Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake11•4 Bodywork and fittings15 minutes after spraying on the final coat ofpaint.Allow the new paint at least two weeks toharden, then, using a paintwork renovator, ora very fine cutting paste, blend the edges ofthe paint into the existing paintwork. Finally,apply wax polish.Plastic componentsWith the use of more and more plastic bodycomponents by the vehicle manufacturers (egbumpers. spoilers, and in some cases majorbody panels), rectification of more seriousdamage to such items has become a matterof either entrusting repair work to a specialistin this field, or renewing completecomponents. Repair of such damage by theDIY owner is not really feasible, owing to thecost of the equipment and materials requiredfor effecting such repairs. The basic techniqueinvolves making a groove along the line of thecrack in the plastic, using a rotary burr in apower drill. The damaged part is then weldedback together, using a hot-air gun to heat upand fuse a plastic filler rod into the groove.Any excess plastic is then removed, and thearea rubbed down to a smooth finish. It isimportant that a filler rod of the correct plasticis used, as body components can be made ofa variety of different types (eg polycarbonate,ABS, polypropylene).Damage of a less serious nature (abrasions,minor cracks etc) can be repaired by the DIYowner using a two-part epoxy filler repairmaterial. Once mixed in equal proportions,this is used in similar fashion to the bodyworkfiller used on metal panels. The filler is usuallycured in twenty to thirty minutes, ready forsanding and painting.If the owner is renewing a completecomponent himself, or if he has repaired itwith epoxy filler, he will be left with theproblem of finding a suitable paint for finishingwhich is compatible with the type of plasticused. At one time, the use of a universal paintwas not possible, owing to the complex rangeof plastics encountered in body componentapplications. Standard paints, generallyspeaking, will not bond to plastic or rubbersatisfactorily. However, it is now possible toobtain a plastic body parts finishing kit whichconsists of a pre-primer treatment, a primerand coloured top coat. Full instructions arenormally supplied with a kit, but basically, themethod of use is to first apply the pre-primerto the component concerned, and allow it todry for up to 30 minutes. Then the primer isapplied, and left to dry for about an hourbefore finally applying the special-colouredtop coat. The result is a correctly-colouredcomponent, where the paint will flex with theplastic or rubber, a property that standardpaint does not normally possess.5 Major body damage -repair5Where serious damage has occurred, orlarge areas need renewal due to neglect, itmeans that complete new panels will needwelding-in, and this is best left toprofessionals. If the damage is due to impact,it will also be necessary to check completelythe alignment of the bodyshell, and this canonly be carried out accurately by a Forddealer, using special jigs. If the body is leftmisaligned, it is primarily dangerous, as thecar will not handle properly; secondly, unevenstresses will be imposed on the steering,suspension and possibly transmission,causing abnormal wear, or complete failure,particularly to such items as the tyres.6 Bonnet - removal,refitting and adjustment1Removal1 Raise the bonnet and support it on its stay.2 Using a felt tip marker pen or similar, markaround the hinge positions on the bonnet.3 Cut the windscreen washer jet hose in theengine compartment, or release it from its onewayvalve (if already fitted), then release the hosefrom the bonnet hinge clip (see illustration).4 With the aid of an assistant, support thebonnet assembly and remove the four boltssecuring it to its hinges. Remove the bonnetassembly, taking care to disengage the staybefore the bonnet is moved.Refitting and adjustment5 To refit, first align the marks made on thebonnet with the hinges, then refit and fullytighten the four securing bolts. Support thebonnet on its stay.6 Refit the windscreen washer jet hose intothe bonnet hinge clip, and join it up using aone-way (non-return) valve, having ensuredcorrect routing. Ensure that the valve isinstalled the correct way round, allowing flowto the jets but resisting return flow back to thereservoir.7 Close the bonnet and ensure that there isan equal gap at each side, between thebonnet and the wings, and that it sits flush inrelation to its surrounding panels.8 The bonnet should close smoothly andpositively with no excessive pressure beingapplied. If this is not the case, adjustment willbe necessary.9 To adjust the bonnet closure, adjustablebump stops are fitted to the closure panel(see illustration). These may be raised orlowered by screwing in or out, as necessary.The bonnet latch may also be adjusted, asrequired, and this is covered in Section 8 ofthis Chapter.7 Bonnet release mechanism -removal and refitting1Removal1 Remove the screws securing the lowersteering column shroud to its location and,where applicable, detach the choke warninglight switch/pull control assembly, from it.2 Operate the bonnet release lever then raiseand support the bonnet. If the release cable isbroken, it will be necessary to detach thelatch from its body location by undoing thethree latch retaining screws through the gapbetween the leading edge of the bonnet andthe radiator grille slot.3 With the bonnet open, remove the threescrews securing the latch to the body.Disengage the release cable from the latch(see illustrations).6.3 Windscreen washer jet hose in enginecompartmentA Hose located to bonnet hinge clipB Position of cut6.9 Altering the setting of a bonnet closurebump stop7.3a Removing the bonnet release latch