Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake5B•4 Ignition system3 Ignition coil - checking,removal and refitting2Distributor ignition systemsChecking1 Accurate checking of the coil outputrequires the use of special test equipment andshould be left to a dealer or suitably equippedautomotive electrician. It is however possibleto check the primary and secondary windingresistance using an ohmmeter as follows.2 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).3 Remove the vehicle jack from its storageposition by unscrewing its retainer. Theignition coil is mounted below.4 To check the primary resistance (with allleads disconnected if the coil is fitted),connect the ohmmeter across the coil positiveand negative terminals. The resistance shouldbe as given in the Specifications at thebeginning of this Chapter.5 To check the secondary resistance (with allleads disconnected if the coil is fitted),connect one lead from the ohmmeter to thecoil negative terminal, and the other lead tothe centre HT terminal. Again the resistanceshould be as given in the Specifications.6 If any of the measured values varysignificantly from the figures given in theSpecifications, the coil should be renewed.7 If a new coil is to be fitted, ensure that it isof the correct type. The appropriate Fordsupplied ignition coil is identified by a redlabel, and will be one of three different makes,all of which are fully interchangeable. Boschand Femsa coils are fitted with protectiveplastic covers, and Polmot coils are fitted withan internal fusible link. Note that contactbreaker ignition coils are not interchangeablewith the required breakerless type and couldcause ignition module failure if used.Removal8 If not already done, remove the vehicle jackfrom its storage position by unscrewing itsretainer. The ignition coil is mounted below.9 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).10 Disconnect the HT lead and the lowtension (LT) connections from the ignition coil.Note that the LT connections on the ignitioncoil are of different sizes. As an aid to refittingthe positive (+) terminal is larger than thenegative (-) terminal (see illustration).11 Remove the two screws or bolts securingthe coil mounting bracket to the inner wingpanel, and withdraw the coil and mountingbracket assembly.Refitting12 Refitting is a reversal of the removalprocedure, ensuring correct LT lead polarity.Distributorless ignition systemsCheckingNote: The ignition coil is located on the rearfacing side of the cylinder block on HCSengines; on the left-hand end of the cylinderhead on CVH, PTE and Zetec engines.13 Having checked that full battery voltage isavailable at the centre terminal of the coil’selectrical connector (see Section 2),disconnect the battery negative (earth) lead(refer to Part A, Section 1).14 Unplug the coil’s electrical connector, ifnot already disconnected.15 Using an ohmmeter, measure theresistance of the coil’s primary windings,connecting the meter between the coil’sterminal pins as follows. Measure first fromone outer pin to the centre pin, then from theother outer pin to the centre. Compare thereadings with the coil primary resistance listedin the Specifications.16 Disconnect the spark plug (HT) leads -note their connections or label them carefully,as described in Chapter 1. Use the meter tocheck that there is continuity between eachpair of (HT) lead terminals; Nos 1 and 4terminals are connected by their secondarywinding, as are Nos 2 and 3. Now switch tothe highest resistance scale, and check thatthere is no continuity between either pair ofterminals and the other - ie, there should beinfinite resistance between terminals 1 and 2,or 4 and 3 - and between any terminal andearth.17 If either of the above tests yield resistancevalues outside the specified amount, orresults other than those described, renew thecoil. Any further testing should be left to adealer service department or other qualifiedrepair facility.RemovalNote: The ignition coil is located on the rearfacing side of the cylinder block on HCSengines; on the left-hand end of the cylinderhead on CVH, PTE and Zetec engines.18 Disconnect the battery negative (earth)lead (refer to Part A, Section 1).19 Disconnect the coil main electricalconnector and (where fitted) the electricalconnector to the suppressor.20 The coil can be removed with the HTleads left attached, in which case disconnectthe leads from their respective spark plugsand from the location clips in the rocker coveror air inlet duct (as applicable). If preferred,the HT leads can be disconnected from thecoil. First check that both the ignition HTleads and their fitted positions are clearlymarked numerically to ensure correct refitting.Spot mark them accordingly if necessary,using quick-drying paint.21 If disconnecting the leads from the sparkplugs, pull them free by gripping on theconnector, not the lead. To detach the leadsfrom the ignition coil, compress the retainingarms of each lead connector at the coil, anddetach each lead in turn (see illustration).22 Unscrew the Torx-type retaining screws,and remove the coil from its mounting on theengine (see illustration).Refitting23 Refitting is the reverse of the removalprocedure. Ensure that the spark plug (HT)leads are correctly reconnected, and tightenthe coil screws securely.3.10 Ignition coil fitted to distributorignition systemsA Retaining boltsB LT connectionsC HT lead to distributor cap3.21 Removing an HT lead from thedistributorless ignition system ignition coil.Note the corresponding markings on theignition coil and HT lead (arrowed)3.22 Distributorless ignition system ignitioncoil and mounting bracket removal (HCSengine shown)
Ignition system 5B•55.3 Disconnecting the vacuum pipe fromthe ignition module5.4a Disconnecting the ignition modulemulti-plug5.4b Undoing the ignition module multiplugsecuring bolt4 Ignition amplifier module(distributor ignition systems)- removal and refitting25 Ignition module -removal and refitting 16 Crankshaft position sensor -removal and refitting2Note: The ignition amplifier module is onlyfitted to carburettor engine models.Removal1 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).2 Remove the distributor, as described inSection 8.3 With the distributor on the workbench,remove both screws securing the module tothe distributor body, then slide the modulefrom its trigger coil connector and remove it.4 Check that the rubber grommet isserviceable. If it is not, it must be renewed butensure that the correct type is obtained.Refitting5 Apply heat sink compound (seeSpecifications) to the module metal face,ensuring a good earth. This is an essentialpart of the procedure, protecting the moduleelectronic circuitry from excessive heat buildupand subsequent malfunction.6 Slide the module into its trigger coilconnector and secure with both screws.7 Refit the distributor in accordance withSection 8, then reconnect the battery.Note: Various designs of ignition module maybe fitted depending on ignition system type.Although the units may differ in appearancefrom the those shown in the accompanyingillustrations, the procedures described beloware applicable to all types.Removal1 The ignition module is located on theengine compartment bulkhead.2 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).3 Where applicable, detach the vacuum hosefrom the module (see illustration).4 According to type, either compress thelocktab securing the wiring multi-plug inposition, or where applicable, undo theretaining bolt, then withdraw the plug from themodule (see illustrations).5 Undo the retaining screws, and removethe module from the bulkhead (seeillustration).Refitting6 Refitting is the reverse of the removalprocedure.Removal1 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and vehicle support”).3 If working on the Zetec engine, remove thestarter motor as described in Part A of thisChapter.4 Compress the retaining clip and pull freethe wiring multi-plug connector from thesensor unit, but take care to pull on theconnector, not the lead (see illustration).5 Undo the Torx-type retaining screw, andwithdraw the sensor from its location in thecylinder block bellhousing flange.Refitting6 Refitting is the reversal of removal.7 Distributor cap and rotorarm - removal and refitting1Removal5B5.5 Ignition module location on bulkheadpanel. Note retaining screws (arrowed)6.4 Crankshaft position sensor removalA Retaining screw B Multi-plug1 Disconnect the battery negative (earth) lead(refer to Part A, Section 1).2 Disconnect the coil HT lead from the centreof the distributor cap and the spark plug HTleads from the spark plugs, having identifiedthem for subsequent refitting. Pull on theconnectors, not the leads. Release the leadsfrom any cable clips or ties.3 On carburettor models, unclip thesuppressor shield (where fitted), remove thedistributor cap securing screws and detachthe cap.4 On CFi fuel injection models, disconnectthe distributor multi-plug for better access tothe rear cap securing clip. Release thedistributor cap securing clips by levering witha screwdriver, withdraw the cap assembly1595Ford 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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2D•1Chapter 2 Part D:Engine remov
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Engine removal and overhaul procedu
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3•1Chapter 3Cooling, heating and
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Cooling, heating and ventilation sy
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4A•1Chapter 4 Part A:Fuel system
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Fuel system - carburettor engines 4
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Page 145 and 146: Fuel system - sequential electronic
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Page 153 and 154: Exhaust and emission control system
Page 159 and 160: 5A•1Chapter 5 Part A:Starting and
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Page 175 and 176: 9•1Chapter 9Braking systemContent
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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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