Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake1•12 Every 10 000 miles or 12 months4.12a Rack-and-pinion type auxiliarydrivebelt adjusterA Adjuster armB Pinion (adjuster) nutC Central (locking) boltV-belt and flat “polyvee” typedrivebelt with rack-and-pinion typeadjuster12 Loosen off the alternator mounting boltsand the adjusting arm mounting bolt. Slackenthe pinion central locking bolt, and turn thepinion nut as required to take up the tensionof the drivebelt. Hold it at the required setting,and tighten the central bolt securely to lockthe adjuster arm and set the tension (seeillustrations).13 Tighten the alternator mounting andadjusting arm bolts securely.14 Refit the auxiliary drivebelt cover (whereapplicable) and roadwheel, then lower thevehicle to the ground.15 Run the engine for about five minutes,then recheck the tension.Flat “polyvee” type drivebelt withtensioner pulley adjuster (HCS enginepower steering pump drivebelt)16 Slacken the tensioner pulley centre boltthen turn the adjuster bolt at the base of thetensioner pulley bracket, as required, to takeup the tension of the drivebelt. When the beltdeflection is correct, tighten the adjusterpulley centre retaining bolt.17 Refit the auxiliary drivebelt cover (whereapplicable) and roadwheel, then lower thevehicle to the ground.18 Run the engine for about five minutes,then recheck the tension.Flat “polyvee” type drivebelt withautomatic adjuster19 As mentioned above, this type of drivebeltis tensioned by an automatic tensioner;regular checks are not required, and manual“adjustment” is not possible.20 If you suspect that the drivebelt is slippingand/or running slack, or that the tensioner isotherwise faulty, it must be renewed. To dothis, remove the drivebelt as described below,then unbolt and remove the tensioner. Onfitting the new tensioner, ensure that it isaligned correctly on its mountings, andtightened to the specified torque wrenchsetting.4.12b When the tension is correct, holdthe adjuster nut, and tighten the centralbolt securely to lock the adjuster armRenewal21 Open the bonnet. Jack up the front righthandside of the vehicle, and support itsecurely on an axle stand. Remove theroadwheel, then remove the auxiliary drivebeltlower cover (where fitted) from inside thewheel arch.22 The routing of the drivebelt around thepulleys is dependent on the drivebelt type,and on whether power steering is fitted.Before removing the drivebelt, it’s a good ideato sketch the belt run around the pulleys; thiswill save a lot of frustration when it comes torefitting. Note that on HCS engines withpower steering, to renew the alternator/water pump drivebelt it will be necessary toremove the power steering pump drivebeltfirst.23 If the existing drivebelt is to be refitted,mark it, or note the maker’s markings on itsflat surface, so that it can be installed thesame way round.24 To renew a drivebelt with manualadjustment, slacken the belt tension fully asdescribed above, according to type. Slip thebelt off the pulleys, then fit the new belt,ensuring that it is routed correctly. If fitting aflat “polyvee” type drivebelt, arrange it on thegrooved pulleys so that it is centred intheir grooves, and not overlapping their raisedsides. With the belt in position, adjust thetension as previously described.25 To renew the flat, “polyvee” type drivebeltwith automatic adjuster, reach up betweenthe body and the engine (above thecrankshaft pulley), and apply a spanner to thehexagon in the centre of the automatictensioner’s pulley. Rotate the tensioner pulleyclockwise to release its pressure on thedrivebelt, then slip the drivebelt off thecrankshaft pulley, and release the tensioneragain (see illustration). Note that on certainmodels, a self-cocking tensioner is fitted, andthat this will remain in the released position.Working from the wheel arch or enginecompartment as necessary, and noting itsrouting, slip the drivebelt off the remainingpulleys and withdraw it.26 Check all the pulleys, ensuring that theirgrooves are clean, and removing all traces of4.25 Automatic drivebelt tensioner -“polyvee” type drivebeltTurn tensioner clockwise to release tensionoil and grease. Check that the tensionerworks properly, with strong spring pressurebeing felt when its pulley is rotated clockwise,and a smooth return to the limit of its travelwhen released.27 If the original drivebelt is being refitted,use the marks or notes made on removal, toensure that it is installed to run in the samedirection as it was previously. To fit thedrivebelt, arrange it on the grooved pulleys sothat it is centred in their grooves, and notoverlapping their raised sides, and is routedcorrectly. Start at the top, and work down tofinish at the crankshaft pulley; rotate thetensioner pulley clockwise, slip the drivebeltonto the crankshaft pulley, then release thetensioner again.28 Using a spanner applied to the crankshaftpulley bolt, rotate the crankshaft through atleast two full turns clockwise to settle thedrivebelt on the pulleys, then check thatthe drivebelt is properly installed.29 Refit the auxiliary drivebelt cover (whereapplicable) and roadwheel, then lower thevehicle to the ground.5 Underbonnet check for fluidleaks and hose condition1General1 High temperatures in the enginecompartment can cause the deterioration ofthe rubber and plastic hoses used for engine,accessory and emissions systems operation.Periodic inspection should be made forcracks, loose clamps, material hardening andleaks.2 Carefully check the large top and bottomradiator hoses, along with the other smallerdiametercooling system hoses and metalpipes; do not forget the heater hoses/pipeswhich run from the engine to the bulkhead.Inspect each hose along its entire length,replacing any that is cracked, swollen orshows signs of deterioration. Cracks maybecome more apparent if the hose is