
5A
1595Ford Fiesta Remake
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 12 volt, negative earth
Battery
Rating - Cold cranking/Reserve capacity . . . . . . . . . . . . . . . . . . . . . . . . 270 A/50 RC, 360 A/60 RC, 500 A/70 RC, 590 A/90 RC or 650 A/130 RC
Charge condition:
Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . . 12.5 volts
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 12.6 volts
Good . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . . 12.7 volts
Alternator
Make/type:
Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . K1-55A, K1-70A, KC-70A or KC-90A
Magneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . A127/55 or 127/70
Mitsubishi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . A5T or A002T
Output (nominal at 13.5 volts with engine speed of 6000 rpm) . . . . . . . 55, 70 or 90 amps
Regulating voltage at 4000 rpm engine speed and 3 to 7 amp load . . . 14.0 to 14.6 volts
Minimum brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 5.0 mm
Starter motor
Make/type:
Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . DM, DW or EV
Magneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . M79 or M80R
Nippondenso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . No type numbers given
Minimum brush length:
Bosch and Magneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
Nippondenso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 9.0 mm
Torque wrench settingsNm lbf ft
Alternator mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
25 18
Alternator adjustment bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Alternator adjustment centre lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Adjuster link-to-mounting bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Alternator pulley nut:
With key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . 50 37
Without key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 60 44
Starter motor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Starter motor support bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Chapter 5 Part A:
Starting and charging systems
Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator brushes and voltage regulator - renewal . . . . . . . . . . . . . 7
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - testing and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . .See
“Weekly Checks” Charging system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
General information, precautions and battery disconnection . . . . . . 1
Starter motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter motor - testing and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 10
Starting system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5A•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
The jack supplied with the vehicle tool kit
should only be used for changing the
roadwheels - see “Wheel changing” at the
front of this manual. When jacking up the
vehicle to carry out repair or maintenance
tasks, a pillar or trolley type jack of suitable
lifting capacity must be used, supplemented
with axle stands positioned only beneath the
appropriate points under the vehicle (see
illustration) . Note that the vehicle must never
be jacked up at the rear under the axle beam. The maximum kerb weight of the vehicle must
not be exceeded when jacking and supporting
the vehicle. Do not under any circumstances
jack up the rear of the vehicle under the rear axle.
Never work under, around or near a raised
vehicle unless it is adequately supported in at
least two places with axle stands.
The radio/cassette unit fitted as standard or
optional equipment may be equipped with a
built-in security code, to deter thieves. If the
power source to the unit is cut, the anti-theft
system will activate. Even if the power source
is immediately reconnected, the radio/
cassette unit will not function until the correct security code has been entered. Therefore,
if you do not know the correct security
code for the radio/cassette unit do not
disconnect either of the battery terminals, or
remove the radio/cassette unit from the
vehicle. To enter the correct security code, follow the instructions provided with the
radio/cassette player or vehicle handbook.
If an incorrect code is entered, the unit will
become locked, and cannot be operated.
If this happens, or if the security code is lost
or forgotten, seek the advice of your Ford
dealer.
Jacking and vehicle supportREF•5
REF
Radio/cassette unit anti-theft system - precaution
Underside view of the vehicle showing the jacking point locations
A Jacking points for trolley jack (always use a suitable block
of wood to protect the
vehicle body)
B Axle stand positions
C Jacking points for owner jack and wheel-free hoist
Buying spare parts
Spare parts are available from many
sources, including maker’s appointed
garages, accessory shops, and motor factors.
To be sure of obtaining the correct parts, it
will sometimes be necessary to quote the
vehicle identification number. If possible, it
can also be useful to take the old parts along
for positive identification. Items such as
starter motors and alternators may be
available under a service exchange scheme -
any parts returned should always be clean.
Our advice regarding spare part sources is
as follows.
Officially-appointed garages
This is the best source of parts which are
peculiar to your car, and which are not
otherwise generally available (eg badges,
interior trim, certain body panels, etc). It is
also the only place at which you should buy
parts if the vehicle is still under warranty.
Accessory shops
These are very good places to buy materials and components needed for the
maintenance of your car (oil, air and fuel
filters, spark plugs, light bulbs, drivebelts, oils
and greases, brake pads, touch-up paint, etc).
Components of this nature sold by a
reputable shop are of the same standard as
those used by the car manufacturer.
Besides components, these shops also sell
tools and general accessories, usually have
convenient opening hours, charge lower
prices, and can often be found not far from
home. Some accessory shops have parts
counters where the components needed for
almost any repair job can be purchased or
ordered.
Motor factors
Good factors will stock all the more
important components which wear out
comparatively quickly, and can sometimes
supply individual components needed for the
overhaul of a larger assembly (eg brake seals
and hydraulic parts, bearing shells, pistons,
valves, alternator brushes). They may also
handle work such as cylinder block reboring,
crankshaft regrinding and balancing, etc.
Tyre and exhaust specialists
These outlets may be independent, or
members of a local or national chain. They
frequently offer competitive prices when
compared with a main dealer or local garage,
but it will pay to obtain several quotes before
making a decision. When researching prices,
also ask what “extras” may be added - for
instance, fitting a new valve and balancing the
wheel are both commonly charged on top of
the price of a new tyre.
Other sources
Beware of parts or materials obtained from
market stalls, car boot sales or similar outlets.
Such items are not invariably sub-standard,
but there is little chance of compensation if
they do prove unsatisfactory. In the case of
safety-critical components such as brake
pads, there is the risk not only of financial loss
but also of an accident causing injury or
death. Second-hand components or assemblies
obtained from a car breaker can be a good
buy in some circumstances, but this sort of
purchase is best made by the experienced
DIY mechanic.
Buying spare parts
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