battery FORD FIESTA 1989 Service Repair Manual

Maintenance – component location1•5
1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Brake fluid reservoir
5 Windscreen/tailgate washer fluid reservoircap
6 Battery
7 Vehicle identification plate
8 Thermostat housing
9 Pre-heat tube
10 Timing belt cover
11 Distributor
12 Fuel filter
13 Heater blower motor cover
14 Windscreen wiper motor mounting bracket
15 Jack and wheelbrace retaining bolt
16 Top of suspension strut mounting
assembly
17 EEC IV engine management module cover
18 CFi unit
19 Fuel injector
20 Fuel pressure regulator
21 Throttle plate control motor
22 Carbon canister
23 Manifold absolute pressure sensor
24 Ignition module
1.1 litre HCS carburettor engine (air cleaner removed for clarity)
1
1595Ford Fiesta Remake
1.4 litre CVH CFi fuel injection engine (air cleaner removed for clarity)
1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Brake fluid reservoir
5 Windscreen/tailgate washer fluid reservoir
cap
6 Battery
7 Vehicle identification plate
8 Thermostat housing
9 Radiator cooling fan thermal switch multi- plug
10 Alternator
11 Starter motor solenoid
12 CTX automatic transmission fluid level
dipstick
13 Exhaust heatshield/airbox
14 Brake pressure control valves
15 Top of suspension strut mounting
assembly
16 Carburettor
17 Fuel feed hose
18 Anti-dieselling (fuel-cut off) solenoid
connection
19 Throttle kicker
20 Throttle kicker control solenoid
21 Ignition module
22 Heater blower motor cover
23 Windscreen wiper motor mounting bracket
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1•6Maintenance – component location
1.6 litre (XR2i) CVH EFi fuel injection engine
1595Ford Fiesta Remake1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Brake fluid reservoir
5 Windscreen/tailgate washer fluid reservoir
cap
6 Battery
7 Vehicle identification plate
8 Thermostat housing
9 Timing belt cover
10 Top of suspension strut mounting
assembly
11 Windscreen wiper motor mounting bracket
12 Jack and wheelbrace retaining bolt
13 Distributorless (E-DIS) ignition coil
14 Fuel filter
15 Air cleaner
16 Air inlet duct
17 Idle speed control valve
18 Fuel pressure regulator
19 Throttle housing
20 Upper section of inlet manifold
21 Intake air temperature sensor
22 Fuel trap
23 EEC IV engine management module cover
24 Manifold absolute pressure sensor
25 Ignition module
1.8 litre (XR2i) Zetec SEFi fuel injection engine
1 Engine oil filler cap
2 Engine oil level dipstick
3 Cooling system expansion tank
4 Braking system fluid reservoir
5 Windscreen/tailgate washer fluid reservoir
cap
6 Battery
7 VIN plate
8 Thermostat housing
9 Timing belt cover
10 Top of suspension strut mounting
assembly
11 Windscreen wiper motor mounting bracket
12 Jack and wheelbrace retaining bolt
13 Distributorless (E-DIS) ignition coil
14 Fuel filter
15 Air cleaner
16 Air inlet duct
17 Idle speed control valve
18 Fuel pressure regulator
19 Throttle housing
20 Inlet manifold
21 Throttle position sensor
22 Fuel system pressure release/test point
23 EEC IV engine management module cover
24 Mass air flow sensor
25 Ignition module
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3 Engine oil and filter renewal
1
1Make sure that you have all the necessary
tools before you begin this procedure (see
illustration) . You should also have plenty of
rags or newspapers handy, for mopping up
any spills.
2 To avoid any possibility of scalding, and to
protect yourself from possible skin irritants
and other harmful contaminants in used
engine oils, it is advisable to wear gloves
when carrying out this work. 3
Access to the underside of the vehicle is
greatly improved if the vehicle can be lifted on a
hoist, driven onto ramps, or supported by axle
stands (see “Jacking and Vehicle Support” ).
Warning: Do not work under a
vehicle which is supported only
by an hydraulic or scissors-type
jack, or by bricks, blocks of
wood, etc. 4
If this is your first oil change, get under the
vehicle and familiarise yourself with the
position of the engine oil drain plug location in
the sump. The engine and exhaust
components will be warm during the actual
work, so try to anticipate any potential
problems while the engine and accessories
are cool.
5 The oil should preferably be changed when
the engine is still fully warmed-up to normal
operating temperature, just after a run (the
needle on the temperature gauge should be in
the “Normal” sector of the gauge); warm oil
and sludge will flow out more easily. Park the
vehicle on firm, level ground, apply the
handbrake firmly, then select 1st or reverse
gear (manual transmission) or the “P” position
(automatic transmission). Open the bonnet
and remove the engine oil filler cap from the
cylinder head cover, then remove the oil level
dipstick from its tube (see “Weekly Checks”).
6 Raise the front of the vehicle, and support it
securely on axle stands (see “Jacking and
Vehicle Support” ). Remove the front right-
hand roadwheel to provide access to the oil
1 Introduction
This Chapter is designed to help the home
mechanic maintain his/her vehicle for safety,
economy, long life and peak performance.
This Chapter contains a master
maintenance schedule, followed by Sections
dealing specifically with each task in the
schedule. Visual checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the engine compartment and
the underside of the vehicle for the locations
of the various components.
Servicing your vehicle in accordance with
the mileage/time maintenance schedule and
the following Sections will provide a planned
maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
items but not others at the specified service
intervals will not produce the same results. As you service your vehicle, you will
discover that many of the procedures can -
and should - be grouped together, because of
the particular procedure being performed, or
because of the close proximity of two
otherwise-unrelated components to one
another. For example, if the vehicle is raised
for any reason, the exhaust should be
inspected at the same time as the suspension
and steering components.
The first step of this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the Sections relevant to the work to be carried
out, then make a list and gather together all
the parts and tools required. If a problem is
encountered, seek advice from a parts
specialist or a dealer service department.
2 Intensive maintenance
1
If, from the time the vehicle is new, the
routine maintenance schedule is followed
closely, and frequent checks are made of fluid
levels and high-wear items, as suggested
throughout this manual, the engine will be
kept in relatively good running condition, and
the need for additional work will be minimised.
2 It is possible that there will be some times
when the engine is running poorly due to the
lack of regular maintenance. This is even more
likely if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
3 If engine wear is suspected, a compression
test (refer to Part A, B or C of Chapter 2) will
provide valuable information regarding the
overall performance of the main internal
components. Such a test can be used as a
basis to decide on the extent of the work to
be carried out. If, for example, a compression
test indicates serious internal engine wear,
conventional maintenance as described in this
Chapter will not greatly improve the
performance of the engine, and may prove a waste of time and money, unless extensive
overhaul work (Chapter 2D) is carried out first.
4
The following series of operations are those
often required to improve the performance of
a generally poor-running engine:
Primary operations
a) Clean, inspect and test the battery (See
“Weekly Checks”).
b) Check all the engine-related fluids (See
“Weekly Checks”).
c) Check the condition of the auxiliary drivebelt (Section 4).
d) Check and if necessary adjust the valve
clearances on HCS engines (Section 7).
e) Renew the spark plugs and clean and inspect the HT leads (Section 21).
f) Check the condition of the air cleaner filter element and renew if necessary
(Section 24).
g) Check and if necessary adjust the idle speed and mixture settings - where
applicable (Section 9).
h) Renew the fuel filter - fuel injection models (Section 30).
i) Check the condition of all hoses, and check for fluid leaks (Section 5).
5 If the above operations do not prove fully
effective, carry out the following operations:
Secondary operations
All the items listed under “Primary
operations”, plus the following: a) Check the charging system (Chapter 5A).
b) Check the ignition system (Chapter 5B).
c) Check the fuel system (Chapter 4A, 4B,
4C and 4D).
e) Renew the ignition HT leads (Section 21).
Maintenance procedures1•9
3.2 These tools are required when changing the engine oil and filter
1
1595Ford Fiesta Remake
Every 5000 miles (8000 km) or 6 months, whichever occurs first
Frequent oil changes are the
best preventive
maintenance the home
mechanic can give the
engine, because ageing oil becomes
diluted and contaminated, which leads
to premature engine wear.
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squeezed (see illustration) . If you are using
non-Ford specification antifreeze, and so
have to renew the coolant every two years or
so, it’s a good idea to renew the hoses at that
time, regardless of their apparent condition.
3 Make sure that all hose connections are
tight. A leak in the cooling system will usually
show up as white- or rust-coloured deposits
on the areas adjoining the leak; if the spring
clamps that are used to secure the hoses in
this system appear to be slackening, they
should be renewed to prevent the possibility
of leaks.
4 Some other hoses are secured to their
fittings with clamps. Where clamps are used,
check to be sure they haven’t lost their
tension, allowing the hose to leak. If clamps
aren’t used, make sure the hose has not
expanded and/or hardened where it slips over
the fitting, allowing it to leak.
5 Check all fluid reservoirs, filler caps, drain
plugs and fittings etc, looking for any signs
of leakage of oil, transmission and/or brake
hydraulic fluid, coolant and power steering
fluid. If the vehicle is regularly parked in the
same place, close inspection of the ground
underneath it will soon show any leaks. As
soon as a leak is detected, its source must
be traced and rectified. Where oil has been
leaking for some time, it is usually necessary
to use a steam cleaner, pressure washer or
similar, to clean away the accumulated
dirt, so that (when the engine is run again)
the exact source of the leak can be
identified.
Vacuum hoses
6 It’s quite common for vacuum hoses,
especially those in the emissions system, to be
colour-coded, or to be identified by coloured stripes moulded into them. Various systems
require hoses with different wall thicknesses,
collapse resistance and temperature
resistance. When renewing hoses, be sure the
new ones are made of the same material.
7
Often the only effective way to check a
hose is to remove it completely from the
vehicle. If more than one hose is removed, be
sure to label the hoses and fittings to ensure
correct installation.
8 When checking vacuum hoses, be sure to
include any plastic T-fittings in the check.
Inspect the fittings for cracks, and check the
hose where it fits over the fitting for distortion,
which could cause leakage.
9 A small piece of vacuum hose (quarter-inch
inside diameter) can be used as a
stethoscope to detect vacuum leaks. Hold
one end of the hose to your ear, and probe
around vacuum hoses and fittings, listening
for the “hissing” sound characteristic of a
vacuum leak. Warning: When probing with the
vacuum-hose stethoscope, be
very careful not to come into
contact with moving engine
components such as the auxiliary
drivebelt, radiator electric cooling fan, etc.
Fuel hoses
Warning: There are certain
precautions which must be
taken when inspecting or
servicing fuel system
components. Work in a well-ventilated
area, and do not allow open flames
(cigarettes, appliance pilot lights, etc.) or
bare light bulbs near the work area. Mop
up any spills immediately, and do not store
fuel-soaked rags where they could ignite.
10 Check all fuel hoses for deterioration and
chafing. Check especially for cracks in areas
where the hose bends, and also just before
fittings, such as where a hose attaches to the
fuel filter.
11 High-quality fuel line, usually identified by
the word “Fluoroelastomer” printed on the
hose, should be used for fuel line renewal.
Never, under any circumstances, use
unreinforced vacuum line, clear plastic tubing
or water hose for fuel lines.
12 Spring- type clamps are commonly used
on fuel lines. These clamps often lose their
tension over a period of time, and can be
“sprung” during removal. Replace all
spring- type clamps with screw clamps
whenever a hose is replaced.
Metal lines
13 Sections of metal piping are often used
for fuel line between the fuel filter and the
engine. Check carefully to be sure the piping
has not been bent or crimped, and that cracks
have not started in the line.
14 If a section of metal fuel line must be
renewed, only seamless steel piping should
be used, since copper and aluminium piping
don’t have the strength necessary to
withstand normal engine vibration. 15
Check the metal brake lines where they
enter the master cylinder and ABS hydraulic
unit (if used) for cracks in the lines or loose
fittings. Any sign of brake fluid leakage calls
for an immediate and thorough inspection of
the brake system.
6 Engine compartment wiring check
1
1With the vehicle parked on level ground,
apply the handbrake firmly and open the
bonnet. Using an inspection light or a small
electric torch, check all visible wiring within
and beneath the engine compartment.
2 What you are looking for is wiring that is
obviously damaged by chafing against sharp
edges, or against moving suspension/
transmission components and/or the auxiliary
drivebelt, by being trapped or crushed
between carelessly-refitted components, or
melted by being forced into contact with the
hot engine castings, coolant pipes, etc. In
almost all cases, damage of this sort is
caused in the first instance by incorrect
routing on reassembly, after previous work
has been carried out.
3 Depending on the extent of the problem,
damaged wiring may be repaired by rejoining
the break or splicing-in a new length of wire,
using solder to ensure a good connection,
and remaking the insulation with adhesive
insulating tape or heat-shrink tubing, as
appropriate. If the damage is extensive, given
the implications for the vehicle’s future
reliability, the best long-term answer may well
be to renew that entire section of the loom,
however expensive this may appear.
4 When the actual damage has been
repaired, ensure that the wiring loom is re-
routed correctly, so that it is clear of other
components, and not stretched or kinked, and
is secured out of harm’s way using the plastic
clips, guides and ties provided.
5 Check all electrical connectors, ensuring
that they are clean, securely fastened, and
that each is locked by its plastic tabs or wire
clip, as appropriate. If any connector shows
external signs of corrosion (accumulations of
white or green deposits, or streaks of “rust”),
or if any is thought to be dirty, it must be
unplugged and cleaned using electrical
contact cleaner. If the connector pins are
severely corroded, the connector must be
renewed; note that this may mean the renewal
of that entire section of the loom - see your
local Ford dealer for details.
6 If the cleaner completely removes the
corrosion to leave the connector in a
satisfactory condition, it would be wise to
pack the connector with a suitable material
which will exclude dirt and moisture,
preventing the corrosion from occurring
again; a Ford dealer may be able to
recommend a suitable product.
7 Check the condition of the battery
Every 10 000 miles or 12 months1•13
5.2 Hoses, like drivebelts, have a habit of
failing at the worst possible time - to
prevent the inconvenience of a blown radiator or heater hose, inspect them
carefully as shown here
1
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connections - remake the connections or
renew the leads if a fault is found. Use the
same techniques to ensure that all earth
points in the engine compartment provide
good electrical contact through clean, metal-
to-metal joints, and that all are securely
fastened. (In addition to the earth connection
at the engine lifting eye, and that from the
transmission to the body/battery, there are
others in various places, so check carefully).
8Refer to Section 21 for details of spark plug
(HT) lead checks.
7 Valve clearance adjustment
2
Refer to Chapter 2, Part A.
8 Manual transmission oil level check
1
1The manual transmission does not have a
dipstick. To check the oil level, raise the
vehicle and support it securely on axle stands,
making sure that the vehicle is level. On the
lower front side of the transmission housing,
you will see the filler/level plug. Unscrew and
remove it - an Allen key or bit will probably be
required (see illustration) .
2 With the plug removed, check the oil level.
To do this accurately, make up an oil level
check dipstick from a short length of welding
rod or similar material. Make a 90º bend in the
rod, then mark the downward leg in 5 mm
increments. The dipstick is then inserted
through the filler plug orifice so that the
unmarked leg rests flat on the plug orifice
threads, with the marked leg dipped in the oil.
Withdraw the dipstick and read off the level of
oil.
3 The oil level must be maintained between 0
and 5 mm below the lower edge of the
filler/level plug hole. Top up (if necessary),
using fresh transmission oil of the specified
type and using a syringe, or a plastic bottle
and tube. Refit and tighten the filler/level plug
to the specified torque on completion. 4
The need for regular topping-up can only
be due to a leak, which should be found and
rectified without delay.
5 Regular oil changing is not specified by the
manufacturer’s, but the oil can be drained, if
required, by removing the selector shaft cap
nut and locking assembly.
9 Idle speed and mixture check and adjustment
4
General
1Many of the engines fitted to Fiesta models
are equipped with fuel injection systems of
one sort or another which are entirely
controlled by the engine management system.
On most of these vehicles, it isn’t possible to
make any adjustments to the idle speed or the
mixture settings without specialist test
equipment of a type usually only found at a
Ford dealer or fuel injection specialist.
However, the very nature of these highly-
sophisticated systems means they don’t go
out of tune very often (if ever), so that it’s one
less maintenance operation to worry about.
2 On carburettor engines and 1.6 litre EFi fuel
injection engines, certain checks and
adjustments are necessary as part of the
service requirements, and these are described
below.
Idle speed and mixture check
and adjustment - carburettor
engines
Note: Later carburettors are fitted with
tamperproof mixture adjusting screws,
consisting of a hexagon-shaped socket with a
pin in the centre. Such screws require the use
of Ford service tool 23-032 to alter their
settings; if this tool (or a suitable equivalent) is
not available, the CO level will have to be
checked, and any necessary adjustment will
have to be made, by a Ford dealer.
3 Before carrying out the following checks
and adjustments, ensure that the spark plugs
are in good condition and correctly gapped
(Section 21). To carry out the checks/adjustments, an accurate tachometer
and an exhaust gas analyser (CO meter) will
be required.
4
Make sure that all electrical components
are switched off during the following
procedures.
5 Connect a tachometer to the engine in
accordance with its manufacturer’s
instructions, and insert the probe of an
exhaust gas analyser (CO meter) into the
exhaust tailpipe. As previously mentioned,
these items are essential in obtaining an
accurate setting. If they are not available, an
approximate check/adjustment can be made
as a temporary measure, providing they are
further checked out as soon as is possible
using a tachometer and a CO meter (or by a
Ford dealer).
6 Run the engine at a fast idle speed until it
reaches its normal operating temperature and
the radiator cooling fan cuts in. Turn the
engine off, then disconnect the radiator
cooling fan lead at the thermostatic switch
connector. Now connect a temporary wire to
the fan switch multi-plug, as shown (see
illustration) to enable the fan to operate
continuously during the following checks and
adjustments (if this is specified). Take care to
keep clear of the fan during the following
operations when working in the engine
compartment.
7 Where fitted, disconnect the throttle kicker
vacuum pipe, and plug the end. To identify
the throttle kicker unit, refer to Chapter 4A.
8 Check that the vehicle lighting and other
electrical loadings (apart from the radiator
cooling fan) are switched off, then restart the
engine. Increase the engine speed to 3000 rpm
for 30 seconds, and repeat this at three-minute
intervals during the check/adjustment
procedures. This will ensure that any excess
fuel is cleared from the inlet manifold.
9 Ensure that the throttle is fully released, allow
the meters to stabilise for a period of 5 to
30 seconds is normally sufficient, then check
the idle speed against that specified. If adjust-
ment is necessary, turn the idle speed
adjusting screw until the engine is idling at the
specified speed (see illustrations) . Any checks
and adjustments must be completed within
30 seconds of the meters stabilising.
1•14Every 10 000 miles or 12 months
9.9a Idle speed adjusting screw (A) and
mixture adjusting screw (B) (Weber TLM
carburettor)9.6 Cooling fan thermostatic switch multi-plug with temporary bridging wire
connected8.1 Manual transmission oil level/filler
plug (A), and selector shaft cap nut (B)
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the specified type of fluid. It is essential that
no dirt is introduced into the transmission
during this operation.
7Depending on the extent to which the fluid
was allowed to drain, it is possible that the
amount of fluid required when filling the
transmission may be more than the specified
amount (see “Lubricants, fluids and tyre
pressures” ). However, due to fluid remaining in
the system, it is more likely that less than the
specified amount will be required. Add about
half the specified amount, then run the engine
up to its normal operating temperature and
check the level on the dipstick. When the level
approaches the maximum mark, proceed as
detailed in Section 20 to check the level and
complete the final topping-up as described.
27 Handbrake adjustment
3
1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Fully
release the handbrake.
2 Check that the handbrake cables are
correctly routed and secured by the retaining
clips at the appropriate points under the vehicle.
3 The handbrake is checked for adjustment
by measuring the amount of movement
possible in the handbrake adjuster plungers.
These are located on the inside face of each
rear brake backplate (see illustration) . Thetotal movement of the two plungers combined
should be between 0.5 and 2.0 mm. If the
movement measured is outside of this
tolerance, the handbrake is in need of
adjustment. Adjustment is made altering the
position of the in-line cable adjuster sleeve.
4
When adjustment to the handbrake is
necessary, a new adjustment sleeve locking
pin will be required, and this must therefore
be obtained before making the adjustment.
5 To adjust the handbrake, first ensure that it
is fully released, then firmly apply the
footbrake a few times to ensure that the rear
brake adjustment is taken up by the automatic
adjusters. Extract the locking pin from
the adjuster sleeve (see illustration), then
turn the sleeve to set the combined move-
ment of the plungers within the tolerance range specified (0.5 to 2.0 mm). Turn the
locking nut by hand as tight as is possible
(two clicks) against the adjustment sleeve.
Now grip the locknut with a suitable wrench,
and turn it a further two clicks (maximum).
6
Secure the adjustment by inserting the new
lock pin.
7 Check that the operation of the handbrake
is satisfactory, then lower the vehicle to the
ground, apply the handbrake and remove the
chocks from the front wheels.
28 Front wheel alignment check
4
Refer to Chapter 10, Section 29.
Every 30 000 miles or three years1•25
27.5 Handbrake cable adjuster locking
pin (A), locknut (B) and adjuster sleeve (C)27.3 Handbrake adjustment plunger
located on the inside face of each rear brake backplate
1
1595Ford Fiesta Remake
Every 40 000 miles
29 Timing belt renewal
4
Refer to Chapter 2, Part B or C as
applicable.
Every 60 000 miles
30 Fuel filter renewal
1
Warning: Petrol is extremely
flammable, so extra precautions
must be taken when working on
any part of the fuel system. Do
not smoke, or allow open flames or bare
light bulbs, near the work area. Also, do
not work in a garage if a natural gas-type appliance with a pilot light is present.
While performing any work on the fuel system, wear safety glasses, and have a
suitable (Class B) fire extinguisher on
hand. If you spill any fuel on your skin,
rinse it off immediately with soap and
water.
1
On fuel injection engines, an in-line fuel
filter is provided in the fuel pump outlet line.
The filter is located in the engine compartment
either below and behind the battery, or on the
left-hand side of the engine compartment
bulkhead. The renewal procedure is the same
for both locations. The filter performs a vital
role in keeping dirt and other foreign matter
out of the fuel system, and so must be renewed at regular intervals, or whenever you
have reason to suspect that it may be
clogged. It is always unpleasant working
under a vehicle - pressure-washing or hosing
clean the underbody in the filter’s vicinity will
make working conditions more tolerable, and
will reduce the risk of getting dirt into the fuel
system.
2
Depressurise the fuel system as described
in the relevant Part of Chapter 4.
3 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1), then position
a suitable container beneath the fuel filter to
catch escaping fuel. Have a rag handy to soak
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up the fuel when the feed and outlet pipe
unions are disconnected.
4On models without quick-release couplings
on the fuel lines, slowly slacken the fuel feed
pipe union allowing the pressure in the fuel
pipe to reduce. When the pressure is fully
released, disconnect the fuel feed and outlet
pipe unions.
5 On models with quick-release couplings on
the fuel lines, release the fuel feed and outlet
pipe unions from the filter, by squeezing
together the protruding locking lugs on each
union, and carefully pulling the union off the
filter stub (see illustration) . Where the unions are colour-coded, the feed and outlet pipes
cannot be confused; where both unions are
the same colour, note carefully which pipe is
connected to which filter stub, and ensure that
they are correctly reconnected on refitting.
6
Noting the arrows and/or other markings on
the filter showing the direction of fuel flow
(towards the engine), slacken the filter clamp
bolt and withdraw the filter from the car (see
illustrations) . Note that the filter will still
contain fuel; care should be taken, to avoid
spillage and to minimise the risk of fire.
7 On installation, slide the filter into its clamp
so that the arrow marked on it faces the correct way, then reconnect and tighten the
pipe unions or slide each pipe union on to its
(correct) respective filter stub, and press it
down until the locking lugs click into their
groove. Tighten the clamp bolt carefully, until
the filter is just prevented from moving; do not
overtighten, or the filter casing may be
crushed.
8
Refit the fuel pump fuse and reconnect the
battery earth terminal, then switch the ignition
on and off five times, to pressurise the
system. Check for any sign of fuel leakage
around the filter unions before lowering the
vehicle to the ground and starting the engine.
1•26Every 60 000 miles
30.6b Removing the bulkhead mounted fuel filter. Clamp bolt (arrowed)30.6a Fuel filter location below battery
showing clamp bolt (arrowed). Note fuel flow direction arrows on filter body30.5 Releasing the fuel pipe unions fromthe filter on models with quick-release couplings
1595Ford Fiesta Remake
Every 3 years
31 Brake fluid renewal
3
The procedure is similar to that for the
bleeding of the hydraulic system as described
in Chapter 9, except that the brake fluid
reservoir should be emptied by syphoning,
and allowance should be made for the old
fluid to be removed from the circuit when
bleeding a section of the circuit.
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connecting rods (after removing the cylinder
head and sump) without removing the engine.
However, this is not recommended. Work of
this nature is more easily and thoroughly
completed with the engine on the bench, as
described in Chapter 2D.
2 Compression test-
description and interpretation
2
1 When engine performance is down, or if
misfiring occurs which cannot be attributed to
the ignition or fuel systems, a compression
test can provide diagnostic clues as to the
engine’s condition. If the test is performed
regularly, it can give warning of trouble before
any other symptoms become apparent.
2 The engine must be fully warmed-up to
normal operating temperature, the oil level
must be correct and the battery must be fully
charged. The aid of an assistant will also be
required.
3 On fuel injection engines, refer to Chap-
ter 12 and remove the fuel pump fuse from the
fusebox. Now start the engine and allow it to
run until it stalls.
4 Disable the ignition system by
disconnecting the multi-plug from the DIS or
E-DIS ignition coil. Remove all the spark plugs
with reference to Chapter 1 if necessary.
5 Fit a compression tester to the No 1
cylinder spark plug hole - the type of tester
which screws into the plug thread is to be
preferred.
6 Arrange for an assistant to hold the
accelerator pedal fully depressed to the floor,
while at the same time cranking the engine
over for several seconds on the starter motor.
Observe the compression gauge reading. The
compression will build up fairly quickly in a
healthy engine. Low compression on the first
stroke, followed by gradually-increasing
pressure on successive strokes, indicates
worn piston rings. A low compression on the
first stroke which does not rise on successive
strokes, indicates leaking valves or a blown
head gasket (a cracked cylinder head could
also be the cause). Deposits on the underside
of the valve heads can also cause low
compression. Record the highest gauge
reading obtained, then repeat the procedure
for the remaining cylinders.
7 Due to the variety of testers available, and
the fluctuation in starter motor speed when
cranking the engine, different readings
are often obtained when carrying out
the compression test. For this reason, actual
compression pressure figures are not quoted
by Ford. However, the most important factor
is that the compression pressures are uniform
in all cylinders, and that is what this test is
mainly concerned with.
8 Add some engine oil (about three squirts
from a plunger type oil can) to each cylinder
through the spark plug holes, and then repeat
the test. 9
If the compression increases after the oil is
added, it is indicative that the piston rings are
definitely worn. If the compression does not
increase significantly, the leakage is occurring
at the valves or the head gasket. Leakage
past the valves may be caused by burned
valve seats and/or faces, or warped, cracked
or bent valves.
10 If two adjacent cylinders have equally low
compressions, it is most likely that the head
gasket has blown between them. The
appearance of coolant in the combustion
chambers or on the engine oil dipstick would
verify this condition.
11 If one cylinder is about 20 percent lower
than the other, and the engine has a slightly
rough idle, a worn lobe on the camshaft could
be the cause.
12 On completion of the checks, refit the
spark plugs and reconnect the HT leads and
the ignition coil plug. Refit the fuel pump fuse
to the fusebox.
3 Top Dead Centre (TDC) for No 1 piston - locating
2
1Top dead centre (TDC) is the highest point
of the cylinder that each piston reaches as the
crankshaft turns. Each piston reaches its TDC
position at the end of its compression stroke,
and then again at the end of its exhaust
stroke. For the purpose of engine timing, TDC
at the end of the compression stroke for No 1
piston is used. On the HCS engine, No 1
cylinder is at the crankshaft pulley/timing
chain end of the engine. Proceed as follows.
2 Ensure that the ignition is switched off.
Disconnect the HT leads from the spark plugs,
then unscrew and remove the plugs as
described in Chapter 1.
3 Turn the engine over by hand (using a
spanner on the crankshaft pulley) to the point
where the timing mark on the crankshaft
pulley aligns with the TDC (0) mark or TDC
reference pointer on the timing cover (see
illustration) . As the pulley mark nears the
timing mark, the No 1 piston is simultaneously
approaching the top of its cylinder. To ensure
that it is on its compression stroke, place a
finger over the No 1 cylinder plug hole, and feel to ensure that air pressure exits from the
cylinder as the piston reaches the top of its
stroke.
4
A further check to ensure that the piston is
on its compression stroke can be made by
first removing the air cleaner (refer to the
relevant Part of Chapter 4), then unbolting and
removing the rocker cover, so that the
movement of the valves and rockers can be
observed.
5 With the TDC timing marks on the
crankshaft pulley and timing cover in
alignment, rock the crankshaft back and forth
a few degrees each side of this position, and
observe the action of the valves and rockers
for No 1 cylinder. When No 1 piston is at the
TDC firing position, the inlet and exhaust valve
of No 1 cylinder will be fully closed, but the
corresponding valves of No 4 cylinder will be
seen to rock open and closed.
6 If the inlet and exhaust valves of No 1
cylinder are seen to rock whilst those of
No 4 cylinder are shut, the crankshaft will
need to be turned one full rotation to bring
No 1 piston up to the top of its cylinder on the
compression stroke.
7 Once No 1 cylinder has been positioned at
TDC on the compression stroke, TDC for any
of the other cylinders can then be located by
rotating the crankshaft clockwise (in its
normal direction of rotation), 180º at a time,
and following the firing order (see
Specifications).
4 Cylinder head rocker cover -
removal and refitting
1
Removal
1 Where necessary for access, remove the air
cleaner as described in the relevant Part of
Chapter 4.
2 Detach the HT leads from the spark plugs.
Pull on the connector of each lead (not the
lead itself), and note the order of fitting.
3 Remove the engine oil filler cap and
breather hose (where fitted).
4 Unscrew the four retaining bolts, and lift the
rocker cover clear of the cylinder head.
Remove the gasket.
HCS engine in-car repair procedures 2A•3
3.3 Timing mark on the crankshaft pulley aligned with the TDC (0) mar\
k on the timing cover
2A
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8Reassemble in the reverse order of
dismantling. Make sure that the “flat” on the
rear end of the rocker shaft is to the same side
as the rocker arm adjusting screws (closest to
the thermostat end of the cylinder head when
fitted) (see illustration) . This is essential for
the correct lubrication of the cylinder head
components.
9 Refit the rocker shaft assembly. As it is
fitted, ensure that the rocker adjuster screws
engage with their corresponding pushrods.
10 Refit the rocker shaft retaining bolts,
hand-tighten them and then tighten them to
the specified torque wrench setting. As they
are tightened, some of the rocker arms will
apply pressure to the ends of the valve stems,
and some of the rocker pedestals will not
initially be in contact with the cylinder head -
these should pull down as the bolts are
tightened to their specified torque. If for any
reason they do not, avoid the temptation to
overtighten in order to pull them into position;
loosen off the bolts, and check the cause of
the problem. It may be that the rocker adjuster
screws require loosening off in order to allow
the assembly to be tightened down as
required.
11 Adjust the valve clearances as described
in Section 5.
7 Cylinder head -
removal and refitting
3
Removal
Note: The following procedure describes
removal and refitting of the cylinder head
complete with inlet and exhaust manifolds. If
wished, the manifolds may be removed first,
as described in the relevant Part of Chapter 4,
and the cylinder head then removed on its
own.
1 On fuel injection engines, depressurise the
fuel system as described in Chapter 4, Part B.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Refer to Chapter 4A or 4B as applicable
and remove the air cleaner.
4 Refer to Section 4 and remove the rocker
cover. 5
Refer to Chapter 1 and drain the cooling
system.
6 Disconnect the hoses from the thermostat
housing.
7 Disconnect the heater (coolant) hoses from
the inlet manifold and CFi unit, where
applicable.
8 Disconnect the accelerator and choke
cables as applicable (see Chapter 4A or 4B).
9 Disconnect the vacuum and breather hoses
from the carburettor/CFi unit, and inlet
manifold as applicable.
10 Disconnect the fuel feed and return lines
at the carburettor, or at the quick-release
couplings, then unclip the fuel hoses from the
inlet manifold; use rag to soak up any spilt
fuel.
11 Disconnect the HT leads from the spark
plugs and the support bracket. Unscrew and
remove the spark plugs.
12 Disconnect the electrical leads from the
temperature gauge sender, radiator cooling
fan, the engine coolant temperature sender,
and the anti-run-on (anti-dieselling) valve at
the carburettor.
13 Disconnect the remaining wiring multi-
plugs from the engine sensors at the inlet
manifold and from the oxygen sensor (where
fitted) in the exhaust manifold or downpipe.
14 On vehicles equipped with a pulse-air
system, remove the pulse-air piping and filter
assembly as described in Chapter 4E.
15 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
16 Undo the retaining nuts and bolts, and
disconnect the exhaust downpipe from the
manifold. Remove the flange gasket. (Note
that both the gasket and the joint self-locking
nuts must be renewed.) To prevent the
exhaust system from being strained, tie the
downpipe up using strong wire or a length of
cord to support it. Lower the vehicle.
17 Undo the four retaining bolts and lift clear
the rocker gear assembly from the cylinder
head.
18 Lift out the pushrods. Keep them in order
of fitting by labelling them 1 to 8, starting from
the thermostat end of the cylinder head.
Alternatively, push them through a piece of
card in their fitted sequence.
19 Progressively unscrew and loosen off the
cylinder head retaining bolts in the reverse
sequence to that shown for tightening (see
illustration 7.27a). When they are all loosened off, remove the bolts, then lift the
cylinder head clear and remove the gasket. If
it is stuck, tap it upwards using a hammer and
block of wood. Do not try to turn it, as it is
located by dowels; make no attempt
whatsoever to prise it free using a screwdriver
inserted between the block and head faces.
The gasket must always be renewed; it should
be noted that the cylinder head retaining bolts
may be re-used, but only once. They should
be marked accordingly with a punch or paint
mark. If there is any doubt as to how many
times the bolts have been used, they must be
renewed.
20
To dismantle/overhaul the cylinder head,
refer to Part D of this Chapter. It is normal for
the cylinder head to be decarbonised and the
valves to be reground whenever the head is
removed.
Preparation for refitting
21 The mating faces of the cylinder head and
cylinder block must be perfectly clean before
refitting the head. Use a hard plastic or wood
scraper to remove all traces of gasket and
carbon; also clean the piston crowns. Take
particular care during the cleaning operations,
as aluminium alloy is easily damaged. Also,
make sure that the carbon is not allowed to
enter the oil and water passages - this is
particularly important for the lubrication
system, as carbon could block the oil supply
to the engine’s components. Using adhesive
tape and paper, seal the water, oil and bolt
holes in the cylinder block.
22 Check the mating surfaces of the cylinder
block and the cylinder head for nicks, deep
scratches and other damage. If slight, they
may be removed carefully with a file, but if
excessive, machining may be the only
alternative to renewal.
23 If warpage of the cylinder head gasket
surface is suspected, use a straight-edge to
check it for distortion. Refer to Part D of this
Chapter if necessary.
24 Clean the threads of the cylinder head
bolts or fit new ones (as applicable) and clean
out the bolt holes in the block. Screwing a bolt
into an oil-filled hole can (in extreme cases)
cause the block to fracture, due to the
hydraulic pressure.
Refitting
25 Check that the new cylinder head gasket
is the same type as the original, and that the
“TOP” (or “OBEN”) marking is facing
upwards. Locate the new cylinder head
HCS engine in-car repair procedures 2A•5
6.8 Flat on the rocker shaft (arrowed) to
same side as rocker arm adjusting screws
2A
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Whenever you disconnect
any vacuum lines, coolant or
emissions hoses, wiring
connectors and fuel lines,
always label them clearly, so that they
can be correctly reassembled. Masking
tape and/or a touch-up paint applicator
work well for marking items. Take
instant photos, or sketch the locations
of components and brackets.
To prevent carbon entering
the gap between the pistons
and bores, smear a little
grease in the gap. After
cleaning each piston, use a small brush
to remove all traces of grease and
carbon from the gap, then wipe away
the remainder with a clean rag.
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gasket onto the top face of the cylinder block
and over the dowels. Ensure that it is correctly
aligned with the coolant passages and
oilways (see illustration) .
26 Lower the cylinder head carefully into
position, then insert the retaining bolts and
hand-tighten them.
27 Tightening of the cylinder head bolts must
done in three stages, and in the correct
sequence (see illustration) . First tighten all of
the bolts in the sequence shown to the
Stage 1 torque setting (see illustration).
When all of the bolts are tightened to the
Stage 1 setting, further tighten each bolt (in
sequence) through the Stage 2 specified
angle of rotation. When the second stage
tightening is completed on all of the bolts,
further tighten them to the Stage 3 angle
setting (in sequence) to complete. Where
possible, use an angular torque setting gauge
attachment tool for accurate tightening of
stages two and three (see illustration).
28 Lubricate the pushrods with clean engine
oil, and then insert them into their original
locations in the engine.
29 Refit the rocker shaft assembly. As it is
fitted, ensure that the rocker adjuster screws
engage with their corresponding pushrods.
30 Refit the rocker shaft retaining bolts,
hand-tighten them and then tighten them
to the specified torque wrench setting. As
they are tightened, some of the rocker arms
will apply pressure to the ends of the valve
stems, and some of the rocker pedestals will
not initially be in contact with the cylinder head - these should pull down as the bolts are
tightened. If for any reason they do not, avoid
the temptation to overtighten in order to pull
them into position; loosen off the bolts, and
check the cause of the problem. It may be
that the rocker adjuster screws require
loosening off in order to allow the assembly to
be tightened down as required.
31
Adjust the valve clearances as described
in Section 5.
32 Refit the rocker cover as described in
Section 4.
33 The remainder of the refitting procedure is
a reversal of the removal process. Tighten all
fastenings to their specified torque setting
(where given). Refer to the appropriate Parts
of Chapter 4 for details on reconnecting the
fuel and exhaust system components. Ensure
that all coolant, fuel, vacuum and electrical
connections are securely made.
34 On completion, refill the cooling system
and top-up the engine oil (see Chapter 1 and
“Weekly Checks” ). When the engine is
restarted, check for any sign of fuel, oil and/or
coolant leakages from the various cylinder
head joints.
8 Crankshaft pulley -
removal and refitting
2
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Remove
the right-hand front roadwheel.
3 Remove the auxiliary drivebelt as described
in Chapter 1.
4 Loosen off the crankshaft pulley retaining
bolt. To prevent the crankshaft from turning,
unbolt and remove the clutch housing cover
plate. Lock the starter ring gear on the
flywheel using a large screwdriver or similar
tool inserted through the cover plate aperture.
Alternatively, remove the starter motor
(Chapter 5A) and lock the ring gear through
the starter motor aperture. 5
Fully unscrew the crankshaft pulley bolt,
and withdraw the pulley from the front end of
the crankshaft. If it does not pull off by hand,
lever it free using a pair of suitable levers
positioned diagonally opposite each other
behind the pulley.
6 If required, the crankshaft front oil seal can
be renewed at this stage, as described in
Section 14.
Refitting
7 Refitting is a reversal of the removal
procedure ensuring that the pulley retaining
bolt is tightened to the specified torque
setting.
8 Refit the auxiliary drivebelt as described in
Chapter 1, and lower the vehicle to complete.
9 Timing chain cover -
removal and refitting
2
Removal
1 Remove the sump as described in Sec-
tion 11.
2 Remove the crankshaft pulley as described
in the previous Section.
3 A combined timing cover and water pump
gasket is fitted during production; if this is still
in position, it will be necessary to drain the
cooling system and remove the water pump
as described in Chapter 3. If the water pump
and/or the timing cover have been removed at
any time, the single gasket used originally will
have been replaced by an individual gasket
for each component, in which case the water
pump can remain in position.
4 Unscrew the retaining bolts, and carefully
prise free the timing chain cover.
5 Clean the mating faces of the timing chain
cover, and the engine.
6 If necessary, renew the crankshaft front oil
seal in the timing cover prior to refitting the
cover (see Section 14).
Refitting
7 Lightly lubricate the front end of the
crankshaft and the radial lip of the timing
chain cover oil seal (already installed in the
2A•6 HCS engine in-car repair procedures
7.27c Cylinder head bolt tightening
(Stages 2 and 3) using an angle gauge
7.27b Tightening the cylinder head bolts (Stage 1)7.27a Cylinder head bolt tighteningsequence7.25 Cylinder head gasket top-facemarking (“OBEN”)
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