1989 FORD FIESTA engine

1595 Ford Fiesta Remake
failure of components such as fuses or spark
plugs may only be pointers to some
underlying fault.
The pages which follow provide an easy
reference guide to the more common
problems which may occur during the
operation of the vehicle. These problems and
their possible causes are grouped under
headings denoting various components or
systems, such as Engine, Cooling system,
etc. The Chapter and/or Section which deals
with the problem is also shown in brackets.
Whatever the fault, certain basic principles
apply. These are as follows:
Verify the fault . This is simply a matter of
being sure that you know what the symptoms are before starting work. This is particularly
important if you are investigating a fault for
someone else, who may not have described it
very accurately.
Don’t overlook the obvious . For example, if
the vehicle won’t start, is there petrol in the
tank? (Don’t take anyone else’s word on this
particular point, and don’t trust the fuel gauge
either!) If an electrical fault is indicated, look
for loose or broken wires before digging out
the test gear. Cure the disease, not the symptom .
Substituting a flat battery with a fully-charged
one will get you off the hard shoulder, but if
the underlying cause is not attended to, the
new battery will go the same way. Similarly, changing oil-fouled spark plugs for a new set
will get you moving again, but remember that
the reason for the fouling (if it wasn’t simply an
incorrect grade of plug) will have to be
established and corrected.
Don’t take anything for granted . Particularly,
don’t forget that a “new” component may
itself be defective (especially if it’s been
rattling around in the boot for months), and
don’t leave components out of a fault
diagnosis sequence just because they are
new or recently fitted. When you do finally
diagnose a difficult fault, you’ll probably
realise that all the evidence was there from
the start.
Fault findingREF•15
REF
Engine
Engine fails to rotate when attempting to start
m
m Battery terminal connections loose or corroded (Chapter 5A).
m
m Battery discharged or faulty (Chapter 5A).
m
m Broken, loose or disconnected wiring in the starting circuit
(Chapter 5A).
m m Defective starter solenoid or switch (Chapter 5A).
m
m Defective starter motor (Chapter 5A).
m
m Flywheel ring gear or starter pinion teeth loose or broken
(Chapters 2A, 2B, 2C or 5A).
m m Engine earth strap broken or disconnected (Chapter 5A).
m
m Automatic transmission not in Park/Neutral position, or starter
inhibitor switch faulty (Chapter 7B).
Engine rotates, but will not start
m mFuel tank empty.
m
m Battery discharged (engine rotates slowly) (Chapter 5A).
m
m Battery terminal connections loose or corroded (Chapter 5A).
m
m Ignition components damp or damaged (Chapters 1 and 5B).
m
m Broken, loose or disconnected wiring in the ignition circuit
(Chapters 1 and 5B).
m m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Major mechanical failure (eg camshaft drive) (Chapters 2A, 2B
or 2C).
Engine difficult to start when cold
m mBattery discharged (Chapter 5A).
m
m Battery terminal connections loose or corroded (Chapter 5A).
m
m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Other ignition system fault (Chapters 1 and 5B).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Low cylinder compressions (Chapters 2A, 2B or 2C).
Engine difficult to start when hot
m
mAir filter element dirty or clogged (Chapter 1).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Low cylinder compressions (Chapters 2A, 2B or 2C).
m
m Faulty hydraulic tappet(s) (Chapters 2B or 2C).
Starter motor noisy or excessively-rough in
engagement
m mFlywheel ring gear or starter pinion teeth loose or broken
(Chapters 2A, 2B, 2C or 5A).
m m Starter motor mounting bolts loose or missing (Chapter 5A).
m
m Starter motor internal components worn or damaged (Chapter 5A).
Engine starts but stops immediately
m
mLoose or faulty electrical connections in the ignition circuit
(Chapters 1 and 5B).
m m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Vacuum leak at the inlet manifold (Chapters 1, 4A, 4B, 4C, 4D or 4E).
Engine idles erratically
m
mEngine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Air filter element clogged (Chapter 1).
m
m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
m m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Incorrect valve clearances (Chapter 2A).
m
m Faulty hydraulic tappet(s) (Chapters 2B or 2C).
m
m Uneven or low cylinder compressions (Chapters 2A, 2B or 2C).
m
m Camshaft lobes worn (Chapters 2A, 2B or 2C).
m
m Timing chain and sprockets worn (Chapter 2A).
m
m Timing belt incorrectly-tensioned (Chapters 2B or 2C).
Engine misfires at idle speed
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Faulty spark plug HT leads (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 or 4E).
m m Incorrect valve clearances (Chapter 2A).
m
m Faulty hydraulic tappet(s) (Chapters 2B or 2C).
m
m Uneven or low cylinder compressions (Chapters 2A, 2B and 2C).
m
m Disconnected, leaking or perished crankcase ventilation hoses
(Chapters 1 and 4E).
Engine misfires throughout the driving speed range
m mFuel 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).
m m Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4A, 4B, 4C, 4D or 4E).
m m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m
m Faulty spark plug HT leads (Chapter 1).
m
m Faulty ignition coil (Chapter 5B).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Uneven or low cylinder compressions (Chapters 2A, 2B or 2C).
procarmanuals.com
http://vnx.su

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).
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
Fault findingREF•17
REF
Fuel and exhaust systems
Excessive fuel consumption
m
mUnsympathetic driving style, or adverse conditions.
m
m Air filter element dirty or clogged (Chapter 1).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
m m Tyres under-inflated ( “Weekly Checks”).
Fuel leakage and/or fuel odour
m
mDamaged or corroded fuel tank, pipes or connections (Chapter 1).
m
m Charcoal canister and/or connecting pipes leaking (Chapters 1
and 4E).
Excessive noise or fumes from exhaust system
m mLeaking exhaust system or manifold joints (Chapters 1 or 4E).
m
m Leaking, corroded or damaged silencers or pipe (Chapters 1 or 4E).
m
m Broken mountings, causing body or suspension contact (Chap-
ters 1 or 4E).
Clutch
Pedal travels to floor - no pressure or very little
resistance
m mBroken clutch cable (Chapter 6).
m
m Faulty clutch automatic adjuster (Chapter 6).
m
m Broken clutch release bearing or fork (Chapter 6).
m
m Broken diaphragm spring in clutch pressure plate (Chapter 6).
Clutch fails to disengage (unable to select gears)
m
mFaulty clutch automatic adjuster (Chapter 6).
m
m Clutch disc sticking on transmission input shaft splines (Chapter 6).
m
m Clutch disc sticking to flywheel or pressure plate (Chapter 6).
m
m Faulty pressure plate assembly (Chapter 6).
m
m Clutch release mechanism worn or incorrectly assembled (Chapter 6).
Clutch slips (engine speed increases, with no
increase in vehicle speed)
m mFaulty clutch automatic adjuster (Chapter 6).
m
m Clutch disc linings excessively worn (Chapter 6).
m
m Clutch disc linings contaminated with oil or grease (Chapter 6).
m
m Faulty pressure plate or weak diaphragm spring (Chapter 6).
Judder as clutch is engaged
m
mClutch disc linings contaminated with oil or grease (Chapter 6).
m
m Clutch disc linings excessively worn (Chapter 6).
m
m Clutch cable sticking or frayed (Chapter 6).
m
m Faulty or distorted pressure plate or diaphragm spring (Chapter 6).
m
m Worn or loose engine/transmission mountings (Chapters 2A, 2B
or 2C).
m m Clutch disc hub or transmission input shaft splines worn (Chap-
ter 6).
Noise when depressing or releasing clutch pedal
m mWorn clutch release bearing (Chapter 6).
m
m Worn or dry clutch pedal bushes (Chapter 6).
m
m Faulty pressure plate assembly (Chapter 6).
m
m Pressure plate diaphragm spring broken (Chapter 6).
m
m Broken clutch disc cushioning springs (Chapter 6).
Manual transmission
Noisy in neutral with engine running
m
mInput shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7A).*
m m Clutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 6).
Noisy in one particular gear
m mWorn, damaged or chipped gear teeth (Chapter 7A).*
Difficulty engaging gears
m
mClutch fault (Chapter 6).
m
m Worn or damaged gear linkage (Chapter 7A).
m
m Incorrectly-adjusted gear linkage (Chapter 7A).
m
m Worn synchroniser assemblies (Chapter 7A).*
Vibration
m
mLack of oil (Chapter 1).
m
m Worn bearings (Chapter 7A).*
Jumps out of gear
m
mWorn or damaged gear linkage (Chapter 7A).
m
m Incorrectly-adjusted gear linkage (Chapter 7A).
m
m Worn synchroniser assemblies (Chapter 7A).*
m
m Worn selector forks (Chapter 7A).*
Lubricant leaks
m
mLeaking differential side gear oil seal (Chapter 7A).
m
m Leaking housing joint (Chapter 7A).*
m
m Leaking input shaft oil seal (Chapter 7A).*
m
m Leaking selector shaft oil seal (Chapter 7A).
m
m Leaking speedometer drive pinion O-ring (Chapter 7A).
* Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition,
so that the owner can communicate clearly with a professional
mechanic.
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
REF•18Fault finding
Braking system
Note:Before assuming that a brake problem exists, make sure that the
tyres are in good condition and correctly inflated, that the front wheel\
alignment is correct, and that the vehicle is not loaded with weight in \
an
unequal manner. Apart from checking the condition of all pipe and
hose connections, any faults occurring on the Anti-lock Braking System
(ABS) should be referred to a Ford dealer for diagnosis.
Vehicle pulls to one side under braking
m m Worn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).
m m Seized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).
m m A mixture of brake pad/shoe lining materials fitted between sides
Chapter 1).
m m Brake caliper mounting bolts loose (Chapter 9).
m
m Rear brake backplate mounting bolts loose (Chapter 9).
m
m Worn or damaged steering or suspension components (Chap-
ter 10).
Noise (grinding or high-pitched squeal) when
brakes applied
m mBrake pad or shoe friction lining material worn down to metal
backing Chapter 1).
m m Excessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).
Excessive brake pedal travel
m mInoperative rear brake self-adjust mechanism (Chapter 9).
m
m Faulty master cylinder (Chapter 9).
m
m Air in hydraulic system (Chapter 9).
Rear wheels locking under normal braking
m
mRear brake shoe linings contaminated (Chapter 1).
m
m Faulty brake pressure regulator (Chapter 9).
Brake pedal feels spongy when depressed
m
mAir in hydraulic system (Chapter 9).
m
m Deteriorated flexible rubber brake hoses (Chapter 9).
m
m Master cylinder mounting nuts loose (Chapter 9).
m
m Faulty master cylinder (Chapter 9).
Excessive brake pedal effort required to stop
vehicle
m mFaulty vacuum servo unit (Chapter 9).
m
m Disconnected, damaged or insecure brake servo vacuum hose
(Chapter 9).
m m Primary or secondary hydraulic circuit failure (Chapter 9).
m
m Seized brake caliper or wheel cylinder piston(s) (Chapter 9).
m
m Brake pads or brake shoes incorrectly fitted (Chapter 9).
m
m Incorrect grade of brake pads or brake shoes fitted (Chapter 1).
m
m Brake pads or brake shoe linings contaminated (Chapter 1).
Judder felt through brake pedal or steering wheel
when braking
m mExcessive run-out or distortion of front discs or rear drums
Chapter 9).
m m Brake pad or brake shoe linings worn (Chapter 1).
m
m Brake caliper or rear brake backplate mounting bolts loose
(Chapter 9).
m m Wear in suspension or steering components or mountings
(Chapter 10).
Brakes binding
m mSeized brake caliper or wheel cylinder piston(s) (Chapter 9).
m
m Faulty handbrake mechanism (Chapter 9).
m
m Faulty master cylinder (Chapter 9).
Automatic transmission
Note: Due to the complexity of the automatic transmission, it is difficult
for the home mechanic to properly diagnose and service this unit. For
problems other than the following, the vehicle should be taken to a
dealer service department or automatic transmission specialist.
Fluid leakage
m m Automatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.
m m To determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
a) Transmission fluid sump (Chapters 1 and 7B).
b) Dipstick tube (Chapters 1 and 7B).
c) Transmission-to-fluid cooler pipes/unions (Chapter 7B).
d) Speedometer drive pinion O-ring.
e) Differential output fluid seals (Chapter 7B).
Transmission fluid brown, or has burned smell
m m Transmission fluid level low, or fluid in need of renewal (Chapter 1).\
Engine will not start in any gear, or starts in gears
other than Park or Neutral
m mStarter inhibitor switch faulty (Chapter 7B).
m
m Incorrect selector cable adjustment (Chapter 7B).
General gear selection problems
m
mChapter 7B deals with checking and adjusting the selector cable
on automatic transmissions. The following are common problems
which may be caused by a poorly-adjusted cable:
a) Engine starting in gears other than Park or Neutral.
b) Indicator on gear selector lever pointing to a gear other than the
one actually being used.
c) Vehicle moves when in Park or Neutral.
d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7B for the selector cable adjustment procedure.
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
m m Low transmission fluid level (Chapter 1).
m
m Incorrect selector cable adjustment (Chapter 7B).
m
m Engine management system fault (Chapters 1, 4A, 4B, 4C, 4D, 4E
or 5B).
Transmission slips, is noisy, or has no drive in
forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
REF•20Fault finding
Electrical system
Note:For problems associated with the starting system, refer to the
faults listed under “Engine” earlier in this Section.
Battery will not hold a charge for more than a few
days
m m Battery defective internally (Chapter 5A).
m
m Battery terminal connections loose or corroded (Chapter 5A).
m
m Auxiliary drivebelt worn or incorrectly-adjusted (Chapter 1).
m
m Alternator not charging at correct output (Chapter 5A).
m
m Alternator or voltage regulator faulty (Chapter 5A).
m
m Short-circuit causing continual battery drain (Chapters 5A and 12).
Ignition (no-charge) warning light remains
illuminated with engine running
m mAuxiliary drivebelt broken, worn, or incorrectly-adjusted (Chap-
ter 1).
m m Alternator brushes worn, sticking, or dirty (Chapter 5A).
m
m Alternator brush springs weak or broken (Chapter 5A).
m
m Internal fault in alternator or voltage regulator (Chapter 5A).
m
m Broken, disconnected, or loose wiring in charging circuit (Chap-
ter 5A).
Ignition (no-charge) warning light fails to come on
m mWarning light bulb blown (Chapter 12).
m
m Broken, disconnected, or loose wiring in warning light circuit
(Chapters 5A and 12).
m m Alternator faulty (Chapter 5A).
Lights inoperative
m
mBulb blown (Chapter 12).
m
m Corrosion of bulb or bulbholder contacts (Chapter 12).
m
m Blown fuse (Chapter 12).
m
m Faulty relay (Chapter 12).
m
m Broken, loose, or disconnected wiring (Chapter 12).
m
m Faulty switch (Chapter 12).
Instrument readings inaccurate or erratic
Instrument readings increase with engine speed
m
mFaulty voltage regulator (Chapter 12).
Fuel or temperature gauges give no reading
m
mFaulty gauge sender unit (Chapters 3 or 4A, 4B, 4C, or 4D).
m
m Wiring open-circuit (Chapter 12).
m
m Faulty gauge (Chapter 12).
Fuel or temperature gauges give continuous maximum
reading
m mFaulty gauge sender unit (Chapters 3 or 4A, 4B, 4C, or 4D).
m
m Wiring short-circuit (Chapter 12).
m
m Faulty gauge (Chapter 12).
Horn inoperative, or unsatisfactory in operation
Horn fails to operate
m
mBlown fuse (Chapter 12).
m
m Cable or cable connections loose, broken or disconnected
(Chapter 12).
m m Faulty horn (Chapter 12).
Horn emits intermittent or unsatisfactory sound
m
mCable connections loose (Chapter 12).
m
m Horn mountings loose (Chapter 12).
m
m Faulty horn (Chapter 12).
Horn operates all the time
m
mHorn push either earthed or stuck down (Chapter 12).
m
m Horn cable to horn push earthed (Chapter 12).
Windscreen/tailgate wipers inoperative or
unsatisfactory in operation
Wipers fail to operate, or operate very slowly
m mWiper blades stuck to screen, or linkage seized or binding
(Chapter 12).
m m Blown fuse (Chapter 12).
m
m Cable or cable connections loose, broken or disconnected
(Chapter 12).
m m Faulty relay (Chapter 12).
m
m Faulty wiper motor (Chapter 12).
Wiper blades sweep over too large or too small an area of
the glass
m mWiper arms incorrectly-positioned on spindles (Chapter 1).
m
m Excessive wear of wiper linkage (Chapter 1).
m
m Wiper motor or linkage mountings loose or insecure (Chapter 12).
Wiper blades fail to clean the glass effectively
m
mWiper blade rubbers worn or perished ( “Weekly Checks”).
m
m Wiper arm tension springs broken, or arm pivots seized (Chap-
ter 1).
m m Insufficient windscreen washer additive to adequately remove
road film ( “Weekly Checks” ).
Windscreen/tailgate washers inoperative, or
unsatisfactory in operation
One or more washer jets inoperative
m mBlocked washer jet ( “Weekly Checks”or Chapter 1).
m
m Disconnected, kinked or restricted fluid hose (Chapter 1).
m
m Insufficient fluid in washer reservoir ( “Weekly Checks”).
Washer pump fails to operate
m
mBroken or disconnected wiring or connections (Chapter 12).
m
m Blown fuse (Chapter 12).
m
m Faulty washer switch (Chapter 12).
m
m Faulty washer pump (Chapter 12).
Washer pump runs for some time before fluid is emitted
from jets
m mFaulty one-way valve in fluid supply hose (Chapter 12).
Electric windows inoperative, or unsatisfactory in
operation
Window glass will only move in one direction
m mFaulty switch (Chapter 12).
Window glass slow to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m
m Regulator seized or damaged, or in need of lubrication (Chapter
11).
m m Door internal components or trim fouling regulator (Chapter 11).
m
m Faulty motor (Chapter 12).
Window glass fails to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m
m Blown fuse (Chapter 12).
m
m Faulty relay (Chapter 12).
m
m Broken or disconnected wiring or connections (Chapter 12).
m
m Faulty motor (Chapter 12).
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
REF•22Glossary of technical terms
A
ABS (Anti-lock brake system)A system,
usually electronically controlled, that senses
incipient wheel lockup during braking and
r elieves hydraulic pressure at wheels that are
about to skid.
Air bag An inflatable bag hidden in the
steering wheel (driver’s side) or the dash or
glovebox (passenger side). In a head-on
collision, the bags inflate, preventing the
driver and front passenger from being thrown
forwar d into the steering wheel or windscreen.
Air cleaner A metal or plastic housing,
containing a filter element, which removes
dust and dirt from the air being drawn into the
engine.
Air filter element The actual filter in an air
cleaner system, usually manufactured fr om
pleated paper and requiring renewal at regular
intervals.
Allen key A hexagonal wrench which fits into
a recessed hexagonal hole.
Alligator clip A long-nosed spring-loaded
metal clip with meshing teeth. Used to make
temporary electrical connections.
Alternator A component in the electrical
system which converts mechanical energy
fr om a drivebelt into electrical energy to
char ge the battery and to operate the starting
system, ignition system and electrical
accessories.
Amper e (amp) A unit of measurement for the
flow of electric current. One amp is the
amount of current produced by one volt
acting through a resistance of one ohm.
Anaer obic sealer A substance used to
pr event bolts and screws from loosening.
Anaer obic means that it does not require
oxygen for activation. The Loctite brand is
widely used.
Antifreeze A substance (usually ethylene
glycol) mixed with water, and added to a
vehicle’ s cooling system, to prevent freezing
of the coolant in winter. Antifreeze also
contains chemicals to inhibit corrosion and
the formation of rust and other deposits that would tend to clog the radiator and coolant
passages and reduce cooling efficiency.
Anti-seize compound A coating that
r educes the risk of seizing on fasteners that
ar e subjected to high temperatures, such as
exhaust manifold bolts and nuts.
Asbestos A natural fibrous mineral with great
heat resistance, commonly used in the
composition of brake friction materials.
Asbestos is a health hazard and the dust
cr eated by brake systems should never be
inhaled or ingested.
Axle A shaft on which a wheel revolves, or
which revolves with a wheel. Also, a solid
beam that connects the two wheels at one
end of the vehicle. An axle which also
transmits power to the wheels is known as a
live axle.
Axleshaft A single rotating shaft, on either
side of the differential, which delivers power
fr om the final drive assembly to the drive
wheels. Also called a driveshaft or a halfshaft.
BBall bearing An anti-friction bearing
consisting of a hardened inner and outer race
with hardened steel balls between two races. Bearing
The curved surface on a shaft or in a
bor e, or the part assembled into either, that
permits relative motion between them with
minimum wear and friction.
Big-end bearing The bearing in the end of
the connecting rod that’s attached to the crankshaft.
Bleed nipple A valve on a brake wheel
cylinder , caliper or other hydraulic component
that is opened to purge the hydraulic system
of air. Also called a bleed screw.
Brake bleeding Procedure for removing air
fr om lines of a hydraulic brake system.
Brake disc The component of a disc brake
that rotates with the wheels.
Brake drum The component of a drum brake
that rotates with the wheels.
Brake linings The friction material which
contacts the brake disc or drum to retard the
vehicle’ s speed. The linings are bonded or
riveted to the brake pads or shoes.
Brake pads The replaceable friction pads
that pinch the brake disc when the brakes are
applied. Brake pads consist of a friction
material bonded or riveted to a rigid backing
plate.
Brake shoe The crescent-shaped carrier to
which the brake linings are mounted and
which forces the lining against the rotating drum during braking.
Braking systems For more information on
braking systems, consult the Haynes
Automotive Brake Manual .
Br eaker bar A long socket wrench handle
pr oviding greater leverage.
Bulkhead The insulated partition between
the engine and the passenger compartment.
CCaliper The non-rotating part of a disc-brake
assembly that straddles the disc and carries
the brake pads. The caliper also contains the
hydraulic components that cause the pads to
pinch the disc when the brakes are applied. A
caliper is also a measuring tool that can be set
to measure inside or outside dimensions of an
object.
Brake bleeding
Bearing
Axle assembly
Anti-seize compound
Alter nator (exploded view)
Air filter
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
Glossary of technical termsREF•23
REF
CamshaftA rotating shaft on which a series
of cam lobes operate the valve mechanisms.
The camshaft may be driven by gears, by
spr ockets and chain or by sprockets and a
belt.
Canister A container in an evaporative
emission control system; contains activated
char coal granules to trap vapours from the
fuel system.
Carburettor A device which mixes fuel with
air in the proper proportions to provide a
desir ed power output from a spark ignition
inter nal combustion engine.
Castellated Resembling the parapets along
the top of a castle wall. For example, a
castellated balljoint stud nut.
Castor In wheel alignment, the backward or
forwar d tilt of the steering axis. Castor is
positive when the steering axis is inclined
rearwar d at the top. Catalytic converter
A silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
Circlip A ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
gr oove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
Clearance The amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil spring A spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
Compression Reduction in volume, and
incr ease in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compr ession ratio The relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) joint A type of
universal joint that cancels out vibrations
caused by driving power being transmitted
thr ough an angle.
Cor e plug A disc or cup-shaped metal device
inserted in a hole in a casting through which
cor e was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
Crankcase The lower part of the engine
block in which the crankshaft rotates.
Crankshaft The main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
r ods are attached. Crocodile clip
See Alligator clip
DDiagnostic code Code numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
wher e a malfunction may be located.
Disc brake A brake design incorporating a
r otating disc onto which brake pads are
squeezed. The resulting friction converts the
ener gy of a moving vehicle into heat.
Double-overhead cam (DOHC) An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s) The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor , etc. off the crankshaft pulley.
Driveshaft Any shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brake A type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pr essed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
Castellated nut
Catalytic converter
Crankshaft assembly
Carburettor
Canister
Drum brake assembly
Accessor y drivebelts
Driveshaft
procarmanuals.com
http://vnx.su

1595 Ford Fiesta Remake
REF•24Glossary of technical terms
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electr onic control unit (ECU) A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electr onic Fuel Injection (EFI) A computer
contr olled fuel system that distributes fuel
thr ough an injector located in each intake port
of the engine.
Emergency brake A braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depr essed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.
Endfloat The amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS) A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifold A part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
FFan clutch A viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds. Feeler blade
A thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing order The order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
ener gy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Fr ee play The amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
Fuse An electrical device which protects a
cir cuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible link A circuit protection device
consisting of a conductor surrounded by
heat-r esistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.
GGap The distance the spark must travel in
jumping from the centre electrode to the side electr
ode in a spark plug. Also refers to the
spacing between the points in a contact
br eaker assembly in a conventional points-
type ignition, or to the distance between the
r eluctor or rotor and the pickup coil in an
electr onic ignition.
Gasket Any thin, soft material - usually cork,
cardboar d, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
Gauge An instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
r eadout is called a digital gauge.
HHalfshaft A rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear axle.
Harmonic balancer A device designed to
r educe torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
Hone An abrasive tool for correcting small
irr egularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappet A tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
r educe valve noise.
IIgnition timing The moment at which the
spark plug fires, usually expressed in the number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifold A tube or housing with
passages through which flows the air-fuel mixtur e (carburettor vehicles and vehicles with
thr ottle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
Exhaust manifold
Feeler blade
Adjusting spark plug gap
Gasket
EGR valve
procarmanuals.com
http://vnx.su