Chapter 1 Routine maintenance and servicing

Engine removal and overhaul procedures 2D•94.11 Vacuum hose to MAP sensor (A) andbrake servo (B)4.12a Disconnect the wiring at thetemperature gauge sender unit . . .4.12b . . . the oil pressure switch . . .Whenever you disconnectany vacuum lines, coolant oremissions hoses, wiringconnectors and fuel lines,always label them clearly, so that theycan be correctly reassembled. Maskingtape and/or a touch-up paint applicatorwork well for marking items. Takeinstant photos, or sketch the locationsof components and brackets.7 Refer to the relevant Part of Chapter 4 fordetails, and disconnect the accelerator cablefrom the throttle linkage and support/adjusterbracket. Where applicable, also disconnectthe choke cable. Position the cable(s) out ofthe way.8 On carburettor models, disconnect the fuelsupply hose from the fuel pump, and thereturn hose from the carburettor.9 On CFi models, detach the fuel hose at theinjector/pressure regulator unit, and the returnline, by compressing the couplings whilstpulling the hoses free from their connections.On EFi and SEFi models, unscrew the unionnut to detach the fuel line from the fuel rail;release the retaining clip to detach the returnpipe from the pressure regulator. Plug theexposed ends of the hoses and connections,to prevent fuel spillage and the ingress of dirt.Position the hoses out of the way.10 Press the clamp ring inwards, andsimultaneously pull free the brake servo hose4.12c . . . and the crankshaft positionsensorfrom the inlet manifold. Position it out of theway.11 On CFi and EFi models, detach thevacuum hose from the MAP sensor, and thehose between the carbon canister and the fuelinjection unit (see illustration).12 Note their connections and routings, anddetach the following wiring connections,according to model (see illustrations):a) Coolant temperature sender unit.b) Oil pressure switch.c) E-DIS ignition coil unit. or distributor.d) Coolant temperature sensor.e) Cooling fan thermostatic switch.f) Carburettor.g) Earth lead (radio).h) Reversing light switch (from transmission).i) Crankshaft position sensor.j) Earth leads from the transmission andengine.13 Disconnect the wiring at the followingadditional items specific to fuel injectionmodels only.a) Inlet air temperature sensor.b) Vehicle speed sensor.c) Throttle plate control motor (CFimodels).d) Throttle position sensor.e) Injector harness connector.f) Idle speed control valve (EFi and SEFimodels).14 Unscrew the retaining bolt and detach thebracket locating the wiring and coolant hosesabove the transmission.4.24 Manual transmission shift rod clampbolt (A), stabiliser-to-transmission bolt (B)and washer (C)15 Disconnect the speedometer drive cablefrom the transmission.16 On manual transmission models,disconnect the clutch cable from the releaselever at the transmission (see Chapter 6 fordetails). Position the cable out of the way.17 On vehicles fitted with the anti-lockbraking system, refer to Chapter 9 and releasethe left-hand modulator from its mountingbracket, without disconnecting the rigid brakepipes or return hose. Tie the modulatorsecurely to the bulkhead.18 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Allowsufficient clearance under the vehicle towithdraw the engine and transmission unitsfrom under the front end.19 On XR2i models, refer to Chapter 10 andremove the front suspension crossmember.20 Where applicable on catalytic converterequippedvehicles, release the multi-plug fromthe bracket and disconnect the wiringconnector from the oxygen sensor in theexhaust downpipe.21 Undo the three retaining bolts, detach theexhaust downpipe from the manifold, andcollect the gasket from the flange joint. Nowdisconnect the exhaust downpipe from therest of the system, and remove it from thevehicle.22 Where fitted, undo the four retaining nutsand two bolts securing the front part of theexhaust heat shield to the floor, then removethe heat shield.23 Refer to Chapter 5A and remove thealternator and starter motor. On models withpower steering, refer to Chapter 10 andremove the power steering pump.Manual transmission models24 On 4-speed models, select 2nd gear; on5-speed models, select 4th gear, to assist incorrect adjustment of the gearchange duringreassembly. If it is likely that the gear lever willbe moved from this position before refitting,mark the relative position of the transmissionshift rod and the selector shaft beforeseparating them. Undo the clamp bolt, andthen pull free and detach the shift rod from theselector shaft (see illustration).2D1595Ford Fiesta Remake