Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake2A•10 HCS engine in-car repair procedures14.11b Fitting the rear oil seal housingwith a new gasket in position on the rearface of the cylinder block(see illustration). Centralise the seal on theshaft, then insert and tighten the housingretaining bolts to the specified torque setting.Refit the sump with reference to Section 11.12 Check that the crankshaft rear flangeand the flywheel mating faces are clean, thenrefit the flywheel as described in Section 16.15 Engine/transmissionmountings - inspection and2renewalInspection1 The engine/transmission mountings seldomrequire attention, but broken or deterioratedmountings should be renewed immediately, orthe added strain placed on the drivelinecomponents may cause damage or wear.2 During the check, the engine/transmissionmust be raised slightly, to remove its weightfrom the mountings.3 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Positiona jack under the sump, with a large block ofwood between the jack head and the sump,then carefully raise the engine/transmissionjust enough to take the weight off themountings.4 Check the mountings to see if the rubber iscracked, hardened or separated from the15.8 Unscrew and remove the enginemounting side bolt (arrowed) from underthe wheel archmetal components. Sometimes, the rubberwill split right down the centre.5 Check for relative movement between eachmounting’s brackets and theengine/transmission or body (use a largescrewdriver or lever to attempt to move themountings). If movement is noted, lower theengine and check-tighten the mountingfasteners.Renewal6 The engine mountings can be removed ifthe weight of the engine/transmission issupported by one of the following alternativemethods.7 Either support the weight of the assemblyfrom underneath using a jack and a suitablepiece of wood between the jack saddle andthe sump or transmission (to preventdamage), or from above by attaching a hoistto the engine. A third method is to use asuitable support bar with end pieces whichwill engage in the water channel each side ofthe bonnet lid aperture. Using an adjustable15.9 Unscrew and remove the mountingretaining nut and washer from thesuspension strut cup retaining platehook and chain connected to the engine, theweight of the engine and transmission canthen be taken from the mountings.Engine right-hand mounting8 Unscrew and remove the mounting sidebolt from under the right-hand wheel arch(see illustration).9 Unscrew and remove the mountingretaining nut and washer from the suspensionstrut cup retaining plate (see illustration).10 Undo the three bolts securing themounting unit to the cylinder block. Themounting unit and bracket can then belowered from the engine (see illustration).11 Unbolt and remove the mounting from itssupport bracket.Transmission bearer and mountings12 Unscrew and remove the two nutssecuring the mountings (front and rear) to thetransmission bearer (see illustration).13 Support the transmission bearer, thenundo and remove the four retaining bolts fromthe floorpan, two at the front and two at the15.10 Undo the three bolts securing themounting assembly to the cylinder blockand withdraw the mounting15.12 Exploded view of the transmission bearer mountings
HCS engine in-car repair procedures 2A•11rear, and lower the transmission bearer fromthe vehicle. Note plate fitment, as applicable,for reassembly.14 Unscrew the single nut securing eachmounting and its retainer to the transmissionsupport bracket, and remove. Thetransmission support brackets are fixedexternally to the transmission casing and donot need to be removed for this operation.All mountings15 Refitting of all mountings is a reversal ofremoval. Make sure that the original sequenceof assembly of washers and plates ismaintained.16 Do not fully tighten any mounting boltsuntil they are all located. As the mountingbolts and nuts are tightened, check that themounting rubbers do not twist.16 Flywheel - removal, inspectionand refitting3Refitting1 Remove the transmission as described inChapter 7A, then remove the clutch asdescribed in Chapter 6.2 Unscrew the six retaining bolts, and removethe flywheel from the rear end flange of thecrankshaft - take care not to drop theflywheel, as it is heavy. A tool similar to thatshown in illustration 16.5 can be fitted toprevent the flywheel/crankshaft from rotatingas the bolts are removed. If on removal, theretaining bolts are found to be in poorcondition (stretched threads, etc) they mustbe renewed.Inspection3 Inspect the starter ring gear on the flywheelfor any broken or excessively-worn teeth. Ifevident, the ring gear must be renewed; this isa task best entrusted to a Ford dealer or acompetent garage. Alternatively, obtain acomplete new flywheel.4 The clutch friction surface on the flywheelmust be carefully inspected for grooving orhairline cracks (caused by overheating). Ifthese conditions are evident, it may bepossible to have the flywheel surface-groundto renovate it, providing that the balance isnot upset. Regrinding is a task for anautomotive engineer. If surface-grinding is notpossible, the flywheel must be renewed.Refitting5 Check that the mating faces of the flywheel16.5 Tightening the flywheel retainingbolts to the specified torqueNote the “peg” tool (arrowed) locking the ringgear teeth to prevent the flywheel/crankshaftfrom rotatingand the crankshaft are clean before refitting.Lubricate the threads of the retaining boltswith engine oil before they are screwed intoposition. Locate the flywheel onto thecrankshaft, and insert the bolts. Hand-tightenthem initially, then tighten them in aprogressive sequence to the specified torquewrench setting (see illustration).6 Refit the clutch as described in Chapter 6and the transmission as described in Chapter7A.2A1595Ford Fiesta Remake
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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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4E•1Chapter 4 Part E:Exhaust and
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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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5B•1Chapter 5 Part B:Ignition sys
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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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Suspension and steering 10•52.17
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Suspension and steering 10•7A Sus
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Suspension and steering 10•99.6 P
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Suspension and steering 10•11posi
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Suspension and steering 10•1319.1
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Suspension and steering 10•15that
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Suspension and steering 10•17Refi
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11•1Chapter 11Bodywork and fittin
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Bodywork and fittings 11•3almost
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Bodywork and fittings 11•57.3b Bo
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Bodywork and fittings 11•715.2 Ra
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Bodywork and fittings 11•918.2 Mi
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Bodywork and fittings 11•1121.5 D
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Bodywork and fittings 11•1327.3 T
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Bodywork and fittings 11•1531.20
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Bodywork and fittings 11•17to avo
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Bodywork and fittings 11•1942.1 A
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Bodywork and fittings 11•2146.12
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12•1Chapter 12Body electrical sys
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Body electrical systems 12•3Bulbs
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Body electrical systems 12•53.1a
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Body electrical systems 12•750 Un
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Body electrical systems 12•96.13
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Body electrical systems 12•1727 A
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Wiring diagrams 12•1912Notes, int
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Wiring diagrams 12•21Diagram 1a:
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Wiring diagrams 12•23Diagram 1c:
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Wiring diagrams 12•25Diagram 1e:
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Wiring diagrams 12•27Diagram 2a:
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1595Ford Fiesta RemakeDiagram 3: An
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1595Ford Fiesta RemakeDiagram 3b: A
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Wiring diagrams 12•33Diagram 4: I
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REF•2 Conversion factorsWeightsKe
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REF•4 General repair proceduresWh
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REF•6 Conversion FactorsLength (d
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REF•8 Tools and working facilitie
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REF•10 MOT test checksThis is a g
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REF•12 MOT test checksExhaust sys
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REF•14 Fault findingEngine Engine
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REF•16 Fault findingEngine (conti
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REF•18 Fault findingAutomatic tra
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REF•20 Fault findingElectrical sy
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REF•22 Glossary of technical term
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REF•28 IndexFault finding - clutc
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Preserving Our Motoring HeritageJoh
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Chapter 1 Routine maintenance and servicing

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