bonnet FORD FIESTA 1989 Service Repair Manual

1
1595Ford Fiesta Remake
Chapter 1
Routine maintenance and servicing
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 20
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . 26
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 4
Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . 18
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 14
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 31
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 23
Door, tailgate and bonnet check and lubrication . . . . . . . . . . . . . . . 16
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 11
Emission control system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front wheel alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 30Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Idle speed and mixture check and adjustment . . . . . . . . . . . . . . . . 9
Idle speed control valve cleaning and maintenance . . . . . . . . . . . . . 22
Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 1
Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 8
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 19
Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 17
Spark plug renewal and HT component check . . . . . . . . . . . . . . . . . 21
Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 10
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 29
Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 13
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 5
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1•1
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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The maintenance schedule for these
vehicles, based on the manufacturer’s
recommendations, is as described below -
note that the schedule starts from the
vehicle’s date of registration. These are the
minimum maintenance intervals recommen-
ded by the factory for Fiestas driven daily, but
subjected only to “normal” use. If you wish to
keep your vehicle in peak condition at all
times, you may wish to perform some of these
procedures even more often. Because
frequent maintenance enhances the
efficiency, performance and resale value of
your vehicle, we encourage you to do so. If
your usage is not “normal”, shorter intervals are also recommended - the most important
examples of these are noted in the schedule.
These shorter intervals apply particularly if
you drive in dusty areas, tow a caravan or
trailer, sit with the engine idling or drive at low
speeds for extended periods (ie, in heavy
traffic), or drive for short distances (less
than four miles) in below-freezing
temperatures.
When your vehicle is new, it should be
serviced by a Ford dealer service department
to protect the factory warranty. In many
cases, the initial maintenance check is done
at no cost to the owner. Note that this first
free service (carried out by the selling dealer 1500 miles or 3 months after delivery),
although an important check for a new
vehicle, is not part of the regular maintenance
schedule, and is therefore not mentioned
here.
It should be noted that for the 1992 model
year, for all models except RS Turbo, the
service time/mileage intervals were
extended by the manufacturer to the periods
shown in this schedule. Although these
intervals can be applied retrospectively,
owners of earlier vehicles may notice a
discrepancy between this schedule and the
one shown in the Service Guide supplied
with the vehicle.
1•4Maintenance schedule
1595Ford Fiesta Remake
Every 250 miles (400 km) or weekly
m
m Refer to “Weekly Checks” .
Every 5000 miles (8000 km) or
6 months, whichever occurs first
Note: Frequent oil and filter changes are good for the engine. We
recommend changing the oil at the mileage specified here, or at least
twice a year if the mileage covered is less.
m m Renew the engine oil and filter (Section 3).
Every 10 000 miles (16 000 km) or
12 months, whichever occurs first
Carry out all operations listed above, plus the following:
m mCheck the auxiliary drivebelt (Section 4).
m
m Check under the bonnet for fluid leaks and hose condition
(Section 5).
m
m Check the condition of all engine compartment wiring (Sec-
tion 6).
m
m Check the valve clearance adjustment - HCS engines only
(Section 7).
m
m Check the manual transmission oil level (Section 8).
m
m Check the engine idle speed and mixture - HCS and CVH
engines only, where possible (Section 9).
m
m Check the steering, suspension and roadwheels (Section 10).
m
m Check the driveshaft rubber gaiters and CV joints (Section 11).
m
m Check the exhaust system (Section 12).
m
m Check the underbody, and all fuel/brake lines (Section 13).
m
m Check the brake system (Section 14).
m
m Check the security of all roadwheel nuts (Section 15).
m
m Check the doors, tailgate and bonnet, and lubricate their hinges
and locks (Section 16).
m
m Check the seat belts (Section 17).
m
m Check the condition of the bodywork, paint and exterior trim
(Section 18).
m
m Road test (Section 19).
m
m Check the automatic transmission fluid level (Section 20).
Every 20 000 miles (32 000 km) or
two years, whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the spark plugs and check the condition of the HT leads
- all engines except Zetec (Section 21).
m
m Clean the idle speed control valve (Weber type) - CVH EFi
engines only (Section 22).
Every 30 000 miles (48 000 km) or
three years, whichever occurs first
Carry out all operations listed above, plus the following:
m m Renew the coolant (Section 23).
m
m Renew the air cleaner filter element and check the air cleaner
temperature control system - carburettor engines only (Sec-
tion 24).
m m Check the emission control systems (Section 25).
m
m Renew the spark plugs and check the condition of the HT leads
- Zetec engines (Section 21).
m
m Renew the automatic transmission fluid (Section 26).
m
m Check the handbrake adjustment (Section 27).
m
m Check the front wheel alignment (Section 28).
Note: If the vehicle is used regularly in dusty or polluted conditions,
the air cleaner filter element should be renewed at more frequent
intervals.
Every 40 000 miles
m
m Renew the timing belt - CVH and PTE engines only (Section 29).
Every 60 000 miles
m
mRenew the timing belt - Zetec engines only (Section 29).
m
m Renew the fuel filter (Section 30).
Every three years
(regardless of mileage)
m m Renew the brake fluid (Section 31).
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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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4 Auxiliary drivebelt check andrenewal
2
General
1The number of auxiliary drivebelts fitted and
their type depends on engine, and on whether
the vehicle is equipped with power steering.
The drivebelt(s) are located on the right-hand
end of the engine and will be either of the V-
belt type or the flat, multi-ribbed (or “polyvee”)
type. The belt drives the alternator, water
pump and, on CVH and Zetec engines with
power steering, the power steering pump
from the engine’s crankshaft pulley. On HCS
engines with power steering, one belt drives
the alternator and water pump and a separate
belt drives the power steering pump.
2 The good condition and proper tension of
the auxiliary drivebelt is critical to the
operation of the engine. Because of their
composition and the high stresses to which
they are subjected, drivebelts stretch and
deteriorate as they get older. They must,
therefore, be regularly inspected.
Check
3 With the engine switched off, open and
support the bonnet, then locate the auxiliary
drivebelt(s) on the right-hand end of the
engine (Be very careful, and wear protective
gloves to minimise the risk of burning your
hands on hot components, if the engine has
recently been running). For improved access,
jack up the front right-hand side of the
vehicle, support it securely on an axle
stand, remove the roadwheel, then (where
fitted) remove the auxiliary drivebelt lower
cover from inside the wheel arch (see
illustration) .
4 Using an inspection light or an electric
torch, and rotating the engine when necessary
with a spanner applied to the crankshaft
pulley bolt, check the whole length of the drivebelt(s) for cracks, separation of the
rubber, and torn or worn ribs
(see
illustration) . Also check for fraying and
glazing, which gives the drivebelt a shiny
appearance. Both sides of the drivebelt(s)
should be inspected, which means you will
have to twist the drivebelt(s) to check the
underside. Feel the relevant drivebelt where
you can’t see it. If you are in any doubt as to
the condition of the drivebelt(s), renewal is
necessary (go to paragraph 23).
Drivebelt tension
5 The tension must be adjusted manually on
all V-belt type drivebelts, on flat “polyvee”
type drivebelts fitted to early Zetec engines,
and on “polyvee” type drivebelts fitted to HCS
engines to drive the power steering pump.
The “polyvee” type drivebelts used on later
Zetec engines and PTE engines are fitted with
an automatic tensioner to maintain the correct
belt adjustment.
6 For models on which the tension can be
adjusted manually, open the bonnet. Jack up the front right-hand side of the vehicle, and
support it securely on an axle stand. Remove
the roadwheel, then (where fitted) remove the
auxiliary drivebelt lower cover from inside the
wheel arch.
7
Ford technicians use a special tension gauge
and various other special tools for checking
drivebelt adjustment, but for DIY purposes,
checking the belt tension using finger pressure
gives a good indication of correct adjustment.
Apply firm finger pressure midway between the
pulleys on the longest run of the belt, and look
for a deflection of approximately 2.0 mm (i.e. a
total drivebelt “swing” of approximately
4.0 mm) (see illustration) .
8 If adjustment is necessary, proceed as
follows according to belt type.
V-belt with sliding arm type adjuster
9 Loosen off the alternator mounting bolts
and sliding arm adjustment bolts, pivot the
alternator as required to provide the correct
drivebelt tension, then retighten the bolts to
secure (see illustration) .
10 Refit the auxiliary drivebelt cover (where
applicable) and roadwheel, then lower the
vehicle to the ground.
11 Run the engine for about five minutes,
then recheck the tension.
Every 10 000 miles (16 000 km) or 12 months,
whichever comes first
Every 10 000 miles or 12 months1•11
4.9 Alternator sliding arm adjustment
bolt (A) and sliding arm mounting bolt (B) - V-belt with sliding arm type adjuster
4.7 Checking drivebelt adjustment - V-belt types
Note that the 4 mm dimension is the total belt swing and is equal to 2 mm of deflection
4.3 Remove the auxiliary drivebelt lower cover from inside the wheel arch
1
1595Ford Fiesta Remake
4.4 Check the auxiliary drivebelt forsigns of wear like these. Very small
cracks across the drivebelt ribs are acceptable. If the cracks are deep, or if the drivebelt looks worn or
damaged in any other way, renew it. This is the “polyvee” type belt, butthe checks on the V-belt type are the same
Turning the engine will be
much easier if the spark
plugs are removed first
(Section 21).
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V-belt and flat “polyvee” type
drivebelt with rack-and-pinion type
adjuster
12Loosen off the alternator mounting bolts
and the adjusting arm mounting bolt. Slacken
the pinion central locking bolt, and turn the
pinion nut as required to take up the tension
of the drivebelt. Hold it at the required setting,
and tighten the central bolt securely to lock
the adjuster arm and set the tension (see
illustrations) .
13 Tighten the alternator mounting and
adjusting arm bolts securely.
14 Refit the auxiliary drivebelt cover (where
applicable) and roadwheel, then lower the
vehicle to the ground.
15 Run the engine for about five minutes,
then recheck the tension.
Flat “polyvee” type drivebelt with
tensioner pulley adjuster (HCS engine
power steering pump drivebelt)
16 Slacken the tensioner pulley centre bolt
then turn the adjuster bolt at the base of the
tensioner pulley bracket, as required, to take
up the tension of the drivebelt. When the belt
deflection is correct, tighten the adjuster
pulley centre retaining bolt.
17 Refit the auxiliary drivebelt cover (where
applicable) and roadwheel, then lower the
vehicle to the ground.
18 Run the engine for about five minutes,
then recheck the tension.
Flat “polyvee” type drivebelt with
automatic adjuster
19 As mentioned above, this type of drivebelt
is tensioned by an automatic tensioner;
regular checks are not required, and manual
“adjustment” is not possible.
20 If you suspect that the drivebelt is slipping
and/or running slack, or that the tensioner is
otherwise faulty, it must be renewed. To do
this, remove the drivebelt as described below,
then unbolt and remove the tensioner. On
fitting the new tensioner, ensure that it is
aligned correctly on its mountings, and
tightened to the specified torque wrench
setting.
Renewal
21 Open the bonnet. Jack up the front right-
hand side of the vehicle, and support it
securely on an axle stand. Remove the
roadwheel, then remove the auxiliary drivebelt
lower cover (where fitted) from inside the
wheel arch.
22 The routing of the drivebelt around the
pulleys is dependent on the drivebelt type,
and on whether power steering is fitted.
Before removing the drivebelt, it’s a good idea
to sketch the belt run around the pulleys; this
will save a lot of frustration when it comes to
refitting. Note that on HCS engines with
power steering, to renew the alternator/
water pump drivebelt it will be necessary to
remove the power steering pump drivebelt
first.
23 If the existing drivebelt is to be refitted,
mark it, or note the maker’s markings on its
flat surface, so that it can be installed the
same way round.
24 To renew a drivebelt with manual
adjustment, slacken the belt tension fully as
described above, according to type. Slip the
belt off the pulleys, then fit the new belt,
ensuring that it is routed correctly. If fitting a
flat “polyvee” type drivebelt, arrange it on the
grooved pulleys so that it is centred in
their grooves, and not overlapping their raised
sides. With the belt in position, adjust the
tension as previously described.
25 To renew the flat, “polyvee” type drivebelt
with automatic adjuster, reach up between
the body and the engine (above the
crankshaft pulley), and apply a spanner to the
hexagon in the centre of the automatic
tensioner’s pulley. Rotate the tensioner pulley
clockwise to release its pressure on the
drivebelt, then slip the drivebelt off the
crankshaft pulley, and release the tensioner
again (see illustration) . Note that on certain
models, a self-cocking tensioner is fitted, and
that this will remain in the released position.
Working from the wheel arch or engine
compartment as necessary, and noting its
routing, slip the drivebelt off the remaining
pulleys and withdraw it.
26 Check all the pulleys, ensuring that their
grooves are clean, and removing all traces of oil and grease. Check that the tensioner
works properly, with strong spring pressure
being felt when its pulley is rotated clockwise,
and a smooth return to the limit of its travel
when released.
27
If the original drivebelt is being refitted,
use the marks or notes made on removal, to
ensure that it is installed to run in the same
direction as it was previously. To fit the
drivebelt, arrange it on the grooved pulleys so
that it is centred in their grooves, and not
overlapping their raised sides, and is routed
correctly. Start at the top, and work down to
finish at the crankshaft pulley; rotate the
tensioner pulley clockwise, slip the drivebelt
onto the crankshaft pulley, then release the
tensioner again.
28 Using a spanner applied to the crankshaft
pulley bolt, rotate the crankshaft through at
least two full turns clockwise to settle the
drivebelt on the pulleys, then check that
the drivebelt is properly installed.
29 Refit the auxiliary drivebelt cover (where
applicable) and roadwheel, then lower the
vehicle to the ground.
5 Underbonnet check for fluid leaks and hose condition
1
General
1High temperatures in the engine
compartment can cause the deterioration of
the rubber and plastic hoses used for engine,
accessory and emissions systems operation.
Periodic inspection should be made for
cracks, loose clamps, material hardening and
leaks.
2 Carefully check the large top and bottom
radiator hoses, along with the other smaller-
diameter cooling system hoses and metal
pipes; do not forget the heater hoses/pipes
which run from the engine to the bulkhead.
Inspect each hose along its entire length,
replacing any that is cracked, swollen or
shows signs of deterioration. Cracks may
become more apparent if the hose is
1•12Every 10 000 miles or 12 months
4.25 Automatic drivebelt tensioner - “polyvee” type drivebelt
Turn tensioner clockwise to release tension4.12b When the tension is correct, hold
the adjuster nut, and tighten the central bolt securely to lock the adjuster arm4.12a Rack-and-pinion type auxiliary drivebelt adjuster
A Adjuster arm
B Pinion (adjuster) nut
C Central (locking) bolt
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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
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3Check that the roadwheel nuts are tightened
to the specified torque wrench setting.
4 Refit the wheel covers.
16 Door, tailgate and bonnet
check and lubrication
1
1Check that the doors and tailgate/boot lid
close securely. Check that the bonnet safety
catch operates correctly. Check the operation
of the door check straps.
2 Lubricate the hinges, door check straps,
the striker plates and the bonnet catch
sparingly with a little oil or grease.
17 Seat belt check
1
1 Check the seat belts for satisfactory
operation and condition. Inspect the webbing
for fraying and cuts. Check that they retract
smoothly and without binding into their reels.
2 Check that the seat belt mounting bolts are
tight, and if necessary tighten them to the
specified torque wrench settings as given in
Chapter 11.
18 Bodywork, paint and exterior trim check
1
1The best time to carry out this check is after
the car has been washed so that any surface
blemish or scratch will be clearly evident and
not hidden by a film of dirt.
2 Starting at one front corner check the
paintwork all around the car, looking for minor
scratches or more serious dents. Check all
the trim and make sure that it is securely
attached over its entire length.
3 Check the security of all door locks, door
mirrors, badges, bumpers, front grille and
wheel trim. Anything found loose, or in need of
further attention should be done with reference
to the relevant Chapters of this manual.
4 Rectify any problems noticed with the
paintwork or body panels as described in
Chapter 11.
19 Road test
1
Check the operation and
performance of the braking
system
1 Make sure that the vehicle does not pull to
one side when braking, and that the wheels
do not lock prematurely when braking hard.
2 Check that there is no vibration through the
steering when braking. 3
Check that the handbrake operates
correctly, without excessive movement of the
lever, and that it holds the vehicle stationary
on a slope.
4 Test the operation of the brake servo unit
as follows. With the engine switched off,
depress the footbrake four or five times to
exhaust the vacuum, then hold the pedal
depressed. Start the engine, and there should
be a noticeable “give” in the brake pedal as
vacuum builds up. Allow the engine to run for
at least two minutes, and then switch it off. If
the brake pedal is depressed again, it should
be possible to detect a hiss from the servo as
the pedal is depressed. After about four or five
applications, no further hissing should be
heard, and the pedal should feel considerably
firmer.
Steering and suspension
5 Check for any abnormalities in the steering,
suspension, handling or road “feel”.
6 Drive the vehicle, and check that there are
no unusual vibrations or noises.
7 Check that the steering feels positive, with
no excessive sloppiness or roughness, and
check for any suspension noises when
cornering and driving over bumps.
Drivetrain
8 Check the performance of the engine,
transmission and driveshafts.
9 Check that the engine starts correctly, both
when cold and when hot.
10 Listen for any unusual noises from the
engine and transmission.
11 Make sure that the engine runs smoothly
when idling, and that there is no hesitation
when accelerating.
12 On manual transmission models, check
that all gears can be engaged smoothly
without noise, and that the gear lever action is
not abnormally vague or “notchy”.
13 On automatic transmission models, make
sure that the drive seems smooth without
jerks or engine speed “flare-ups”. Check that
all the gear positions can be selected with the
vehicle at rest. If any problems are found, they
should be referred to a Ford dealer.
14 Listen for a metallic clicking sound from
the front of the vehicle, as the vehicle is driven
slowly in a circle with the steering on full-lock.
Carry out this check in both directions. If a
clicking noise is heard, this indicates wear in a
driveshaft joint, in which case renew the joint
if necessary.
Clutch
15 Check that the clutch pedal moves
smoothly and easily through its full travel, and
that the clutch itself functions correctly, with
no trace of slip or drag. If the movement is
uneven or stiff in places, check that the cable
is routed correctly, with no sharp turns.
16 Inspect both ends of the clutch inner
cable, both at the transmission end and inside
the car, for signs of wear and fraying.
Instruments and electrical
equipment
17 Check the operation of all instruments
and electrical equipment.
18 Make sure that all instruments read
correctly, and switch on all electrical equipment
in turn, to check that it functions properly.
20 Automatic transmission fluid level check
1
1The level of the automatic transmission fluid
should be carefully maintained. Low fluid level
can lead to slipping or loss of drive, while
overfilling can cause foaming, loss of fluid and
transmission damage.
2 The transmission fluid level should only be
checked when the transmission is hot (at its
normal operating temperature). If the vehicle
has just been driven over 10 miles (15 miles in
a cold climate), and the fluid temperature is 60
to 70ºC, the transmission is hot.
Caution: If the vehicle has just been driven
for a long time at high speed or in city
traffic in hot weather, or if it has been
pulling a trailer, an accurate fluid level
reading cannot be obtained. In these
circumstances, allow the fluid to cool
down for about 30 minutes.
3 Park the vehicle on level ground, apply the
handbrake, and start the engine. While the
engine is idling, depress the brake pedal and
move the selector lever through all the gear
positions three times, beginning and ending in
“P”.
4 Allow the engine to idle for one minute, then
(with the engine still idling) remove the
dipstick from its tube. Note the condition and
colour of the fluid on the dipstick.
5 Wipe the fluid from the dipstick with a clean
rag, and re-insert it into the filler tube until the
cap seats.
6 Pull the dipstick out again, and note the
fluid level. The level should be between
the “MIN” and “MAX” marks. If the level is
on the “MIN” mark, stop the engine, and add
the specified automatic transmission fluid
through the dipstick tube, using a clean funnel
if necessary. It is important not to introduce
dirt into the transmission when topping-up.
7 Add the fluid a little at a time, and keep
checking the level as previously described
until it is correct. The difference between the
“MIN” and “MAX” marks on the dipstick is
approximately 0.4 litres.
8 The need for regular topping-up of the
transmission fluid indicates a leak, which
should be found and rectified without delay.
9 The condition of the fluid should also be
checked along with the level. If the fluid on the
dipstick is black or a dark reddish-brown
colour, or if it has a burned smell, the fluid
should be changed. If you are in doubt about
the condition of the fluid, purchase some new
fluid, and compare the two for colour and smell.
1•18Every 10 000 miles or 12 months
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21 Spark plug renewal and HTcomponent check
1
Note: Spark plug renewal at this service
interval is only necessary on the HCS, CVH
and PTE engines. On Zetec engines, the
recommended interval for spark plug renewal
is every 30 000 miles or three years.
Spark plug check and renewal
1 It is vital for the correct running, full
performance and proper economy of the engine
that the spark plugs perform with maximum
efficiency. The most important factor in ensuring
this is that the plugs fitted are appropriate for the
engine. The suitable type is given in the
Specifications Section at the beginning of this
Chapter, on the Vehicle Emissions Control
Information (VECI) label located on the
underside of the bonnet (only on models sold in
some areas) or in the vehicle’s Owner’s
Handbook. If the correct type is used and the
engine is in good condition, the spark plugs
should not need attention between scheduled
renewal intervals. Spark plug cleaning is rarely
necessary, and should not be attempted unless
specialised equipment is available, as damage
can easily be caused to the firing ends.
2 Spark plug removal and refitting requires a
spark plug socket, with an extension which can
be turned by a ratchet handle or similar. This
socket is lined with a rubber sleeve, to protect
the porcelain insulator of the spark plug, and to
hold the plug while you insert it into the spark
plug hole. You will also need a set of feeler
gauges, to check the spark plug electrode gap,
and a torque wrench to tighten the new plugs
to the specified torque (see illustration).
3 To remove the spark plugs, first open the
bonnet; the plugs are easily reached at the
top of the engine. Note how the spark plug
(HT) leads are routed and secured by clips,
and on some engines, how they’re positioned
along the channel in the cylinder head cover.
To prevent the possibility of mixing up spark
plug (HT) leads, it is a good idea to try to work
on one spark plug at a time.
4 If the marks on the original-equipment spark
plug (HT) leads cannot be seen, mark the leads
1 to 4, to correspond to the cylinder the lead
serves (No 1 cylinder is at the timing belt/chain
end of the engine). Pull the leads from the plugs
by gripping the rubber boot, not the lead,
otherwise the lead connection may be fractured.
5 It is advisable to soak up any liquid in the
spark plug recesses with a rag, and to remove
any dirt from them using a clean brush,
vacuum cleaner or compressed air before
removing the plugs, to prevent any dirt or
water from dropping into the cylinders. Warning: Wear eye protection
when using compressed air!
6 Unscrew the spark plugs, ensuring that the
socket is kept in alignment with each plug - if
the socket is forcibly moved to either side, the
porcelain top of the plug may be broken off. If
any undue difficulty is encountered when
unscrewing any of the spark plugs, carefully
check the cylinder head threads and tapered
sealing surfaces for signs of wear, excessive
corrosion or damage; if any of these
conditions is found, seek the advice of a Ford
dealer as to the best method of repair.
7 As each plug is removed, examine it as
follows - this will give a good indication of the
condition of the engine. If the insulator nose is
covered with light tan to greyish-brown
deposits, then the mixture is correct, and it is
likely that the engine is in good condition.
8 If the tip and insulator nose are covered
with hard black-looking deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
9 If the insulator nose of the spark plug is clean and white, with no deposits, this is
indicative of a weak mixture.
10
If you are renewing the spark plugs,
purchase the new plugs, then check each of
them first for faults such as cracked insulators
or damaged threads. Note also that,
whenever the spark plugs are renewed as a
routine service operation, the spark plug (HT)
leads should be checked as described below.
11 The spark plug electrode gap is of
considerable importance as, if it is too large or
too small, the size of the spark and its
efficiency will be seriously impaired. The gap
should be set to the value given in the
Specifications Section of this Chapter. New
plugs will not necessarily be set to the correct
gap, so they should always be checked
before fitting.
12 The spark plug gap is correct when the
correct-size feeler gauge or wire gauge is a
firm sliding fit between the electrodes (see
illustrations) .
13 To adjust the electrode gap, bend open, or
close up, the outer plug electrode until the
correct gap is achieved (see illustration). The
centre electrode should never be bent, as this
may crack the insulation and cause plug failure,
Every 20 000 miles (32 000 km) or two years, whichever
comes first
Every 20 000 miles or two years1•19
21.12b Spark plug manufacturers
recommend using a wire-type gauge when
checking the gap - if the wire or feeler gauge
does not slide between the electrodes with a slight drag, adjustment is required
21.12a Measuring a spark plug gap with a feeler gauge21.2 Tools required for changing spark plugs
21.13 To change the gap, bend the outer
electrode only, and be very careful not to crack or chip the porcelain insulator
surrounding the centre electrode
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SEFi fuel injection models
7Disconnect the mass air flow sensor wiring
multi-plug (see illustration) .
8 Slacken the hose clip and disconnect the
flexible rubber intake hose from the black
plastic air intake duct (see illustration).
9 Undo the retaining screws or release the
clips and lift off the air cleaner lid complete
with mass air flow sensor (see illustration).
All models
10Lift out the element, and wipe out the
housing (see illustrations) . Check that no
foreign matter is visible, either in the air inlet
or in the air mass meter, as applicable.
11 If carrying out a routine service, the
element must be renewed regardless of its
apparent condition. Note that on models so
equipped, the small foam PCV filter in the rear
right-hand corner of the air cleaner housing
must be cleaned whenever the air filter
element is renewed (see Section 25).
12 If you are checking the element for any
other reason, inspect its lower surface; if it is
oily or very dirty, renew the element. If it is
only moderately dusty, it can be re-used after
blowing it clean from the upper to the lower
surface with compressed air. Warning: Wear eye protection
when using compressed air!
Because it is a pleated-paper
type filter, it cannot be washed
or re-oiled. If it cannot be cleaned satisfactorily with compressed air,
discard and renew it.
Caution: Never drive the vehicle with the
air cleaner filter element removed.
Excessive engine wear could result, and
backfiring could even cause a fire under
the bonnet.
13
Refitting is the reverse of the removal
procedure. Ensure that the element and cover
are securely seated, so that unfiltered air
cannot enter the engine.Air cleaner temperature control
system check (carburettor
models)
14 In order for the engine to operate
efficiently, the temperature of the air entering
the inlet system must be controlled within
certain limits.
15 The air cleaner has two sources of air, one
direct from the outside of the engine
compartment, and the other from a shroud on
the exhaust manifold. On HCS engines, a
wax-controlled thermostatic valve controls a
flap inside the air cleaner inlet. When the
ambient air temperature is below a
predetermined level, the flap admits air
heated from the exhaust manifold shroud; as
the ambient temperature rises, the flap opens
to admit more cool air from the engine
compartment until eventually it is fully open. A
similar system is used on CVH engines,
except that a vacuum actuator modifies any opening or closing action of the temperature
sensor on the flap valve, according to the level
of the inlet manifold vacuum under running
conditions.
HCS engines
16
This check must be made when the
engine is cold. Detach and remove the air
cleaner inlet trunking. Examine the position of
the check valve within the duct. When the
underbonnet air temperature is below 28ºC,
the valve must be open to allow hot air to
enter the filter (see illustration) .
17 Refit the inlet trunking. Start the engine
and run it until it reaches its normal operating
temperature, then stop the engine, remove
the inlet trunking and check that the valve has
closed off the air passage from the exhaust
and opened the main (cool) air inlet.
18 If the flap does not operate correctly,
check that it is not seized. Apart from this
there is no adjustment possible, and the unit
should be renewed if faulty. Refit the air inlet
trunking on completion.
CVH engines
19 This check must be made when the
engine is cold. Disconnect the main air inlet
duct, and visibly check that the flap to the
hot-air inlet is closed (i.e. open to the passage
of cold air).
20 Start the engine, and check that with the
Every 30 000 miles or three years1•23
24.9 . . . then undo the retaining screws or
release the clips and lift off the air cleaner lid complete with mass air flow sensor24.8 . . . slacken the hose clip and
disconnect the intake hose from the air intake duct . . .24.7 On SEFi fuel injection engines,
disconnect the mass air flow sensor wiring multi-plug . . .
24.16 Air cleaner inlet and flap valve onthe HCS engine
A Main air cleaner inlet (cool air)
B Warm air duct (flap open)
24.10b . . . and on EFi and SEFi fuel injection engine models24.10a Removing the air filter element oncarburettor engine models . . .
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(see illustration). Centralise the seal on the
shaft, then insert and tighten the housing
retaining bolts to the specified torque setting.
Refit the sump with reference to Section 11.
12 Check that the crankshaft rear flange
and the flywheel mating faces are clean, then
refit the flywheel as described in Section 16.
15 Engine/transmission mountings - inspection and
renewal
2
Inspection
1 The engine/transmission mountings seldom
require attention, but broken or deteriorated
mountings should be renewed immediately, or
the added strain placed on the driveline
components may cause damage or wear.
2 During the check, the engine/transmission
must be raised slightly, to remove its weight
from the mountings.
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Position
a jack under the sump, with a large block of
wood between the jack head and the sump,
then carefully raise the engine/transmission
just enough to take the weight off the
mountings.
4 Check the mountings to see if the rubber is
cracked, hardened or separated from the metal components. Sometimes, the rubber
will split right down the centre.
5
Check for relative movement between each
mounting’s brackets and the
engine/transmission or body (use a large
screwdriver or lever to attempt to move the
mountings). If movement is noted, lower the
engine and check-tighten the mounting
fasteners.
Renewal
6 The engine mountings can be removed if
the weight of the engine/transmission is
supported by one of the following alternative
methods.
7 Either support the weight of the assembly
from underneath using a jack and a suitable
piece of wood between the jack saddle and
the sump or transmission (to prevent
damage), or from above by attaching a hoist
to the engine. A third method is to use a
suitable support bar with end pieces which
will engage in the water channel each side of
the bonnet lid aperture. Using an adjustable hook and chain connected to the engine, the
weight of the engine and transmission can
then be taken from the mountings.
Engine right-hand mounting
8
Unscrew and remove the mounting side
bolt from under the right-hand wheel arch
(see illustration) .
9 Unscrew and remove the mounting
retaining nut and washer from the suspension
strut cup retaining plate (see illustration).
10 Undo the three bolts securing the
mounting unit to the cylinder block. The
mounting unit and bracket can then be
lowered from the engine (see illustration).
11 Unbolt and remove the mounting from its
support bracket.
Transmission bearer and mountings
12 Unscrew and remove the two nuts
securing the mountings (front and rear) to the
transmission bearer (see illustration).
13 Support the transmission bearer, then
undo and remove the four retaining bolts from
the floorpan, two at the front and two at the
2A•10 HCS engine in-car repair procedures
15.12 Exploded view of the transmission bearer mountings
15.10 Undo the three bolts securing the
mounting assembly to the cylinder block
and withdraw the mounting
15.9 Unscrew and remove the mountingretaining nut and washer from the
suspension strut cup retaining plate15.8 Unscrew and remove the engine
mounting side bolt (arrowed) from under the wheel arch14.11b Fitting the rear oil seal housing
with a new gasket in position on the rear face of the cylinder block
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