Chapter 1 Routine maintenance and servicing

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1595Ford Fiesta Remake1•8 Maintenance – component locationRear underside view of the 1.4 litre CVH CFi fuel injection model1 Fuel tank2 Fuel filler pipe3 Fuel tank ventilation hose4 Twist beam rear axle assembly5 Underbody heatshields6 Exhaust rear silencer7 Exhaust rubber insulator mounting8 Load apportioning valves (on vehicles withthe anti-lock braking system)9 Handbrake cable10 Rear towing eye11 Spare wheel carrier hook (on the retainingbolt)Rear underside view of the Courier van model1 Fuel tank2 Fuel filler pipe3 Fuel tank ventilation hose4 Rear axle assembly - spring torsion barsvisible5 Rear axle pivot brackets6 Rear suspension dampers7 Exhaust system rear silencer8 Braking system light-laden valve9 Handbrake cables10 Rear towing eye11 Spare wheel carrier
Maintenance procedures 1•91 IntroductionThis Chapter is designed to help the homemechanic maintain his/her vehicle for safety,economy, long life and peak performance.This Chapter contains a mastermaintenance schedule, followed by Sectionsdealing specifically with each task in theschedule. Visual checks, adjustments,component renewal and other helpful itemsare included. Refer to the accompanyingillustrations of the engine compartment andthe underside of the vehicle for the locationsof the various components.Servicing your vehicle in accordance withthe mileage/time maintenance schedule andthe following Sections will provide a plannedmaintenance programme, which should resultin a long and reliable service life. This is acomprehensive plan, so maintaining someitems but not others at the specified serviceintervals will not produce the same results.As you service your vehicle, you willdiscover that many of the procedures can -and should - be grouped together, because ofthe particular procedure being performed, orbecause of the close proximity of twootherwise-unrelated components to oneanother. For example, if the vehicle is raisedfor any reason, the exhaust should beinspected at the same time as the suspensionand steering components.The first step of this maintenanceprogramme is to prepare yourself before theactual work begins. Read through all theSections relevant to the work to be carriedout, then make a list and gather together allthe parts and tools required. If a problem isencountered, seek advice from a partsspecialist or a dealer service department.2 Intensive maintenance1 If, from the time the vehicle is new, theroutine maintenance schedule is followedclosely, and frequent checks are made of fluidlevels and high-wear items, as suggestedthroughout this manual, the engine will bekept in relatively good running condition, andthe need for additional work will be minimised.2 It is possible that there will be some timeswhen the engine is running poorly due to thelack of regular maintenance. This is even morelikely if a used vehicle, which has not receivedregular and frequent maintenance checks, ispurchased. In such cases, additional workmay need to be carried out, outside of theregular maintenance intervals.3 If engine wear is suspected, a compressiontest (refer to Part A, B or C of Chapter 2) willprovide valuable information regarding theoverall performance of the main internalcomponents. Such a test can be used as abasis to decide on the extent of the work tobe carried out. If, for example, a compressiontest indicates serious internal engine wear,conventional maintenance as described in thisChapter will not greatly improve theperformance of the engine, and may prove awaste of time and money, unless extensiveoverhaul work (Chapter 2D) is carried out first.4 The following series of operations are thoseoften required to improve the performance ofa generally poor-running engine:Primary operationsa) Clean, inspect and test the battery (See“Weekly Checks”).b) Check all the engine-related fluids (See“Weekly Checks”).c) Check the condition of the auxiliarydrivebelt (Section 4).d) Check and if necessary adjust the valveclearances on HCS engines (Section 7).e) Renew the spark plugs and clean andinspect the HT leads (Section 21).f) Check the condition of the air cleanerfilter element and renew if necessary(Section 24).g) Check and if necessary adjust the idlespeed and mixture settings - whereapplicable (Section 9).h) Renew the fuel filter - fuel injectionmodels (Section 30).i) Check the condition of all hoses, andcheck for fluid leaks (Section 5).5 If the above operations do not prove fullyeffective, carry out the following operations:Secondary operationsAll the items listed under “Primaryoperations”, plus the following:a) Check the charging system (Chapter 5A).b) Check the ignition system (Chapter 5B).c) Check the fuel system (Chapter 4A, 4B,4C and 4D).e) Renew the ignition HT leads (Section 21).1Every 5000 miles (8000 km) or 6 months, whichever occurs first3 Engine oil and filter renewal1Frequent oil changes are thebest preventivemaintenance the homemechanic can give theengine, because ageing oil becomesdiluted and contaminated, which leadsto premature engine wear.1 Make sure that you have all the necessarytools before you begin this procedure (seeillustration). You should also have plenty ofrags or newspapers handy, for mopping upany spills.2 To avoid any possibility of scalding, and toprotect yourself from possible skin irritantsand other harmful contaminants in usedengine oils, it is advisable to wear gloveswhen carrying out this work.3 Access to the underside of the vehicle isgreatly improved if the vehicle can be lifted on ahoist, driven onto ramps, or supported by axlestands (see “Jacking and Vehicle Support”).Warning: Do not work under avehicle which is supported onlyby an hydraulic or scissors-typejack, or by bricks, blocks ofwood, etc.3.2 These tools are required whenchanging the engine oil and filter4 If this is your first oil change, get under thevehicle and familiarise yourself with theposition of the engine oil drain plug location inthe sump. The engine and exhaustcomponents will be warm during the actualwork, so try to anticipate any potentialproblems while the engine and accessoriesare cool.5 The oil should preferably be changed whenthe engine is still fully warmed-up to normaloperating temperature, just after a run (theneedle on the temperature gauge should be inthe “Normal” sector of the gauge); warm oiland sludge will flow out more easily. Park thevehicle on firm, level ground, apply thehandbrake firmly, then select 1st or reversegear (manual transmission) or the “P” position(automatic transmission). Open the bonnetand remove the engine oil filler cap from thecylinder head cover, then remove the oil leveldipstick from its tube (see “Weekly Checks”).6 Raise the front of the vehicle, and support itsecurely on axle stands (see “Jacking andVehicle Support”). Remove the front righthandroadwheel to provide access to the oil1595Ford 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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11•1Chapter 11Bodywork and fittin
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Bodywork and fittings 11•3almost
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Bodywork and fittings 11•1942.1 A
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12•1Chapter 12Body electrical sys
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Body electrical systems 12•3Bulbs
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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•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•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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