Ford Fiesta (1989-1995). Instruction - part 37

2 The exhaust manifold is secured the
cylinder head by studs and nuts, and is
similarly attached to the exhaust downpipe. A
shroud/heat shield is bolted to the manifold,
to direct exhaust-heated air into the air inlet
system when the engine is cold. Access to the
exhaust manifold retaining nuts is gained by
first removing this shroud (see illustration).
3 On vehicles equipped with a pulse-air
system, remove the pulse-air piping as
described in Section 7.
4 Support the exhaust downpipe on a jack or
suitable blocks, and undo the downpipe-to-
manifold retaining nuts. Separate the pipe
from the manifold, and remove the gasket. On
catalytic converter-equipped vehicles with an
oxygen sensor fitted to the exhaust
downpipe, take care not to stretch the sensor
wiring; if necessary, disconnect the sensor’s
multi-plug.
5 Undo the retaining nuts, and withdraw the
manifold from the cylinder head studs.
Remove the manifold gasket.

Zetec engines

Note: In addition to the new gasket and any
other parts, tools or facilities needed to carry
out this operation, a new plastic guide sleeve
will be required on reassembly.
6 Disconnect the battery negative (earth) lead
- see Chapter 5A, Section 1.
7 Remove the air inlet components as
described in Part D of this Chapter.
8 Drain the cooling system (see Chapter 1).
9 Disconnect the coolant hose and the
coolant pipe/hose from the thermostat
housing; secure them clear of the working
area.
10 Unbolt the exhaust manifold heat shield,
and withdraw both parts of the shield (see
illustration).
11 While the manifold can be removed with
the pulse-air system components attached -
unbolt the filter housing and disconnect its
vacuum hose if this is to be done - it is easier
to remove the pulse-air assembly first, as
described in Section 7.

12 Unplug the oxygen sensor electrical
connector, to avoid straining its wiring.
Unscrew the nuts to disconnect the exhaust
system front downpipe from the manifold.
13 Remove the nuts and detach the manifold
and gasket (see illustration). When removing
the manifold with the engine in the vehicle,
additional clearance can be obtained by
unscrewing the studs from the cylinder head;
a female Torx-type socket will be required.
14 Always fit a new gasket on reassembly, to
carefully-cleaned components. Do not
attempt to re-use the original gasket.

Inspection

15 Use a scraper to remove all traces of old
gasket material and carbon deposits from the
manifold and cylinder head mating surfaces.
Provided both mating surfaces are clean and
flat, a new gasket will be sufficient to ensure
that the joint is gastight. Do not use any kind
of exhaust sealant upstream of the catalytic
converter, where fitted.
16 Note that on some models, the downpipe is
secured to the manifold by two bolts, with a coil
spring, spring seat and self-locking nut on each.
On refitting, tighten the nuts until they stop on
the bolt shoulders; the pressure of the springs
will then suffice to make a gastight joint.
17 Do not overtighten the nuts to cure a leak -
the bolts will shear; renew the gasket and the
springs if a leak is found. The bolts themselves
are secured by spring clips to the manifold,
and can be renewed easily if damaged.

Refitting

18 Refitting is the reverse of the removal
procedure, noting the following points:

a) Position a new gasket over the cylinder

head studs, and on Zetec engines, fit a
new plastic guide sleeve to the stud
nearest to the thermostat housing, so that
the manifold will be correctly located (see
illustration). Do not refit the manifold
without this sleeve.

b) Refit the manifold, and finger-tighten the

mounting nuts.

c) Working from the centre out, and in three

or four equal steps, tighten the nuts to the
torque wrench settings given in the
Specifications.

4E•4 Exhaust and emission control systems

3.18  Fit a new plastic guide sleeve to the

stud (arrowed) when refitting the manifold

(Zetec engine models)

3.13  Exhaust manifold retaining nuts

(Zetec engine models)

3.10  Exhaust manifold heat shield bolts

(arrowed) (Zetec engine models)

3.2  Exploded view of the exhaust manifold arrangement (1.6 litre CVH EFi engine models)

1 Retaining stud
2 Gasket
3 Heatshield

4 Exhaust manifold
5 Manifold retaining nut
6 Centring hole

7 Heatshield retaining bolt
8 Cylinder head

1595Ford Fiesta Remake

d) Refit the remaining parts in the reverse

order of removal. Tighten all fasteners to
the specified torque wrench settings
where given.

e) Where drained, refill the cooling system

(see Chapter 1).

f) Run the engine, and check for exhaust

leaks. Check the coolant level when fully
warmed-up to normal operating
temperature.

4

Catalytic converter - general
information and precautions

The catalytic converter is a reliable and

simple device, which needs no maintenance
in itself, but there are some facts of which an
owner should be aware if the converter is to
function properly for its full service life.

a) DO NOT use leaded petrol in a vehicle

equipped with a catalytic converter - the
lead will coat the precious metals,
reducing their converting efficiency, and
will eventually destroy the converter.

b) Always keep the ignition and fuel systems

well-maintained in accordance with the
manufacturer’s schedule (see Chapter 1).

c) If the engine develops a misfire, do not

drive the vehicle at all (or at least as little
as possible) until the fault is cured.

d) DO NOT push - or tow-start the vehicle -

this will soak the catalytic converter in
unburned fuel, causing it to overheat
when the engine does start.

e) DO NOT switch off the ignition at high

engine speeds, ie do not “blip” the
throttle immediately before switching off.

f) DO NOT use fuel or engine oil additives -

these may contain substances harmful to
the catalytic converter.

g) DO NOT continue to use the vehicle if the

engine burns oil to the extent of leaving a
visible trail of blue smoke.

h) Remember that the catalytic converter

operates at very high temperatures. DO
NOT, therefore, park the vehicle in dry
undergrowth, over long grass or piles of
dead leaves, after a long run.

I) Remember that the catalytic converter is

FRAGILE. Do not strike it with tools
during servicing work.

j) In some cases, a sulphurous smell (like

that of rotten eggs) may be noticed from
the exhaust. This is common to many
catalytic converter-equipped vehicles.
Once the vehicle has covered a few
thousand miles, the problem should
disappear. Low quality fuel with a high
sulphur content will exacerbate this effect.

k) The catalytic converter used on a well-

maintained and well-driven vehicle should
last for between 50 000 and 
100 000 miles. If the converter is no
longer effective, it must be renewed.

5

Positive crankcase
ventilation system - checking
and component renewal

2

Checking

1 Checking procedures for the system
components are included in Chapter 1.

Component renewal - all
engines except Zetec

Air cleaner components

2 See Chapter 1.

Filter/oil separator and hoses

3 All the components relating to the positive
crankcase ventilation system, with the
exception of the HCS engine filter/adapter
located on the underside of the air cleaner,
may be removed by simple disconnection and
withdrawal (having noted all connections for
subsequent refitting).
4 The refitting of all components is a reversal
of the removal procedure, ensuring that the
connections are correctly made.

Component renewal - Zetec
engines

Air cleaner components

5 See Chapter 1.

Positive Crankcase Ventilation (PCV)
valve

6 The valve is plugged into the oil separator
on Zetec engines (see illustration).

Depending on the tools available, access to
the valve may be possible once the pulse-air
assembly has been removed (see Section 7).
If this is not feasible, proceed as outlined in
paragraph 7 below.

Oil separator

7 Remove the exhaust manifold (see Sec-
tion 3). The positive crankcase ventilation
valve can now be unplugged and flushed, or
renewed, as required, as described in Chap-
ter 1.
8 Unbolt the oil separator from the cylinder
block/crankcase, and withdraw it; remove and
discard the gasket.
9 Flush out or renew the oil separator, as
required (see Chapter 1).
10 Refitting is the reverse of the removal
procedure, but use a new gasket between the
oil separator and cylinder block. Refill the
cooling system (see Chapter 1). Run the
engine, check for exhaust leaks, and check
the coolant level when it is fully warmed-up.

6

Evaporative emissions
control system - checking
and component renewal

2

Checking

1 Poor idle, stalling and poor driveability can
be caused by an inoperative canister-purge
solenoid valve, a damaged canister, split or
cracked hoses, or hoses connected to the
wrong fittings. Check the fuel filler cap for a
damaged or deformed gasket.

Exhaust and emission control systems  4E•5

5.6  Crankcase emission control system (Zetec engine models)

1 Oil separator
2 Gasket
3 Positive crankcase ventilation (PCV) valve

4 Cylinder block/crankcase opening
5 Crankcase breather pipe and flexible

hoses

4E

1595Ford Fiesta Remake

2 Fuel loss or fuel odour can be caused by
liquid fuel leaking from fuel lines, a cracked or
damaged canister, an inoperative canister-
purge solenoid valve, or disconnected,
misrouted, kinked or damaged vapour or
control hoses.
3 Inspect each hose attached to the canister
for kinks, leaks and cracks along its entire
length. Repair or renew as necessary.
4 Inspect the canister. If it is cracked or
damaged, renew it. Look for fuel leaking from
the bottom of the canister. If fuel is leaking,
renew the canister, and check the hoses and
hose routing.
5 If the canister-purge solenoid valve is
thought to be faulty, unplug its electrical
connector and disconnect its vacuum hoses.
Connect a battery directly across the valve
terminals. Check that air can flow through the
valve passages when the solenoid is thus
energised, and that nothing can pass when
the solenoid is not energised.
6 Further testing should be left to a dealer
service department.

Component renewal

Charcoal canister-purge solenoid
valve

7 The solenoid is located at or near to the
bulkhead, behind the engine on the right-hand
side  (see illustrations). Locate the solenoid,
then remove any components as necessary to
improve access.

8 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1), then unplug
the valve’s electrical connector. Unclip the
valve from its location, then disconnect its
vacuum hoses and withdraw it.
9 Refitting is the reverse of the removal
procedure.

Charcoal canister

10 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
11 The canister is located in the front right-
hand corner of the engine compartment.
12 Disconnect the vapour pipe from the unit,
and plug it to prevent the ingress of dirt (see
illustrations)
13 Undo the retaining screw and withdraw
the unit upwards, releasing it from its bracket
(see illustration).
14 Refit in the reverse order of removal.
Unplug the vapour pipe before reconnecting
it, and ensure that it is clean and securely
connected.

7

Pulse-air system - checking
and component renewal

2

Checking

1 Poor idle, stalling, backfiring and poor
driveability can be caused by a fault in the
pulse-air system.

2 Inspect the vacuum pipe/hose for kinks,
leaks and cracks along its entire length.
Repair or renew as necessary.
3 Inspect the filter housing and piping. If
either is cracked or damaged, renew it.
4 If the pulse-air solenoid valve is thought to
be faulty, unplug its electrical connector and
disconnect its vacuum hoses. Connect a
battery directly across the valve terminals,
and check that air can flow through the valve
passages when the solenoid is thus
energised, and that nothing can pass when
the solenoid is not energised.
5 Further testing should be left to a dealer
service department.

Component renewal

Pulse-air valve, filter and housing
(HCS engines)

6 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
7 Disconnect the vacuum hose from the rear
of the pulse-air valve assembly (see
illustration).
8 Undo the retaining screws, and withdraw
the air-valve, filter and housing assembly from
the mounting bracket.
9 To dismantle the filter housing, undo the
four screws and separate the top from the
base of the housing; extract the foam filter,
and clean it in a suitable solvent. If any of the
housing’s components are worn or damaged,
the assembly must be renewed.

4E•6 Exhaust and emission control systems

7.7  Location of pulse-air valve (arrowed)

(1.3 litre HCS CFi engine models)

6.13  Undo the retaining screw and

withdraw the canister upwards, releasing

the tag (arrowed) from its bracket

6.12b  Canister location and fuel vapour

pipe (arrowed) (Zetec engine models)

6.12a  Fuel vapour pipe (A) and canister

retaining screw (B) (1.4 litre CVH 

CFi engine models)

6.7b  Canister purge solenoid valve

(arrowed) (Zetec engine models)

6.7a  Canister purge solenoid valve (A) and

multi-plug (B) (1.4 litre CVH CFi engine

models)

1595Ford Fiesta Remake

10 Refitting is the reverse of the removal
procedure.

Pulse-air valve, filter and housing
(Zetec engines)

11 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
12 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
13 Disconnect the vacuum hose from 
the base of the filter housing (see illustration).
14 Remove the air cleaner air inlet components
for access (refer to Part D of this Chapter).
15 Remove the screws securing the filter
housing to the piping, unscrew the mounting
bolt, then withdraw the housing.
16 To dismantle the filter housing, undo the
four screws and separate the top from the
base of the housing. Extract the foam filter,
and clean it in a suitable solvent. If any of the
housing’s components are worn or damaged,
the assembly must be renewed.
17 Refitting is the reverse of the removal
procedure.

Pulse-air solenoid valve

18 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
19 Releasing its wire clip, unplug the
electrical connector, then release the valve
from its mounting bracket. Withdraw the
valve, then label and disconnect the two
vacuum hoses (see illustration).
20 Refitting is the reverse of the removal
procedure; ensure that the hoses are correctly
reconnected.

Pulse-air piping (HCS engines)

21 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).

22 Remove the air cleaner if necessary for
improved access (refer to Part B of this
Chapter).
23 Disconnect the vacuum hose from the
pulse-air valve.
24 Unbolt and detach the air tube from its
fixing to the exhaust manifold, cylinder head
and transmission, according to engine type.
25 Loosen off the four nuts securing the air
delivery tubes to the cylinder head exhaust
ports, then carefully withdraw the delivery
tubes as a unit (see illustration). Do not apply
undue force to the tubes as they are
detached.
26 Carefully clean the piping, particularly its
threads and those of the manifold. Remove all
traces of corrosion, which might prevent the
pipes seating properly, causing air leaks when
the engine is restarted.
27 On refitting, insert the piping carefully into
the cylinder head ports, taking care not to
bend or distort it. Apply anti-seize compound
to the threads, and tighten the retaining 
sleeve nuts while holding each pipe firmly in
its port.
28 The remainder of the refitting procedure is
the reverse of removal.

Pulse-air piping (Zetec engines)

29 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
30 Remove the air cleaner air inlet
components for access (refer to Part D of this
Chapter).
31 Unbolt the exhaust manifold heat shield;
unclip the coolant hose to allow the upper
part to be withdrawn.
32 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).

33 Disconnect the vacuum hose at the base
of the pulse-air filter housing.
34 Unscrew the two bolts securing the pipe
assembly to the support bracket and the four
sleeve nuts securing the pipes into the
exhaust manifold (see illustration). Remove
the pipes and filter housing as an assembly,
taking care not to distort them.
35 Carefully clean the piping, particularly its
threads and those of the manifold. Remove all
traces of corrosion, which might prevent the
pipes seating properly, causing air leaks when
the engine is restarted.
36 On refitting, insert the piping carefully into
the cylinder head ports, taking care not to bend
or distort it. Apply anti-seize compound to the
threads, and tighten the retaining sleeve nuts
while holding each pipe firmly in its port; if a
suitable spanner is available, tighten the 
sleeve nuts to the specified torque wrench
setting.
37 The remainder of the refitting procedure is
the reverse of removal.

Exhaust and emission control systems  4E•7

7.25  Pulse-air piping sleeve nuts (3 of 4

arrowed) (1.3 litre HCS CFi engine models)

7.19  Pulse-air solenoid valve location

(arrowed) under ignition module

7.13 Disconnecting the vacuum hose from

the base of the filter housing - note the

housing retaining bolts (arrowed) (Zetec

engine models)

7.34  Pulse-air piping sleeve nuts (arrowed)

(Zetec engine models)

4E

1595Ford Fiesta Remake