Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake4B•4 Fuel system - central fuel injection engines4 Air cleaner assembly and airinlet components -removal and refitting1Note: Air cleaner element renewal and aircleaner temperature control system checks(where applicable) are described in Chapter 1.Air cleaner assembly1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Undo the retaining bolts and partially lift theair cleaner from the CFi unit, so that the hoseand wiring connections to the underside ofthe air cleaner body are accessible.3 Note their connections and routings, thendetach the wiring and hoses from theunderside of the air cleaner.4 Lift the air cleaner clear from the CFi unit.5 Refit in the reverse order of removal.6 Renew any hoses that are perished orcracked, and ensure that all fittings aresecurely and correctly reconnected.Air inlet components7 The air cleaner inlet spout and relatedcomponents are removed with the air cleanerassembly as described above.5 Accelerator cable - removal,refitting and adjustment1Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Fold back the carpet and insulation in thedriver’s footwell to gain access to theaccelerator pedal.3 Detach the accelerator cable from thepedal.4 Remove the air cleaner assembly asdescribed in Section 4.5 Working at the throttle housing end of thecable, pivot the throttle quadrant by hand torelease the tension from the cable, thendetach the inner cable nipple from the throttlelever.6 Detach the outer cable from theadjuster/support bracket, then remove thecable.Refitting and adjustment7 Refit in the reverse order of removal. Whenthe cable is reconnected at each end, have anassistant depress the accelerator, and checkthat the throttle fully opens and shuts withoutbinding. Ensure that there is a small amount ofslack in the inner cable when the throttle isfully released. If adjustment is required,release the outer cable retaining clip from thecable at the adjustment/support bracket, slidethe cable through the adjuster grommet to thepoint required, then refit the retaining clip tosecure it in the set position.6 Accelerator pedal -removal and refitting 1Refer to Part A, Section 5.7 Fuel pump/fuel pressure -checking 3Note: Refer to the warning note in Section 1before proceeding.Fuel pump operation check1 Switch on the ignition, and listen for the fuelpump (the sound of an electric motor running,audible from beneath the rear seats). Assumingthere is sufficient fuel in the tank, the pumpshould start and run for approximately one ortwo seconds, then stop, each time the ignitionis switched on. Note: If the pump runscontinuously all the time the ignition is switchedon, the electronic control system is running inthe backup (or “limp-home”) mode referred toby Ford as “Limited Operation Strategy” (LOS).This almost certainly indicates a fault in theEEC IV module itself, and the vehicle shouldtherefore be taken to a Ford dealer for a full testof the complete system, using the correctdiagnostic equipment; do not waste time or riskdamaging the components by trying to test thesystem without such facilities.2 Listen for fuel return noises from the fuelpressure regulator. It should be possible tofeel the fuel pulsing in the regulator and in thefeed hose from the fuel filter.3 If the pump does not run at all, check thefuse, relay and wiring (see Chapter 12). Checkalso that the fuel cut-off switch has not beenactivated and if so, reset it.Fuel pressure check4 A fuel pressure gauge will be required for thischeck and should be connected in the fuel linebetween the fuel filter and the CFi unit, inaccordance with the gauge maker’s instructions.5 Start the engine and allow it to idle. Notethe gauge reading as soon as the pressurestabilises, and compare it with the figuresgiven for regulated fuel pressure in theSpecifications. If the pressure is high, checkfor a restricted fuel return line. If the pressureis low, renew the fuel pressure regulator.9.2 Ford Special tool engaged on the fuelpump/sender unit6 Switch off the engine, and check that afterone minute, the hold pressure has not fallenbelow that specified. If it has, check the sealson the fuel injector (see Section 14) and renewthem if they appear in any way suspect. If theseals are okay, then the fuel pressureregulator or CFi unit are suspect.7 Carefully disconnect the fuel pressuregauge, depressurising the system first asdescribed in Section 2.8 Run the engine, and check that there are nofuel leaks.8 Fuel tank - removal,inspection and refitting 3Proceed as described in Part A, Section 8, butbefore disconnecting the battery, relieve theresidual pressure in the fuel system (see Section2), and equalise tank pressure by removingthe fuel filler cap. Note also that it will benecessary to release any additional ventilationtubes from their retaining clips, and to repositionor remove the underbody heat shields on certainmodels for access to the tank retaining bolts.9 Fuel pump/fuel gaugesender unit - removal and 3refittingNote: Refer to the warning note in Section 1before proceeding. Ford specify the use of theirservice tool 23-026 (a large box spanner withprojecting teeth to engage the fuel pump/senderunit retaining ring’s slots) for this task. Whilealternatives are possible, in view of the difficultyexperienced in removing and refitting thepump/sender unit, it is strongly advised that thecorrect tool is obtained before starting work.Removal1 A combined fuel pump and fuel gaugesender unit are located in the top face of thefuel tank. The combined unit can only bedetached and withdrawn from the tank afterthe tank is released and lowered fromunder the vehicle. Refer to Section 8 andremove the fuel tank, then proceed as follows.2 With the fuel tank removed, thepump/sender unit can be unscrewed usingthe special tool (see illustration).3 Withdraw the unit upwards from the tank(see illustration), and detach the seal ring.9.3 Fuel pump (A) and sender unit (B)