1989 FORD FIESTA fog light

12
1595Ford Fiesta Remake
Fuses - pre-1992 models
Main fuse board:
No Rating (amps) Circuit(s) protected
1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . Electronic engine control system
2 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Interior light, cigarette lighter, clock and radio memory
3 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Central locking system
4 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated rear window element
5 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Dim-dip lighting
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand side lights and rear fog light
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand side lights
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand dipped beam
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand dipped beam
10 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand main beam and right-hand auxiliary driving light
11 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand main beam and left-hand auxiliary driving light
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heater fan motor and reversing light
13 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Radiator cooling fan motor
14 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Front foglights (XR2i only)
15 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Horn
16 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Wiper motor and windscreen/tailgate washer pump
17 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Brake stop lights, instrument illumination and instrument warning
18 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electrically operated windows
19 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electric fuel pump
20 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Oxygen sensor (vehicles with catalytic converter)
21 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand direction indicators
22 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand direction indicators
Chapter 12
Body electrical systems
Air bag (driver’s side) - removal and refitting . . . . . . . . . . . . . . . . . . 28
Air bag (passenger’s side) - removal and refitting . . . . . . . . \
. . . . . . . 29
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 31
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 30
Anti-theft systems - general information . . . . . . . . . . . . . . . . . . . . . . 27
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . . .See
“Weekly checks”
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cigarette lighter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 12
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electric window regulator motor - removal and refitting . . . . . . . . . . 20
Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . 2
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses and relays - general information . . . . . . . . . . . . . . . . . . . . . . . 3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight and auxiliary light beam alignment - checking and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 8
Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel components - removal and refitting . . . . . . . . . . . 10
“Lights-on” warning module - removal and refitting . . . . . . . . . . . . . 26
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . 22
Screen washer fluid level check . . . . . . . . . . . . . .See
“Weekly checks”
Speaker balance control joystick - removal and refitting . . . . . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate remote release motor - removal and refitting . . . . . . . . . . . 21
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 18
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Windscreen wiper pivot shaft - removal and refitting . . . . . . . . . . . . 17
Windscreen/tailgate washer system components - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 19
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
12•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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Additional fuses behind main fuse board:
NoRating (amps) Circuit(s) protected
23 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . Unused
24/25 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
26 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Tailgate remote release
27/28 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
Fuses - 1992 models onward
Main fuse board:
Fuses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . Unchanged from pre-1992 models
Additional fuses behind main fuse board:
No Rating (amps) Circuit(s) protected
23* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Unused
23** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
24* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Unused 24** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
25 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Tailgate remote release, anti-theft warning system
26 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
27 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
28* 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Full-length sunroof
28** 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Automatic transmission starter inhibitor
29 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Air bag
* Pre-1994 models
** 1994 models onward
Relays (pre-1992 models)
Note: Relay locations and circuits controlled are liable to change from year t\
o year. Consult a Ford dealer, for specific information.
No Circuit(s) controlled
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated rear window
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Windscreen wiper delay
III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . CFi (fuel injection) delay relay
IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Ignition switch
VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Automatic transmission starter inhibitor/electric fuel pump (bridge fitted to carburettor engines without automatic transmission)
VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight main beam
VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated windscreen
XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Idle speed control (automatic transmission) two-tone horn (where fitt\
ed)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Front foglights (XR2i)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight dipped beam
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
Relays (1992 models onward)
Note: Relay locations and circuits controlled are liable to change from year t\
o year. Consult a Ford dealer, for specific information.
No Circuit(s) controlled
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated rear window
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Windscreen wiper delay
III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . CFi delay relay or EFi supply relay (fuel injection)
IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Ignition switch
VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Automatic transmission starter inhibitor, anti-theft warning system
VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight main beam
VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system and/or dim-dip lighting
IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated windscreen
XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Idle speed control (automatic transmission) or two-tone horn (where f\
itted)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Fuel pump
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Front foglights (XR2i, RS Turbo and RS 1800)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight dipped beam
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
12•2 Body electrical systems
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BulbsWattage
Headlight (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . H4, 60/55
Sidelight (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 5
Direction indicators (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Side direction indicator repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Auxiliary driving and foglights (S and XR2i) . . . . . . . . . . . . . . . . . . . . . . H3, 55
Stop/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 21/5
Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 21
Reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 21
Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 10
Interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 10
Luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
1.3 or 2.6
Panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1.3 or 2.6
Cigarette lighter illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Automatic transmission selector illumination . . . . . . . . . . . . . . . . . . . . . 2
Lubricants
Grease for windscreen wiper linkage and pivots . . . . . . . . . . . . . . . . . . To Ford specification SAM-1C-911-A
Torque wrench settingsNm lbf ft
Wiper motor to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 8 to 9 6 to 7
Wiper motor bracket to bulkhead/tailgate . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Windscreen wiper crank to driving shaft nut . . . . . . . . . . . . . . . . . . . . . 22 to 24 16 to 18
Windscreen/tailgate wiper arm retaining nut . . . . . . . . . . . . . . . . . . . . . 17 to 18 12 to 13
Windscreen wiper pivot shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 7 to 9
Windscreen/tailgate washer reservoir securing bolts . . . . . . . . . . . . . . . 2.5 to 3.5 2 to 3
Headlight retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 5.4 to 7.0 4 to 5
Tail light securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1.5 to 2.5 1 to 2
Auxiliary light retaining nut (S models) . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 to 9.2 5 to 7
Horn bracket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 33 18 to 24
Starter inhibitor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 9 to 14 7 to 10
Body electrical systems 12•3
12
1595Ford Fiesta Remake
1 General information and
precautions
General information
The electrical system is of 12-volt negative
earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid battery, which is charged by the
engine-driven alternator.
This Chapter covers repair and service
procedures for the various electrical
components not associated with the engine.
Information on the battery, ignition system,
alternator, and starter motor can be found in
Chapter 5A and B.
All models from 1994 onwards are fitted
with a driver’s air bag, which is designed to
prevent serious chest and head injuries to the
driver during an accident. A similar bag for the
front seat passenger is also available. The
combined sensor and electronics for the air
bag is located next to the steering column
inside the vehicle, and contains a back-up
capacitor, crash sensor, decelerometer,
safety sensor, integrated circuit and
microprocessor. The air bag is inflated by a
gas generator, which forces the bag out of the module cover in the centre of the steering
wheel. A “clock spring” ensures that a good
electrical connection is maintained with the air
bag at all times - as the steering wheel is
turned in each direction, the spring winds and
unwinds.
An anti-theft alarm system is available on
later models, and is triggered if the vehicle is
broken into through the doors, bonnet, or
tailgate. The alarm will also be triggered if the
ignition or audio equipment is tampered with.
Additionally, from the 1994 model year
onwards, a Passive Anti-Theft System (PATS)
is fitted. This system, (which works
independently of the standard alarm) prevents
the engine from being started unless a
specific code, programmed into the ignition
key, is recognised by the PATS transceiver.
Precautions
Warning: Before carrying out
any work on the electrical
system, read through the
precautions given in “Safety
first!” at the beginning of this manual and
in Chapter 5A, Section 1.
Caution: Prior to working on any
component in the electrical system, the
battery negative lead should first be
disconnected, to prevent the possibility of electrical short-circuits and/or fires. If a
radio/cassette player with anti-theft
security code is fitted, refer to the
information given in the reference sections
of this manual before disconnecting the
battery.
2 Electrical fault-finding
-
general information
2
Note: Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before starting work. The following tests relate
to testing of the main electrical circuits, and
should not be used to test delicate electronic
circuits (such as engine management
systems), particularly where an electronic
control unit is used. Also refer to the
precautions given in Chapter 5A, Section 1.
General
1 A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
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the inside face of the cover to remove and fit
the fuses (see illustrations) .
2 To remove a fuse, use the tweezers
provided to pull it out of the holder. Slide the
fuse sideways from the tweezers. The wire
within the fuse is clearly visible, and it will be
broken if the fuse is blown.
3 Always renew a fuse with one of an
identical rating. Never renew a fuse more than
once without tracing the source of the trouble.
The fuse rating is stamped on top of the fuse.
4 With the exception of the indicator flasher
relay, the remainder of the relays are fitted to
the reverse side of the main fuse/relay board.
Access is as described in paragraph 1.
5 The various relays can be removed from
their respective locations on the fuse board by
carefully pulling them from the sockets.
6 The direction indicator flasher relay is
attached to the multi-function switch unit on
the steering column. Access to the relay is
made by undoing the retaining screws and
removing the steering column shrouds. The
relay can then be withdrawn from the switch.
7 If a system controlled by a relay becomes
inoperative and the relay is suspect, listen to
the relay as the circuit is operated. If the relay
is functioning, it should be possible to hear it
click as it is energised. If the relay proves
satisfactory, the fault lies with the
components or wiring of the system. If the
relay is not being energised, then it is not
receiving a main supply voltage or a switching
voltage, or the relay is faulty.
4 Switches -
removal and refitting
2
Ignition switch (loom plate and
lock barrel)
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the manual choke control knob,
where fitted, by depressing the lug securing it,
and pulling it from its shaft. The lug is found
on the side of the control knob shank. 3
Remove the lower steering column shroud
by undoing its four retaining screws, then
detach the choke warning light switch/pull
control assembly from the lower shroud by
unscrewing its retaining collar (bayonet-type
fixing), using a suitable tool to locate in the
collar recesses.
4 Remove the two screws securing the upper
steering column shroud from above, and the
two screws securing it from below, the latter
accessible only with the lower shroud
removed.
5 Disconnect the ignition switch wiring multi-
plug connector. Insert a thin-bladed
screwdriver into the lock tab aperture, release
the locking tab and remove the loom plate
from its location on the left-hand side of the
steering column.
6 Where applicable, undo the single screw
and withdraw the Passive Anti-Theft System
(PATS) transceiver from the ignition
switch/steering lock barrel.
7 Insert the key and turn the ignition switch to
position ”I”. Depress the lock barrel plunger
through the steering column lock housing. As
the lock barrel plunger is depressed, pull
on the ignition key to remove the lock barrel
(see illustration) .
8 Refitting is a reversal of the removal
procedure. When relocating the switch to the
steering lock, the barrel driveshaft must align with the switch shaft as it is pushed into
position. Check the switch for satisfactory
operation on completion.
Steering column multi-function
switch
9
Carry out the operations described in
paragraphs 1 to 4 above.
10 Disconnect the wiring multi-plugs from
the multi-function switch assembly, then
remove the single screw securing the switch
assembly to the steering column lock
housing. This retaining screw is located
directly forward of the hazard warning light
switch. Remove the switch assembly.
11 Refitting is a reversal of the removal
procedure.
Facia centre panel switches
(below heater controls)
12 These switches individually control the
front and rear foglights, heated windscreen
and heated rear window element. Where
these features are not fitted to the vehicle,
blanking plates are installed instead of
switches.
13 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
14 Remove the radio/cassette player as
described in Section 22.
15 Remove the ashtray, then undo the three
screws from the base of the centre panel.
Withdraw the centre panel, disconnecting the
cigarette lighter connections as it is
withdrawn.
16 Push the required switch/switches out
from behind, disconnect the multi-plug and
remove the switch.
17 Refitting is a reversal of the removal
procedure.
Centre console switches
18 The switches mounted on the centre
console control the electrically operated
Body electrical systems 12•5
3.1c Component layout on the fuse/relay board. See Specifications for relay
identification
3.1b Withdrawing the fuse/relay board downwards into the driver’s footwell3.1a Method of fuse/relay board retention
A Retaining screws C Support
B Retaining lugs
4.7 Withdraw the lock barrel after
depressing its plunger through the
aperture in the steering column lock
housing (arrowed)12
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8Refitting is a reversal of the removal
procedure.
Front direction indicator side
repeater
9 Remove the appropriate front wheel arch
liner as described in Chapter 11.
10 Remove the appropriate sill scuff plate as
described in Chapter 11, and release the clip
securing the insulation to the panel forward of
the lower A-pillar.
11 Disconnect the supply lead connector and
the earth lead, then release their grommet
from its panel location.
12 From outside the vehicle, twist the light
assembly to release it, then withdraw it and its
leads.
13 Refitting is a reversal of the removal
procedure, ensuring that the grommet is
seated correctly in its panel location.
Rear light cluster
14 Disconnect the multi-plug from the
bulbholder, then press the retaining lugs on
the bulbholder together and remove it (see
illustration) . 15
Unscrew the four nuts securing the light
unit, then remove the unit and its seal.
16 Refitting is a reversal of the removal
procedure. Tighten the light unit securing nuts
to their specified torque.
Number plate light
17 Insert a thin flat-bladed screwdriver
between the light assembly and the bumper,
and carefully prise the light out. Use a rag, or
a piece of card, between the screwdriver and
the bumper, to prevent damage to the
bumper.
18 Detach the connections on the underside
of the light assembly.
19 Refitting is a reversal of the removal
procedure.
Auxiliary lights
S models
20 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
21 Disconnect the light wiring multi-plug then
unscrew its retaining nut, withdraw the bolt
and remove the light unit (see illustration).22
Refitting is a reversal of the removal
procedure, tightening the retaining nut to the
specified torque. On completion, check the
auxiliary light beam alignment as described in
Section 8.
XR2i models
23 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
24 Undo the four Torx retaining screws
securing the relevant dual light assembly to its
bumper location. Note that the retaining and
adjusting screws are captive within the light
assembly - they cannot be removed from
the assembly (see illustration) .
25 Withdraw the light assembly from its
location, then remove the caps protecting the
bulbs and disconnect the wiring.
26 If required, the lights may be removed
individually from their housing at this stage.
Each light is secured to its housing unit by a
combination of two types of clips - foglight
retention differs from driving light retention.
27 The adjusting/retaining clips are removed
by undoing the adjustment screws on the
front of the housing unit, then turning the clips
using pliers or similar tool, before
withdrawing. To remove a retaining-only clip,
lift the lug on the side of the clip using a
screwdriver, then turn the clip using pliers or
similar tool, before withdrawing.
28 Refitting is a reversal of the removal
procedure. On completion, check the auxiliary
light beam alignment as described in Section 8.
8 Headlight and auxiliary light
beam alignment - checking
and adjustment
2
1 Accurate adjustment of the headlight and
auxiliary light beams is only possible using
optical beam-setting equipment, and this
12•10 Body electrical systems
7.24 Auxiliary light assembly (XR2i models) - left-hand unit shown
A Light assembly retaining screws
B Fog light vertical adjustment screw
C Driving light vertical adjustment screw D Driving light horizontal
adjustment screw
E Bulb protective caps
F Fog light bulb connector
G Bulb earth leads
H Driving light bulb connector
7.21 Auxiliary light fixture (S models)
A Bracket retaining nuts C Auxiliary light multi-plug
B Auxiliary light retaining nut
7.14 Press the retaining lugs on the rear
light cluster bulbholder together (broken arrows) to release the bulbholder7.7b . . . then pull the light unit out to
enable the multi-plug (arrowed) to be disconnected
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work should therefore be carried out by a
Ford dealer or service station with the
necessary facilities.
2Temporary adjustment can be made when
the headlight has been removed and refitted,
or to compensate for normal adjustment
whenever a heavy load is being carried. Turn
the adjustment screws at the rear of the
headlight unit to make the adjustment (see
illustration) .
3 Before making any adjustments to the
headlight settings, it is important that the tyre
pressures are correct, and that the vehicle is
standing on level ground. Bounce the front of
the vehicle a few times to settle the
suspension. Ideally, somebody of normal size
should sit in the driver’s seat during the
adjustment, and the vehicle should have a full
tank of fuel.
4 S model auxiliary lights are adjusted by
slackening the light retaining nuts and
swivelling the light assemblies (see
illustration 7.21) . Tighten the nuts upon
completion.
5 XR2i model auxiliary lights are individually
adjustable within their housings, provision
being made for both vertical and horizontal
adjustment of the driving lights, and vertical adjustment only of the foglights. Adjustment is
made via Torx-head captive screws on the
front of the housings
(see illustration 7.24) .
6 Whenever temporary adjustments are
made, the settings must be reset as soon as
possible once the vehicle is in normal use.
9 Instrument panel -
removal and refitting
2
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Disconnect the speedometer cable at the
transmission casing (see Section 11).
3 Remove the two screws securing the
instrument panel bezel from its underside.
Remove the bezel.
4 Remove the four screws securing the
instrument panel to its location, then carefully
pull it out to allow access to the speedometer
cable and multi-plug connections. Disconnect
the speedometer cable and multi-plug, then
remove the instrument panel from the vehicle
(see illustrations) .
Refitting
5Refitting is a reversal of removal. On
completion check the function of all electrical
components.
10 Instrument panel
components -
removal and refitting
1
Removal
1 Remove the instrument panel as described
in Section 9.
Panel illumination and warning light
bulbs
2 All bulbholders are a bayonet fit, requiring a
“twist and withdraw” removal technique (see
illustration) . Bulbs cannot be removed from
their holders -they are renewed complete.
Printed circuit
3 Insert a thin flat-bladed screwdriver into the
multi-plug retainer and carefully unclip it,
having noted its orientation (see illustration).
4 Remove all panel illumination and warning
light bulbholders.
5 Using a suitable tool (a trim clip removal
tool is ideal), carefully prise the printed circuit
off its instrument terminals, and release it from
its retainers before removing.
Speedometer
6 Remove the two bulbholders on the top of
the panel assembly, and release their strip of
printed circuit from its retainers, so that the
instrument panel halves may be separated.
7 Separate the panel halves by releasing the
Body electrical systems 12•11
9.4b Disconnect the speedometer cable
from the rear of the instrument cluster . . .9.4a Instrument cluster securing screws (arrowed)8.2 Exploded view of the headlight unit
A Sidelight bulb holder
B Sidelight bulb
C Headlight bulb retainer
D Headlight bulb
E Bulb protective cap
F Horizontal adjustment screw
G Vertical adjustment screw
10.3 Unclipping the multi-plug retainer from the rear of the instrument cluster10.2 Removing a bulbholder from the rear of the instrument cluster (bayonet type
fitting)9.4c . . . then disconnect the multi-plug
12
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Wiring diagrams 12•27
Diagram 2a: Exterior lighting – stop, reversing, fog and direction in\
dicator lamps
12
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1595 Ford Fiesta Remake
MOT test checksREF•11
REF
Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
M Examine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible
fr om inside the vehicle.
M The front seats themselves must be
secur ely attached and the backrests must
lock in the upright position.
Doors
M Both front doors must be able to be opened
and closed from outside and inside, and must
latch securely when closed.
V ehicle identification
M Number plates must be in good condition,
secur e and legible, with letters and numbers
corr ectly spaced – spacing at (A) should be
twice that at (B).
M The VIN plate and/or homologation plate
must be legible.
Electrical equipment
M Switch on the ignition and check the
operation of the horn.
M Check the windscreen washers and wipers,
examining the wiper blades; renew damaged
or perished blades. Also check the operation
of the stop-lights.
M Check the operation of the sidelights and
number plate lights. The lenses and reflectors
must be secure, clean and undamaged.
M Check the operation and alignment of the
headlights. The headlight reflectors must not
be tarnished and the lenses must be
undamaged.
M Switch on the ignition and check the
operation of the direction indicators (including
the instrument panel tell-tale) and the hazard
war ning lights. Operation of the sidelights and
stop-lights must not affect the indicators - if it
does, the cause is usually a bad earth at the
r ear light cluster.
M Check the operation of the rear foglight(s),
including the warning light on the instrument
panel or in the switch.
Footbrake
M Examine the master cylinder, brake pipes
and servo unit for leaks, loose mountings,
corr osion or other damage.
M The fluid reservoir must be secure and the
fluid level must be between the upper ( A) and
lower ( B) markings. M
Inspect both front brake flexible hoses for
cracks or deterioration of the rubber . Turn the
steering from lock to lock, and ensure that the
hoses do not contact the wheel, tyre, or any
part of the steering or suspension mechanism.
With the brake pedal firmly depressed, check
the hoses for bulges or leaks under pressure.
Steering and suspension
M Have your assistant turn the steering wheel
fr om side to side slightly, up to the point where
the steering gear just begins to transmit this
movement to the roadwheels. Check for
excessive free play between the steering
wheel and the steering gear, indicating wear or
insecurity of the steering column joints, the
column-to-steering gear coupling, or the
steering gear itself.
M Have your assistant turn the steering wheel
mor e vigorously in each direction, so that the
r oadwheels just begin to turn. As this is done,
examine all the steering joints, linkages,
fittings and attachments. Renew any
component that shows signs of wear or
damage. On vehicles with power steering,
check the security and condition of the
steering pump, drivebelt and hoses.
M Check that the vehicle is standing level,
and at approximately the correct ride height.
Shock absorbers
M Depr ess each corner of the vehicle in turn,
then release it. The vehicle should rise and
then settle in its normal position. If the vehicle
continues to rise and fall, the shock absorber
is defective. A shock absorber which has
seized will also cause the vehicle to fail.
2Checks carried out
WITH THE VEHICLE ON THE
GROUND
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