Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake4D•2 Fuel system - sequential electronic fuel injection engines1 General information andprecautionsGeneral informationThe fuel system consists of a fuel tank(mounted under the body, beneath the rearseats), fuel hoses, an electric fuel pumpmounted in the fuel tank, and a sequentialelectronic fuel injection system.The electric fuel pump supplies fuel underpressure to the fuel rail, which distributes fuelevenly to all injectors. A pressure regulatorcontrols the system pressure in relation toinlet tract depression. From the fuel rail, fuel isinjected into the inlet ports, just above theinlet valves, by four fuel injectors. The systemalso includes features such as the flushing offresh (ie, cold) fuel around each injector onstart-up, thus improving hot starts.The amount of fuel supplied by the injectorsis precisely controlled by the EEC IV enginemanagement module. The module uses thesignals derived from the crankshaft positionsensor and the camshaft position sensor, totrigger each injector separately in cylinderfiring order (sequential injection), with benefitsin terms of better fuel economy and lowerexhaust emissions.The EEC IV module is the heart of the entireengine management system, controlling thefuel injection, ignition and emissions controlsystems. The module receives informationfrom various sensors which is then computedand compared with pre-set values stored init’s memory, to determine the required periodof injection.Information on crankshaft position andengine speed is generated by a crankshaftposition sensor. The inductive head of thesensor runs just above the engine flywheeland scans a series of 36 protrusions on theflywheel periphery. As the crankshaft rotates,the sensor transmits a pulse to the system’signition module every time a protrusionpasses it. There is one missing protrusion inthe flywheel periphery at a pointcorresponding to 90° BTDC. The ignitionmodule recognises the absence of a pulsefrom the crankshaft position sensor at thispoint to establish a reference mark forcrankshaft position. Similarly, the time intervalbetween absent pulses is used to determineengine speed. This information is then fed tothe EEC IV module for further processing.The camshaft position sensor is located inthe cylinder head so that it registers with alobe on the camshaft. The camshaft positionsensor functions in the same way as thecrankshaft position sensor, producing a seriesof pulses; this gives the EEC IV module areference point, to enable it to determine thefiring order, and operate the injectors in theappropriate sequence.The mass air flow sensor is based on a “hotwire”system, sending the EEC IV module aconstantly-varying (analogue) voltage signalcorresponding to the mass of air passing intothe engine. Since air mass varies withtemperature (cold air being denser than warm),measuring air mass provides the module witha very accurate means of determining thecorrect amount of fuel required to achieve theideal air/fuel mixture ratio.Engine temperature information is supplied bythe coolant temperature sensor. Thiscomponent is an NTC (Negative TemperatureCoefficient) thermistor - that is, a semiconductorwhose electrical resistancedecreases as its temperature increases. Itprovides the EEC IV module with a constantlyvarying(analogue) voltage signal, correspondingto the temperature of the engine coolant. This isused to refine the calculations made by themodule, when determining the correct amountof fuel required to achieve the ideal air/fuelmixture ratio.Inlet air temperature information is suppliedby the inlet air temperature sensor. Thiscomponent is also an NTC thermistor - seethe previous paragraph - providing themodule with a signal corresponding to thetemperature of air passing into the engine.This is used to refine the calculations made bythe module, when determining the correctamount of fuel required to achieve the idealair/fuel mixture ratio.A throttle position sensor is mounted on theend of the throttle valve spindle, to providethe EEC IV module with a constantly-varying(analogue) voltage signal corresponding to thethrottle opening. This allows the module toregister the driver’s input when determiningthe amount of fuel required by the engine.Road speed is monitored by the vehiclespeed sensor. This component is a Hall-effectgenerator, mounted on the transmission’sspeedometer drive. It supplies the modulewith a series of pulses corresponding to thevehicle’s road speed, enabling the module tocontrol features such as the fuel shut-off onoverrun.Where power steering is fitted, a pressureoperatedswitch is screwed into the powersteering system’s high-pressure pipe. Theswitch sends a signal to the EEC IV module toreduce engine speed should the powersteering fluid pressure become excessivelyhigh.The oxygen sensor in the exhaust systemprovides the module with constant feedback -“closed-loop” control - which enables it toadjust the mixture to provide the best possibleconditions for the catalytic converter tooperate.The air inlet side of the system consists ofan air cleaner housing, the mass air flowsensor, an inlet hose and duct, and a throttlehousing.The throttle valve inside the throttle housingis controlled by the driver, through theaccelerator pedal. As the valve opens, theamount of air that can pass through thesystem increases. As the throttle valve opensfurther, the mass air flow sensor signal alters,and the EEC IV module opens each injectorfor a longer duration, to increase the amountof fuel delivered to the inlet ports.Both the idle speed and mixture are underthe control of the EEC IV module, and cannotbe adjusted. Not only can they not beadjusted, they cannot even be checked,except with the use of special Ford diagnosticequipment.PrecautionsWarning: Petrol is extremelyflammable - great care must betaken when working on any partof the fuel system. Do notsmoke or allow any naked flames oruncovered light bulbs near the work area.Note that gas powered domesticappliances with pilot flames, such asheaters, boilers and tumble dryers, alsopresent a fire hazard - bear this in mind ifyou are working in an area where suchappliances are present. Always keep asuitable fire extinguisher close to the workarea and familiarise yourself with itsoperation before starting work. Wear eyeprotection when working on fuel systemsand wash off any fuel spilt on bare skinimmediately with soap and water. Notethat fuel vapour is just as dangerous asliquid fuel; a vessel that has just beenemptied of liquid fuel will still containvapour and can be potentially explosive.Petrol is a highly dangerous and volatileliquid, and the precautions necessarywhen handling it cannot be overstressed.Many of the operations described in thisChapter involve the disconnection of fuellines, which may cause an amount of fuelspillage. Before commencing work, referto the above Warning and the informationin “Safety first” at the beginning of thismanual.When working with fuel systemcomponents, pay particular attention tocleanliness - dirt entering the fuel systemmay cause blockages which will lead topoor running.Note: Residual pressure will remain in the fuellines long after the vehicle was last used,when disconnecting any fuel line, it will benecessary to depressurise the fuel system asdescribed in Section 2.2 Fuel system -depressurisation 1Refer to Part B, Section 2.3 Fuel lines and fittings -general informationRefer to Part B, Section 3.
Fuel system - sequential electronic fuel injection engines 4D•34.2a Disconnect the mass air flow sensorwiring multi-plug . . .4.2b . . . release the retaining clips . . .4.2c . . . and withdraw the sensor4 Air cleaner assembly and airinlet components - removaland refitting1Air cleaner assembly1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Disconnect the mass air flow sensor wiringmulti-plug, then release the clips andwithdraw the sensor, complete with inlethose, from the air cleaner cover (seeillustrations). Carefully position the mass airflow sensor and hose assembly to one side.3 Detach the fresh air inlet duct from the aircleaner housing.4 Unscrew the air cleaner housing retainingnut, then pull the housing upwards to releasethe locating pegs from their rubber grommets.As the housing is withdrawn, detach thecrankcase breather hose (see illustration).Remove the assembly from the car.5 Refitting is the reverse of the removalprocedure. Ensure that the housing pegs seatfully in their grommets, and that the mass airflow sensor is correctly located.Air inlet components6 On PTE engines, disconnect the HT leadsfrom the spark plugs, labelling them ifnecessary to avoid confusion on refitting.7 Slacken the hose clip, and detach theflexible air inlet hose from the mass air flowsensor.8 On PTE engines, disconnect the ventilationhose from the inlet duct over the top of theengine.9 On PTE engines undo the two inlet ductretaining bolts; On Zetec engines , undo thetwo bolts and lift off the air inlet duct retainingstrap (see illustration). Withdraw the inletduct from the throttle housing and remove theduct and flexible hose from the engine.10 Refitting is the reverse of the removalprocedure.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 From within the engine compartment,detach the outer cable from theadjuster/support bracket by removing themetal retaining clip (see illustration).5 Pivot the throttle quadrant by hand, detachthe inner cable nipple from the throttle leverand remove the cable.Refitting6 Refit in the reverse order of removal. Whenthe cable is reconnected at each end, adjustthe cable as follows.Adjustment7 Remove the outer cable metal retaining clipat the adjuster/support bracket and lubricatethe cable adjuster grommet with soapy water.8 Remove any slack by pulling the cableouter as far as possible out of the adjuster.Have an assistant depress the acceleratorpedal fully - the cable outer will move backinto the adjuster - and hold it there while theclip is refitted.9 Check that the throttle quadrant movessmoothly and easily from the fully-closed tothe fully-open position and back again as theassistant depresses and releases theaccelerator pedal. Re-adjust the cable ifrequired.6 Accelerator pedal -removal and refitting1Refer to Part A, Section 5.4D4.4 Unscrew front retaining nut and lift theair cleaner housing, disconnecting thebreather hose (arrowed)4.9 Unscrew the nuts (arrowed) to releasethe air intake duct on Zetec engines5.4 Detach the accelerator outer cableretaining clip (arrowed)1595Ford Fiesta Remake
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1•1Chapter 1Routine maintenance a
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CVH and PTE engine in-car repair pr
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CVH and PTE engine in-car repair pr
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2C•1Chapter 2 Part C:Zetec engine
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Zetec engine in-car repair procedur
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Engine removal and overhaul procedu
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Page 95 and 96: 3•1Chapter 3Cooling, heating and
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Page 105 and 106: 4A•1Chapter 4 Part A:Fuel system
Page 107 and 108: Fuel system - carburettor engines 4
Page 123 and 124: 4B•1Chapter 4 Part B:Fuel system
Page 125 and 126: Fuel system - central fuel injectio
Page 133 and 134: 4C•1Chapter 4 Part C:Fuel system
Page 135 and 136: Fuel system - electronic fuel injec
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Page 147 and 148: Fuel system - sequential electronic
Page 149 and 150: Fuel system - sequential electronic
Page 151 and 152: 4E•1Chapter 4 Part E:Exhaust and
Page 153 and 154: Exhaust and emission control system
Page 159 and 160: 5A•1Chapter 5 Part A:Starting and
Page 161 and 162: Starting and charging systems 5A•
Page 167 and 168: 5B•1Chapter 5 Part B:Ignition sys
Page 169 and 170: Ignition system 5B•3flux can pass
Page 171 and 172: Ignition system 5B•55.3 Disconnec
Page 173 and 174: Ignition system 5B•79.3 Distribut
Page 175 and 176: 9•1Chapter 9Braking systemContent
Page 177 and 178: Braking system 9•34 Withdraw the
Page 179 and 180: Braking system 9•56.3 Depress and
Page 181 and 182: Braking system 9•78.3 Compress th
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Page 187 and 188: Braking system 9•1318.4 Handbrake
Page 189 and 190: Braking system 9•1524.6 Belt-brea
Page 191 and 192: Braking system 9•17cylinder reser
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Suspension and steering 10•31 Gen
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Suspension and steering 10•52.17
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Suspension and steering 10•7A Sus
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Suspension and steering 10•99.6 P
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Suspension and steering 10•11posi
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Suspension and steering 10•1319.1
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Suspension and steering 10•17Refi
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11•1Chapter 11Bodywork and fittin
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Bodywork and fittings 11•3almost
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Bodywork and fittings 11•57.3b Bo
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Bodywork and fittings 11•715.2 Ra
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Bodywork and fittings 11•918.2 Mi
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Bodywork and fittings 11•1121.5 D
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Bodywork and fittings 11•1327.3 T
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Bodywork and fittings 11•1531.20
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Bodywork and fittings 11•1942.1 A
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12•1Chapter 12Body electrical sys
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Body electrical systems 12•3Bulbs
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Body electrical systems 12•53.1a
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Body electrical systems 12•96.13
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Body electrical systems 12•1727 A
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Wiring diagrams 12•1912Notes, int
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Wiring diagrams 12•21Diagram 1a:
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Wiring diagrams 12•23Diagram 1c:
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Wiring diagrams 12•25Diagram 1e:
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Wiring diagrams 12•27Diagram 2a:
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1595Ford Fiesta RemakeDiagram 3: An
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1595Ford Fiesta RemakeDiagram 3b: A
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Wiring diagrams 12•33Diagram 4: I
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REF•2 Conversion factorsWeightsKe
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REF•4 General repair proceduresWh
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REF•6 Conversion FactorsLength (d
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REF•8 Tools and working facilitie
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REF•10 MOT test checksThis is a g
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REF•12 MOT test checksExhaust sys
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REF•14 Fault findingEngine Engine
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REF•16 Fault findingEngine (conti
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REF•18 Fault findingAutomatic tra
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REF•20 Fault findingElectrical sy
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REF•22 Glossary of technical term
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REF•28 IndexFault finding - clutc
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Preserving Our Motoring HeritageJoh
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Chapter 1 Routine maintenance and servicing

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