Ford Fiesta (1989-1995). Instruction - part 31

5 Bend over the locking tabs retaining the
injector screws, then undo and remove the
screws. Withdraw the injector retaining collar,
then carefully withdraw the injector from the
CFi unit (noting its orientation) followed by its
seals. Withdraw the seal from the retaining
collar (see illustrations).
6 Refit in the reverse order of removal.
Always use new seals in the CFi unit and the
retaining collar, and lightly lubricate them with
clean engine oil prior to assembly. Take care
not to damage the seals as they are fitted and
as the injector is fitted, check that the location
peg engages correctly.

Fuel pressure regulator

7 Refer to paragraphs 14 to 22 in this Section
and remove the CFi unit from the vehicle.
8 Unscrew and remove the four regulator
retaining screws, and remove the regulator
(see illustration). As they are removed, note
the fitting positions and the orientation of the
components.  Do not (unless absolutely
necessary) attempt to prise out the plug or
adjust the screw in the centre of the housing
(if no plug is fitted), as this will alter the system
pressure.
9 Examine the components, and renew any
that are defective or suspect.
10 To refit, position the regulator on its side,
then insert the small spring, the valve,
diaphragm (ensuring that it seats correctly),
large spring, cup and then the regulator cover.
Insert and tighten the retaining screws, but

take care not overtighten them, or the cover
will be distorted.
11 Carefully place the ball into position on
the spring cup, and ensure that it seats
correctly.
12 If removed, fit the central Allen type
adjuster screw, hand-tighten it and then
unscrew it (from the hand-tight position) three
full turns to make a provisional adjustment.
13 Refit the CFi unit in accordance with
paragraphs 23 to 25 in this Section, but note
that further checks for fuel leaks must be
made with the engine running. The fuel
system pressure must be checked by a Ford
dealer or other suitable specialist at the
earliest opportunity.

CFi unit

14 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap. 

Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
15 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
16 Refer to Section 4 and remove the air
cleaner.
17 Position a suitable drain tray under the
coolant hose connections to the CFi unit.

Ensure that the cooling system is not
pressurised (see Chapter 1), then detach the
hoses from the unit. Plug or clamp the hoses
to prevent further coolant spillage whilst the
hoses are detached.

Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the

engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap
further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.

18 Disconnect the fuel return pipe from the
CFi unit.
19 Refer to Section 5 and disconnect the
accelerator cable from the CFi unit.
20 Disconnect the inlet air temperature
sensor, throttle plate control motor and
throttle position sensor wiring multi-plug
connectors.

4B•6 Fuel system - central fuel injection engines

14.8  Exploded view of the fuel pressure

regulator assembly

14.5e  Withdrawing the seal from the

injector retaining collar

14.5d  Injector seals in the CFi unit

14.5c  Withdrawing the injector from the

CFi unit

14.5b  Removing the injector retaining

collar

14.5a  Removing an injector retaining

collar securing bolt and its locktab

1595Ford Fiesta Remake

21 Disconnect the vacuum hose from the CFi
unit.
22 Unscrew and remove the four retaining
screws, and remove the CFi unit from the inlet
manifold  (see illustration). Remove the
gasket.
23 Clean the CFi unit and the inlet manifold
mating faces.
24 Refit in the reverse order of removal.
Tighten the retaining bolts to the specified
torque wrench setting. Check and top-up the
cooling system as required (see “Weekly
Checks” and Chapter 1).
25 When the CFi unit is refitted, turn the
ignition on and off at least five times to
pressurise the system, and check for leaks.

Throttle plate control motor

26 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
27 Refer to Section 4 and remove the air
cleaner.
28 Detach the wiring multi-plugs from the
throttle position sensor and the throttle plate
control motor, and release the retaining clips
on the bracket (see illustrations).
29 Undo and remove the motor support
bracket screws, and remove the bracket
complete with the motor from the CFi unit
(see illustration).
30 Undo the motor retaining screws and
remove it from the support bracket.
31 Refit in the reverse order of removal, but
note the following points:

a) When refitting the motor and its support

bracket to the injector unit, the throttle
position sensor must locate on the
accelerator linkage, and the bracket must
align with the pegs.

b) On completion, the idle speed should be

checked by a Ford dealer or fuel injection
specialist who has the required
equipment to link up with the EEC IV
engine management module.

Fuel trap

32 A fuel trap is fitted to the manifold
absolute pressure sensor vacuum hose on
certain models.
33 To remove the fuel trap, disconnect the
vacuum hoses from the fuel trap and withdraw it.
34 Refit in the reverse order of removal. It is
important to ensure that the trap is correctly
orientated, with the “CARB” mark on one end

face towards the inlet manifold, and the
“DIST” mark towards the MAP sensor (see
illustration).

EEC IV engine management
module

Note: The module is fragile. Take care not to
drop it, or subject it to any other kind of
impact. Do not subject it to extremes of
temperature, or allow it to get wet.
35 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
36 Unscrew and remove the two nuts
securing the module cover in the engine
compartment, then carefully draw the cover
away from its location. Unscrew the module
multi-plug retaining bolt and disconnect the
multi-plug from the module (see illustrations).
37 The aid of an assistant will be required at
this stage, to support and withdraw the

Fuel system - central fuel injection engines  4B•7

14.28b  Disconnecting the throttle plate

control motor multi-plug

14.28a  Release the throttle position

sensor multi-plug from its retaining clip

and disconnect it

14.22  CFi unit securing screws (arrowed)

14.36b  Undoing the EEC IV engine

management module multi-plug retaining

bolt

14.34  Fuel trap vacuum connection markings

14.29  Throttle-plate control motor and

throttle position sensor assembly

mounting bracket securing screws

(arrowed)

14.36a  Undoing the EEC IV engine

management module cover retaining nuts

(vehicle jack removed for clarity)

4B

1595Ford Fiesta Remake

module from inside the passenger
compartment as its mounting bracket
retaining tags are compressed and released
from the engine compartment. Do not allow
the module to drop into the passenger
compartment as irreparable damage is likely
to result (see illustration). The module may
be separated from its mounting bracket by
undoing the securing bolts.
38 Refitting is a reversal of the removal
procedure, ensuring that the module
mounting bracket retaining tags are felt to
snap into position

Crankshaft position sensor

39 Refer to Chapter 5B.

Coolant temperature sensor

40 Refer to Chapter 3.

Inlet air temperature sensor

41 Remove the air cleaner assembly as
described in Section 4.
42 Releasing its clip, unplug the sensor’s
electrical connector, then unscrew the sensor
from the CFi unit (see illustration).
43 Refitting is the reverse of the removal
procedure. Tighten the sensor to the specified
torque wrench setting; if it is overtightened, its
tapered thread may crack the resonator.

Throttle position sensor

44 Remove the air cleaner assembly as
described in Section 4.
45 Releasing its wire clip, unplug the
sensor’s wiring connector. Remove the
retaining screws, and withdraw the unit from
the throttle plate control motor bracket (see
illustration). Do not force the sensor’s centre
to rotate past its normal operating sweep; the
unit will be seriously damaged.
46 Refitting is the reverse of the removal
procedure, ensuring that the sensor actuating
arm is correctly located.

Vehicle speed sensor

47 The sensor is mounted at the base of the
speedometer drive cable, and is removed with
the speedometer drive pinion. Refer to the
relevant Section of Chapter 7A or B, as
applicable.

Manifold absolute pressure
sensor

48 The sensor is located near the centre of
the engine compartment bulkhead.
49 Disconnect the wiring multi-plug, and
detach the vacuum hose from the base of the
sensor (see illustration).
50 Undo the two retaining screws, and
withdraw the sensor from its location.

51 Refitting is the reverse of the removal
procedure.

Power steering pressure switch

52 Releasing its clip, unplug the switch’s
electrical connector, then unscrew the switch
from the power steering high pressure pipe.
Place a wad of rag underneath, to catch any
spilt fluid. If a sealing washer is fitted, renew it
if it is worn or damaged.
53 Refitting is the reverse of the removal
procedure; tighten the switch securely, then
top-up the fluid reservoir (see “Weekly
Checks”) to replace any fluid lost from the
system, and bleed out any trapped air (see
Chapter 10). 

Oxygen sensor

Note: The sensor is delicate, and will not work
if it is dropped or knocked, if its power supply
is disrupted, or if any cleaning materials are
used on it.
54 Release the sensor’s electrical connector
from its bracket and unplug it to disconnect
the sensor (see illustration).
55 Raise and support the front of the vehicle
if required to remove the sensor from
underneath (“see Jacking and vehicle
support”). Remove the sensor heat shield then
unscrew the sensor from the exhaust system
front downpipe; collect the sealing washer
(where fitted).
56 On refitting, clean the sealing washer
(where fitted) and renew it if it is damaged or

4B•8 Fuel system - central fuel injection engines

14.54  Oxygen sensor (A) (shown with its

heatshield removed), and its multi-plug (B)

14.49  Manifold absolute pressure sensor location

A  Securing screws              B  Multi-plug             C  Vacuum hose

Arrows indicate ignition module retaining screws

14.45  Throttle position sensor retaining

screws (arrowed) (shown with throttle

plate control motor removed)

14.42  Disconnecting the intake air

temperature sensor multi-plug

1595Ford Fiesta Remake

14.37  Withdrawing the EEC IV engine

management module into the passenger

footwell

worn. Apply a smear of anti-seize compound
to the sensor’s threads, to prevent them from
welding themselves to the downpipe in
service. Refit the sensor, tightening it to its
specified torque wrench setting; a slotted
socket will be required to do this. Reconnect
the wiring, and heat shield then refit the
connector plug.

Inlet manifold heater

57 The heater is located in a recess in the
inlet manifold, directly underneath the CFi
unit. While access is possible from
underneath, it is preferable, depending on the
tools available, to remove the complete
manifold (Section 15) to reach the heater.
58 Assuming the work is being carried out
without removing the manifold, disconnect
the battery negative (earth) lead (refer to
Chapter 5A, Section 1).
59 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
60 Disconnect the heater wiring, and extract
the circlip retaining the heater (see
illustration). Withdraw the heater.
61 Refitting is the reverse of the removal
procedure. Ensure that both the heater and its
circlip are correctly located in the manifold.

Injector ballast resistor

62 When fitted, this component is located on
the engine compartment bulkhead, next to the
manifold absolute pressure sensor.
63 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
64 Disconnect the resistor wiring at its multi-
plug, remove the retaining screw and
withdraw the resistor.
65 Refitting is the reverse of the removal
procedure.

15 Inlet manifold - 

removal and refitting

3

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

Removal

1 Drain the cooling system as described in
Chapter 1.
2 Remove the CFi unit as described in
Section 14.
3 Noting their locations, disconnect the
coolant, vacuum and breather hoses from the
manifold.
4 Disconnect the wiring multi-plugs from the

engine sensors at the inlet manifold.
Disconnect the radio earth lead at the inlet
manifold connector.
5 Undo the retaining bolts, and withdraw the
manifold from the cylinder head. Remove the
gasket.
6 With the manifold removed, clean all traces
of the old gasket from the mating surfaces of
the manifold and the cylinder head.

Refitting

7 Refitting is the reversal of removal. Use a
new gasket, and tighten the retaining bolts to
the specified torque. Refit the remainder of
the components with reference to the
appropriate Chapters of this instruction.

Fuel system - central fuel injection engines  4B•9

14.60  Inlet manifold heater components

4B

1595Ford Fiesta Remake