28 When the valve is refitted, restart the
engine and check that there are no induction
leaks. Run the engine until its normal
operating temperature is reached, and check
that the idle speed is stable. Stop the engine,
connect up a tachometer in accordance with
its maker’s instructions, then restart the
engine and check that the idle speed is as
specified with all electrical items (lights, heater
blower motor, etc) switched off, then on. The
idle speed should remain the same. Switch off
the electrical items, turn the engine off and
detach the tachometer to complete the test.
Throttle housing
29 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
30 Disconnect the ignition HT lead
connectors from the spark plugs, and release
the leads from their locating grooves in the air
inlet duct. Position them out of the way.
31 Remove the air inlet components as
described in Section 4.
32 Unscrew the retaining nuts and the bolt,
and detach the accelerator cable support
bracket at the throttle housing.
33 Disconnect the wiring connector from the
throttle position sensor.
34 Unscrew the four retaining bolts, and
remove the throttle housing and its mating
face gasket (see illustration 14.7) .
35 Refit in the reverse order of removal.
Check that the mating faces are clean, and fit
a new gasket.
EEC IV engine management
module
Note: The module is fragile. Take care not to
drop it, or subject it to any other kind of
impact. Do not subject it to extremes of
temperature, or allow it to get wet. Refer to
Part B, Section 14 for illustrations of the
following procedure.
36 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
37 Unscrew and remove the two nuts
securing the module cover in the engine
compartment, then carefully draw the cover
away from its location. Unscrew the module
multi-plug retaining bolt and disconnect
the multi-plug from the module.
38 The aid of an assistant will be required at
this stage, to support and withdraw the
module from inside the passenger
compartment as its mounting bracket retaining
tags are compressed and released from the
engine compartment. Do not allow the module
to drop into the passenger compartment as
irreparable damage is likely to result. The
module may be separated from its mounting
bracket by undoing the securing bolts.
39 Refitting is a reversal of the removal
procedure, ensuring that the module
mounting bracket retaining tags are felt to
snap into position
4C•6 Fuel system - electronic fuel injection engines
14.24 Disconnect the multi-plug from the idle speed control valve. Upper valve
retaining bolt (arrowed)14.20 Fuel pressure regulator showingvacuum pipe (A) and fuel return pipe
connection (B)
14.13 Remove the seals from the injectors14.12b . . . and withdraw the fuel rail and injectors
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