Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake3•2 Cooling, heating and ventilation systemsTorque wrench settings Nm lbf ftThermostat housing to cylinder head:HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 21 13 to 16CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 7 to 9PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 21 13 to 16Water outlet to thermostat housing (Zetec engines) . . . . . . . . . . . . . . . 9 to 12 7 to 9Water pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.5Water pump retaining bolts:HCS, CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13Coolant temperature gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4Coolant temperature sensor:HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17CVH engines:1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 141.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11Radiator mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 27 15 to 20Radiator cooling fan shroud retaining bolt . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 2 to 4Radiator cooling fan motor to shroud nuts . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 7 to 9Automatic transmission fluid cooling pipe connections to radiator . . . . 17 to 21 13 to 161 General information andprecautionsEngine cooling systemThe cooling system is of the pressurisedtype consisting of a belt-driven pump,aluminium crossflow radiator, expansion tank,electric cooling fan and a thermostat. Thesystem functions as follows. Cold coolant inthe bottom of the radiator passes through thebottom hose to the water pump, where it ispumped around the cylinder block and headpassages. After cooling the cylinder bores,combustion surfaces and valve seats, thecoolant reaches the underside of thethermostat, which is initially closed. Thecoolant passes through the heater andinlet manifold and is returned to the waterpump.When the engine is cold, the coolantcirculates through the cylinder block, cylinderhead, heater and inlet manifold. When thecoolant reaches a predetermined temperature,the thermostat opens, and the coolantthen passes through the top hose tothe radiator. As the coolant circulatesthrough the radiator, it is cooled by the inrushof air when the car is in forward motion.Airflow is supplemented by the action of theelectric cooling fan when necessary. Uponreaching the bottom of the radiator, thecoolant is now cooled, and the cycle isrepeated.When the engine is at normal operatingtemperature, the coolant expands, and someof it is displaced into the expansion tank. Thiscoolant collects in the tank, and is returned tothe radiator when the system cools.The electric cooling fan, mounted behindthe radiator, is controlled by a thermostaticswitch. At a predetermined coolanttemperature, the switch contacts close, thusactuating the fan.Heating/ventilation systemThe heating system consists of a blower fanand heater matrix (radiator) located in theheater unit, with hoses connecting the heatermatrix to the engine cooling system. Hotengine coolant is circulated through theheater matrix. Air is forced through the matrixby the three-speed fan, dispersing the heatinto the vehicle interior. Fresh air enters thevehicle through the grille slats between thewindscreen and the rear edge of the bonnet,and passes through to the heater casing.Depending on the position of the heater slidecontrols, which actuate cable-controlled flapvalves within the heater casing, the air isdistributed, either heated or unheated, via theducting to outlet vents. The main outlet ventsin the facia are adjustable. The airflow passesthrough the passenger compartment to exit atthe rear of the vehicle.PrecautionsWarning: DO NOT attempt toremove the expansion tank fillercap, or to disturb any part of thecooling system, while it or theengine is hot, as there is a very great riskof scalding. If the expansion tank filler capmust be removed before the engine andradiator have fully cooled down (eventhough this is not recommended) thepressure in the cooling system must firstbe released. Cover the cap with a thicklayer of cloth, to avoid scalding, and slowlyunscrew the filler cap until a hissing soundcan be heard. When the hissing hasstopped, showing that pressure isreleased, slowly unscrew the filler capfurther until it can be removed; if morehissing sounds are heard, wait until theyhave stopped before unscrewing the capcompletely. At all times, keep well awayfrom the filler opening.Warning: Do not allow antifreezeto come in contact with yourskin, or with the paintedsurfaces of the vehicle. Rinse offspills immediately with plenty of water.Never leave antifreeze lying around in anopen container, or in a puddle in thedriveway or on the garage floor. Childrenand pets are attracted by its sweet smell,but antifreeze can be fatal if ingested.Warning: If the engine is hot, theelectric cooling fan may startrotating even if the engine is notrunning, so be careful to keephands, hair and loose clothing well clearwhen working in the engine compartment.2 Antifreeze -general informationNote: Refer to the warnings given in Section 1of this Chapter before proceeding.The cooling system should be filled with awater/ethylene glycol-based antifreezesolution, of a strength which will preventfreezing down to at least -25ºC, or lower if thelocal climate requires it. Antifreeze alsoprovides protection against corrosion, andincreases the coolant boiling point.The cooling system should be maintainedaccording to the schedule described inChapter 1. If antifreeze is used that is not toFord’s specification, old or contaminatedcoolant mixtures are likely to cause damage,and encourage the formation of corrosion andscale in the system. Use distilled water with theantifreeze, if available - if not, be sure to useonly soft water. Clean rainwater is suitable.