1989 FORD FIESTA fuses

2If not already done, remove the inlet and
exhaust manifolds with reference to the
relevant Part of Chapter 4.
3 Proceed as follows according to engine
type.
HCS engines
4 Valve removal should commence with No 1
valve (nearest the timing chain end).
5 To remove the valve springs and valves
from the cylinder head, a standard valve
spring compressor will required. Fit the spring
compressor to the first valve and spring to be
removed. Take care not to damage the valve
stem with the compressor, and do not over-
compress the spring, or the valve stem may
bend. When tightening the compressor, it may
be found that the spring retainer does not
release and the collets are then difficult to
remove. In this instance, remove the
compressor, then press a piece of tube (or a
socket of suitable diameter) so that it does not
interfere with the removal of the collets,
against the retainer’s outer rim. Tap the tube
(or socket) with a hammer to unsettle the
components.
6 Refit the compressor, and wind it in to
enable the collets to be extracted (see
illustration) .
7 Loosen off the compressor, and remove the
retainer and spring. Withdraw the valve from
the cylinder head (see illustrations) .
8 Prise up and remove the valve stem seal.
9 Repeat the removal procedure with each of the remaining seven valve assemblies in turn.
As they are removed, keep the individual
valves and their components together, and in
their respective order of fitting, by placing
them in a separate labelled bag
(see
illustration) .CVH and PTE engines
10Remove the camshaft, rocker arms and
tappets as described in Part B of this Chapter,
being careful to store the hydraulic tappets as
described.
11 Valve removal should commence with
No 1 valve (nearest the timing belt end).
12 Using a standard valve spring com-
pressor, compress the valve spring (and
upper retainer) just enough to enable the split
collets to be released from the groove in the
top of the valve stem, then separate and
extract the split collets from the valve. Do not
compress the spring any further than is
necessary, or the valve stem may bend. If the
valve spring retainer does not release from the
collets as the spring is compressed, remove
the compressor, and position a piece of
suitable tube over the end of the retainer, so
that it does not impinge on the collets. Place a
small block of wood under the valve head
(with the head resting face down on the
workbench), then tap the end of the tube with
a hammer. Now refit the compressor tool, and
compress the valve spring. The collets should
release.
13 Extract the split collets, then slowly unscrew, release and remove the compressor.
14
Withdraw the upper retainer and the valve
spring from the valve stem, then remove the
valve from the underside of the cylinder head.
Use a suitable screwdriver or pliers to prise
free and remove the valve stem oil seal from
the guide (see illustration) .
15 Remove the lower retainer.
16 Repeat the removal procedure with each
of the remaining valve assemblies in turn. As
they are removed, keep the valves and their
associated components together, and in the
originally-installed order, by placing them in a
separate labelled bag (see illustration 7.9).
Zetec engines
17Remove the camshafts and hydraulic
tappets as described in Part C of this Chapter,
being careful to store the hydraulic tappets as
described.
18 Using a valve spring compressor,
compress each valve spring in turn until the
split collets can be removed. A special valve
spring compressor will be required, to reach
into the deep wells in the cylinder head
without risk of damaging the hydraulic tappet
bores; such compressors are now widely
available from most good motor accessory
shops. Release the compressor, and lift off
the spring upper seat and spring.
19 If, when the valve spring compressor is
screwed down, the spring upper seat refuses
to free and expose the split collets, gently tap
the top of the tool, directly over the upper
seat, with a light hammer. This will free the
seat.
20 Withdraw the valve through the
combustion chamber. If it binds in the guide
(won’t pull through), push it back in, and de-
burr the area around the collet groove with a
fine file or whetstone; take care not to mark
the hydraulic tappet bores.
21 Ford recommend the use of their service
tool 21-160 to extract the valve spring lower
seat/stem oil seals; while this is almost
indispensable if the seals are to be removed
without risk of damage to the cylinder head, a
serviceable substitute can be made from a
strong spring of suitable size. Screw on the
tool or spring so that it bites into the seal, then
Engine removal and overhaul procedures 2D•13
7.7b . . . followed by the valve7.7a Remove the valve spring retainer and spring . . .7.6 Compress the valve spring to removethe collets
7.14 Prise off the valve stem oil seal7.9 Use a labelled plastic bag to store andidentify valve components
2D
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the radiator top hose from the thermostat
housing’s water outlet (see illustration).
9 Unscrew the retaining bolts, and remove
the water outlet from the thermostat housing.
10 Withdraw the thermostat from the housing
noting the position of the air bleed valve, and
how the thermostat is installed (which end is
facing outwards) (see illustration).
Testing
General check
11Before assuming the thermostat is to
blame for a cooling system problem, check
the coolant level, auxiliary drivebelt tension
and condition (see Chapter 1) and
temperature gauge operation.
12 If the engine seems to be taking a long
time to warm up (based on heater output or
temperature gauge operation), the thermostat
is probably stuck open. Renew the thermostat.
13 If the engine runs hot, use your hand to
check the temperature of the radiator top
hose. If the hose isn’t hot, but the engine is,
the thermostat is probably stuck closed,
preventing the coolant inside the engine from
escaping to the radiator - renew the
thermostat.
Caution: Don’t drive the vehicle without a
thermostat. The lack of a thermostat will
slow warm-up time. The engine
management system’s ECU will then stay
in warm-up mode for longer than
necessary, causing emissions and fuel
economy to suffer. 14
If the radiator top hose is hot, it means
that the coolant is flowing and the thermostat
is open. Consult the “Fault finding” section at
the end of this manual to assist in tracing
possible cooling system faults.
Thermostat test
15 If the thermostat remains in the open
position at room temperature, it is faulty, and
must be renewed as a matter of course.
16 To test it fully, suspend the (closed)
thermostat on a length of string in a container
of cold water, with a thermometer beside it;
ensure that neither touches the side of the
container (see illustration) .
17 Heat the water, and check the temperature
at which the thermostat begins to open;
compare this value with that specified. It’s not
possible to check the fully-open temperature,
because this occurs above the boiling point of
water at normal atmospheric pressure. If the
temperature at which the thermostat began to
open was as specified, then it is most likely
that the thermostat is working properly at all
temperatures. Remove the thermostat, and
allow it to cool down; check that it closes fully.
18 If the thermostat does not open and close
as described, if it sticks in either position, or if
it does not open at the specified temperature,
it must be renewed.
Refitting
All models
19 Refitting is a reversal of removal. Clean
the mating surfaces carefully, and renew the thermostat’s O-ring seal or housing gasket, as
applicable.
20
On Zetec engines, ensure that the
thermostat is fitted with its air bleed valve
uppermost.
21 Tighten the thermostat housing/water
outlet bolts to the specified torque.
22 Refill the cooling system (see Chapter 1).
23 Refit the air cleaner or air inlet components,
as applicable, if removed for access.
24 Start the engine and allow it to reach
normal operating temperature, then check for
leaks and proper thermostat operation.
5 Radiator electric cooling fan assembly - testing, removal
and refitting
2
Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
Testing
1 If it is suspected that the cooling fan is not
operating when high engine temperature
would normally require it to do so, first check
the relevant fuses and relays (see Chapter 12).
2 Detach the wiring multi-plug from the
thermostatic switch, which is located either in
the thermostat housing or at the right-hand end
of the radiator, next to the bottom hose (see
illustration) . Using a suitable piece of wire,
bridge the two connections within the plug.
Switch the ignition on and check if the cooling
fan operates. If the fan now operates, the
thermostatic switch is at fault, and should be
renewed as described in Section 6. Remove the
bridging wire from the plug, and reconnect the
wiring connector to complete the test.
3 If the fan failed to operate in the previous
test, either the fan motor is at fault, or there is
a fault in the wiring loom (see Chapter 12 for
testing details).
Removal
All models except Turbo
4 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
5 Detach the wiring multi-plug from the fan
motor and unclip the wiring from the retaining
clips on the shroud (see illustration).
3•4 Cooling, heating and ventilation systems
5.5 Disconnecting the multi-plug from the
radiator cooling fan motor5.2 Radiator cooling fan thermostatic
switch location on CVH engine thermostat
housing
4.16 Testing the thermostat4.10 Zetec engine thermostat removal4.8 Disconnect the coolant hoses from thewater outlet on a Zetec engine
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6Unscrew the nut securing the cooling fan
shroud to the radiator, noting the insulating
washer arrangement, then lift the fan shroud
and motor assembly from the vehicle (see
illustration) .
7 To separate the fan from the motor shaft,
first remove its retaining clip and washer, then
withdraw the fan (see illustration) . A new clip
will be needed upon reassembly. Remove the
three nuts securing the motor to the shroud
and separate the two components.
Turbo models
8 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
9 Undo the two retaining screws and move
the HT lead bracket clear of the working area,
disconnecting the HT leads as required.
10 Disconnect the fan motor wiring multi-
plug and the two auxiliary lamp wiring multi-
plugs. Unclip the wiring from any local
retaining clips.
11 Remove the front bumper as described in
Chapter 11.
12 Undo the two lower fan shroud retaining
bolts, release the shroud upper locating
tongue from the radiator and withdraw the
assembly from the front of the car.
13 To separate the fan from the motor shaft,
pull off the fan guard from the shroud, flatten
back the raised lockwasher tab, and unscrew
clockwise (a left-hand thread is employed)
the nut securing the fan to the motor shaft.
Remove the fan then undo the three nuts
securing the motor to the shroud and
separate the two components.
Refitting
All models
14 Refitting is a reversal of the removal
procedure. On non-Turbo models, ensure that
the locating tags on the base of the shroud
locate correctly in their slots in the body
crossmember. On Turbo models, if the fan
was removed, use a new lockwasher when
refitting. On all models, ensure that the wiring
connections are cleanly and securely made,
and locate the loom in the retaining clips.
6 Cooling system electrical switches and sensors -
testing, removal and refitting
2
Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
Coolant temperature gauge
sender
Testing
1 If the coolant temperature gauge is
inoperative, check the fuses first (see Chap-
ter 12).
2 If the gauge indicates overheating at any
time, consult the “Fault finding” section at the
end of this manual, to assist in tracing
possible cooling system faults. 3
If the gauge indicates overheating shortly
after the engine is started from cold,
disconnect the temperature gauge sender’s
wiring multi-plug. The sender is located below
the thermostat housing on HCS engines,
adjacent to the thermostat housing on CVH
and PTE engines, and on the forward-facing
side of the thermostat housing on Zetec
engines. If the gauge reading now drops,
renew the sender. If the reading remains high,
the wire to the gauge may be shorted to earth,
or the gauge is faulty.
4 If the gauge fails to indicate after the engine
has been warmed up (approximately
10 minutes) and the fuses are known to be
sound, switch off the engine. Disconnect the
sender’s wiring multi-plug, and use a jumper
wire to ground the connector to a clean earth
point (bare metal) on the engine. Switch on
the ignition without starting the engine.
If the gauge now indicates Hot, renew the
sender.
5 If the gauge still does not work, the circuit
may be open, or the gauge may be faulty. See
Chapter 12 for additional information.
Removal
6 Refer to the relevant Part of Chapter 4 and
remove the air cleaner or air inlet hoses,
according to engine type as necessary, to
gain access to the sender unit.
7 Drain the cooling system (see Chapter 1).
8 On Zetec engines, disconnect the
expansion tank coolant hose and the radiator
top hose from the thermostat housing’s water
outlet.
9 Disconnect the wiring multi-plug from the
sender unit.
10 Unscrew the sender and withdraw it.
Refitting
11Clean as thoroughly as possible the
sender unit location, then apply a light coat of
sealant to the sender’s threads. Screw in the
sender, tighten it to the specified torque, and
reconnect the wiring multi-plug.
12 Reconnect the hoses, and refit any
components disconnected for access. Refill
or top-up the cooling system (see “Weekly
Checks” or Chapter 1) and run the
engine. Check for leaks and proper gauge
operation.
Engine coolant temperature
sensor
Testing
13 Disconnect the battery negative (earth)
lead (see Chapter 5A, Section 1).
14 Locate the coolant temperature sensor,
which will be found below the inlet manifold
on HCS engines, on the side or centre of the
inlet manifold on CVH and PTE engines, or on
top of the thermostat housing on Zetec
engines. Once located, refer to the relevant
Part of Chapter 4 and remove the air cleaner
or air inlet hoses, according to engine type as
necessary, to improve access to the sensor
unit.
15 Disconnect the wiring multi-plug from the
sensor.
16 Using an ohmmeter, measure the
resistance between the sensor terminals.
Depending on the temperature of the sensor
tip, the resistance measured will vary, but
should be within the broad limits given in the
Specifications of this Chapter. If the sensor’s
temperature is varied - by removing it (see
below) and placing it in a freezer for a while, or
by warming it gently - its resistance should
alter accordingly.
17 If the results obtained show the sensor to
be faulty, renew it.
18 On completion, reconnect the wiring
multi-plug and refit any components removed
for access, then reconnect the battery.
Removal
19 Disconnect the battery negative (earth)
lead (see Chapter 5A, Section 1).
20 Locate the sensor as described
previously, and remove any components as
necessary for access.
21 Drain the cooling system (see Chapter 1).
22 Disconnect the wiring multi-plug from the
sensor.
23 Unscrew the sensor and withdraw it.
Refitting
24Clean as thoroughly as possible the
sensor location, then apply a light coat of
sealant to the sensor’s threads. Refit and
tighten the sensor to the specified torque
Cooling, heating and ventilation systems 3•5
5.7 Nuts securing fan motor to shroud (A),
and shroud to body crossmember locating tags (B). Inset shows fan to motor shaft retaining clip (arrowed)5.6 Radiator cooling fan shroud securing nut (arrowed)
3
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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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suitable adhesive; it is recommended that this
task be left to a Ford dealer or similar expert.
15To remove the window glass, remove their
retaining screws and withdraw the lock
assemblies, slide the front glass as far to the
rear as possible, then prise up and withdraw
the front glass guide; it will be necessary to
pull the last part of the guide from under the
glass.
16 Withdraw the vertical seal and two
support blocks from between the two glasses,
slide the seal to the front of the frame, and
withdraw it. Slide each glass in turn
to the front of the frame and withdraw it,
then prise up and withdraw the rear glass
guide.
Refitting
17 On refitting, check that the glass guides
are undamaged; renew them if necessary.
Ensure that the lock assemblies are removed
from both glasses.
18 Press the rear glass guide into place. Refit
first the rear glass, fitting it to the front of the
frame and sliding it to the rear, then the front
glass, in the same way.
19 To refit the vertical seal, sandwich it
between two strips of thin sheet metal and
install it, with its support blocks, first in the
front part of the frame, then push it into place.
This will require some effort as the glass is
reached, due to the distortion caused by the
location notch on the block. When the seal is
fully in place, withdraw the metal strips, and
check that the seal’s lips have not folded back
on themselves.
20 When refitting the front glass guide, locate
it first around the frame’s detent catch, then
slide it under the glass using soapy water as a
lubricant.
21 Refit the lock assemblies, clean the
glasses, and check the operation of the
windows and locks.
34 Windscreen and tailgate window glass -
removal and refitting
4
Note : The DIY mechanic is advised to leave
windscreen/tailgate window glass removal
and refitting to an expert. For those with the
necessary tools and equipment, the
following paragraphs are a guide to the
procedure.
Removal
1 Remove the windscreen/tailgate wiper arms
as described in Chapter 12.
2 If removing the windscreen, remove both A-
pillar trims, and release the front of the
headlining by removing the sun visors and
courtesy light. If a heated windscreen is fitted,
disconnect its electrical contacts at the
windscreen. If removing the tailgate window
glass, disconnect the wiring to the heating
element. 3
As a precautionary measure to prevent
damage to the paintwork, cover the
surrounding bodywork with an old blanket or
similar.
4 Using a suitable tool, release the
weatherseal from the top and sides of the
body aperture flange before exerting pressure
from the inside of the vehicle to remove the
assembly. It is strongly advised that an
assistant outside the vehicle is ready to
receive the glass as it is pushed out.
5 With the assembly removed from the
vehicle, detach the weatherseal from the
windscreen/tailgate glass.
Refitting
6 With reference to the procedures described
for the fixed side window glass in Section 33,
clean the weatherseal, then refit in
accordance with the rest of that Section.
7 Any trim and equipment removed during
preparation should now be refitted.
35 Sunroof panel -
removal and refitting
1
Removal
1 Open the sunroof fully using the handwheel.
2 Detach the sunroof from its rearward
mounting point by pressing in the red locking
bar on the handwheel, then raise it and
remove.
Refitting
3 To refit, engage the hinges in their
locations, in the forward edge of the sunroof
opening, then lower the sunroof. Allow the
handwheel to click into its safety lock.
4 Check that the safety lock mechanism
retains the panel securely.
5 Close the sunroof fully using the
handwheel.
36 Sunroof panel seal -
renewal
1
1 Remove the sunroof panel, as described in
Section 35, then lay the panel on a soft cloth.
2 Remove the two hinge plate assemblies
from the panel by undoing the hinge plate
retaining screws.
3 Pull the seal from the panel edge, noting the
position of its join.
4 Starting from the position of the original
join, press the seal into position, ensuring that
it sits evenly right around. Adjust as necessary
so that the ends butt tightly together.
5 Refit the two hinge plate assemblies to the
panel.
6 Refit the sunroof panel, as described in
Section 35.
37 Sunroof weatherseal -
removal and refitting
1
Removal
1 Remove the sunroof panel, as described in
Section 35.
2 Starting from the joint on the rearward
opening edge, pull the seal up and remove.
Refitting
3 Refitting is a reversal of the removal
procedure, ensuring that the weatherseal
does not deform at the corners, or split at the
joint.
38 Full-length sunroof -
general information
1 The full-length sunroof is electrically-
operated, the operating system consisting of
the motor and the roof-mounted switch. The
circuit is fed via fuses 18 and 28 from the
ignition switch; switch illumination is via
fuse 6.
2 All components are mounted in the roof of
the passenger compartment, above the
headlining at the front of the vehicle.
3 To open the sunroof, press the switch
lightly on the upper side; to close it, check
first that the opening is completely
unobstructed, and press the switch on the
lower side.
4 Maintenance is confined to checking for
freedom of action and a snug fit when shut.
Check that the seals are in good clean
condition and not scratched or damaged.
5 Owners must note the following to ensure
that the maximum trouble-free life from this
feature:
a) It is normal for the motor to slow down as
the sunroof approaches full opening.
b) If the sunroof stops before it is fully
opened in cold weather, this may be due
to the material being too hard to fold
correctly; do not force the sunroof open if
this is suspected.
c) If the material does not fold correctly on
opening at any time, close the sunroof
again, correct the folds by hand, and try
again.
d) Never open or close the sunroof with the
vehicle travelling at more than 70 mph
(120 km/h), and never allow passengers to
travel standing up or with any part of their
bodies in the opening.
e) Ensure that any collected water, snow or ice is removed from the sunroof before
opening it. Check that the deflector is
clear of water, particularly after washing
the vehicle; sponge it dry if necessary.
f) Never place heavy objects on the sunroof or its surrounds.
g) The sunroof should be cleaned frequently
11•16 Bodywork and fittings
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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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