Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake1•14 Every 10 000 miles or 12 monthsconnections - remake the connections orrenew the leads if a fault is found. Use thesame techniques to ensure that all earthpoints in the engine compartment providegood electrical contact through clean, metalto-metaljoints, and that all are securelyfastened. (In addition to the earth connectionat the engine lifting eye, and that from thetransmission to the body/battery, there areothers in various places, so check carefully).8 Refer to Section 21 for details of spark plug(HT) lead checks.7 Valve clearance adjustmentRefer to Chapter 2, Part A.28 Manual transmission oil levelcheck11 The manual transmission does not have adipstick. To check the oil level, raise thevehicle and support it securely on axle stands,making sure that the vehicle is level. On thelower front side of the transmission housing,you will see the filler/level plug. Unscrew andremove it - an Allen key or bit will probably berequired (see illustration).2 With the plug removed, check the oil level.To do this accurately, make up an oil levelcheck dipstick from a short length of weldingrod or similar material. Make a 90º bend in therod, then mark the downward leg in 5 mmincrements. The dipstick is then insertedthrough the filler plug orifice so that theunmarked leg rests flat on the plug orificethreads, with the marked leg dipped in the oil.Withdraw the dipstick and read off the level ofoil.3 The oil level must be maintained between 0and 5 mm below the lower edge of thefiller/level plug hole. Top up (if necessary),using fresh transmission oil of the specifiedtype and using a syringe, or a plastic bottleand tube. Refit and tighten the filler/level plugto the specified torque on completion.4 The need for regular topping-up can onlybe due to a leak, which should be found andrectified without delay.5 Regular oil changing is not specified by themanufacturer’s, but the oil can be drained, ifrequired, by removing the selector shaft capnut and locking assembly.9 Idle speed and mixturecheck and adjustment4General1 Many of the engines fitted to Fiesta modelsare equipped with fuel injection systems ofone sort or another which are entirelycontrolled by the engine management system.On most of these vehicles, it isn’t possible tomake any adjustments to the idle speed or themixture settings without specialist testequipment of a type usually only found at aFord dealer or fuel injection specialist.However, the very nature of these highlysophisticatedsystems means they don’t goout of tune very often (if ever), so that it’s oneless maintenance operation to worry about.2 On carburettor engines and 1.6 litre EFi fuelinjection engines, certain checks andadjustments are necessary as part of theservice requirements, and these are describedbelow.Idle speed and mixture checkand adjustment - carburettorenginesNote: Later carburettors are fitted withtamperproof mixture adjusting screws,consisting of a hexagon-shaped socket with apin in the centre. Such screws require the useof Ford service tool 23-032 to alter theirsettings; if this tool (or a suitable equivalent) isnot available, the CO level will have to bechecked, and any necessary adjustment willhave to be made, by a Ford dealer.3 Before carrying out the following checksand adjustments, ensure that the spark plugsare in good condition and correctly gapped(Section 21). To carry out thechecks/adjustments, an accurate tachometerand an exhaust gas analyser (CO meter) willbe required.4 Make sure that all electrical componentsare switched off during the followingprocedures.5 Connect a tachometer to the engine inaccordance with its manufacturer’sinstructions, and insert the probe of anexhaust gas analyser (CO meter) into theexhaust tailpipe. As previously mentioned,these items are essential in obtaining anaccurate setting. If they are not available, anapproximate check/adjustment can be madeas a temporary measure, providing they arefurther checked out as soon as is possibleusing a tachometer and a CO meter (or by aFord dealer).6 Run the engine at a fast idle speed until itreaches its normal operating temperature andthe radiator cooling fan cuts in. Turn theengine off, then disconnect the radiatorcooling fan lead at the thermostatic switchconnector. Now connect a temporary wire tothe fan switch multi-plug, as shown (seeillustration) to enable the fan to operatecontinuously during the following checks andadjustments (if this is specified). Take care tokeep clear of the fan during the followingoperations when working in the enginecompartment.7 Where fitted, disconnect the throttle kickervacuum pipe, and plug the end. To identifythe throttle kicker unit, refer to Chapter 4A.8 Check that the vehicle lighting and otherelectrical loadings (apart from the radiatorcooling fan) are switched off, then restart theengine. Increase the engine speed to 3000 rpmfor 30 seconds, and repeat this at three-minuteintervals during the check/adjustmentprocedures. This will ensure that any excessfuel is cleared from the inlet manifold.9 Ensure that the throttle is fully released, allowthe meters to stabilise for a period of 5 to30 seconds is normally sufficient, then checkthe idle speed against that specified. If adjustmentis necessary, turn the idle speedadjusting screw until the engine is idling at thespecified speed (see illustrations). Any checksand adjustments must be completed within30 seconds of the meters stabilising.8.1 Manual transmission oil level/fillerplug (A), and selector shaft cap nut (B)9.6 Cooling fan thermostatic switch multiplugwith temporary bridging wireconnected9.9a Idle speed adjusting screw (A) andmixture adjusting screw (B) (Weber TLMcarburettor)