Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake5B•8 Ignition systemaccordance with the manufacturer’sinstructions.8 Start the engine, bring it up to normaloperating temperature and allow it to idle.9 Disconnect the vacuum pipe from thedistributor and fit blanking plugs.10 If the timing light is now directed at theengine timing marks, the pulley notch willappear to be stationary and opposite thespecified mark on the scale. If the marks arenot in alignment, release the distributor clampbolts slightly and turn the distributor body inwhichever direction is necessary to align thepulley notch to the appropriate scale mark.Tighten the clamp bolts fully when the settingis correct.11 Using a suitable punch, re-mark thecylinder head and/or the distributor flange toindicate the new distributor timing position forany future repair operations.12 The operation of the centrifugal advanceweights in the distributor can be checked byincreasing the engine speed with the timinglight pointing at the engine timing marks andobserving that the pulley notch advances fromits initial position.13 To check the vacuum advance, run theengine at a fast idle speed and reconnect thevacuum pipe. The pulley notch should againadvance.14 Stop the engine, disconnect thetachometer and timing light and reconnect thevacuum pipe. Refit the timing aperture cover.15 If the timing notch did not appear to moveduring the centrifugal advance check, a faultin the distributor centrifugal advancemechanism is indicated. No increasedmovement of the notch during the vacuumadvance check indicate a punctureddiaphragm in the vacuum unit, or a leak in thevacuum line.16 On completion of the adjustments andchecks, switch the engine off, disconnect thetiming light and ensure that the distributorvacuum pipe is securely connected.Distributor ignition systems (pre-September 1990 CVH engines withCFi fuel injection)Note: When an engine is timed in productionit is set, using a microwave timing system, toan accuracy of within half a degree. Unless itis essential, do not remove the distributor oralter the ignition timing. If no distributor timingposition punch marks are present on thecylinder head and distributor body flange,make your own before disturbing the setting(see illustration 8.2).17 The method of obtaining correct ignitiontiming, with both original punch markspresent, is described in paragraph 3 above.18 If (due to component renewal) one or bothof the punch marks is missing, anapproximate ignition timing setting can beobtained to enable starting of the engine byfollowing the instruction given in Section 8,paragraph 16.19 Accurate ignition timing adjustment canonly be carried out using specialisedequipment - this is a task for your Ford dealeror other suitably equipped specialist. Thereason for this is that the EEC IV enginemanagement module has to “lock” its internalignition advance compensations and its idlespeed control whilst the timing is set. The“locking” of the EEC IV module is performedin “self-test” mode when connected to theFord STAR test (Self-Test Automatic Readout)equipment, which is also used to access faultcodes stored in the module memory andanalyse the performance of the systemcomponents. New punch marks should bemade after accurate timing has been carriedout, as necessary.
9•1Chapter 9Braking systemContentsABS modulator drivebelt check . . . . . . . . . . . . . . . . . . . .See Chapter 1Anti-lock braking system (ABS) - general information . . . . . . . . . . . 23Anti-lock braking system (ABS) components - removal and refitting . . 24Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1Brake fluid level check . . . . . . . . . . . . . . . . . . . . .See “Weekly Checks”Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 10Brake pedal-to-servo cross-link - removal and refitting . . . . . . . . . . 11Brake pressure control valves - removal and refitting . . . . . . . . . . . 20Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . 3Front brake disc - inspection, removal and refitting . . . . . . . . . . . . . 4Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 17Handbrake primary cable - removal and refitting . . . . . . . . . . . . . . . 18Handbrake rear cable - removal and refitting . . . . . . . . . . . . . . . . . . 19Hydraulic pipes and hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . 12Hydraulic system - bleeding (anti-lock braking system) . . . . . . . . . . 14Hydraulic system - bleeding (conventional braking system) . . . . . . . 13Light-laden valve (Courier models) - adjustment . . . . . . . . . . . . . . . 22Light-laden valve (Courier models) - removal and refitting . . . . . . . . 21Load-apportioning valve (ABS models) - adjustment . . . . . . . . . . . . 25Load-apportioning valve (ABS models) - removal and refitting . . . . 26Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 9Rear brake backplate - removal and refitting . . . . . . . . . . . . . . . . . . 8Rear brake drum - removal, inspection and refitting . . . . . . . . . . . . . 5Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 7Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . 15Vacuum servo unit vacuum hose and non-return valve - removal,testing and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Degrees of difficultyEasy, suitable fornovice with littleexperience1Fairly easy, suitablefor beginner withsome experience2Fairly difficult,suitable for competentDIY mechanic3Difficult, suitable forexperienced DIYmechanic4Very difficult,suitable for expert DIYor professional5SpecificationsFront brakesType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disc thickness:Solid disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum disc thickness:Solid disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum disc run-out (disc fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum brake pad thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear brakesType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nominal drum diameter:All except XR2i and ABS equipped models . . . . . . . . . . . . . . . . . . . .XR2i and ABS equipped models . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum drum diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel cylinder bore diameter:All except XR2i and ABS equipped models . . . . . . . . . . . . . . . . . . . .XR2i models with conventional braking system . . . . . . . . . . . . . . . . .All ABS equipped models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . .Solid or ventilated disc, with single-piston sliding calipers240.0 mm10.0 mm20.0 mm8.0 mm18.0 mm0.1 mm1.5 mmDrum with leading and trailing shoes and automatic adjusters180 mm203 mm1.0 mm above nominal diameter17.5 mm19.0 mm22.0 mm1.0 mm91595Ford Fiesta Remake
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1•1Chapter 1Routine maintenance a
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1595Ford Fiesta Remake2B•2 CVH an
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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 123 and 124: 4B•1Chapter 4 Part B:Fuel system
Page 125 and 126: Fuel system - central fuel injectio
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Page 135 and 136: Fuel system - electronic fuel injec
Page 143 and 144: 4D•1Chapter 4 Part D: Fuel system
Page 145 and 146: 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: Ignition system 5B•79.3 Distribut
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
Page 183 and 184: Braking system 9•911.6 Servo moun
Page 185 and 186: Braking system 9•11Bleeding - usi
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
Page 193 and 194: 10•1Chapter 10Suspension and stee
Page 195 and 196: Suspension and steering 10•31 Gen
Page 197 and 198: Suspension and steering 10•52.17
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Page 201 and 202: Suspension and steering 10•99.6 P
Page 203 and 204: Suspension and steering 10•11posi
Page 205 and 206: Suspension and steering 10•1319.1
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Bodywork and fittings 11•1531.20
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Bodywork and fittings 11•17to avo
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Bodywork and fittings 11•1942.1 A
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Bodywork and fittings 11•2146.12
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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•750 Un
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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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Left blank formanual listingpages15
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Preserving Our Motoring HeritageJoh
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Chapter 1 Routine maintenance and servicing

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