Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake10•18 Suspension and steeringFront wheel toe setting -checking and adjustment2 Due to the special measuring equipmentnecessary to accurately check the wheelalignment, and the skill required to use itproperly, checking and adjustment is best leftto a Ford dealer or similar expert. Note thatmost tyre-fitting shops now possesssophisticated checking equipment. Thefollowing is provided as a guide, should theowner decide to carry out a DIY check.3 The front wheel toe setting is checked bymeasuring the distance between the front andrear inside edges of the roadwheel rims.Proprietary toe measurement gauges areavailable from motor accessory shops.Adjustment is made by screwing the trackrods in or out of their track rod end balljoints,to alter the effective length of the track rodassemblies.4 For accurate checking, the vehicle mustbe at the kerb weight, ie unladen and with afull tank of fuel.5 Before starting work, check the tyrepressures and tread wear, the condition of thehub bearings, the steering wheel free play,and the condition of the front suspensioncomponents (see Chapter 1). Correct anyfaults found.6 Park the vehicle on level ground, check thatthe front roadwheels are in the straight-aheadposition, then rock the rear and front ends tosettle the suspension. Release the handbrake,and roll the vehicle backwards 1 metre, thenforwards again, to relieve any stresses in thesteering and suspension components.7 Measure the distance between the frontedges of the wheel rims and the rear edges ofthe rims. Subtract the smallest measurementfrom the largest, and check that the result iswithin the specified range.8 If adjustment is necessary, apply thehandbrake, then jack up the front of thevehicle and support it securely on axle stands(see “Jacking and Vehicle Support”). Turn thesteering wheel onto full-left lock, and recordthe number of exposed threads on the righthandtrack rod. Now turn the steering ontofull-right lock, and record the number ofthreads on the left-hand side. If there are thesame number of threads visible on both sides,then subsequent adjustment should be madeequally on both sides. If there are morethreads visible on one side than the other, itwill be necessary to compensate for thisduring adjustment. Note: It is most importantthat after adjustment, the same number ofthreads are visible on each track rod.9 First clean the track rod end; if they arecorroded, apply penetrating fluid beforestarting adjustment. Release the rubber gaiteroutboard clips (where necessary), and peelback the gaiter; apply a smear of grease tothe inside of the gaiter, so that both are free,and will not be twisted or strained as theirrespective track rods are rotated.10 Use a straight-edge and a scriber orsimilar to mark the relationship of each trackrod to its track rod end balljoint, then, holdingeach track rod in turn, unscrew its locknutfully.11 Alter the length of the track rods, bearingin mind the note made in paragraph 8. Screwthem into or out of the track rod end balljoints,rotating the track rods using a self-gripwrench. Shortening the track rods (screwingthem into their track rod end balljoints) willreduce toe-in/increase toe-out.12 When the setting is correct, hold the trackrods and securely tighten the track rod endballjoint locknuts. Count the exposed threadsto check the length of both track rods. If theyare not the same, then the adjustment has notbeen made equally, and problems will beencountered with tyre scrubbing in turns;also, the steering wheel spokes will no longerbe horizontal when the wheels are in thestraight-ahead position.13 If the track rod lengths are the same, lowerthe vehicle to the ground and re-check thetoe setting; re-adjust if necessary. When thesetting is correct, securely tighten the track rodend balljoint locknuts. Ensure that the rubbergaiters are seated correctly, and are nottwisted or strained, and secure them in positionwith new retaining clips (where necessary).
11•1Chapter 11Bodywork and fittingsContentsBody adhesive emblems - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . 9Body trim mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . 10Bodywork, paint and exterior trim check . . . . . . . . . . . .See Chapter 1Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . 6Bonnet latch - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Bonnet release mechanism - removal and refitting . . . . . . . . . . . . . 7Bumper and rear quarter mouldings - renewal . . . . . . . . . . . . . . . . . 17Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 45Door aperture weatherstrip - removal and refitting . . . . . . . . . . . . . . 11Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . . 32Door window regulator - removal and refitting . . . . . . . . . . . . . . . . . 31Door, tailgate and bonnet check and lubrication . . . . . .See Chapter 1Exterior mirror and glass - removal and refitting . . . . . . . . . . . . . . . . 18Facia - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Front seat and slide assembly - removal and refitting . . . . . . . . . . . 39Full-length sunroof - general information . . . . . . . . . . . . . . . . . . . . . 38General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Interior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 19Interior trim panels - removal and refitting . . . . . . . . . . . . . . . . . . . . 42Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . 2Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . 3Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Parcel shelf support/loudspeaker housing - removal and refitting . . 43Degrees of difficultyEasy, suitable fornovice with littleexperience1Fairly easy, suitablefor beginner withsome experience2Fairly difficult,suitable for competentDIY mechanicPassenger grab handle - removal and refitting . . . . . . . . . . . . . . . . . 44Rear door inner trim panels (Courier models) - removal and refitting . . 29Rear door lock, catches and handles (Courier models) -removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Rear doors (Courier models) - removal and refitting . . . . . . . . . . . . . 28Rear seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1Seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Side door inner trim panel - removal and refitting . . . . . . . . . . . . . . . 21Side door lock, lock cylinder and handles - removal and refitting . . 22Side doors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Side window glass - removal and refitting . . . . . . . . . . . . . . . . . . . . 33Sill extension moulding - removal and refitting . . . . . . . . . . . . . . . . . 12Sunroof panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 35Sunroof panel seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Sunroof weatherseal - removal and refitting . . . . . . . . . . . . . . . . . . . 37Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Tailgate inner trim panel - removal and refitting . . . . . . . . . . . . . . . . 26Tailgate lock components - removal and refitting . . . . . . . . . . . . . . . 27Tailgate spoiler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 25Tailgate support strut - removal and refitting . . . . . . . . . . . . . . . . . . 23Wheelarch liners - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 13Wheelarch mouldings - removal and refitting . . . . . . . . . . . . . . . . . . 14Wind deflector/radiator grille slat - removal and refitting . . . . . . . . . 15Windscreen and tailgate window glass - removal and refitting . . . . 343Difficult, suitable forexperienced DIYmechanic4Very difficult,suitable for expert DIYor professional5SpecificationsTorque wrench settings Nm lbf ftFront seat slide mechanism-to-floor mounting bolts . . . . . . . . . . . . . . . 25 to 32 18 to 24Rear seat backrest hinge to backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 to 4.6 2.7 to 3.4Rear seat backrest hinge to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 25 15 to 18Rear seat belt anchors and stalks to body . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 34Rear seat belt retractor assembly to body . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 34Front seat belt stalks to floorpan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 34Front seat belt lower anchor bolt to body . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 34Front seat belt lower anchor slide bar bolt to body . . . . . . . . . . . . . . . . 25 to 45 18 to 34Front seat belt retractor to B-pillar bolt . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 34Front seat belt upper anchor bolt to B-pillar (non-adjustable type) . . . . 25 to 45 18 to 34Front seat belt upper anchor adjuster plate-to-B-pillar bolts . . . . . . . . . 19 to 28 14 to 22Front seat belt upper anchor bolt to adjuster slide . . . . . . . . . . . . . . . . 25 to 45 18 to 34Bonnet hinge-to-bonnet bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 12 6.5 to 9Bonnet latch retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9Tailgate hinge-to-tailgate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 12 6.5 to 9Tailgate latch retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9Rear door lower hinge cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 12 6.5 to 9Rear door latch retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 12 6.5 to 9Front and rear bumper retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9111595Ford 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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4B•1Chapter 4 Part B:Fuel system
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Fuel system - central fuel injectio
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4C•1Chapter 4 Part C:Fuel system
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Fuel system - electronic fuel injec
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4D•1Chapter 4 Part D: Fuel system
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Fuel system - sequential electronic
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4E•1Chapter 4 Part E:Exhaust and
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Exhaust and emission control system
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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
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 203 and 204: Suspension and steering 10•11posi
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Page 233 and 234: 12•1Chapter 12Body electrical sys
Page 235 and 236: Body electrical systems 12•3Bulbs
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Page 251 and 252: Wiring diagrams 12•1912Notes, int
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1595Ford Fiesta RemakeDiagram 3: An
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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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