Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake4C•4 Fuel system - electronic fuel injection engines1 Fresh air intake2 Air cleaner lid3 Turbocharger4 Intercooler5 Air inlet duct6 Throttle housing7 Inlet manifold8 (Hitachi-built) idlespeed control valve4.12 Air intake, turbocharger and intercooler details on Turbo models11 On non-Turbo models, disconnect theflexible hose between the air cleaner lid andthe air inlet duct.12 On Turbo models, disconnect the idlespeed control valve air bypass hose from theair inlet duct and the flexible hose betweenthe air inlet duct and intercooler (seeillustration).13 Undo the two retaining bolts, and removethe air inlet duct from the rocker cover.14 Refitting is the reverse of the removalprocedure.5 Accelerator cable - removal,refitting and adjustment 1Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Remove the air inlet components asdescribed in Section 4.3 Fold back the carpet and insulation in thedriver’s footwell to gain access to theaccelerator pedal.4 Detach the accelerator cable from thepedal.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 (see illustration).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 test5.45 Accelerator cable retentionarrangement at the throttle linkageof 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 forthis check and should be connected in thefuel line between the fuel filter and the fuel rail,in accordance with the gauge maker’sinstructions.5 Disconnect the wiring from the E-DISignition coil and the fuel injectors.6 Switch the ignition on and off twice, andcheck that the pump pressure is as listed inthe Specifications.7 If the pressure is not as specified, check thefuel system for leaks or damage. If the systemappears okay, renew the fuel pump.8 Reconnect the wiring to the ignition coil andfuel injectors.9 If the pump pressure was satisfactory, startthe engine and allow it to idle. Disconnect thevacuum hose at the fuel pressure regulator,and plug the hose. Note the gauge reading assoon as the pressure stabilises, and compareit with the figures given for regulated fuelpressure in the Specifications.10 If the regulated fuel pressure is not asspecified, remove the plug from the top of thefuel pressure regulator, and using a suitableAllen key, adjust the pressure regulator asnecessary.11 Switch off the engine, and check that thefuel pressure stays at the specified holdpressure for two minutes after the engine isturned off.12 Carefully disconnect the fuel pressuregauge, depressurising the system first asdescribed in Section 2. Reconnect the ignitioncoil and fuel injector wiring.13 Run the engine, and check that there areno fuel leaks.