1989 FORD FIESTA brake sensor

4D
1595Ford Fiesta Remake
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . Sequential Electronic Fuel injection (SEFi)
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 1.4 litre PTE engines and 1.6 and 1.8 litre Zetec engines
Fuel grade
Fuel octane requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 95 RON unleaded
Fuel pressure
Regulated fuel pressure:*Pressure regulator vacuum hose disconnected . . . . . . . . . . . . . . . . . 2.7 ± 0.2 bars
With engine running and pressure regulator vacuum hose connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 2.1 ± 0.2 bars
Hold pressure - engine stopped after five minutes* . . . . . . . . . . . . . . . . 1.8 bars minimum
*The figures quoted are specific to Zetec engines. No values are quoted \
by the manufacturer for PTE engines, however they are likely to be similar.
Torque wrench settingsNm lbf ft
PTE engines
Inlet air duct to cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Inlet manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13
Inlet manifold upper to lower sections . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13
Inlet air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Fuel rail-to-lower inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Camshaft position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
6 4
Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 60 44
Zetec engines
Throttle housing-to-inlet manifold screws . . . . . . . . . . . . . . . . . . . . . . . 9 7
Inlet manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13
Idle speed control valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4
Inlet air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Fuel pressure regulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4
Fuel injector bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 6 4
Fuel rail-to-inlet manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Camshaft position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
8 6
Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 60 44
Chapter 4 Part D: Fuel system -
sequential electronic fuel injection engines
Accelerator cable - removal, refitting and adjustment . . . . . . . . . . . 5
Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Air cleaner assembly and air inlet components - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 4
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel cut-off switch - removal and refitting . . . . . . . . . . . . . . . . . . . . 12
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .See Chapter 1
Fuel injection system - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injection system components - removal and refitting . . . . . . . . 14
Fuel lines and fittings - general information . . . . . . . . . . . . . . . . . . . 3
Fuel pump/fuel gauge sender unit - removal and refitting . . . . . . . . 9 Fuel pump/fuel pressure - checking . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel system - depressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 8
Fuel tank filler pipe - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
Fuel tank ventilation tube - removal and refitting . . . . . . . . . . . . . . . 10
General fuel system checks . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 15
Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See\
Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
4D•1
Specifications Contents
Easy,
suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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12
1595Ford Fiesta Remake
Fuses - pre-1992 models
Main fuse board:
No Rating (amps) Circuit(s) protected
1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . Electronic engine control system
2 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Interior light, cigarette lighter, clock and radio memory
3 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Central locking system
4 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated rear window element
5 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Dim-dip lighting
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand side lights and rear fog light
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand side lights
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand dipped beam
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand dipped beam
10 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand main beam and right-hand auxiliary driving light
11 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand main beam and left-hand auxiliary driving light
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heater fan motor and reversing light
13 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Radiator cooling fan motor
14 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Front foglights (XR2i only)
15 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Horn
16 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Wiper motor and windscreen/tailgate washer pump
17 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Brake stop lights, instrument illumination and instrument warning
18 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electrically operated windows
19 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electric fuel pump
20 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Oxygen sensor (vehicles with catalytic converter)
21 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand direction indicators
22 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand direction indicators
Chapter 12
Body electrical systems
Air bag (driver’s side) - removal and refitting . . . . . . . . . . . . . . . . . . 28
Air bag (passenger’s side) - removal and refitting . . . . . . . . \
. . . . . . . 29
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 31
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 30
Anti-theft systems - general information . . . . . . . . . . . . . . . . . . . . . . 27
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . . .See
“Weekly checks”
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cigarette lighter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 12
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electric window regulator motor - removal and refitting . . . . . . . . . . 20
Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . 2
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses and relays - general information . . . . . . . . . . . . . . . . . . . . . . . 3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight and auxiliary light beam alignment - checking and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 8
Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel components - removal and refitting . . . . . . . . . . . 10
“Lights-on” warning module - removal and refitting . . . . . . . . . . . . . 26
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . 22
Screen washer fluid level check . . . . . . . . . . . . . .See
“Weekly checks”
Speaker balance control joystick - removal and refitting . . . . . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate remote release motor - removal and refitting . . . . . . . . . . . 21
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 18
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Windscreen wiper pivot shaft - removal and refitting . . . . . . . . . . . . 17
Windscreen/tailgate washer system components - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 19
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
12•1
Specifications Contents
Easy,suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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1595 Ford Fiesta Remake
REF•16Fault finding
Cooling system
Overheating
m
mInsufficient coolant in system (Chapter 1).
m
m Thermostat faulty (Chapter 3).
m
m Radiator core blocked or grille restricted (Chapter 3).
m
m Radiator electric cooling fan(s) or coolant temperature sensor
faulty Chapter 3).
m m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Pressure cap faulty (Chapter 3).
m
m Auxiliary drivebelt worn or slipping (Chapter 1).
m
m Inaccurate coolant temperature gauge sender (Chapter 3).
m
m Airlock in cooling system (Chapter 1).
Overcooling
m
mThermostat faulty (Chapter 3).
m
m Inaccurate coolant temperature gauge sender (Chapter 3).
External coolant leakage
m
mDeteriorated or damaged hoses or hose clips (Chapter 1).
m
m Radiator core or heater matrix leaking (Chapter 3).
m
m Pressure cap faulty (Chapter 3).
m
m Water pump seal leaking (Chapter 3).
m
m Boiling due to overheating (Chapter 3).
m
m Core plug leaking (Chapter 2D).
Internal coolant leakage
m
mLeaking cylinder head gasket (Chapters 2A, 2B or 2C).
m
m Cracked cylinder head or cylinder bore (Chapter 2D).
Corrosion
m
mInfrequent draining and flushing (Chapter 1).
m
m Incorrect antifreeze mixture, or inappropriate antifreeze type
(Chapters 1 and 3).
Engine (continued)
Engine hesitates on acceleration
m
m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D, 4E or 5B).
Engine stalls
m mEngine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E,
or 5B).
m m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
m m Fuel filter choked (Chapter 1).
m
m Fuel pump faulty or delivery pressure low (Chapters 4A, 4B, 4C
or 4D).
m m Fuel tank vent blocked or fuel pipes restricted (Chapters 4A, 4B,
4C. 4D or 4E).
Engine lacks power
m mEngine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Timing chain or belt incorrectly fitted or incorrectly tensioned
(Chapters 2A, 2B or 2C).
m m Fuel filter choked (Chapter 1).
m
m Fuel pump faulty or delivery pressure low (Chapters 4A, 4B, 4C
or 4D).
m m Uneven or low cylinder compressions (Chapters 2A, 2B or 2C).
m
m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
m m Brakes binding (Chapters 1 and 9).
m
m Clutch slipping (Chapter 6).
m
m Automatic transmission fluid level incorrect (Chapter 1).
Oil pressure warning light illuminated with engine
running
m mLow oil level or incorrect oil grade (Chapter 1).
m
m Faulty oil pressure warning light switch (Chapters 2A, 2B or 2C).
m
m Worn engine bearings and/or oil pump (Chapters 2A, 2B, 2C
or 2D).
m m High engine operating temperature (Chapter 3).
m
m Oil pressure relief valve defective (Chapters 2A, 2B or 2C).
m
m Oil pick-up strainer clogged (Chapters 2A, 2B or 2C).
Engine backfires
m
mEngine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Timing chain or belt incorrectly fitted or incorrectly tensioned
(Chapters 2A, 2B or 2C).
m m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
Engine runs-on after switching off
m mIdle speed excessively high (Chapters 4A, 4B, 4C or 4D).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Excessive carbon build-up in engine (Chapters 2A, 2B or 2C).
m
m High engine operating temperature (Chapter 3).
Engine noises
Pre-ignition (pinking) or knocking during acceleration or
under load
m mIncorrect grade of fuel (Chapters 4A, 4B, 4C or 4D).
m
m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
m m Excessive carbon build-up in engine (Chapters 2A, 2B or 2C).
Whistling or wheezing noises
m
mLeaking inlet manifold gasket (Chapters 4A, 4B, 4C, 4D).
m
m Leaking exhaust manifold gasket or downpipe-to-manifold joint
(Chapter 4E).
m m Leaking vacuum hose (Chapters 1, 4A, 4B, 4C, 4D, 4E or 9).
m
m Blowing cylinder head gasket (Chapters 2A, 2B or 2C).
Tapping or rattling noises
m
mIncorrect valve clearance adjustment (Chapter 2A).
m
m Faulty hydraulic tappet(s) (Chapters 2B or 2C).
m
m Worn valve gear or camshaft (Chapters 2A, 2B, 2C or 2D).
m
m Worn timing chain, belt or tensioner (Chapters 2A, 2B or 2C).
m
m Ancillary component fault (water pump, alternator, etc) (Chapters 3
and 5A).
Knocking or thumping noises
m mWorn big-end bearings (regular heavy knocking, perhaps less
under load) Chapter 2D).
m m Worn main bearings (rumbling and knocking, perhaps worsening
under load) Chapter 2D).
m m Piston slap (most noticeable when cold) (Chapter 2D).
m
m Ancillary component fault (water pump, alternator, etc) (Chapters 3
and 5A).
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1595 Ford Fiesta Remake
Glossary of technical termsREF•25
REF
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV) A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
Locknut A nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
Lockwasher A form of washer designed to
pr event an attaching nut from working loose.
MMacPherson strut A type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
cr eates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location. Multimeter An electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOx Oxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhm The unit of electrical resistance. One
volt applied to a resistance of one ohm will
pr oduce a current of one amp.
Ohmmeter An instrument for measuring
electrical resistance.
O-ring A type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action. Overhead cam (ohc) engine
An engine with
the camshaft(s) located on top of the cylinder
head(s).
Overhead valve (ohv) engine An engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensor A device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screw A type of screw head having a
cr oss instead of a slot for a corresponding
type of screwdriver.
Plastigage A thin strip of plastic thread,
available in different sizes, used for measuring clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts areassembled and dismantled; the width of the
crushed strip indicates the clearance between
jour nal and bearing.
Pr opeller shaft The long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential on front-engined rear wheel drive vehicles.
Pr oportioning valve A hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steering A steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
r ods to the steering arms at the wheels.
Radiator A liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
Refrigerant Any substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful to the ozone in the upper atmosphere.
Rocker arm
A lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
Rotor In a distributor, the rotating device
inside the cap that connects the centre
electr ode and the outer terminals as it turns,
distributing the high voltage from the coil
secondary winding to the proper spark plug.
Also, that part of an alternator which rotates
inside the stator. Also, the rotating assembly
of a turbocharger, including the compressor
wheel, shaft and turbine wheel.
Runout The amount of wobble (in-and-out
movement) of a gear or wheel as it’ s rotated.
The amount a shaft rotates “out-of-true.” The
out-of-r ound condition of a rotating part.
SSealant A liquid or paste used to prevent
leakage at a joint. Sometimes used in
conjunction with a gasket.
Sealed beam lamp An older headlight design
which integrates the reflector, lens and
filaments into a hermetically-sealed one-piece
unit. When a filament burns out or the lens
cracks, the entire unit is simply replaced.
Serpentine drivebelt A single, long, wide
accessory drivebelt that’s used on some
newer vehicles to drive all the accessories,
instead of a series of smaller, shorter belts.
Serpentine drivebelts are usually tensioned by
an automatic tensioner.
Shim Thin spacer, commonly used to adjust
the clearance or relative positions between
two parts. For example, shims inserted into or
under bucket tappets control valve
clearances. Clearance is adjusted by
changing the thickness of the shim.
Slide hammer A special puller that screws
into or hooks onto a component such as a
shaft or bearing; a heavy sliding handle on the
shaft bottoms against the end of the shaft to
knock the component free.
Sprocket A tooth or projection on the
periphery of a wheel, shaped to engage with a
chain or drivebelt. Commonly used to refer to
the sprocket wheel itself.
Starter inhibitor switch On vehicles with an
O-ring
Serpentine drivebelt
Plastigage
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1595 Ford Fiesta Remake
IndexREF•27
REF
Note: References throughout this index relate to Chapter•page number
A
Accelerator cable -4A•4, 4B•4, 4C•4, 4D•3
Accelerator pedal - 4A•4, 4B•4, 4C•4, 4D•3
Accelerator pump - 4A•8
Acknowledgements - 0•4
Aerial - 12•16
Air bags - 0•5, 12•17
Air cleaner - 1•22, 1•23, 4A•3, 4B•4, 4C•3,
4D•3, 4E•5
Air temperature control system - 1•23,
4B•8, 4C•7, 4D•6
Alarm system - 12•17, REF• 5
Alternator - 5A•4
Anti-lock braking system (ABS) - 9•11,
9•14, 9•16
Anti-roll bar - 10•7, 10•11
Anti-theft alarm system - 12•17, REF•5
Antifreeze - 0•12, 0•17, 1•21, 1•22, 3•2
Asbestos - 0•5
ATF - 0•17, 1•18, 1•24
Automatic choke - 4A•16, 4A•17
Automatic transmission -2A•10, 2B•13,
2C•15, 2D•6, 2D•8, 2D•10, 7B•1 et seq,
12 •6, 12 •8
Automatic transmission fault finding - REF• 18
Automatic transmission fluid - 0•17, 1•18,
1•24
Auxiliary lights - 12•7, 12•10
Axle - 10•10
B
Backfire - REF•16
Backrest - 11•17
Ballast resistor - 4B•9
Balljoint - 10•17
Battery - 0•5, 0•14, 5A•2, 5A•3
Battery fault - REF•20
Big-end bearings - 2D•21, 2D•24
Bleeding braking system - 9•10, 9•11
Bleeding power steering - 10•17
Body electrical systems -1•18, 12 •1et seq,
REF• 11
Body electrical system fault finding - 5A•2,
12 •3, REF •20
Bodywork and fittings -1•18, 11 •1et seq,
REF• 13
Bonnet - 1•18, 11•4,11•5
Boot - 1•16
Boots - 8•3, 8•4, 10 •15
Brake fluid - 0•13, 0•17, 1•26, 12 •6
Braking system -1•17, 9•1 et seq, 12•6,
REF• 10, REF•11, REF• 12
Braking system fault finding - REF•18 Bulbs -
0•16, 12 •7,12•8
Bumpers - 11•7, 11•8
Burning - 0•5
Buying spare parts - REF•5
C
Cables -4A•4, 4B•4, 4C•4, 4D•3, 6•1, 7B•2,
9•12, 9•13, 12 •12
Calipers - 9•3
Camshaft - 2B•6, 2B•7, 2C•7, 2C•8, 2D•16
Camshaft position sensor - 4D•6
Carburettor - 4A•7, 4A•8, 4A•9, 4A•11,
4A•13, 4A•14, 4A•15, 4A•17, 4A•18
Carpets - 11•2
Cassette player - 12•15, REF •5
Catalytic converter - 4E•2, 4E•5
Centre console - 11•20, 12 •5
Charcoal canister - 4E•6
Charging system - 5A•3
Choke - 4A•4, 4A•16, 4A•17
Cigarette lighter - 12•9, 12 •12
Clock - 12•8, 12•12
Clutch -1•18, 6•1 et seq
Clutch fault finding - REF•17
Coil - 5B•4
Compression test - 2A•3, 2B•3, 2C•3
Connecting rods - 2D•17, 2D•24, 2D•25
Console - 11•20, 12•5
Contents - 0•2
Conversion factors - REF•6
Coolant - 0•12, 0•17, 1•21, 1•22, 3•2
Coolant pump - 3•7
Coolant temperature sensor - 4B•8, 4C•7,
4D•6
Cooling ,heating and ventilation systems -
3•1 et seq
Cooling system fault finding - REF•16
Courtesy light - 12•6, 12•9
Crankcase - 2D•19
Crankcase ventilation system - 1•24
Crankshaft - 2A•6, 2A•9, 2B•4, 2B•6,
2B•12, 2C•4, 2C•7, 2C•14, 2D•18,
2D•22, 2D•24
Crankshaft position sensor - 4B•8, 4C•7,
4D•6, 5B•5
Crossmember - 10•7
Crushing - 0•5
Cushion - 11•17
CV joint - 1•16, 8•3, 8•4
CVH and PTE engine in-car repair
procedures -2B•1 et seq
Cylinder block - 2D•19
Cylinder head - 2A•4, 2A•5, 2B•4, 2B•9,
2C•3, 2C•10, 2D•12, 2D•14, 2D•15
D
Dents in bodywork - 11•2
Depressurising fuel system - 4B•3, 4C•3,
4D•2
Differential - 7A•3, 7B•3
Dimensions - REF•1
Direction indicators - 12•7, 12•9, 12•10
Discs - 9•4
Distributor - 1•20, 5B•5, 5B•6, 5B•7
Doors - 1•18, 11• 6,11•9, 11 •10,,11 •11,
11 •13, 11•14, 11•15, REF •11
Drip rail moulding - 11•5
Drivebelt - 1•11
Driveplate - 2B•14, 2C•16
Driveshafts -1•16, 8•1 et seq,REF•12
Driveshafts fault finding - REF•19
Drivetrain - 1•18
Drums - 9•4
E
Earth fault - 12•4
EEC IV engine management module - 4C•6
Electric shock - 0•5
Electric windows - 11•14, 12 •7, 12•15,
REF•20
Emblems - 11•5
Emission control system - 1•24, 4E•1
Engine fault finding - REF•15, REF•16,
REF •18
Engine oil - 0•12, 0•17, 1•9
Engine removal and overhaul procedures -
2D•1 et seq
Environmental considerations - REF•4
Evaporative emission control systems - 1•24, 4E•2, 4E•5
Exhaust and emission control systems -
4E•1 et seq
Exhaust emission checks - REF•13
Exhaust manifold - 4E•3
Exhaust system - 1•16, 4E•1, 4E•2, REF •5,
REF •12
Exhaust system fault - REF•17
Expansion tank - 3•6
F
Facia - 11•20, 12 •5
Fan - 3•4
Fast-idle speed adjustment - 4A•13, 4A•15,
4A•9, 4A•7
Fault finding - REF•14et seq
Fault finding - automatic transmission -
REF •18
Fault finding - braking system - REF•18
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Fault finding - clutch - REF•17
Fault finding - cooling system - REF•16
Fault finding - driveshafts - REF•19
Fault finding - electrical system - 5A•2,
12 •3, REF •20
Fault finding - engine - REF•15, REF•16,
REF•18
Fault finding - fuel and exhaust systems -
REF•17
Fault finding - manual transmission - REF•17
Fault finding - suspension and steering
systems - REF•19
Filling - 11•3
Filter, air -1•22, 1•23, 4A•3, 4B•4, 4C•3,
4D•3, 4E•5
Filter, oil -1•9
Filter, fuel -1•25
Fire - 0•5
Float - 4A•7, 4A•9, 4A•16
Fluid seals - 7B•3
Fluids - 0•17
Flywheel - 2A•11, 2B•14, 2C•16
Fuel consumption high - REF•17
Fuel cut-off switch - 4B•5, 4C•5, 4D•4
Fuel filler pipe - 4A•6, 4B•5, 4C•5, 4D•4
Fuel filter - 1•25
Fuel gauge - 4A•6, 4B•4, 4C•5, 4D•4, 12 •12
Fuel gauge fault - REF•20
Fuel hoses - 1•13
Fuel injectors - 4B•5, 4C•5, 4D•5
Fuel lines - 1•17, 4B•3, 4C•3, 4D•2
Fuel pressure check - 4C•4
Fuel pressure regulator - 4B•6, 4C•6, 4D•5
Fuel pump - 4A•5, 4B•4, 4C•4, 4C•5, 4D•4
Fuel rail - 4C•5, 4D•5
Fuel system - carburettor engines -4A•1 et
seq
Fuel system - central fuel injection engines
-4B•1 et seq
Fuel system - electronic fuel injection engines -4C•1 et seq
Fuel system - sequential electronic fuel
injection engines -4D•1 et seq
Fuel and exhaust systems - REF•13
Fuel and exhaust systems fault finding - REF•17
Fuel tank - 4A•5, 4A•6, 4B•4, 4B•5, 4C•5,
4D•4
Fuel trap - 4B•7
Fume or gas intoxication - 0•5
Fuses - 0•16, 12 •4
G
Gaiters - 1•16, 8•3, 8•4, 10 •15
Gashes in bodywork - 11•3
Gaskets - REF •4
Gear lever - 7A•2
Gear selection problems - REF•18
Gear selector - 7B•2
Gearbox oil - 0•17, 1•14
Gearbox - See Manual gearbox
Gearchange linkage - 7A•2
Gearchange selector - 7A•3
Glossary of technical terms - REF•22 et seq
Grab handle - 11•20
H
Handbrake - 1•25, 9•12, 9•13, 12 •6,
REF•10
Handles - 11•11, 11•13, 11 •20
Hazard warning switch - 12•8
HC emissions - REF•13
HCS engine in-car repair procedures -
2A•1 et seq
Headlight - 12•7, 12 •9, 12 •10
Heater - 3•2, 3•8, 12 •6, 12•9
Horn - 12•12
Horn fault - REF•20
HT lead - 1•20
Hub bearings - 10•5, 10•8, REF •12
Hydraulic pipes and hoses - 9•9
Hydraulic tappets - 2C•8
Hydrofluoric acid - 0•5
I
Idle speed -1•14, 1•15, 1•20, 4C•6
Idle speed control valve - 4D•6
Idling fault - REF•15
Ignition amplifier - 5B•5
Ignition switch - 12•5
Ignition system -5B•1 et seq
Ignition fault - REF•20
Ignition timing - 5B•7
Indicators - 12•7, 12•9, 12 •10
Injector ballast resistor - 4B•9
Injectors - 4C•5, 4D•5
Inlet manifold - 4A•18, 4B•9, 4C•8, 4D•7
Instruments - 1•18, 12•8, 12•11
Instrument fault - REF•20
Intercooler - 4C•8
Interior light - 12•6, 12 •9
J
Jacking and vehicle support - REF•5
Joint mating faces - REF•4
Joystick - 12•16
Jump starting - 0•7
L
Leaks -0•9, 1•12, REF •16, REF•17, REF•18,
REF•20
Light-laden valve - 9•13, 9•14
Lighter - 12•9, 12 •12
Lights-on warning module - 12•16
Load compartment - 11•20
Load-apportioning valve - 9•16
Locknuts ,locktabs and washers - REF•4
Locks - 11•11, 11•12, 11•13, 12 •5
Loudspeaker housing - 11•20
Lower arm - 10•8
Lubricants - 0•17
Luggage area - 12•6, 12•9
M
Main bearings - 2D•21, 2D•22
Manifold absolute pressure sensor - 4B•8,
4C•7 Manifolds -
4A•18, 4B•9, 4C•8, 4D•7, 4E•3
Manual gearbox
Manual transmission -2A•10, 2B•13,
2C•15, 2D•6, 2D•8, 2D•10, 7A•1 et seq
Manual transmission fault finding - REF•17
Manual transmission oil - 0•17, 1•14
Mass air flow sensor - 4D•6
Master cylinder - 9•7
Minor scratches in bodywork - 11•2
Mirrors - 11 •8, 11•9, REF •10
Misfire - REF•15
Mixture - 1•14, 1•15, 4C•7, REF•13
Modulator - 9•16
MOT test checks - REF•10et seq
Mountings - 2A•10, 2B•13, 2C•15
N
Needle valve - 4A•7, 4A•9, 4A•16
Number plate light - 12•8, 12 •10
O
Oil filter - 1•9
Oil pressure fault - REF•16
Oil pump - 2A•8, 2A•9, 2B•11, 2B•12,
2C•13
Oil seals - 2A•9, 2B•7, 2B•12, 2C•8, 2C•14,
7A•3, 7B•3, REF •4
Oil separator - 4E•5
Oil, engine - 0•12, 0•17, 1•9
Oil, manual transmission - 0•17, 1•14
Open-circuit - 12•4
Overcooling - REF•16
Overheating - REF•16
Oxygen sensor - 4B•8, 4C•7, 4D•7
P
Pads -9•2
Paint - 1•18
Parcel shelf - 11•20
Parking light - 12•7
Passive Anti-Theft System (PATS) - 12•17
Pedals - 4A•4, 4B•4, 4C•4, 4D•3, 6•2, 9•8,
9•9
Pinking - REF•16
Piston rings - 2D•22
Pistons - 2D•17, 2D•24, 2D•25
Plastic components - 11•4
Poisonous or irritant substances - 0•5
Positive crankcase ventilation system - 4E•1, 4E•5
Power steering - 10•14, 10•15, 10•16,
10 •17
Power steering fluid - 0•13, 0•17
Power steering pressure switch - 4B•8,
4C•7, 4D•7
Pre-ignition - REF•16
Printed circuit - 12•11
Pulse-air system - 4E•2, 4E•6, 4E•7
Q
Quarter mouldings - 11•8
REF•28Index
1595 Ford Fiesta Remakeprocarmanuals.com
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