Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake4A•4 Fuel system – carburettor engines5 Accelerator pedal -removal and refitting13.5a Remove the accelerator outer cablesecuring clip . . .3 Accelerator cable (manualtransmission models) -removal, refitting and adjustment1Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Working inside the vehicle, disconnect thecable from the top of the accelerator pedal,release the grommet and pull the cable freefrom the pedal. Withdraw the cable throughthe engine side of the bulkhead.3 Refer to Section 2 and remove the aircleaner.4 Detach the inner cable from the carburettorlinkage.5 Prise free the retaining clip, detach theouter cable from the support bracket, andremove the cable (see illustrations).Refitting and adjustment6 To refit the cable, feed the inner cablethrough the bulkhead, and reconnect the innercable to the accelerator pedal. Note that aplastic sleeve is supplied with new cables forthe purpose of routing through the bulkheadpanel.7 Locate the grommet in the bulkhead, thenpush the outer cable into it to secure it in thebulkhead.8 Lubricate the cable grommet at thecarburettor end with a mild soapy solution,6.5a Disconnect the inner cable from thechoke linkage3.5b . . . then release from its supportbracketthen reconnect the cable to the carburettor.Locate the outer cable by pulling it towardsthe rocker cover.9 Have an assistant depress the acceleratorpedal fully, and hold it in this position. Theouter cable should be seen to move in itsgrommet. Refit the securing clip to thebracket, then release the accelerator pedal.10 Depress the accelerator pedal, thenrelease it and check that the throttle opensand shuts fully. Further adjust if necessarybefore refitting the air cleaner andreconnecting the battery.4 Accelerator cable (CTXautomatic transmission 4models) - adjustmentThe system for operating the throttle-platein the carburettor on CTX automatictransmission equipped vehicles is completelydifferent to that employed on manualtransmission vehicles. The cable from theaccelerator pedal leads to a linkagemechanism which is bolted to thetransmission housing. Two further cables leadfrom this linkage mechanism, one of whichoperates the throttle-plate in the carburettor.As all three cables have to be adjusted atthe same time, and access to a Ford specialtool is required, it is recommended that a Forddealer be entrusted with cable adjustments,or renewal.6.5b Choke outer cable retaining clipreleasedRemoval1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Peel back the carpet and insulation fromthe driver’s footwell to allow access to theaccelerator pedal.3 Detach the accelerator cable from the pedal(see Section 3), then release the circlip fromthe pivot shaft and remove the acceleratorpedal.Refitting4 Refit in the reverse order of removal. Oncompletion, check the action of the pedal andthe cable to ensure that the throttle has fullunrestricted movement, and fully returnswhen released.5 Reconnect the battery negative lead.6 Choke cable - removal,refitting and adjustment1Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Refer to Section 2 and remove the aircleaner.3 Referring to Chapter 10, Section 20, forfurther details and illustrations, remove thechoke control knob on the side of the steeringcolumn shroud by pushing in the pin locatedon the side of the knob and withdrawing.4 Detach the steering column lower shroud,disconnect the multi-plug from the chokewarning light switch/pull control assembly,and unscrew the collar securing theswitch/pull control assembly to the shroud.5 Disconnect the choke inner cable from itslocation on the carburettor choke linkage,then release the outer cable retaining clip (seeillustrations).6 Push the bulkhead panel grommet throughthe bulkhead and remove the cable.Refitting7 Route the cable through the bulkhead thensecure the bulkhead panel grommet to itslocation.8 Reconnect the choke inner cable to itslocation on the carburettor choke linkage.9 Refit the choke warning light switch/pullcontrol assembly to the lower steering columnshroud and secure with the collar, thenreconnect the multi-plug.10 Refit and secure the lower steeringcolumn shroud, then refit the choke controlknob.11 Pull the choke control knob to the fully-onposition. Hold the choke in the fully-on
Fuel system – carburettor engines 4A•57.1a Fuel pump location on HCS engine(shown from below)A Fuel inlet hoseB Fuel return hose to tankC Fuel outlet hose to carburettorD Pump securing boltsposition at the carburettor, then secure theouter cable with its retaining clip.Adjustment12 To check that the choke cable is correctlyadjusted, the control knob must be pulled outto the full-on position and the choke levermust be in contact with its stop. Adjust asrequired if necessary.13 Press the choke knob fully in (to the offposition), then check that the choke linkage atthe carburettor has fully returned to its offposition and the choke valve plate in thecarburettor is at a right angle (90º) to theventuri.14 Refit the air cleaner.15 Reconnect the battery, turn the ignitionon, operate the choke and check that thechoke warning light operates correctly.7 Fuel pump -testing, removal and refitting 2Note: Refer to the warning note in Section 1before proceeding.Testing1 Access to the fuel pump on HCS engine7.1b Fuel pump assembly fitted to CVHengines (securing nuts arrowed)A Fuel feed from tankB Fuel return to tankC Fuel feed to carburettormodels is best gained from underneath thevehicle (see illustrations). Apply thehandbrake, then raise and support it on axlestands at the front end (see “Jacking andvehicle support”).2 The fuel pump may be tested bydisconnecting the fuel feed pipe from thecarburettor, and placing the pipe’s open endin a suitable container.3 Detach the multi-plug from the DIS ignitioncoil, or the LT lead from the negative terminalof the ignition coil, to prevent the engine fromfiring.4 Actuate the starter motor. If the fuel pumpis in good working order, regular well-definedspurts of fuel should eject from the open endof the disconnected fuel pipe.5 If this does not occur, and there is fuel inthe tank, the pump is defective and must berenewed. The fuel pump is a sealed unit, andcannot be repaired.Removal6 Two types of mechanical fuel pump arefitted, the application depending on theengine type. Some models may also be fittedwith a fuel vapour separator (see illustration);if this is removed, its hoses should be labelledto avoid the possibility of confusion andincorrect attachment on refitting.7 To remove the fuel pump, first disconnectthe battery negative (earth) lead (refer toChapter 5A, Section 1).8 Where applicable, remove the air cleaner toimprove access to the fuel pump (see Section2).9 Disconnect the fuel hoses from the fuelpump, noting their respective connections forrefitting. Where quick-release couplings areused on the fuel hoses, release the protrudinglocking lugs on each union, by squeezingthem together and carefully pulling thecoupling apart. Use rag to soak up any spiltfuel. Where the unions are colour-coded, thepipes cannot be confused. Where both unionsare the same colour, note carefully which pipeis connected to which, and ensure that theyare correctly reconnected on refitting. Plugthe hoses to prevent fuel spillage and theingress of dirt.10 Unscrew and remove the retaining boltsor nuts (as applicable) and remove the fuelpump.11 Recover the gasket/spacer (seeillustration) and if required, withdraw thepump operating pushrod (CVH engines only).12 Thoroughly clean the mating faces on thepump and engine.Refitting13 Refit in the reverse order of removal. Besure to use a new gasket, and tighten thesecuring bolts/nuts securely. Ensure that thehoses are correctly and securely reconnected.If they were originally secured with crimpedtype hose clips, discard them and fitscrew type clips. Where quick-releasecouplings are fitted, press them together untilthe locking lugs snap into their groove.14 When the engine is restarted, checkthe pump connections for any signs of fuelleaks.8 Fuel tank - removal,inspection and refitting3Note: Refer to the warning note in Section 1before proceeding.Removal1 Run the fuel level as low as possible prior toremoving the tank.2 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).3 Remove the fuel filler cap, then syphon orpump out the remaining fuel from the fuel tank(there is no drain plug). The fuel must beemptied into a suitable container for storage.4 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and vehicle support”). Removethe rear roadwheels.5 Unclip and disconnect the fuel feed andreturn hoses located in front of the fuel tank,and allow any residual fuel to drain into a4A7.6 Fuel pump and fuel vapour separatorarrangement on HCS engine (shown frombelow)7.11 Gasket/spacer fitment on HCSengine. Note position of the lug (arrowed)1595Ford Fiesta Remake
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1•1Chapter 1Routine maintenance a
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1595Ford Fiesta Remake2B•2 CVH an
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CVH and PTE engine in-car repair pr
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CVH and PTE engine in-car repair pr
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2C•1Chapter 2 Part C:Zetec engine
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Zetec engine in-car repair procedur
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Page 95 and 96: 3•1Chapter 3Cooling, heating and
Page 97 and 98: Cooling, heating and ventilation sy
Page 105 and 106: 4A•1Chapter 4 Part A:Fuel system
Page 107: Fuel system - carburettor engines 4
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Page 123 and 124: 4B•1Chapter 4 Part B:Fuel system
Page 125 and 126: Fuel system - central fuel injectio
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Page 135 and 136: Fuel system - electronic fuel injec
Page 143 and 144: 4D•1Chapter 4 Part D: Fuel system
Page 145 and 146: Fuel system - sequential electronic
Page 151 and 152: 4E•1Chapter 4 Part E:Exhaust and
Page 153 and 154: Exhaust and emission control system
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5A•1Chapter 5 Part A:Starting and
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Starting and charging systems 5A•
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5B•1Chapter 5 Part B:Ignition sys
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Ignition system 5B•3flux can pass
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Ignition system 5B•55.3 Disconnec
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Ignition system 5B•79.3 Distribut
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9•1Chapter 9Braking systemContent
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Braking system 9•34 Withdraw the
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Braking system 9•56.3 Depress and
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Braking system 9•78.3 Compress th
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Braking system 9•911.6 Servo moun
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Braking system 9•11Bleeding - usi
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Braking system 9•1318.4 Handbrake
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Braking system 9•1524.6 Belt-brea
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Braking system 9•17cylinder reser
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10•1Chapter 10Suspension and stee
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Suspension and steering 10•31 Gen
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Suspension and steering 10•52.17
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Suspension and steering 10•7A Sus
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Suspension and steering 10•99.6 P
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Suspension and steering 10•11posi
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Suspension and steering 10•1319.1
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Suspension and steering 10•15that
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Suspension and steering 10•17Refi
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11•1Chapter 11Bodywork and fittin
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Bodywork and fittings 11•3almost
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Bodywork and fittings 11•57.3b Bo
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Bodywork and fittings 11•715.2 Ra
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Bodywork and fittings 11•918.2 Mi
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Bodywork and fittings 11•1121.5 D
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Bodywork and fittings 11•1327.3 T
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Bodywork and fittings 11•1531.20
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Bodywork and fittings 11•17to avo
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Bodywork and fittings 11•1942.1 A
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Bodywork and fittings 11•2146.12
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12•1Chapter 12Body electrical sys
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Body electrical systems 12•3Bulbs
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Body electrical systems 12•53.1a
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Body electrical systems 12•750 Un
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Body electrical systems 12•96.13
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Body electrical systems 12•1727 A
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Wiring diagrams 12•1912Notes, int
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Wiring diagrams 12•21Diagram 1a:
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Wiring diagrams 12•23Diagram 1c:
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Wiring diagrams 12•25Diagram 1e:
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Wiring diagrams 12•27Diagram 2a:
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1595Ford Fiesta RemakeDiagram 3: An
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1595Ford Fiesta RemakeDiagram 3b: A
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Wiring diagrams 12•33Diagram 4: I
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REF•2 Conversion factorsWeightsKe
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REF•4 General repair proceduresWh
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REF•6 Conversion FactorsLength (d
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REF•8 Tools and working facilitie
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REF•10 MOT test checksThis is a g
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REF•12 MOT test checksExhaust sys
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REF•14 Fault findingEngine Engine
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REF•16 Fault findingEngine (conti
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REF•18 Fault findingAutomatic tra
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REF•20 Fault findingElectrical sy
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REF•22 Glossary of technical term
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REF•28 IndexFault finding - clutc
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Left blank formanual listingpages15
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Preserving Our Motoring HeritageJoh
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Chapter 1 Routine maintenance and servicing

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