Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
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1595 Ford Fiesta RemakeFuel <strong>and</strong> exhaust systemsFault finding REF•17Excessive fuel consumption Unsympathetic driving style, or adverse conditions. Air filter element dirty or clogged (<strong>Chapter</strong> 1). Engine management system fault (<strong>Chapter</strong>s 1, 4A, 4B, 4C, 4D, 4Eor 5B). Tyres under-inflated (“Weekly Checks”).Fuel leakage <strong>and</strong>/or fuel odour Damaged or corroded fuel tank, pipes or connections (<strong>Chapter</strong> 1). Charcoal canister <strong>and</strong>/or connecting pipes leaking (<strong>Chapter</strong>s 1<strong>and</strong> 4E).Excessive noise or fumes from exhaust systemLeaking exhaust system or manifold joints (<strong>Chapter</strong>s 1 or 4E).Leaking, corroded or damaged silencers or pipe (<strong>Chapter</strong>s 1 or 4E).Broken mountings, causing body or suspension contact (<strong>Chapter</strong>s1 or 4E).ClutchPedal travels to floor - no pressure or very littleresistance Broken clutch cable (<strong>Chapter</strong> 6). Faulty clutch automatic adjuster (<strong>Chapter</strong> 6). Broken clutch release bearing or fork (<strong>Chapter</strong> 6). Broken diaphragm spring in clutch pressure plate (<strong>Chapter</strong> 6).Clutch fails to disengage (unable to select gears) Faulty clutch automatic adjuster (<strong>Chapter</strong> 6). Clutch disc sticking on transmission input shaft splines (<strong>Chapter</strong> 6). Clutch disc sticking to flywheel or pressure plate (<strong>Chapter</strong> 6). Faulty pressure plate assembly (<strong>Chapter</strong> 6). Clutch release mechanism worn or incorrectly assembled (<strong>Chapter</strong> 6).Clutch slips (engine speed increases, with noincrease in vehicle speed) Faulty clutch automatic adjuster (<strong>Chapter</strong> 6). Clutch disc linings excessively worn (<strong>Chapter</strong> 6). Clutch disc linings contaminated with oil or grease (<strong>Chapter</strong> 6). Faulty pressure plate or weak diaphragm spring (<strong>Chapter</strong> 6).Judder as clutch is engaged Clutch disc linings contaminated with oil or grease (<strong>Chapter</strong> 6). Clutch disc linings excessively worn (<strong>Chapter</strong> 6). Clutch cable sticking or frayed (<strong>Chapter</strong> 6). Faulty or distorted pressure plate or diaphragm spring (<strong>Chapter</strong> 6). Worn or loose engine/transmission mountings (<strong>Chapter</strong>s 2A, 2Bor 2C). Clutch disc hub or transmission input shaft splines worn (<strong>Chapter</strong>6).Noise when depressing or releasing clutch pedal Worn clutch release bearing (<strong>Chapter</strong> 6). Worn or dry clutch pedal bushes (<strong>Chapter</strong> 6). Faulty pressure plate assembly (<strong>Chapter</strong> 6). Pressure plate diaphragm spring broken (<strong>Chapter</strong> 6). Broken clutch disc cushioning springs (<strong>Chapter</strong> 6).Manual transmissionNoisy in neutral with engine running Input shaft bearings worn (noise apparent with clutch pedalreleased, but not when depressed) (<strong>Chapter</strong> 7A).* Clutch release bearing worn (noise apparent with clutch pedaldepressed, possibly less when released) (<strong>Chapter</strong> 6).Noisy in one particular gearWorn, damaged or chipped gear teeth (<strong>Chapter</strong> 7A).*Difficulty engaging gears Clutch fault (<strong>Chapter</strong> 6). Worn or damaged gear linkage (<strong>Chapter</strong> 7A). Incorrectly-adjusted gear linkage (<strong>Chapter</strong> 7A). Worn synchroniser assemblies (<strong>Chapter</strong> 7A).*Vibration Lack of oil (<strong>Chapter</strong> 1). Worn bearings (<strong>Chapter</strong> 7A).*Jumps out of gearWorn or damaged gear linkage (<strong>Chapter</strong> 7A).Incorrectly-adjusted gear linkage (<strong>Chapter</strong> 7A).Worn synchroniser assemblies (<strong>Chapter</strong> 7A).*Worn selector forks (<strong>Chapter</strong> 7A).*Lubricant leaksLeaking differential side gear oil seal (<strong>Chapter</strong> 7A).Leaking housing joint (<strong>Chapter</strong> 7A).*Leaking input shaft oil seal (<strong>Chapter</strong> 7A).*Leaking selector shaft oil seal (<strong>Chapter</strong> 7A).Leaking speedometer drive pinion O-ring (<strong>Chapter</strong> 7A).* Although the corrective action necessary to remedy the symptomsdescribed is beyond the scope of the home mechanic, the aboveinformation should be helpful in isolating the cause of the condition,so that the owner can communicate clearly with a professionalmechanic.REF
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