Chapter 1 Routine maintenance and servicing

Cooling, heating and ventilation systems 3•56 Unscrew the nut securing the cooling fanshroud to the radiator, noting the insulatingwasher arrangement, then lift the fan shroudand motor assembly from the vehicle (seeillustration).7 To separate the fan from the motor shaft,first remove its retaining clip and washer, thenwithdraw the fan (see illustration). A new clipwill be needed upon reassembly. Remove thethree nuts securing the motor to the shroudand separate the two components.Turbo models8 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).9 Undo the two retaining screws and movethe HT lead bracket clear of the working area,disconnecting the HT leads as required.10 Disconnect the fan motor wiring multiplugand the two auxiliary lamp wiring multiplugs.Unclip the wiring from any localretaining clips.11 Remove the front bumper as described inChapter 11.12 Undo the two lower fan shroud retainingbolts, release the shroud upper locatingtongue from the radiator and withdraw theassembly from the front of the car.13 To separate the fan from the motor shaft,pull off the fan guard from the shroud, flattenback the raised lockwasher tab, and unscrewclockwise (a left-hand thread is employed)the nut securing the fan to the motor shaft.Remove the fan then undo the three nutssecuring the motor to the shroud andseparate the two components.RefittingAll models14 Refitting is a reversal of the removalprocedure. On non-Turbo models, ensure thatthe locating tags on the base of the shroudlocate correctly in their slots in the bodycrossmember. On Turbo models, if the fanwas removed, use a new lockwasher whenrefitting. On all models, ensure that the wiringconnections are cleanly and securely made,and locate the loom in the retaining clips.6 Cooling system electricalswitches and sensors -2testing, removal and refittingNote: Refer to the warnings given in Section 1of this Chapter before starting work.Coolant temperature gaugesenderTesting1 If the coolant temperature gauge isinoperative, check the fuses first (see Chapter12).2 If the gauge indicates overheating at anytime, consult the “Fault finding” section at theend of this manual, to assist in tracingpossible cooling system faults.5.6 Radiator cooling fan shroud securingnut (arrowed)3 If the gauge indicates overheating shortlyafter the engine is started from cold,disconnect the temperature gauge sender’swiring multi-plug. The sender is located belowthe thermostat housing on HCS engines,adjacent to the thermostat housing on CVHand PTE engines, and on the forward-facingside of the thermostat housing on Zetecengines. If the gauge reading now drops,renew the sender. If the reading remains high,the wire to the gauge may be shorted to earth,or the gauge is faulty.4 If the gauge fails to indicate after the enginehas been warmed up (approximately10 minutes) and the fuses are known to besound, switch off the engine. Disconnect thesender’s wiring multi-plug, and use a jumperwire to ground the connector to a clean earthpoint (bare metal) on the engine. Switch onthe ignition without starting the engine.If the gauge now indicates Hot, renew thesender.5 If the gauge still does not work, the circuitmay be open, or the gauge may be faulty. SeeChapter 12 for additional information.Removal6 Refer to the relevant Part of Chapter 4 andremove the air cleaner or air inlet hoses,according to engine type as necessary, togain access to the sender unit.7 Drain the cooling system (see Chapter 1).8 On Zetec engines, disconnect theexpansion tank coolant hose and the radiatortop hose from the thermostat housing’s wateroutlet.9 Disconnect the wiring multi-plug from thesender unit.10 Unscrew the sender and withdraw it.Refitting11 Clean as thoroughly as possible thesender unit location, then apply a light coat ofsealant to the sender’s threads. Screw in thesender, tighten it to the specified torque, andreconnect the wiring multi-plug.12 Reconnect the hoses, and refit anycomponents disconnected for access. Refillor top-up the cooling system (see “WeeklyChecks” or Chapter 1) and run theengine. Check for leaks and proper gaugeoperation.5.7 Nuts securing fan motor to shroud (A),and shroud to body crossmember locatingtags (B). Inset shows fan to motor shaftretaining clip (arrowed)Engine coolant temperaturesensorTesting13 Disconnect the battery negative (earth)lead (see Chapter 5A, Section 1).14 Locate the coolant temperature sensor,which will be found below the inlet manifoldon HCS engines, on the side or centre of theinlet manifold on CVH and PTE engines, or ontop of the thermostat housing on Zetecengines. Once located, refer to the relevantPart of Chapter 4 and remove the air cleaneror air inlet hoses, according to engine type asnecessary, to improve access to the sensorunit.15 Disconnect the wiring multi-plug from thesensor.16 Using an ohmmeter, measure theresistance between the sensor terminals.Depending on the temperature of the sensortip, the resistance measured will vary, butshould be within the broad limits given in theSpecifications of this Chapter. If the sensor’stemperature is varied - by removing it (seebelow) and placing it in a freezer for a while, orby warming it gently - its resistance shouldalter accordingly.17 If the results obtained show the sensor tobe faulty, renew it.18 On completion, reconnect the wiringmulti-plug and refit any components removedfor access, then reconnect the battery.Removal19 Disconnect the battery negative (earth)lead (see Chapter 5A, Section 1).20 Locate the sensor as describedpreviously, and remove any components asnecessary for access.21 Drain the cooling system (see Chapter 1).22 Disconnect the wiring multi-plug from thesensor.23 Unscrew the sensor and withdraw it.Refitting24 Clean as thoroughly as possible thesensor location, then apply a light coat ofsealant to the sensor’s threads. Refit andtighten the sensor to the specified torque31595Ford Fiesta Remake