Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake1•24 Every 30 000 miles or three years24.20 Air cleaner inlet and flap valve onthe CVH engineA Flap open (cool air inlet closed)B Warm air inletengine idling, the hot-air inlet is open to allowwarm air from the exhaust manifold area toenter the air cleaner. If the flap operates asdescribed, it is functioning correctly (seeillustration).21 If the flap fails to operate as described,check the condition of the vacuum pipe andits connections, and check that the flap valvehas not seized. If these are in order, either thetemperature sensor or vacuum actuator isfaulty, and a new air cleaner assembly mustbe obtained. Refit the main air duct oncompletion.25 Emission control systemcheck1General1 Of the emission control systems that maybe fitted, only the crankcase ventilationsystem and the evaporative emission controlsystems require regular checking, and eventhen, the components of these systemsrequire minimal attention.2 Should it be felt that the other systems arenot functioning correctly, the advice of adealer should be sought.Crankcase ventilation system3 The function of the crankcase ventilationsystem is to reduce the emission of unburnedhydrocarbons from the crankcase, and tominimise the formation of oil sludge. Byensuring that a depression is created in thecrankcase under most operating conditions,particularly at idle, and by positively inducingfresh air into the system, the oil vapours and“blow-by” gases collected in the crankcaseare drawn from the crankcase, through the aircleaner or oil separator, into the inlet tract, tobe burned by the engine during normalcombustion.4 On HCS engines, the system consists of avented oil filler cap (with an integral meshfilter) and a hose connecting it to the oilseparator/engine breather valve connector onthe underside of the air cleaner housing. A25.5 Crankcase ventilation system filter onCVH enginesfurther hose leads from the adapter/filter tothe inlet manifold.5 On CVH engines, a closed-circuit typecrankcase ventilation system is used, thefunction of which is basically the same as thatdescribed for the HCS engine types, but thebreather hose connects directly to the rockercover. A separate filter is fitted in the hose tothe rocker cover in certain applications (seeillustration).6 The system fitted to the PTE engines issimilar to that used on the earlier (CVH)engines on which these engines are based,but with revisions to the hose arrangement tosuit the remotely sited air cleaner and fuelinjection system layout.7 On Zetec engines, the crankcase ventilationsystem main components are the oilseparator mounted on the front (radiator) sideof the cylinder block/crankcase, and thePositive Crankcase Ventilation (PCV) valve setin a rubber grommet in the separator’s lefthandupper end. The associated pipeworkconsists of a crankcase breather pipe and twoflexible hoses connecting the PCV valve to aunion on the left-hand end of the inletmanifold, and a crankcase breather hoseconnecting the cylinder head cover to the aircleaner assembly. A small foam filter in theair cleaner prevents dirt from being drawndirectly into the engine.8 Check that all components of the systemare securely fastened, correctly routed (withno kinks or sharp bends to restrict flow) and insound condition; renew any worn or damagedcomponents.9 On HCS engines, remove and inspect theoil filler cap to ensure that it is in goodcondition, and not blocked up with sludge.10 Disconnect the hoses at the cap, andclean the cap if necessary by brushing theinner mesh filter with petrol, and blowingthrough with light pressure from an air line.Renew the cap if it is badly congested.11 If oil leakage is noted, disconnect thevarious hoses and pipes, and check that allare clear and unblocked. Remove the aircleaner lid, and check that the hose from thecylinder head cover to the air cleaner housingis clear and undamaged.25.13 The crankcase ventilation systemfoam filter is located in the air cleanerhousing on Zetec engines12 Where fitted, the PCV valve is designed toallow gases to flow out of the crankcase only,so that a depression is created in thecrankcase under most operating conditions,particularly at idle. Therefore, if either the oilseparator or the PCV valve are thought to beblocked, they must be renewed (see Chapter4E). In such a case, however, there isnothing to be lost by attempting to flush outthe blockage using a suitable solvent. ThePCV valve should rattle when shaken.13 While the air filter element is removed (seeSection 24), wipe out the housing, and onZetec engines, withdraw the small foam filterfrom its location in the rear right-hand cornerof the housing (see illustration). If the foam isbadly clogged with dirt or oil, it must becleaned by soaking it in a suitable solvent,and allowed to dry before being refitted.Evaporative emission controlsystems14 Refer to the checks contained in Chapter4E.26 Automatic transmission fluidrenewal11 The automatic transmission fluid shouldonly be changed when the transmission iscold.2 Position the vehicle over an inspection pit,on vehicle ramps, or jack it up and securelysupport it on axle stands, but make sure thatit is level.3 Place a suitable container beneath the drainplug on the transmission sump pan. Removethe transmission fluid dipstick to speed up thedraining operation.4 Thoroughly clean the area around the drainplug in the transmission sump pan, thenunscrew the plug and allow the fluid to draininto the container.5 When all the fluid has drained (this may takequite some time) clean the drain plug, thenrefit it together with a new seal and tighten itsecurely.6 Place a funnel with a fine mesh screen inthe dipstick tube, and fill the transmission with