Chapter 1 Routine maintenance and servicing

Every 30 000 miles or three years 1•25the specified type of fluid. It is essential thatno dirt is introduced into the transmissionduring this operation.7 Depending on the extent to which the fluidwas allowed to drain, it is possible that theamount of fluid required when filling thetransmission may be more than the specifiedamount (see “Lubricants, fluids and tyrepressures”). However, due to fluid remaining inthe system, it is more likely that less than thespecified amount will be required. Add abouthalf the specified amount, then run the engineup to its normal operating temperature andcheck the level on the dipstick. When the levelapproaches the maximum mark, proceed asdetailed in Section 20 to check the level andcomplete the final topping-up as described.27 Handbrake adjustment31 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”). Fullyrelease the handbrake.2 Check that the handbrake cables arecorrectly routed and secured by the retainingclips at the appropriate points under the vehicle.3 The handbrake is checked for adjustmentby measuring the amount of movementpossible in the handbrake adjuster plungers.These are located on the inside face of eachrear brake backplate (see illustration). The27.3 Handbrake adjustment plungerlocated on the inside face of each rearbrake backplatetotal movement of the two plungers combinedshould be between 0.5 and 2.0 mm. If themovement measured is outside of thistolerance, the handbrake is in need ofadjustment. Adjustment is made altering theposition of the in-line cable adjuster sleeve.4 When adjustment to the handbrake isnecessary, a new adjustment sleeve lockingpin will be required, and this must thereforebe obtained before making the adjustment.5 To adjust the handbrake, first ensure that itis fully released, then firmly apply thefootbrake a few times to ensure that the rearbrake adjustment is taken up by the automaticadjusters. Extract the locking pin fromthe adjuster sleeve (see illustration), thenturn the sleeve to set the combined movementof the plungers within the tolerance27.5 Handbrake cable adjuster lockingpin (A), locknut (B) and adjuster sleeve (C)range specified (0.5 to 2.0 mm). Turn thelocking nut by hand as tight as is possible(two clicks) against the adjustment sleeve.Now grip the locknut with a suitable wrench,and turn it a further two clicks (maximum).6 Secure the adjustment by inserting the newlock pin.7 Check that the operation of the handbrakeis satisfactory, then lower the vehicle to theground, apply the handbrake and remove thechocks from the front wheels.28 Front wheel alignment checkRefer to Chapter 10, Section 29.41Every 40 000 miles29 Timing belt renewal4Refer to Chapter 2, Part B or C asapplicable.Every 60 000 miles30 Fuel filter renewal1Warning: Petrol is extremelyflammable, so extra precautionsmust be taken when working onany part of the fuel system. Donot smoke, or allow open flames or barelight bulbs, near the work area. Also, donot work in a garage if a natural gas-typeappliance with a pilot light is present.While performing any work on the fuelsystem, wear safety glasses, and have asuitable (Class B) fire extinguisher onhand. If you spill any fuel on your skin,rinse it off immediately with soap andwater.1 On fuel injection engines, an in-line fuelfilter is provided in the fuel pump outlet line.The filter is located in the engine compartmenteither below and behind the battery, or on theleft-hand side of the engine compartmentbulkhead. The renewal procedure is the samefor both locations. The filter performs a vitalrole in keeping dirt and other foreign matterout of the fuel system, and so must berenewed at regular intervals, or whenever youhave reason to suspect that it may beclogged. It is always unpleasant workingunder a vehicle - pressure-washing or hosingclean the underbody in the filter’s vicinity willmake working conditions more tolerable, andwill reduce the risk of getting dirt into the fuelsystem.2 Depressurise the fuel system as describedin the relevant Part of Chapter 4.3 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1), then positiona suitable container beneath the fuel filter tocatch escaping fuel. Have a rag handy to soak1595Ford Fiesta Remake