Ford Fiesta Service And Repair Manual

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1•1

Chapter 1
Routine maintenance and servicing
Contents
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Front wheel alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Air cleaner temperature control check . . . . . . . . . . . . . . . . . . . . . . . .29 Gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Handbrake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Battery electrolyte level check . . . . . . . . . . . . . . .see “Weekly checks” Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . . .14
Battery terminal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 HT lead, distributor cap and ignition circuit check . . . . . . . . . . . . . . .13
Brake hydraulic fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Ignition timing and contact breaker gap (dwell angle) check
Brake hydraulic system seal and hose renewal . . . . . . . . . . . . . . . . .32 - OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Brake pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Choke adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Contact breaker point renewal and distributor lubrication Mixture adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
- OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Crankcase ventilation system check . . . . . . . . . . . . . . . . . . . . . . . . .28 Roadwheel security check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Emission control filter element renewal - CVH engines . . . . . . . . . . .30 Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Spark plug check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Engine idle speed check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Steering and suspension security check . . . . . . . . . . . . . . . . . . . . . .24
Engine valve clearance check - OHV engines . . . . . . . . . . . . . . . . . .18 Throttle damper operation check . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Timing belt renewal - CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . .34
Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks”
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks” Underbody inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 1
Front and rear brake pad/shoe check . . . . . . . . . . . . . . . . . . . . . . . . .4 Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . .see “Weekly checks”

Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult, Difficult, suitable for Very difficult,
novice with little
experience
1 for beginner with
some experience
2 suitable for competent
DIY mechanic
3 experienced DIY
mechanic
4 suitable for expert DIY
or professional
5
Servicing Specifications
Lubricants and fluids See end of “Weekly checks”

Capacities
Engine oil
With filter:
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints)
1.3,1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 litres (6.2 Imp pints)
Without filter:
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 litres (4.8 Imp pints)
1.3, 1.4 and 1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 Imp pints)
Cooling system (including heater)
1.0 and 1.1 OHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 litres (9.7 Imp pints)
1.3 and 1.4 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 litres (11.1 Imp pints)
1.6 CVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 litres (14.1 Imp pints)
Fuel tank
All models - pre 1985, except XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 litres (7.5 gallons)
XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 litres (8.4 gallons)
All models - 1985 on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 litres (8.8 gallons)
Gearbox
4-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 litres (4.9 Imp pints)
5-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 litres (5.5 Imp pints)

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1•2 Servicing Specifications
Engine
Oil filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104
Valve clearances (only OHV applicable):
Inlet:
At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in)
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 mm (0.008 to 0.010 in)
Exhaust:
At operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 mm (0.023 in)
Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 to 0.61 mm (0.022 to 0.024 in)

Cooling system
Drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.16 in) total deflection at the midpoint of the belt’s longest run

Fuel system
Air filter element type:
1.0 and 1.1 (OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W153
1.3 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W127
1.4 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W179
1.6 (CVH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W201

Ignition system
Spark plugs:
Make and type:
Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RS9YCC or RS9YC
Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC
Electrode gap:
RS9YCC and RC7YCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in)
RS9YC and RC7YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in)
Note: The spark plug gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other type are to
be fitted, refer to their manufacturer’s recommendations.
Contact breaker points gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.50 mm (0.016 to 0.020 in)
Dwell (mechanical ignition):
Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48° to 52°
Variation (from idle to 2000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4° maximum
Overlap (lobe-to-lobe variation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° maximum
Timing (initial):
1.0 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° BTDC
1.1 litre OHV (pre 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC
Ignition HT lead set:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 k ohms maximum per lead
Type:
Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 8 boxed set
Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion CLS 9 boxed set

Brakes
Front brake pad friction material minimum thickness . . . . . . . . . . . . . . 1.5 mm (0.059 in)
Rear brake shoe friction material minimum thickness . . . . . . . . . . . . . . 1.0 mm (0.04 in)

Tyres
Tyre sizes:
Note: Manufacturers often modify tyre sizes and pressure recommendations. The following is intended as a guide only. Refer to your vehicle
handbook or a Ford dealer for the latest recommendations.
XR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185/60 HR 13
Other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 SR 13, 155/70 SR 13 or 165/65 SR 13
Tyre pressures: See end of “Weekly checks”

Torque wrench settings Nm lbf ft

Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Radiator coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.1
Gearbox oil filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 74
Spark plugs:
OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 20 10 to 15
CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Brake caliper piston housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
 Maintenance schedule 1•3

The maintenance intervals in this manual wish to perform some of these procedures speeds (idling in traffic) or on short journeys,
are provided with the assumption that you will more often. We encourage frequent more frequent maintenance intervals are
be carrying out the work yourself. These are maintenance, because it enhances the recommended.
the minimum maintenance intervals efficiency, performance and resale value of When the vehicle is new, it should be
recommended by the manufacturer for your vehicle. serviced by a factory-authorised dealer
vehicles driven daily. If you wish to keep your If the vehicle is driven in dusty areas, used service department, in order to preserve the
vehicle in peak condition at all times, you may to tow a trailer, or driven frequently at slow factory warranty.

Every 250 miles (400 km) or weekly Every 12 000 miles (20 000 km) or
m Refer to “Weekly checks” 12 months - whichever comes sooner
(continued)
m Renew spark plugs (Section 21)
Every 6000 miles (10 000 km) or m Check gearbox oil level (Section 22)
6 months - whichever comes sooner m Renew distributor contact breaker points and
lubricate distributor - OHV engines (Section 23)
m Renew engine oil and filter (Section 3) m Check security and condition of steering and
m Check brake pads or shoes for wear (front and suspension components, gaiters and boots
rear) (Section 4) (Section 24)
m Check operation of brake fluid level warning m Inspect underbody and panels for corrosion or
indicator (Section 4) other damage (Section 25)
m Inspect engine bay and underside of vehicle for m Inspect brake pipes and hoses (Section 26)
fluid leaks or other signs of damage (Section 5) m Road test (Section 27)
m Check function and condition of seat belts m Check crankcase ventilation system (Section 28) 1
(Section 6)
m Check condition and security of exhaust system
(Section 7)
m Check tightness of wheel nuts (Section 8)
m Check choke adjustment (Section 9) Every 24 000 miles (40 000 km) or 2
m Check idle speed (Section 10)
m Check mixture adjustment (Section 11) years - whichever comes sooner
m Check spark plugs (Section 12) m Check air cleaner temperature control (Section 29)
m Check HT leads, distributor cap and ignition circuit m Renew emission control filter element - CVH
(Section 13) engines (Section 30)
m Check operation of latches, check straps and m Renew air cleaner element (Section 31)
locks; lubricate if necessary (Section 14)
m Check ignition timing and contact breaker gap
(dwell angle) (OHV engines) (Section 15)
m Check operation of throttle damper (where
applicable) (Section 16) Every 36 000 miles (60 000 km) or 3
years - whichever comes sooner
m Renew brake hydraulic system seals and hoses if
Every 12 000 miles (20 000 km) or necessary (Section 32)
m Renew brake hydraulic fluid (Section 33)
12 months - whichever comes sooner m Renew timing belt - CVH engines (Section 34)
m Check tightness of battery terminals, clean and m Check front wheel alignment (Section 35)
neutralise corrosion (Section 17)
m Check engine valve clearances - OHV engines
(Section 18)
m Check handbrake mechanism (Section 19)
m Check condition and tension of auxiliary drivebelt Every 2 years, regardless of mileage
(Section 20) m Renew coolant (Section 36)
1•4 Maintenance - component location
Engine compartment - OHV
1 Coolant expansion tank
2 Engine oil dipstick
3 Oil filter
4 Ignition coil
5 Brake fluid reservoir
6 Battery
7 Cooling fan
8 Oil filler cap
9 Carburettor (air cleaner removed)
10 Alternator
11 Washer reservoir

Engine compartment - CVH

1 Coolant expansion tank
2 Engine oil dipstick
3 Carburettor (air cleaner removed)
4 Fuel pump
5 Distributor
6 Ignition coil
7 Windscreen wiper motor
8 Ignition amplifier module
9 Battery
10 Brake fluid reservoir
11 Cooling fan
12 Oil filler cap
13 Washer reservoir
 Maintenance - component location 1•5

Underside view of car at front - CVH

1 Suspension arm
2 Driveshaft
3 Tie-bar
4 Alternator
5 Sump
6 Exhaust
7 Starter motor
8 Engine/gearbox bearer
9 Gearbox
10 Disc brake caliper
11 Gearchange rod and stabilizer rod

Underside view of car at rear

1 Rear silencer
2 Brake secondary cable
3 Fuel tank
4 Suspension coil spring
5 Shock absorber lower mounting
6 Panhard rod
7 Anti-roll bar (certain models only)
8 Towing eye
9 Axle beam
10 Exhaust system mounting
11 Handbrake adjustment check plunger
12 Suspension trailing arm
13 Brake pressure control valve
1•6 Maintenance procedures
The first step in this maintenance engine wear, conventional maintenance as
1 Introduction programme is to prepare yourself before the described in this Chapter will not greatly
actual work begins. Read through all the improve the performance of the engine, and
Sections relevant to the work to be carried may prove a waste of time and money, unless
out, then make a list and gather together all extensive overhaul work is carried out first.
This Chapter is designed to help the home the parts and tools required. If a problem is The following series of operations are those
mechanic maintain his/her vehicle for safety, encountered, seek advice from a parts most often required to improve the
economy, long life and peak performance. specialist, or a dealer service department. performance of a generally poor-running
The Chapter contains a master engine:
maintenance schedule, followed by Sections 2 Intensive maintenance Primary operations
dealing specifically with each task in the a) Clean, inspect and test the battery
schedule. Visual checks, adjustments, b) Check all the engine-related fluids
component renewal and other helpful items c) Check the condition and tension of the
are included. Refer to the accompanying If, from the time the vehicle is new, the auxiliary drivebelt
illustrations of the engine compartment and routine maintenance schedule is followed d) Renew the spark plugs
the underside of the vehicle for the locations closely, and frequent checks are made of fluid e) Inspect the distributor cap and HT leads -
of the various components. levels and high-wear items, as suggested as applicable
Servicing your vehicle in accordance with throughout this manual, the engine will be f) Check the condition of the air cleaner
the mileage/time maintenance schedule and kept in relatively good running condition, and filter element, and renew if necessary
the following Sections will provide a planned the need for additional work will be minimised. g) Renew the fuel filter (if fitted)
maintenance programme, which should result It is possible that there will be times when h) Check the condition of all hoses, and
in a long and reliable service life. This is a the engine is running poorly due to the lack of check for fluid leaks
comprehensive plan, so maintaining some regular maintenance. This is even more likely i) Check the idle speed and mixture settings
items but not others at the specified service if a used vehicle, which has not received - as applicable
intervals, will not produce the same results. regular and frequent maintenance checks, is If the above operations do not prove fully
As you service your vehicle, you will purchased. In such cases, additional work effective, carry out the following secondary
discover that many of the procedures can - may need to be carried out, outside of the operations:
and should - be grouped together, because of regular maintenance intervals.
the particular procedure being performed, or If engine wear is suspected, a compression Secondary operations
because of the close proximity of two test will provide valuable information a) Check the charging system
otherwise-unrelated components to one regarding the overall performance of the main b) Check the ignition system
another. For example, if the vehicle is raised internal components. Such a test can be used c) Check the fuel system
for any reason, the exhaust can be inspected as a basis to decide on the extent of the work d) Renew the distributor cap and rotor arm -
at the same time as the suspension and to be carried out. If, for example, a as applicable
steering components. compression test indicates serious internal e) Renew the ignition HT leads - as applicable

6000 Mile (10 000 Km) / 6 Month Service

up and supported on axle stands (see 6 Move the container into position under the
3 Engine oil and filter renewal
1 “Jacking and vehicle support”). Whichever
method is chosen, make sure that the vehicle
remains level, or if it is at an angle, so that the
drain plug is at the lowest point.
oil filter.
7 Using an oil filter removal tool if necessary,
slacken the filter initially, then unscrew it by
hand the rest of the way (see illustration).
1 Frequent oil and filter changes are the most 3 Slacken the drain plug about half a turn (see Empty the oil from the old filter into the
important preventative maintenance illustration). Position the draining container container, and discard the filter.
procedures which can be undertaken by the under the drain plug, then remove the plug 8 Use a clean rag to remove all oil, dirt and
DIY owner. As engine oil ages, it becomes completely. If possible, try to keep the plug sludge from the filter sealing area on the
diluted and contaminated, which leads to pressed into the sump while unscrewing it by engine. Check the old filter to make sure that
premature engine wear. hand the last couple of turns. Recover the the rubber sealing ring hasn’t stuck to the
2 Before starting this procedure, gather sealing washer from the drain plug. engine. If it has, carefully remove it.
together all the necessary tools and materials.
Also make sure that you have plenty of clean Remove the engine oil drain
rags and newspapers handy, to mop up any plug quickly so that the
spills. Ideally, the engine oil should be warm, stream of oil runs into the
as it will drain better, and more built-up container, not up your sleeve!
sludge will be removed with it. Take care,
however, not to touch the exhaust or any
other hot parts of the engine when working 4 Allow some time for the old oil to drain,
under the vehicle. To avoid any possibility of noting that it may be necessary to reposition
scalding, and to protect yourself from the container as the oil flow slows to a trickle.
possible skin irritants and other harmful 5 After all the oil has drained, wipe off the
contaminants in used engine oils, it is drain plug with a clean rag. Check the sealing
advisable to wear gloves when carrying out washer for condition, and renew it if
this work. Access to the underside of the necessary. Clean the area around the drain
vehicle will be greatly improved if it can be plug opening, and refit the plug. Tighten the 3.3 Removing the sump drain plug
raised on a lift, driven onto ramps, or jacked plug to the specified torque.
 Every 6000 miles or 6 months 1•7

12 Start the engine and run it for a few 4 The rear brake shoe friction material can be
minutes; check for leaks around the oil filter inspected for wear without removing the
seal and the sump drain plug. Note that there roadwheels. Working beneath the vehicle,
may be a delay of a few seconds before the oil prise the plug from the brake backplate and
pressure warning light goes out when the using an inspection lamp or torch, check that
engine is first started, as the oil circulates the friction material thickness is not less than
through the engine oil galleries and the new oil the minimum given in the Specifications (see
filter, before the pressure builds up. illustrations). If any one of the shoes has
13 Switch off the engine, and wait a few worn below the specified limit, the shoes must
minutes for the oil to settle in the sump once be renewed as an axle set (4 shoes).
more. With the new oil circulated and the filter 5 At the same interval, check the function of
completely full, recheck the level on the the brake fluid level warning light. Chock the
dipstick, and add more oil as necessary. wheels, release the handbrake and switch on
3.7 Removing the engine oil filter with a 14 Dispose of the used engine oil safely. the ignition. Unscrew and raise the brake fluid
clamp wrench reservoir cap whilst an assistant observes the
warning light: it should come on as the level
9 Apply a light coating of clean engine oil to
the sealing ring on the new filter, then screw it
into position on the engine. Tighten the filter
4 Front and rear brake
pad/shoe check 1 sensor is withdrawn from the fluid. Refit the
cap.
6 On completion, refit the wheels and lower
firmly by hand only - do not use any tools. the car to the ground.
Wipe clean the filter and sump drain plug. 1 Firmly apply the handbrake, then jack up
10 Remove the old oil and all tools from the front and rear of the car and support it
securely on axle stands (see “Jacking and
under the car, then lower the car to the
ground (if applicable).
11 Remove the oil filler cap and withdraw the
dipstick. Fill the engine, using the correct
vehicle support”).
2 For a quick check, the front brake disc pads
can be inspected without removing the front
5 Fluid leak check
1
wheels by inserting a mirror between each
grade and type of oil (see “Lubricants and
caliper and roadwheel (see illustrations). If
fluids” and “Capacities” in the Specifications).
any one pad is worn down to the minimum
An oil can spout or funnel may help to reduce Leaks in the cooling system
specified thickness, all four pads (on both
spillage. Pour in half the specified quantity of will usually show up as
front wheels) must be renewed.
oil first, then wait a few minutes for the oil to 3 For a comprehensive check, the brake disc white or rust-coloured
fall to the sump. Continue adding oil a small pads should be removed and cleaned. The deposits around the area 1
quantity at a time until the level is up to the operation of the caliper can then also be adjoining the leak.
lower mark on the dipstick. Finally, bring the checked, and the condition of the brake discs
level up to the upper mark on the dipstick. can be fully examined on both sides. Refer to 1 Visually inspect the engine joint faces,
Insert the dipstick, and refit the filler cap. Chapter 9 for further information. gaskets and seals for any signs of water or oil
leaks. Pay particular attention to the areas
around the rocker cover, cylinder head, oil
filter and sump joint faces. Bear in mind that
over a period of time some very slight
seepage from these areas is to be expected
but what you are really looking for is any
indication of a serious leak. Should a leak be
found, renew the offending gasket or oil seal
by referring to the appropriate Chapter(s) in
this manual.
2 Similarly, check the transmission for oil
leaks, and investigate and rectify and
problems found.
3 Check the security and condition of all the
4.2a Using a mirror to check disc brake 4.2b Inspect the disc brake pads through engine related pipes and hoses. Ensure that
pads for wear the caliper housing aperture all cable-ties or securing clips are in place and
in good condition. Clips which are broken or
missing can lead to chafing of the hoses,
pipes or wiring which could cause more
serious problems in the future.
4 Carefully check the condition of all coolant,
fuel and brake hoses. Renew any hose which
is cracked, swollen or deteriorated. Cracks
will show up better if the hose is squeezed.
Pay close attention to the hose clips that
secure the hoses to the system components.
Hose clips can pinch and puncture hoses,
resulting in leaks. If wire type hose clips are
used, it may be a good idea to replace them
with screw-type clips.
4.4a Remove the inspection plug from the 4.4b . . . to check the rear brake linings for 5 With the vehicle raised, inspect the fuel
rear brake backplate . . . wear tank and filler neck for punctures, cracks and
1•8 Every 6000 miles or 6 months
other damage. The connection between the
filler neck and tank is especially critical.
Sometimes a rubber filler neck or connecting
hose will leak due to loose retaining clamps or
deteriorated rubber.
6 Similarly, inspect all brake hoses and metal
pipes. If any damage or deterioration is
discovered, do not drive the vehicle until the
necessary repair work has been carried out.
Renew any damaged sections of hose or pipe.
7 Carefully check all rubber hoses and metal
fuel lines leading away from the petrol tank.
Check for loose connections, deteriorated
hoses, crimped lines and other damage. Pay 7.1 Inspect the exhaust system rubber
particular attention to the vent pipes and mounting
hoses which often loop up around the filler
neck and can become blocked or crimped.
Follow the lines to the front of the vehicle
carefully inspecting them all the way. Renew
damaged sections as necessary.
9 Choke adjustment check
2 10.2 Ford 1V carburettor idle speed screw
(A) and mixture screw (B)

8 From within the engine compartment,

On models equipped with carburettors of Ford VV carburettor
check the security of all fuel hose attachments
Ford manufacture, refer to Chapter 4, Section 3 This procedure must be carried out with the
and pipe unions, and inspect the fuel hoses 9 and check that the choke is adjusted within radiator cooling fan in operation. To keep the
and vacuum hoses for kinks, chafing and the stated parameters. fan running during the adjustment procedure,
deterioration.
disconnect the wiring multi-plug from the
9 Check the condition of all exposed wiring
thermal switch (located in the thermostat
harnesses.

6 Seat belt check

10 Engine idle speed check
3 housing) and bridge the two contacts in the
plug with a short length of wire (see
illustration). Disconnect the wire and refit the
1 Note: Refer to the precautions given in
Section 1 of Chapter 4 before proceeding.
multi-plug on completion of the adjustments.
Make sure that the engine and ignition are
switched off when connecting and
Note: Before carrying out any carburettor disconnecting the bridging wire.
1 Periodically check the belts for fraying or adjustments, ensure that the ignition timing
other damage. If evident, renew the belt. 4 Ensure that the air cleaner is correctly fitted,
and spark plug gaps are set as specified. To
and that all vacuum hoses and pipes are
2 If the belts become dirty, wipe them with a carry out this adjustment, an accurate
securely connected and free from restrictions,
damp cloth using a little detergent only. tachometer will be required.
then run the engine until it is at normal
3 Check the tightness of the anchor bolts and
if they are ever disconnected, make quite sure
Ford 1V carburettor operating temperature.
1 Ensure that the air cleaner is correctly fitted, 5 With the engine at normal operating
that the original sequence of fitting of
and that all vacuum hoses and pipes are temperature, connect a tachometer in
washers, bushes and anchor plates is
securely connected and free from restrictions, accordance with the manufacturer’s
retained.
then run the engine until it is at normal instructions.
operating temperature. 6 Start the engine, run it at 3000 rpm for 30
7 Exhaust system check seconds and then let it idle. Turn the idle

1
2 With the engine at normal operating
temperature, adjust the idle speed screw (see speed adjusting screw in or out as necessary
illustration) to obtain the specified idle speed, to bring the speed to that given in the Specifi-
using a tachometer to ensure accuracy. cations (see illustration).
With the vehicle raised on a hoist or
supported on axle stands (see “Jacking and
vehicle support”), check the exhaust system
for signs of leaks, corrosion or damage and
check the rubber mountings for condition and
security (see illustration). Where damage or
corrosion are evident, renew the system
complete or in sections, as applicable, using
the information given in Chapter 4.

8 Roadwheel security check

1
With the wheels on the ground, slacken
each wheel bolt by a quarter turn, then
retighten it immediately to the specified 10.3 Temporary bridging wire in cooling 10.6 Ford VV carburettor idle speed screw
torque. fan thermal switch multi-plug (A) and mixture screw (B)
 Every 6000 miles or 6 months 1•9

10.7 Weber 2V carburettor idle speed 10.10 Weber 2V DFTM carburettor mixture 10.11 Weber 2V TLD carburettor mixture
screw (A) and mixture screw (B) screw (A) and idle speed screw (B) screw (A) and idle speed screw (B)

Weber 2V carburettor 6 Turn the idle mixture screw in the desired

7 Refer to the information relating to the Ford
1V carburettor for details, and to the
accompanying illustration (see illustration)
11 Mixture adjustment check
3 direction to achieve the fastest possible
engine speed consistent with smooth, even
running or the correct specified CO reading
on the meter scale.
for the adjusting screws. Ensure that the 7 If necessary, readjust the idle speed setting
Note: Refer to the precautions given in
engine fan is operating by pulling the two on completion. Fit a new tamperproof plug to
Section 1 of Chapter 4 before proceeding.
wires from the sensor, and connecting the the mixture screw.
Note: Before carrying out any carburettor
wires with a jumper lead. adjustments, ensure that the ignition timing Ford VV carburettor
Weber 2V DFTM and spark plug gaps are set as specified. To
8 This procedure must be carried out with the
carry out the adjustments an accurate
8 Before carrying out this adjustment, ensure radiator cooling fan in operation. To keep the
tachometer and an exhaust gas analyser (CO
that the air cleaner is correctly fitted and that fan running during the adjustment procedure,
meter) will be required. Adjustment of the idle
all vacuum hoses and pipes are securely mixture setting should not be attempted in
disconnect the wiring multi-plug from the 1
connected and free from restrictions. Run the thermal switch (located in the thermostat
territories where this may cause a violation of
housing) and bridge the two contacts in the
engine until it is at normal operating exhaust emission regulations. Where these
plug with a short length of wire. Disconnect
temperature. regulations are less stringent the following
the wire and refit the multi-plug on completion
9 The cooling fan must be kept running procedures may be used.
of the adjustments. Make sure that the engine
during the adjustment procedure. To do this, Ford 1V carburettor and ignition are switched off when connecting
disconnect the wiring multi-plug from the and disconnecting the bridging wire.
thermal switch (located in the thermostat 1 Ensure that the air cleaner is correctly fitted
9 To adjust the mixture accurately, connect a
housing) and bridge the two contacts in the and that all vacuum hoses and pipes are
CO (exhaust gas) analyser and a tachometer
securely connected and free from restrictions,
plug with a short length of wire. in accordance with the manufacturer’s
then run the engine until it is at normal
10 Start the engine and turn the idle speed instructions.
operating temperature. 10 Ensure that the air cleaner is correctly
adjustment screw (see illustration) to obtain
2 Using a small screwdriver, prise out the fitted and that all vacuum hoses and pipes are
the specified idle speed, using a tachometer tamperproof plug (if fitted) over the idle
to ensure accuracy. securely connected and free from restrictions,
mixture screw. then run the engine until it is at normal
Weber 2V TLD carburettor 3 Connect the CO meter and tachometer operating temperature.
according to the manufacturer’s instructions. 11 Using a thin, sharp screwdriver, prise out
11 Refer to the information relating to the 4 Adjust the idle speed to the specified setting. the tamperproof plug which covers the
Weber 2V DFTM carburettor for details, and to 5 Run the engine at 3000 rpm for 30 seconds mixture screw.
the accompanying illustration (see illustration) to clear the inlet manifold of excess fuel. 12 Start the engine and run it at 3000 rpm for
for the adjusting screws. Repeat this operation every 30 seconds 30 seconds, then allow it to return to idle. Turn
Weber (1V) TLM carburettor during the adjustment procedure. the mixture screw in (weak) or out (rich) until
the CO level is within the specified range as
12 Before carrying out this adjustment, indicated on the analysing equipment. The
ensure that the air cleaner is correctly fitted adjustment must be carried out within 30
and that all vacuum hoses and pipes are seconds; otherwise, again increase the engine
securely connected and free from restrictions. speed for 30 seconds before continuing with
Run the engine until it is at normal operating the adjustment.
temperature. 13 Once the mixture is correct, adjust the idle
13 Connect a reliable tachometer to the speed then recheck the mixture.
engine in accordance with the manufacturer’s 14 Switch off the engine and remove the
instructions. tachometer and the exhaust gas analyser. Fit
14 Increase the engine speed to 3000 rpm a new tamperproof plug to the mixture screw.
and hold it at this speed for 30 seconds, then 15 In the absence of a suitable exhaust gas
analyser, an approximate setting of the
allow the engine to idle. Adjust the idle speed
mixture screw may be made by turning the
to within the specified range by turning the 10.14 Weber (1V) TLM carburettor idle screw inwards (engine idling) until the idle
idle speed screw (see illustration). speed screw (A) and mixture screw (B) speed just begins to drop. Unscrew the screw
Ford Fiesta Service And Repair Manual
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1•10 Every 6000 miles or 6 months
the smallest amount necessary to achieve
smooth idle. The CO level of the exhaust gas
should be checked by your dealer at the
earliest opportunity and further adjustment
carried out as may be necessary.
Weber 2V carburettor
16 Refer to the information relating to the
Ford 1V carburettor for details. Ensure that
the engine fan is operating by pulling the two
wires from the sensor, and connecting the
wires with a jumper lead.
Weber 2V DFTM carburettor
12.1a Clean around each spark plug . . . 12.1b . . . before using a socket to remove
17 The cooling fan must be kept running
the spark plugs
during the adjustment procedure. To do this,
disconnect the wiring multi-plug from the 27 With the engine at normal operating necessary and should not be attempted unless
thermal switch (located in the thermostat temperature, connect a tachometer and specialised equipment is available as damage
housing) and bridge the two contacts in the exhaust gas analyser in accordance with the can easily be caused to the firing ends.
plug with a short length of wire. manufacturer’s instructions. 4 The appearance of a removed spark plug
18 Ensure that the air cleaner is correctly 28 Prise out the tamperproof plug from the can give some indication of the condition or
fitted and that all vacuum hoses and pipes are mixture screw hole in the throttle valve block. state of tune of the engine, but as modern
securely connected and free from restrictions, 29 Wait for the radiator cooling fan to engines run on a weaker fuel/air mixture in
then run the engine until it is at normal operate, then raise the engine speed to 3000 order to conform to current emission control
operating temperature. rpm, hold it at this speed for 30 seconds, regulations, a rather whiter appearance of the
19 Using a small screwdriver, prise out the return to idle and check the exhaust CO level spark plug electrode area must be expected
tamperproof plug (if fitted) over the idle on the exhaust gas analyser. If it is not as than was the case on older cars. As the
mixture screw. specified, turn the mixture screw (clockwise to mixture control is preset during production, a
20 Connect the CO meter and tachometer weaken) and repeat the checking procedure. black appearance of the plug electrode will
according to the manufacturer’s instructions. 30 On completion, fit a new tamperproof normally be due to oil passing worn piston
21 Adjust the idle speed to the correct setting. plug. rings or valve stem oil seals, unless the
22 Run the engine at 3000 rpm for 30 carburettor has been tampered with.
seconds to clear the inlet manifold of excess
5 When installing the plugs use a long reach

1
fuel. Repeat this operation every 30 seconds 12 Spark plug check socket, apply a little grease to the threads of the
during the adjustment procedure.
plugs (see illustration) and tighten them only to
23 Turn the idle mixture screw in the desired
the specified torque wrench setting. Overtight-
direction to achieve the fastest possible
ening may damage the plug or its seat.
engine speed consistent with smooth, even
1 Pull the HT lead from each plug by grasping
running; or the correct specified CO reading
the end connector. Clean around each spark
on the meter scale.
plug (see illustration). Remove each plug
24 If necessary, readjust the idle speed
(see illustration) and check its electrode gap,
setting. Refit the cooling fan multi-plug and fit
a new tamperproof plug. which should be within the limits stated in
Specifications.
Weber 2V TLD carburettor 2 To adjust the gap, bend the outer electrode
25 Refer to the information relating to the with a proper spark plug gapping tool.
Weber 2V DFTM carburettor for details. Recheck the gap using feeler blades or wire
gauges (see illustrations).
Weber (1V) TLM carburettor 3 Note that the correct functioning of each
26 Ensure that the air cleaner is correctly plug is vital for the correct running and
fitted and that all vacuum hoses and pipes are efficiency of the engine. It is essential that the
securely connected and free from restrictions, plugs fitted are appropriate for the engine and
then run the engine until it is at normal the suitable type is specified at the beginning 12.2a Measuring a spark plug electrode
operating temperature. of this Chapter. Spark plug cleaning is rarely gap with a feeler blade

12.2b Measuring a spark plug electrode 12.2c Adjusting a spark plug electrode 12.5 Lightly grease the spark plug threads
gap with a wire gauge gap with a special tool before fitting

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