Ford Fiesta (1989-1995). Instruction - part 26

3

Accelerator cable (instruction
transmission models) -
removal, refitting and adjustment

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Working inside the vehicle, disconnect the
cable from the top of the accelerator pedal,
release the grommet and pull the cable free
from the pedal. Withdraw the cable through
the engine side of the bulkhead.
3 Refer to Section 2 and remove the air
cleaner.
4 Detach the inner cable from the carburettor
linkage.
5 Prise free the retaining clip, detach the
outer cable from the support bracket, and
remove the cable (see illustrations).

Refitting and adjustment

6 To refit the cable, feed the inner cable
through the bulkhead, and reconnect the inner
cable to the accelerator pedal. Note that a
plastic sleeve is supplied with new cables for
the purpose of routing through the bulkhead
panel.
7 Locate the grommet in the bulkhead, then
push the outer cable into it to secure it in the
bulkhead.
8 Lubricate the cable grommet at the
carburettor end with a mild soapy solution,

then reconnect the cable to the carburettor.
Locate the outer cable by pulling it towards
the rocker cover.
9 Have an assistant depress the accelerator
pedal fully, and hold it in this position. The
outer cable should be seen to move in its
grommet. Refit the securing clip to the
bracket, then release the accelerator pedal.
10 Depress the accelerator pedal, then
release it and check that the throttle opens
and shuts fully. Further adjust if necessary
before refitting the air cleaner and
reconnecting the battery.

4

Accelerator cable (CTX
automatic transmission
models) - adjustment

4

The system for operating the throttle-plate

in the carburettor on CTX automatic
transmission equipped vehicles is completely
different to that employed on instruction
transmission vehicles. The cable from the
accelerator pedal leads to a linkage
mechanism which is bolted to the
transmission housing. Two further cables lead
from this linkage mechanism, one of which
operates the throttle-plate in the carburettor.

As all three cables have to be adjusted at

the same time, and access to a Ford special
tool is required, it is recommended that a Ford
dealer be entrusted with cable adjustments,
or renewal.

5

Accelerator pedal - 
removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Peel back the carpet and insulation from
the driver’s footwell to allow access to the
accelerator pedal.
3 Detach the accelerator cable from the pedal
(see Section 3), then release the circlip from
the pivot shaft and remove the accelerator
pedal.

Refitting

4 Refit in the reverse order of removal. On
completion, check the action of the pedal and
the cable to ensure that the throttle has full
unrestricted movement, and fully returns
when released.
5 Reconnect the battery negative lead.

6

Choke cable - removal,
refitting and adjustment

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Refer to Section 2 and remove the air
cleaner.
3 Referring to Chapter 10, Section 20, for
further details and illustrations, remove the
choke control knob on the side of the steering
column shroud by pushing in the pin located
on the side of the knob and withdrawing.
4 Detach the steering column lower shroud,
disconnect the multi-plug from the choke
warning light switch/pull control assembly,
and unscrew the collar securing the
switch/pull control assembly to the shroud.
5 Disconnect the choke inner cable from its
location on the carburettor choke linkage,
then release the outer cable retaining clip (see
illustrations).
6 Push the bulkhead panel grommet through
the bulkhead and remove the cable.

Refitting

7 Route the cable through the bulkhead then
secure the bulkhead panel grommet to its
location.
8 Reconnect the choke inner cable to its
location on the carburettor choke linkage.
9 Refit the choke warning light switch/pull
control assembly to the lower steering column
shroud and secure with the collar, then
reconnect the multi-plug.
10 Refit and secure the lower steering
column shroud, then refit the choke control
knob.
11 Pull the choke control knob to the fully-on
position. Hold the choke in the fully-on

4A•4 Fuel system – carburettor engines

6.5b  Choke outer cable retaining clip

released

6.5a  Disconnect the inner cable from the

choke linkage

3.5b  . . . then release from its support

bracket

3.5a  Remove the accelerator outer cable

securing clip . . .

1595Ford Fiesta Remake

position at the carburettor, then secure the
outer cable with its retaining clip.

Adjustment

12 To check that the choke cable is correctly
adjusted, the control knob must be pulled out
to the full-on position and the choke lever
must be in contact with its stop. Adjust as
required if necessary.
13 Press the choke knob fully in (to the off
position), then check that the choke linkage at
the carburettor has fully returned to its off
position and the choke valve plate in the
carburettor is at a right angle (90º) to the
venturi.
14 Refit the air cleaner.
15 Reconnect the battery, turn the ignition
on, operate the choke and check that the
choke warning light operates correctly.

7

Fuel pump - 
testing, removal and refitting

2

Note: Refer to the warning note in Section 1
before proceeding.

Testing

1 Access to the fuel pump on HCS engine

models is best gained from underneath the
vehicle  (see illustrations). Apply the
handbrake, then raise and support it on axle
stands at the front end (see “Jacking and
vehicle support”).
2 The fuel pump may be tested by
disconnecting the fuel feed pipe from the
carburettor, and placing the pipe’s open end
in a suitable container.
3 Detach the multi-plug from the DIS ignition
coil, or the LT lead from the negative terminal
of the ignition coil, to prevent the engine from
firing.
4 Actuate the starter motor. If the fuel pump
is in good working order, regular well-defined
spurts of fuel should eject from the open end
of the disconnected fuel pipe.
5 If this does not occur, and there is fuel in
the tank, the pump is defective and must be
renewed. The fuel pump is a sealed unit, and
cannot be repaired.

Removal

6 Two types of mechanical fuel pump are
fitted, the application depending on the
engine type. Some models may also be fitted
with a fuel vapour separator (see illustration);
if this is removed, its hoses should be labelled
to avoid the possibility of confusion and
incorrect attachment on refitting.

7 To remove the fuel pump, first disconnect
the battery negative (earth) lead (refer to
Chapter 5A, Section 1).
8 Where applicable, remove the air cleaner to
improve access to the fuel pump (see Sec-
tion 2).
9 Disconnect the fuel hoses from the fuel
pump, noting their respective connections for
refitting. Where quick-release couplings are
used on the fuel hoses, release the protruding
locking lugs on each union, by squeezing
them together and carefully pulling the
coupling apart. Use rag to soak up any spilt
fuel. Where the unions are colour-coded, the
pipes cannot be confused. Where both unions
are the same colour, note carefully which pipe
is connected to which, and ensure that they
are correctly reconnected on refitting. Plug
the hoses to prevent fuel spillage and the
ingress of dirt.
10 Unscrew and remove the retaining bolts
or nuts (as applicable) and remove the fuel
pump.
11 Recover the gasket/spacer (see
illustration) and if required, withdraw the
pump operating pushrod (CVH engines only).
12 Thoroughly clean the mating faces on the
pump and engine.

Refitting

13 Refit in the reverse order of removal. Be
sure to use a new gasket, and tighten the
securing bolts/nuts securely. Ensure that the
hoses are correctly and securely reconnected.
If they were originally secured with crimped
type hose clips, discard them and fit 
screw type clips. Where quick-release
couplings are fitted, press them together until
the locking lugs snap into their groove.
14 When the engine is restarted, check 
the pump connections for any signs of fuel
leaks.

8

Fuel tank - removal,
inspection and refitting

3

Note: Refer to the warning note in Section 1
before proceeding.

Removal

1 Run the fuel level as low as possible prior to
removing the tank.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Remove the fuel filler cap, then syphon or
pump out the remaining fuel from the fuel tank
(there is no drain plug). The fuel must be
emptied into a suitable container for storage.
4 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the rear roadwheels.
5 Unclip and disconnect the fuel feed and
return hoses located in front of the fuel tank,
and allow any residual fuel to drain into a

Fuel system – carburettor engines  4A•5

7.6  Fuel pump and fuel vapour separator

arrangement on HCS engine (shown from

below)

7.1b  Fuel pump assembly fitted to CVH

engines (securing nuts arrowed)

A Fuel feed from tank
B Fuel return to tank
C Fuel feed to carburettor

7.1a  Fuel pump location on HCS engine

(shown from below)

A Fuel inlet hose
B Fuel return hose to tank
C Fuel outlet hose to carburettor
D Pump securing bolts

7.11  Gasket/spacer fitment on HCS

engine. Note position of the lug (arrowed)

4A

1595Ford Fiesta Remake

container which can be sealed (see
illustration). Where quick-release couplings
are used on the fuel hoses, release the
protruding locking lugs on each union, by
squeezing them together and carefully pulling
the coupling apart. Note that the fuel supply
hose couplings are identified by a white
colour band and the return hose couplings by
a yellow colour band.
6 Disconnect the filler neck sensing pipe
connection from the rear of the tank (see
illustration).
7 Support beneath the tank to hold it in
position and remove its four securing bolts
(see illustration).
8 Partially lower the fuel tank and disconnect
the ventilation tube from the tank top surface
and also disconnect the sender unit multi-
plug. The filler pipe should release from its
fuel tank seal location as the tank is
withdrawn.

Inspection

9 Whilst removed, the fuel tank can be
inspected for damage or deterioration.
Removal of the sender unit (see Section 9) will
allow a partial inspection of the interior. If the
tank is contaminated with sediment or water,
swill it out with clean petrol. Do not under any
circumstances undertake any repairs on a
leaking or damaged fuel tank; this work must
be carried out by a professional who has
experience in this critical and potentially-
dangerous work.
10 Whilst the fuel tank is removed from the
vehicle, it should not be placed in an area
where sparks or open flames could ignite the
fumes coming out of the tank. Be especially
careful inside garages where a natural-gas
type appliance is located, because the pilot
light could cause an explosion.
11 Check the condition of the filler pipe seal
in the fuel tank, and renew it if necessary.

Refitting

All models

12 Refitting is a reversal of the removal
procedure. Apply a light smear of grease to the
filler pipe seal, to ease fitting. Ensure that all
connections are securely fitted. Where quick-
release fuel couplings are fitted, press them

together until the locking lugs snap into their
groove. If evidence of contamination was
found, do not return any previously-drained
fuel to the tank unless it is carefully filtered first.

9

Fuel gauge sender unit -
removal and refitting

3

Note: Ford specify the use of their service tool
23-014 (a large box spanner with projecting
teeth to engage the fuel gauge sender unit
retaining ring’s slots) for this task. While
alternatives are possible, in view of the difficulty
experienced in removing and refitting the
sender unit, owners are strongly advised to
obtain the correct tool before starting work. The
help of an assistant will be required. Refer to the
warning note in Section 1 before proceeding.

Removal

1 Remove the fuel tank as described in
Section 8.
2 Engage the special tool into the sender unit
then carefully turn the sender unit and release
it from the top of the tank.

Refitting

3 Refit the sender unit in the reverse order of
removal. Be sure to fit a new seal, and
lubricate it with a smear of grease to prevent it
from distorting when fitting the sender unit.

10 Fuel tank ventilation tube -

removal and refitting

3

Note: Refer to the warning note in Section 1
before proceeding.

Removal

1 The fuel tank ventilation tube runs from the
top surface of the fuel tank to the combined roll-
over/anti-trickle-fill valve assembly mounted in
the left-hand rear wheelarch (see illustration).
Its purpose is to eliminate any possibility of
vacuum or pressure build-up in the fuel tank.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the left-hand rear roadwheel.
4 Support the fuel tank from underneath on a
suitable jack, using a large thick sheet of
board to spread the weight, then undo and
remove the four fuel tank securing bolts.
5 Lower the fuel tank slightly in such a manner
so as to allow access to disconnect the
ventilation tube from the tank top surface.
Ensure that the fuel tank does not foul or strain
any adjacent components as it is lowered;
take appropriate action, as necessary.
6 Disconnect the ventilation tube from the
combined roll-over/anti-trickle-fill valve, release
the tube from its retaining clips and remove.

Refitting

7 Refitting is a reversal of the removal
procedure, ensuring that the fuel tank filler
pipe is located correctly with the tank.

11 Fuel tank filler pipe - 

removal and refitting

3

Note: Refer to the warning note in Section 1
before proceeding.

Removal

1 Remove the fuel tank as described in
Section 8.

4A•6 Fuel system – carburettor engines

10.1  Combined roll-over anti-trickle-fill

valve assembly

A Tube ventilating to atmosphere
B Ventilation tube from fuel tank

8.7  Fuel tank securing bolts (arrowed)

8.6  Filler neck sensing pipe connection at

the rear of the fuel tank

1595Ford Fiesta Remake

8.5  Fuel feed and return pipe connections

(arrowed)

2 Remove the filler cap surround (see
illustration).
3 Disconnect the ventilation tube from the
combined roll-over/anti-trickle-fill valve,
release the ventilation tube from its retaining
clips and detach the valve from the vehicle.
4 Remove the filler pipe securing bolt, then
twist and withdraw the filler pipe unit.
5 Prior to refitting, check the condition of the
filler pipe seal in the fuel tank and renew if
necessary.

Refitting

6 Refitting is a reversal of the removal
procedure, but apply a light smear of grease
to the filler pipe seal to aid filler pipe entry.

12 Carburettor (Weber TLM) -

description

The carburettor is of the single (fixed)

venturi downdraught type, featuring a fixed
size main jet system with a mechanically-
operated accelerator pump and vacuum-
operated power valve to provide optimum
fuelling.

A instructionly-operated choke system is

fitted, featuring a vacuum-operated pull-down
mechanism which brings the choke partially
off during conditions of high manifold
vacuum.

An anti-dieseling (fuel cut-off) solenoid

(where fitted) prevents the possibility of
engine run-on when the ignition is switched
off.

Idle speed and mixture adjustment

procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.

13 Carburettor (Weber TLM) -

fast-idle speed adjustment

4

Note:  Before carrying out any carburettor
adjustments, ensure that the spark plug gaps
are set as specified, and that all electrical and
vacuum connections are secure. To carry out
checks and adjustments, an accurate
tachometer and an exhaust gas analyser (CO
meter) will be required.
1 Check the idle speed and mixture settings
are as specified (as described in Chapter 1).
These must be correct before
checking/adjusting the fast-idle speed.
2 With the engine at its normal operating
temperature, and a tachometer connected in
accordance with the manufacturer’s
instructions, remove the air cleaner (if not
already done) as described in Section 2.
3 Actuate the choke by pulling its control
knob fully out, then start the engine.
4 Hold the choke plate open using a 5.0 mm
twist drill held between the plate and the

venturi, and record the fast-idle speed
achieved. If adjustment is necessary, turn the
fast-idle adjusting screw until the specified
speed is obtained (see illustration).
5 Re-check the fast-idle and basic idle
speeds.
6 On satisfactory completion of the
adjustment, stop the engine, disconnect the
tachometer and CO meter then refit the air
cleaner.
7 Remove the bridging wire from the radiator
cooling fan thermal switch multi-plug, and
reconnect the multi-plug to the thermal
switch.

14 Needle valve and float (Weber

TLM carburettor) - removal,
refitting and adjustment

4

Note: Refer to the warning note in Section 1
before proceeding. New gaskets and a washer
(seal) will be required when reassembling. A
tachometer and an exhaust gas analyser (CO
meter) will also be required to check the idle
speed and mixture settings on completion.

Removal and refitting

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Clean the exterior of the carburettor, then
disconnect the fuel feed hose.
4 Disconnect the choke cable and the choke
vacuum hose.

5 Remove the four screws securing the
carburettor upper body (two of these screws
are Torx head type), and detach it. Note that
the carburettor lower body is now loose 
on the inlet manifold.
6 Tap out the float retaining pin, remove the
float and withdraw the needle valve. Unscrew
the needle valve housing, as required, noting
washer fitment.
7 Inspect the components for damage and
renew as necessary. Check the needle valve
for wear, and check the float assembly for
leaks by shaking it to see if it contains petrol.
Whilst accessible, clean the float chamber
and jets (refer to Section 17).
8 Using a new washer, refit the needle valve
housing.
9 Refit the needle valve, float and retaining
pin, ensuring that the tag on the float engages
between the ball and clip on the needle valve.
10 Before refitting the carburettor upper
body, check and if necessary adjust the float
level as described in paragraph 15 to 18. Also
check the float and needle valve for full and
free movement.
11 Clean the gasket contact faces (including
the inlet manifold) then, using new gaskets for
the carburettor upper body and the inlet
manifold faces, refit the carburettor upper
body and secure the carburettor assembly to
the inlet manifold.
12 Reconnect the choke vacuum hose. If the
fuel feed hose was originally secured with a
crimped type clip, discard this and secure the
fuel feed hose with a nut and screw type clip.
13 Reconnect and adjust the choke cable,
then refit the air cleaner.
14 Reconnect the battery negative lead, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.

Float level adjustment

15 With the carburettor upper body removed
as described in paragraphs 1 to 5 inclusive,
proceed as follows.
16 Hold the carburettor upper body in the
position shown (see illustration), ensuring
that the needle valve is shut off. Fit the new
upper body gasket to the carburettor upper

Fuel system – carburettor engines  4A•7

13.4  Fast-idle speed adjusting screw

(arrowed) (Weber TLM carburettor)

11.2  Removing the filler cap surround

14.16  Float level adjustment (Weber TLM

carburettor)

A Adjusting tag
B Float level setting dimension

4A

1595Ford Fiesta Remake