Chapter 1 Routine maintenance and servicing

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1595 Ford Fiesta RemakeJacking and vehicle support REF•5The jack supplied with the vehicle tool kitshould only be used for changing theroadwheels - see “Wheel changing” at thefront of this manual. When jacking up thevehicle to carry out repair or maintenancetasks, a pillar or trolley type jack of suitablelifting capacity must be used, supplementedwith axle stands positioned only beneath theappropriate points under the vehicle (seeillustration). Note that the vehicle must neverbe jacked up at the rear under the axle beam.The maximum kerb weight of the vehicle mustnot be exceeded when jacking and supportingthe vehicle. Do not under any circumstancesjack up the rear of the vehicle under the rear axle.Never work under, around or near a raisedvehicle unless it is adequately supported in atleast two places with axle stands.A Jacking points for trolley jack(always use a suitable blockof wood to protect thevehicle body)B Axle stand positionsC Jacking points for owner jackand wheel-free hoistUnderside view of the vehicle showing the jacking point locationsBuying spare partsSpare parts are available from manysources, including maker’s appointedgarages, accessory shops, and motor factors.To be sure of obtaining the correct parts, itwill sometimes be necessary to quote thevehicle identification number. If possible, itcan also be useful to take the old parts alongfor positive identification. Items such asstarter motors and alternators may beavailable under a service exchange scheme -any parts returned should always be clean.Our advice regarding spare part sources isas follows.Officially-appointed garagesThis is the best source of parts which arepeculiar to your car, and which are nototherwise generally available (eg badges,interior trim, certain body panels, etc). It isalso the only place at which you should buyparts if the vehicle is still under warranty.Accessory shopsThese are very good places to buymaterials and components needed for themaintenance of your car (oil, air and fuelfilters, spark plugs, light bulbs, drivebelts, oilsand greases, brake pads, touch-up paint, etc).Components of this nature sold by areputable shop are of the same standard asthose used by the car manufacturer.Besides components, these shops also selltools and general accessories, usually haveconvenient opening hours, charge lowerprices, and can often be found not far fromhome. Some accessory shops have partscounters where the components needed foralmost any repair job can be purchased orordered.Motor factorsGood factors will stock all the moreimportant components which wear outcomparatively quickly, and can sometimessupply individual components needed for theoverhaul of a larger assembly (eg brake sealsand hydraulic parts, bearing shells, pistons,valves, alternator brushes). They may alsohandle work such as cylinder block reboring,crankshaft regrinding and balancing, etc.Buying spare partsTyre and exhaust specialistsThese outlets may be independent, ormembers of a local or national chain. Theyfrequently offer competitive prices whencompared with a main dealer or local garage,but it will pay to obtain several quotes beforemaking a decision. When researching prices,also ask what “extras” may be added - forinstance, fitting a new valve and balancing thewheel are both commonly charged on top ofthe price of a new tyre.Other sourcesBeware of parts or materials obtained frommarket stalls, car boot sales or similar outlets.Such items are not invariably sub-standard,but there is little chance of compensation ifthey do prove unsatisfactory. In the case ofsafety-critical components such as brakepads, there is the risk not only of financial lossbut also of an accident causing injury ordeath.Second-hand components or assembliesobtained from a car breaker can be a goodbuy in some circumstances, but this sort ofpurchase is best made by the experiencedDIY mechanic.Radio/cassette unit anti-theft system - precautionThe radio/cassette unit fitted as standard oroptional equipment may be equipped with abuilt-in security code, to deter thieves. If thepower source to the unit is cut, the anti-theftsystem will activate. Even if the power sourceis immediately reconnected, the radio/cassette unit will not function until the correctsecurity code has been entered. Therefore,if you do not know the correct securitycode for the radio/cassette unit do notdisconnect either of the battery terminals, orremove the radio/cassette unit from thevehicle.To enter the correct security code, followthe instructions provided with theradio/cassette player or vehicle handbook.If an incorrect code is entered, the unit willbecome locked, and cannot be operated.If this happens, or if the security code is lostor forgotten, seek the advice of your Forddealer.REF
REF•6 Conversion FactorsLength (distance)Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in)Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft)Miles x 1.609 = Kilometres (km) x 0.621 = MilesVolume (capacity)Cubic inches (cu in; in 3 ) x 16.387 = Cubic centimetres (cc; cm 3 ) x 0.061 = Cubic inches (cu in; in 3 )Imperial pints (Imp pt) x 0.568 = Litres (l) x 1.76 = Imperial pints (Imp pt)Imperial quarts (Imp qt) x 1.137 = Litres (l) x 0.88 = Imperial quarts (Imp qt)Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)US quarts (US qt) x 0.946 = Litres (l) x 1.057 = US quarts (US qt)Imperial gallons (Imp gal) x 4.546 = Litres (l) x 0.22 = Imperial gallons (Imp gal)Imperial gallons (Imp gal) x 1.201 = US gallons (US gal) x 0.833 = Imperial gallons (Imp gal)US gallons (US gal) x 3.785 = Litres (l) x 0.264 = US gallons (US gal)Mass (weight)Ounces (oz) x 28.35 = Grams (g) x 0.035 = Ounces (oz)Pounds (lb) x 0.454 = Kilograms (kg) x 2.205 = Pounds (lb)ForceOunces-force (ozf; oz) x 0.278 = Newtons (N) x 3.6 = Ounces-force (ozf; oz)Pounds-force (lbf; lb) x 4.448 = Newtons (N) x 0.225 = Pounds-force (lbf; lb)Newtons (N) x 0.1 = Kilograms-force (kgf; kg) x 9.81 = Newtons (N)PressurePounds-force per square inch x 0.070 = Kilograms-force per square x 14.223 = Pounds-force per square inch(psi; lbf/in 2 ; lb/in 2 ) centimetre (kgf/cm 2 ; kg/cm 2 ) (psi; lbf/in 2 ; lb/in 2 )Pounds-force per square inch x 0.068 = Atmospheres (atm) x 14.696 = Pounds-force per square inch(psi; lbf/in 2 ; lb/in 2 ) (psi; lbf/in 2 ; lb/in 2 )Pounds-force per square inch x 0.069 = Bars x 14.5 = Pounds-force per square inch(psi; lbf/in 2 ; lb/in 2 ) (psi; lbf/in 2 ; lb/in 2 )Pounds-force per square inch x 6.895 = Kilopascals (kPa) x 0.145 = Pounds-force per square inch(psi; lbf/in 2 ; lb/in 2 ) (psi; lbf/in 2 ; lb/in 2 )Kilopascals (kPa) x 0.01 = Kilograms-force per square x 98.1 = Kilopascals (kPa)centimetre (kgf/cm 2 ; kg/cm 2 )Millibar (mbar) x 100 = Pascals (Pa) x 0.01 = Millibar (mbar)Millibar (mbar) x 0.0145 = Pounds-force per square inch x 68.947 = Millibar (mbar)(psi; lbf/in 2 ; lb/in 2 )Millibar (mbar) x 0.75 = Millimetres of mercury (mmHg) x 1.333 = Millibar (mbar)Millibar (mbar) x 0.401 = Inches of water (inH 2 O) x 2.491 = Millibar (mbar)Millimetres of mercury (mmHg) x 0.535 = Inches of water (inH 2 O) x 1.868 = Millimetres of mercury (mmHg)Inches of water (inH 2 O) x 0.036 = Pounds-force per square inch x 27.68 = Inches of water (inH 2 O)(psi; lbf/in 2 ; lb/in 2 )Torque (moment of force)Pounds-force inches x 1.152 = Kilograms-force centimetre x 0.868 = Pounds-force inches(lbf in; lb in) (kgf cm; kg cm) (lbf in; lb in)Pounds-force inches x 0.113 = Newton metres (Nm) x 8.85 = Pounds-force inches(lbf in; lb in)(lbf in; lb in)Pounds-force inches x 0.083 = Pounds-force feet (lbf ft; lb ft) x 12 = Pounds-force inches(lbf in; lb in)(lbf in; lb in)Pounds-force feet (lbf ft; lb ft) x 0.138 = Kilograms-force metres x 7.233 = Pounds-force feet (lbf ft; lb ft)(kgf m; kg m)Pounds-force feet (lbf ft; lb ft) x 1.356 = Newton metres (Nm) x 0.738 = Pounds-force feet (lbf ft; lb ft)Newton metres (Nm) x 0.102 = Kilograms-force metres x 9.804 = Newton metres (Nm)(kgf m; kg m)PowerHorsepower (hp) x 745.7 = Watts (W) x 0.0013 = Horsepower (hp)Velocity (speed)Miles per hour (miles/hr; mph) x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph)Fuel consumption*Miles per gallon (mpg) x 0.354 = Kilometres per litre (km/l) x 2.825 = Miles per gallon (mpg)TemperatureDegrees Fahrenheit = (°C x 1.8) + 32 Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 2821595 Ford 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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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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Exhaust and emission control system
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5A•1Chapter 5 Part A:Starting and
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Starting and charging systems 5A•
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Ignition system 5B•3flux can pass
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Ignition system 5B•55.3 Disconnec
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Ignition system 5B•79.3 Distribut
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9•1Chapter 9Braking systemContent
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Braking system 9•34 Withdraw the
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Braking system 9•56.3 Depress and
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Braking system 9•78.3 Compress th
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Braking system 9•911.6 Servo moun
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Braking system 9•11Bleeding - usi
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Braking system 9•1318.4 Handbrake
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Braking system 9•1524.6 Belt-brea
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Braking system 9•17cylinder reser
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10•1Chapter 10Suspension and stee
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Suspension and steering 10•31 Gen
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11•1Chapter 11Bodywork and fittin
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Page 267 and 268: REF•2 Conversion factorsWeightsKe
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Page 275 and 276: REF•10 MOT test checksThis is a g
Page 277 and 278: REF•12 MOT test checksExhaust sys
Page 279 and 280: REF•14 Fault findingEngine Engine
Page 281 and 282: REF•16 Fault findingEngine (conti
Page 283 and 284: REF•18 Fault findingAutomatic tra
Page 285 and 286: REF•20 Fault findingElectrical sy
Page 287 and 288: REF•22 Glossary of technical term
Page 293 and 294: REF•28 IndexFault finding - clutc
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Page 297: Preserving Our Motoring HeritageJoh
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