Chapter 1 Routine maintenance and servicing
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Chapter 1 Routine maintenance and servicing

Chapter 1 Routine maintenance and servicing Chapter 1 Routine maintenance and servicing

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11.07.2015 Views

1595Ford Fiesta Remake3•8 Cooling, heating and ventilation systemsremoval procedure. Refit the timing belt andtensioner as described in Chapter 2C, notingthat a new tensioner spring and retaining pinmust be fitted if the timing belt has beenremoved for the first time. Tighten allfasteners to the specified torque, and refill thesystem with coolant as described in Chapter1.11 Heater/ventilationcomponents - 3removal and refittingHeater controls1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Refer to Chapter 12 and remove the radio.3 Pull off the heater fan motor control knob,then move the air distribution andtemperature controls fully to the right. Unclipand remove the heater slide facia towards theleft-hand side of the vehicle, removing theslide control knobs only as necessary, anddisconnecting its bulbholder (bayonet type) asit is withdrawn.4 Squeeze the two release tabs together onthe heater fan motor control switch, andremove it, disconnecting its multi-plug as it iswithdrawn.5 Disconnect the heater control cables fromthe heater casing assembly by releasing theouter cable abutments and disengaging the11.7a Releasing outer cable clampingcover . . .11.5 Disengaging heater control cablefrom its flap operating mechanism on theheater casingcable inner cores from their flap operatingmechanisms (see illustration).6 Undo the three heater control panelsecuring screws, and remove the controlpanel (with its cables attached) from behindthe facia (see illustration).7 Disconnect the heater control cables fromtheir control panel levers, as required, byreleasing their outer cable clamping coversand inner cable core securing clips (seeillustrations).8 If renewing a heater control panel, note thatthe new unit, is supplied with control cablesand assembly aids fitted (see illustration).The assembly aids ensure correct heatercontrol adjustments during fitting, and mustbe removed thereafter.11.7b . . . and removing it11.6 Heater control panel securingscrews (A), and fan motor controlswitch (B)9 Refitting is a reversal of the removalprocedure, adjusting the heater control cablesto complete. The adjustment is madeautomatically by moving the heater slidecontrol levers from their left-hand stop to theirright-hand stop. When moving the controllevers, a considerable amount of resistancemay be encountered, which must beovercome.Heater fan motor and resistorassembly10 Disconnect the battery negative (earth)lead (refer to Chapter 5A, Section 1).11 Depending on engine type, refer to therelevant Part of Chapter 4 and remove the aircleaner if necessary, to gain access to thebulkhead panel in the engine compartment.12 Remove the expansion tank as describedin Section 7.13 Undo the retaining bolt and remove thejack and wheelbrace.14 Disconnect the modules on the bulkheadpanel. Release the wiring loom and anyconnectors, cable-ties and hoses from thebulkhead panel, and remove its rubber seal.15 Remove the bulkhead panel. The panel issecured by screws, with a nut at either end(behind the panel), and is removed in twosections.16 Detach and remove the cover from theheater fan motor assembly (see illustration).17 Disconnect the wiring from the heater fan11.7c Releasing inner cable core fromheater control lever11.8 Heater control panel. Assemblyaids (A) fitted to heater casing flap valveend of cables11.16 Removing the cover from the heaterfan motor assembly

Cooling, heating and ventilation systems 3•911.17 Disconnecting the wiring from theheater fan motor and resistor assembly(arrowed)11.20a Releasing the heater fan motorretaining strap from the underside of theassembly11.20b Removing the heater fan motormotor and resistor assembly (seeillustration).18 Undo the two nuts securing the assemblyto the bulkhead and remove it from thevehicle.19 Detach the heater fan cover, havingreleased its two retaining clips.20 Release the heater fan motor retainingstrap from underneath, using a flat-bladedscrewdriver, and remove it. Remove theresistor assembly and/or heater fan motor, asrequired (see illustrations).21 Refitting is a reversal of the removal11.25 Exploded view of the heater matrixconnectionsA Cover plate D Hose clipsB GasketE Heater hosesC Heater matrixconnector pipeF Screwprocedure, ensuring that the heater fan motorwires are routed under the retaining strap, butare not pinched by it.Heater matrixNote: Refer to the warnings given in Section 1of this Chapter before starting work.22 Disconnect the battery negative (earth)lead (refer to Chapter 5A, Section 1).23 Drain the cooling system (see Chapter 1).24 Release the hose clips and disconnect thetwo heater hoses from their dual heater matrixconnector on the bulkhead, at the rear of theengine compartment. Plug the hoses toprevent excessive coolant loss, collectingspillage and any remaining coolant from theheater matrix in a suitable container.25 Undo the screws securing the heater11.27 Removing the footwell vent from thebase of the heater casingmatrix connector to the bulkhead, and detachits cover plate and gasket (see illustration).26 Where fitted, remove the centre consoleas described in Chapter 11.27 Unclip and detach the footwell vent fromthe base of the heater casing (seeillustration).28 Unclip the lower cover from the heatercasing and remove the heater matrix, beingcareful to avoid any residual coolant spillagein the passenger compartment (seeillustrations).29 Refitting is a reversal of the removalprocedure. On completion, refill the coolingsystem as described in Chapter 1.Heater casing assembly30 Remove the facia, as described inChapter 11.31 Remove the heater matrix, as describedpreviously in this Section.32 Disconnect the heater control cables fromthe heater casing assembly as describedpreviously in this Section.33 Disconnect the side outlet vent ductingfrom the heater casing. The side outlet ductscan be removed by undoing the screwssecuring them to the bulkhead, as required.34 Undo the two heater casing securing nutsand remove the casing from the vehicle (seeillustration).35 Refitting is a reversal of the removalprocedure, with reference to the applicableChapters and Sections of this manual.311.28a Unclipping the lower heater casingcover11.28b Withdrawing the heater matrix11.34 Heater casing securing nuts(arrowed)1595Ford Fiesta Remake

Cooling, heating <strong>and</strong> ventilation systems 3•911.17 Disconnecting the wiring from theheater fan motor <strong>and</strong> resistor assembly(arrowed)11.20a Releasing the heater fan motorretaining strap from the underside of theassembly11.20b Removing the heater fan motormotor <strong>and</strong> resistor assembly (seeillustration).18 Undo the two nuts securing the assemblyto the bulkhead <strong>and</strong> remove it from thevehicle.19 Detach the heater fan cover, havingreleased its two retaining clips.20 Release the heater fan motor retainingstrap from underneath, using a flat-bladedscrewdriver, <strong>and</strong> remove it. Remove theresistor assembly <strong>and</strong>/or heater fan motor, asrequired (see illustrations).21 Refitting is a reversal of the removal11.25 Exploded view of the heater matrixconnectionsA Cover plate D Hose clipsB GasketE Heater hosesC Heater matrixconnector pipeF Screwprocedure, ensuring that the heater fan motorwires are routed under the retaining strap, butare not pinched by it.Heater matrixNote: Refer to the warnings given in Section 1of this <strong>Chapter</strong> before starting work.22 Disconnect the battery negative (earth)lead (refer to <strong>Chapter</strong> 5A, Section 1).23 Drain the cooling system (see <strong>Chapter</strong> 1).24 Release the hose clips <strong>and</strong> disconnect thetwo heater hoses from their dual heater matrixconnector on the bulkhead, at the rear of theengine compartment. Plug the hoses toprevent excessive coolant loss, collectingspillage <strong>and</strong> any remaining coolant from theheater matrix in a suitable container.25 Undo the screws securing the heater11.27 Removing the footwell vent from thebase of the heater casingmatrix connector to the bulkhead, <strong>and</strong> detachits cover plate <strong>and</strong> gasket (see illustration).26 Where fitted, remove the centre consoleas described in <strong>Chapter</strong> 11.27 Unclip <strong>and</strong> detach the footwell vent fromthe base of the heater casing (seeillustration).28 Unclip the lower cover from the heatercasing <strong>and</strong> remove the heater matrix, beingcareful to avoid any residual coolant spillagein the passenger compartment (seeillustrations).29 Refitting is a reversal of the removalprocedure. On completion, refill the coolingsystem as described in <strong>Chapter</strong> 1.Heater casing assembly30 Remove the facia, as described in<strong>Chapter</strong> 11.31 Remove the heater matrix, as describedpreviously in this Section.32 Disconnect the heater control cables fromthe heater casing assembly as describedpreviously in this Section.33 Disconnect the side outlet vent ductingfrom the heater casing. The side outlet ductscan be removed by undoing the screwssecuring them to the bulkhead, as required.34 Undo the two heater casing securing nuts<strong>and</strong> remove the casing from the vehicle (seeillustration).35 Refitting is a reversal of the removalprocedure, with reference to the applicable<strong>Chapter</strong>s <strong>and</strong> Sections of this manual.311.28a Unclipping the lower heater casingcover11.28b Withdrawing the heater matrix11.34 Heater casing securing nuts(arrowed)1595Ford Fiesta Remake

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