Chapter 1 Routine maintenance and servicing

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