Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
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1595Ford Fiesta Remake3•6 Cooling, heating <strong>and</strong> ventilation systems7.4 Automatic transmission fluid coolingpipe connections (arrowed) at the radiatorwrench setting, <strong>and</strong> reconnect the multi-plug.25 Refit any components disconnected foraccess then refill the cooling system (see<strong>Chapter</strong> 1).Radiator electric cooling fanthermostatic switchTesting26 Refer to the procedures contained inSection 5.Removal27 Disconnect the battery negative (earth)lead (refer to <strong>Chapter</strong> 5A, Section 1).28 Drain the cooling system (see <strong>Chapter</strong> 1).29 Disconnect the wiring multi-plug from thethermostatic switch, <strong>and</strong> then unscrew theswitch from the thermostat housing orradiator side tank, as applicable. Remove thesealing washer.Refitting30 Refitting is a reversal of removal, but fit anew sealing washer <strong>and</strong> tighten the switchsecurely. Refill the cooling system asdescribed in <strong>Chapter</strong> 1, then reconnect thebattery.7 Radiator <strong>and</strong> expansion tank- removal, inspection <strong>and</strong> 2refittingNote: Refer to the warnings given in Section 1of this <strong>Chapter</strong> before starting work.RadiatorIf leakage is the reason forremoving the radiator, bearin mind that minor leaks canoften be cured using aradiator sealant with the radiator insitu.Removal (all models except Turbo)1 Disconnect the battery negative (earth) lead(refer to <strong>Chapter</strong> 5A, Section 1).2 Drain the cooling system (see <strong>Chapter</strong> 1).3 Remove the radiator cooling fan assemblyas described in Section 5.4 Release the hose clips <strong>and</strong> disconnect thehoses from the radiator. Additionally, on7.6a Radiator securing bolt, insulator <strong>and</strong>washerautomatic transmission models, disconnectthe transmission fluid cooling pipeconnections fitting blanking plugs to preventexcessive fluid loss (see illustration).5 On Zetec engine models, disconnect thewiring multi-plug from the cooling fanthermostatic switch6 Remove the radiator securing bolts <strong>and</strong> liftthe radiator out of its locating slots in the bodycrossmember. Note rubber insulators fitted tothe locating lugs on the base of the radiator(see illustrations).7 With the radiator removed, it can beinspected for leaks <strong>and</strong> damage. If it needsrepair, have a radiator specialist or dealerservice department perform the work, asspecial techniques are required.8 Insects <strong>and</strong> dirt can be removed from theradiator with a garden hose or a soft brush.Don’t bend the cooling fins as this is done.Removal (Turbo models)9 Disconnect the battery negative (earth) lead(refer to <strong>Chapter</strong> 5A, Section 1).10 Drain the cooling system (see <strong>Chapter</strong> 1).11 Remove the radiator cooling fan assemblyas described in Section 5.12 Release the hose clips <strong>and</strong> disconnect thehoses from the radiator.13 Disconnect the turbocharger coolant feedby slackening its clamp <strong>and</strong> pulling the hose(at the radiator rear right-h<strong>and</strong> side) off theturbocharger’s metal pipe.14 Remove the intercooler, as described in<strong>Chapter</strong> 4C.15 Remove its three retaining screws, <strong>and</strong>withdraw the exhaust manifold heat shield.7.22a Remove the single bolt retaining theexpansion tank . . .7.6b Rubber insulator on radiator locatinglug16 Lift the radiator out of its locating slots inthe body crossmember. Note rubberinsulators fitted to the locating lugs on thebase of the radiator.17 Clean <strong>and</strong> inspect the radiator withreference to paragraphs 7 <strong>and</strong> 8 above.Refitting (all models)18 Refitting is a reversal of removal, butcheck the rubber insulators, <strong>and</strong> if necessaryrenew them. Refill the cooling system withreference to <strong>Chapter</strong> 1. On automatictransmission models check, <strong>and</strong> if necessarytop-up, the automatic transmission fluid level(<strong>Chapter</strong> 1).Expansion tankRemoval19 Partially drain the cooling system, so thatthe coolant level drops below the expansiontank. Refer to <strong>Chapter</strong> 1 for details.20 Before disconnecting the coolant hosesfrom the expansion tank, it is advisable toclamp them just short of their connections tothe expansion tank, to prevent spillage ofcoolant <strong>and</strong> the ingress of air when they aredetached.21 Loosen off the coolant hose clips at theexpansion tank, <strong>and</strong> detach the hoses from it.If they are not clamped, secure them so thattheir ends are raised, to minimise coolantspillage.22 Remove the single bolt retaining theexpansion tank, <strong>and</strong> slide the other side of thetank free from its retaining bracket (seeillustrations).7.22b . . . <strong>and</strong> release the expansion tankfrom its retaining bracket
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