Ford 1595 Automobile User Manual

12•1
Chapter 12
Body electrical systems
Contents
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”
Degrees of difficulty
Easy, suitable for
novice with little
experience
1
Fairly easy, suitable
for beginner with
some experience
2
Fairly difficult,
suitable for competent
DIY mechanic
3
Difficult, suitable for
experienced DIY
mechanic
4
Very difficult,
suitable for expert DIY
or professional
5
Specifications
Fuses - pre-1992 models
Main fuse board:
No
Rating (amps)
1
3 .................................................
2
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit(s) protected
Electronic engine control system
Interior light, cigarette lighter, clock and radio memory
Central locking system
Heated rear window element
Dim-dip lighting
Left-hand side lights and rear fog light
Right-hand side lights
Left-hand dipped beam
Right-hand dipped beam
Left-hand main beam and right-hand auxiliary driving light
Right-hand main beam and left-hand auxiliary driving light
Heater fan motor and reversing light
Radiator cooling fan motor
Front foglights (XR2i only)
Horn
Wiper motor and windscreen/tailgate washer pump
Brake stop lights, instrument illumination and instrument warning
Electrically operated windows
Electric fuel pump
Oxygen sensor (vehicles with catalytic converter)
Left-hand direction indicators
Right-hand direction indicators
1595Ford Fiesta Remake
12
12•2 Body electrical systems
Additional fuses behind main fuse board:
No
23
24/25
26
27/28
Rating (amps)
- .................................................
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit(s) protected
Unused
Rear fog lights
Tailgate remote release
Heated windscreen
Fuses - 1992 models onward
Main fuse board:
Fuses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional fuses behind main fuse board:
No
Rating (amps)
23*
- ..................................................
23** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24*
- ..................................................
24** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28*
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28** 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Pre-1994 models
** 1994 models onward
Unchanged from pre-1992 models
Circuit(s) protected
Unused
Rear fog lights
Unused
Rear fog lights
Tailgate remote release, anti-theft warning system
Heated windscreen
Heated windscreen
Full-length sunroof
Automatic transmission starter inhibitor
Air bag
Relays (pre-1992 models)
Note: Relay locations and circuits controlled are liable to change from year to 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 fitted)
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 to 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 fitted)
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
1595Ford Fiesta Remake
Body electrical systems 12•3
Bulbs
Headlight (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sidelight (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction indicators (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side direction indicator repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary driving and foglights (S and XR2i) . . . . . . . . . . . . . . . . . . . . . .
Stop/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette lighter illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic transmission selector illumination . . . . . . . . . . . . . . . . . . . . .
Wattage
H4, 60/55
5
21
5
H3, 55
21/5
21
21
10
10
5
1.3 or 2.6
1.3 or 2.6
1.4
2
Lubricants
Grease for windscreen wiper linkage and pivots . . . . . . . . . . . . . . . . . .
To Ford specification SAM-1C-911-A
Torque wrench settings
Nm
8 to 9
6 to 8
22 to 24
17 to 18
9 to 12
2.5 to 3.5
5.4 to 7.0
1.5 to 2.5
6.8 to 9.2
24 to 33
9 to 14
Wiper motor to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper motor bracket to bulkhead/tailgate . . . . . . . . . . . . . . . . . . . . . . .
Windscreen wiper crank to driving shaft nut . . . . . . . . . . . . . . . . . . . . .
Windscreen/tailgate wiper arm retaining nut . . . . . . . . . . . . . . . . . . . . .
Windscreen wiper pivot shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen/tailgate washer reservoir securing bolts . . . . . . . . . . . . . . .
Headlight retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail light securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary light retaining nut (S models) . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn bracket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter inhibitor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
1595Ford Fiesta Remake
lbf ft
6 to 7
4 to 6
16 to 18
12 to 13
7 to 9
2 to 3
4 to 5
1 to 2
5 to 7
18 to 24
7 to 10
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,
12
12•4 Body electrical systems
wiring diagrams are included at the end of this
manual.
2 Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a complete understanding
of the components included in the particular
circuit concerned. The possible sources of a
fault can be narrowed down by noting if other
components related to the circuit are
operating properly. If several components or
circuits fail at one time, the problem is likely to
be related to a shared fuse or earth
connection.
3 Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay (refer to Section 3 for details of testing
relays). Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked
in order to pinpoint the trouble-spot.
4 The basic tools required for electrical faultfinding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used for certain tests); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
Warning: Under no
circumstances may live
measuring instruments such as
ohmmeters, voltmeters or a bulb
and test leads be used to test any of the
air bag circuitry or components. Any
testing in these areas must be left to a
Ford dealer as there is a danger of
activating the system if the correct
procedures are not followed.
5 To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6 Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7 Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working.
8 Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Shortcircuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.
Finding an open-circuit
9 To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
10 Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse. At this point, battery
voltage should be present, unless the lead
from the battery or the fuse itself is faulty
(bearing in mind that some circuits are live
only when the ignition switch is moved to a
particular position).
11 Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
the circuit between the relevant connector
and the switch is problem-free.
13 Continue to check the remainder of the
circuit in the same fashion.
14 When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.
Finding a short-circuit
15 To check for a short-circuit, first
disconnect the load(s) from the circuit (loads
are the components which draw current from
a circuit, such as bulbs, motors, heating
elements, etc).
16 Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17 Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19 If no voltage is present during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).
Finding an earth fault
20 The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission and the vehicle body and many systems are wired so that they only
receive a positive feed, the current returning
via the metal of the car body. This means that
the component mounting and the body form
part of that circuit. Loose or corroded
1595Ford Fiesta Remake
mountings can therefore cause a range of
electrical faults, ranging from total failure of a
circuit, to a puzzling partial failure. In
particular, lights may shine dimly (especially
when another circuit sharing the same earth
point is in operation), motors (eg wiper
motors or the radiator cooling fan motor) may
run slowly, and the operation of one circuit
may have an apparently-unrelated effect on
another. Note that on many vehicles, earth
straps
are
used
between
certain
components,
such
as
the
engine/
transmission and the body, usually where
there is no metal-to-metal contact between
components, due to flexible rubber
mountings, etc.
21 To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5A, Section 1) and connect one
lead of an ohmmeter to a known good earth
point. Connect the other lead to the wire or
earth connection being tested. The resistance
reading should be zero; if not, check the
connection as follows.
22 If an earth connection is thought to be
faulty, dismantle the connection, and clean
both the bodyshell and the wire terminal (or
the component earth connection mating
surface) back to bare metal. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer
or a water-dispersant lubricant.
3 Fuses and relays general information
Note: It is important to note that the ignition
switch and the appropriate electrical circuit
must always be switched off before any of the
fuses (or relays) are removed and renewed.
1 The main fuse and relay board is located
below the facia panel to the right of the
steering wheel. The fuses can be inspected
and if necessary renewed, by removing the
hinged access cover. The remaining
additional fuses and relays (depending on
model) may be accessed by removing the two
fuse board retaining screws, releasing the
retaining lugs on either side of the main fuse
plate and withdrawing the fuse/relay board
downwards into the driver’s footwell. Each
fuse location is numbered - refer to the fuse
chart in the Specifications at the start of this
Chapter to check which circuits are protected
by each fuse. Plastic tweezers are attached to
Body electrical systems 12•5
3.1a Method of fuse/relay board retention
A Retaining screws
B Retaining lugs
C Support
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
3.1b Withdrawing the fuse/relay board
downwards into the driver’s footwell
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 multiplug 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
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.
4.7 Withdraw the lock barrel after
depressing its plunger through the
aperture in the steering column lock
housing (arrowed)
1595Ford Fiesta Remake
3.1c Component layout on the fuse/relay
board. See Specifications for relay
identification
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
12
12•6 Body electrical systems
4.20a Prise the centre console switch up
from its location . . .
4.20b . . . then disconnect its multiplug
and remove the switch
4.23 Heater fan motor control switch
removal
windows (early models) and the tailgate
remote release mechanism, where fitted.
19 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
20 To remove a switch, carefully prise it from
its location using a thin flat-bladed
screwdriver, then disconnect the multi-plug
(see illustrations).
21 To refit, connect the multi-plug then push
home to secure.
28 Insert the switch into its retainer, press it
lightly against the brake pedal until all free
play is just taken up, then turn the switch
clockwise to secure. Reconnect the switch
wiring connector and the battery.
piece of string to it, so that it can be retrieved
if it drops down into the door pillar.
37 Disconnect the wiring from the switch.
38 Refitting is a reversal of removal.
Heater fan motor control switch
22 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
23 Pull the heater fan motor control knob off,
then move the air distribution and
temperature controls fully to the right. Unclip
and remove the heater slide facia towards the
left-hand side of the vehicle, removing the
slide control knobs only as necessary, and
disconnecting its bulbholder (bayonet type) as
it is withdrawn (see illustration).
24 Squeeze the two release tabs together on
the heater fan motor control switch, and
remove it, disconnecting its multi-plug as it is
withdrawn.
25 Refit by reversing the removal procedure.
Brake stop-light switch
26 The brake stop-light switch is attached to
the brake pedal mounting bracket.
27 Detach the wiring multi-plug from the
switch, then twist the switch through a quarter
of a turn (90º) anticlockwise and withdraw it
from the bracket.
Handbrake warning light
switch
29 Push the carpet mounding down as
necessary to gain access to the switch,
located on the handbrake lever.
30 Remove the cover, then disconnect the
warning light switch wiring multi-plug (see
illustration). Undo the two screws securing
the switch to the handbrake lever assembly
and remove the switch.
31 Refit by reversing the removal procedure.
Low brake fluid level warning
light switch
32 This is incorporated into the brake fluid
reservoir cap, and senses fluid level in the
reservoir. It cannot be renewed separately
from the cap.
33 To remove, disconnect the warning
indicator loom multi-plug and unscrew the
reservoir cap.
34 Refit by reversing the removal procedure.
Courtesy light switches
35 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
36 With the door open, undo the retaining
screw and withdraw the switch from the door
pillar. Pull out the wiring slightly, and tie a
Reversing light switch
39 Refer to Chapter 7A, Section 6.
Starter inhibitor switch
(automatic transmission)
40 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
41 The starter inhibitor switch is located on
the transmission housing, and prevents the
engine from being started with the selector
lever in any position except “P” or “N”.
Access to the switch is gained after raising
and supporting the vehicle at the front end on
axle stands (see “Jacking and vehicle
support”).
42 Detach the switch multi-plug, then
unscrew and remove the switch from the
transmission, together with its O-ring. As the
switch is removed, catch any fluid spillage in a
suitable container, and plug the switch
aperture in the transmission to prevent any
further loss.
43 Refitting is a reversal of the removal
procedure. Use a new O-ring, and tighten the
switch securely. Ensure that the wiring
connection is securely made. On completion,
check and if necessary top-up the automatic
transmission fluid (see Chapter 1) then check
that the engine only starts when the selector
is in the “P” or “N” position.
Luggage area contact plate
44 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
45 Open the tailgate and release the contact
plate side retaining clips using a thin-bladed
screwdriver. Push the contact plate from its
location in the body.
46 Disconnect the wiring multi-plug and
remove the plate (see illustration).
47 Refit in the reverse order of removal.
Luggage area contact switch
4.30 Removing the cover from the
handbrake warning light switch
4.46 Withdrawing the luggage area
contact plate for access to disconnect the
multi-plug
1595Ford Fiesta Remake
48 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
49 Open the tailgate and remove its inner
trim panel (see Chapter 11).
Body electrical systems 12•7
50 Undo the two screws securing the contact
switch and withdraw it from its tailgate
location.
51 Unclip and disconnect the switch multiplug, and disconnect the earth wiring.
Remove the switch.
52 Refit in the reverse order of removal.
Make sure that the pins and their contacts are
clean. On completion, check the operation of
the rear wipers, courtesy light, heated rear
window and the tailgate release/central
locking system.
Electric window switches
(1992 models onward)
53 On later models the electric window
switches are located in the upper surfaces of
the door stowage pockets. Removal and
refitting is the same as for the earlier centre
console mounted switches described
previously in this Section.
5 Bulbs (exterior lights) renewal
1
Note: Ensure that all exterior lights are
switched off before disconnecting the wiring
connectors to any exterior light bulbs. Note
that if a bulb fails, and has just been in use, it
will still be extremely hot, particularly in the
case of a headlight bulb.
Headlight
1 From within the engine compartment,
disconnect the multi-plug from the back of the
headlight.
2 Remove the rubber bulb protective cap,
then unlock the bulb retaining spring clip or
retaining ring (according to type) and
withdraw the bulb (see illustrations).
Caution: Take care not to touch the bulb
glass with your fingers - if accidentally
touched, clean the bulb with methylated
spirit.
5.2a Remove the protective cap . . .
5.2b . . . then unlock the headlight bulb
retaining spring and withdraw the bulb
3 Refitting is a reversal of the removal
procedure.
the earth lead, then release their grommet
from its panel location.
13 From outside the vehicle, twist the light
assembly to release it, then withdraw it and its
leads (see illustration).
14 Refitting is a reversal of the removal
procedure, ensuring that the grommet is
seated correctly in its panel location.
Front sidelight
4 The bulbholder is located on the side of the
headlight unit, and is removed by twisting
anti-clockwise and withdrawing from within
the engine compartment.
5 Withdraw the push-fit bulb from its holder.
6 Refitting is a reversal of the removal
procedure.
Front direction indicator
7 Remove the direction indicator light unit by
releasing the retaining spring from its body
location, then pulling the light assembly
forwards. Disconnect its multi-plug as it is
withdrawn.
8 Turn the bulbholder anti-clockwise and
remove it (see illustration). The bulb is a
bayonet type fitting in its holder.
9 Refitting is a reversal of the removal
procedure.
Front direction indicator side
repeater
10 Remove the appropriate front wheel arch
liner as described in Chapter 11.
11 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.
12 Disconnect the supply lead connector and
Auxiliary lights
S models
15 Undo the screw at the base of the light,
then withdraw the lens and reflector assembly
from the light housing.
16 Disconnect the wiring then release the
bulb retainer and remove the bulb.
17 Refitting is a reversal of the removal
procedure.
XR2i models
18 Remove the auxiliary light assembly from
its bumper location, as described in Section 7.
19 Release the bulb retainer, then remove the
bulb (see illustration).
20 Refitting is a reversal of the removal
procedure.
Rear light cluster (all models
except Courier)
21 Access to the rear light cluster bulbholder
is gained from the luggage compartment.
Disconnect the multi-plug from the
bulbholder, then press the retaining lugs on
5.8 Remove the front direction indicator
light bulbholder by turning it anticlockwise
A Light unit
B Bulbholder
C Multi-plug
D Retaining spring
12
5.13 Removing the direction indicator side
repeater bulbholder assembly
1595Ford Fiesta Remake
5.19 Releasing the auxiliary light bulb
retainer (XR2i models)
12•8 Body electrical systems
5.21a Disconnect the ear light cluster
multi-plug from the bulbholder . . .
5.21b . . . then having pressed its retaining
lugs, withdraw the bulbholder for access
to the bulbs
5.24a On Courier models, unscrew the two
black plastic nuts securing the rear light
cluster assembly . . .
6 Bulbs (interior lights) renewal
2
Instrument panel illumination
and warning lights
1 Refer to Section 10.
Automatic transmission selector
illumination
5.24b . . . then withdraw the assembly to
the outside of the vehicle
the bulbholder together and remove it (see
illustrations).
22 All bulbs are of bayonet type fitting.
23 Refitting is a reversal of the removal
procedure.
5.29 Release the number plate light
securing tab (arrowed) and separate the
bulbholder and light cover
Number plate lights
24 Working inside the load compartment,
unscrew the two black plastic nuts securing
the light cluster assembly. Withdraw the
assembly to the outside of the vehicle,
disconnecting the wiring from the bulbholder
(see illustrations).
25 All bulbs are of bayonet type fitting.
26 Refitting is a reversal of the removal
procedure.
27 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.
28 Detach the connections on the underside
of the light assembly.
29 Release the tab securing the light cover to
the bulbholder, and remove the cover (see
illustration).
30 The bulb is a bayonet type fitting in its
holder.
31 Refitting is a reversal of the removal
procedure.
6.3a Remove the selector illumination bulb
cover . . .
6.3b . . . followed by the (bayonet fitting)
bulb
Rear light cluster (Courier
models)
1595Ford Fiesta Remake
2 Using a thin flat-bladed screwdriver, prise
up the selector cover and remove it.
3 Pull the bulb assembly to release it from the
selector lever, then remove its cover. The bulb
is a bayonet fit in its holder (see illustrations).
4 Refitting is a reversal of the removal
procedure.
Hazard warning switch
5 The hazard warning light switch, an integral
part of the steering column multi-function
switch assembly, has a bulb cover which pulls
off. The bulb is removed by pulling it from its
location.
6 Refitting is a reversal of the removal
procedure.
Clock illumination
7 Carefully prise the clock out of its facia
location, as described in Section 13.
8 Twist the bulbholder and withdraw it from
the rear of the clock (see illustration). Note
6.8 Withdrawing the clock illumination
bulb and its integral holder from the rear of
the clock
Body electrical systems 12•9
6.13 Heater fan illumination arrangement
6.16a Releasing the interior (courtesy)
light from its location
that the bulb and bulbholder cannot be
separated - they are replaced as an assembly.
9 Refitting is a reversal of the removal
procedure.
removal, then insert the switch end of the light
to the aperture, pivot the light upwards and
push home to secure.
Cigarette lighter illumination
10 Remove the cigarette lighter, as described
in Section 12.
11 Pull the bulbholder from its location in the
illuminated surround, then pull the bulb out of
the bulbholder.
12 Refitting is a reversal of the removal
procedure.
Heater facia illumination
13 Pull the heater fan motor control knob off,
then move the air distribution and
temperature controls fully to the right. Unclip
and remove the heater slide facia towards the
left-hand side of the vehicle, removing the
slide control knobs only as necessary, and
disconnecting its bulbholder (bayonet type) as
it is withdrawn (see illustration).
14 The bulb is removed by pulling it from its
bulbholder.
15 Refitting is a reversal of the removal
procedure.
Interior (courtesy) light
16 Insert a thin flat-bladed screwdriver into
the slot in the light assembly, and carefully
lever it out of its aperture. The bulb is a
bayonet fit (see illustrations).
17 Refit the bulb by reversing the method of
6.16b Interior (courtesy) light pivoted for
access to the bulb
Luggage compartment
(courtesy) light
18 Carefully prise the luggage compartment
(courtesy) light assembly out of its location,
using a thin flat-bladed screwdriver. Twist the
bulbholder anti-clockwise to remove.
19 The bulb is removed by pulling it from its
bulbholder.
20 Refitting is a reversal of the removal
procedure.
7 Exterior light units removal and refitting
2
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1), before
removing any of the light units.
Headlight
2 Disconnect the multi-plug from the back of
the headlights (see illustration).
3 Twist the sidelight bulb holder to release,
then withdraw it.
4 Remove the headlight securing bolt and
depress the headlight retaining spring, to
allow the headlight assembly to be hinged
7.2 Disconnecting the multi-plug from the
back of the headlight
forwards and out of its location (see
illustration).
5 Refitting is a reversal of the removal
procedure, ensuring that the lower headlight
mounting guide is inserted correctly, and that
the retaining spring engages fully (see
illustration).
6 On completion, check the headlight beam
alignment as described in Section 8.
Front direction indicator
7 To remove, release the indicator light
retaining spring from its body location, then
pull the light assembly forwards and
disconnect its multi-plug as it is withdrawn
(see illustrations).
12
7.4 Headlight retaining bolt (A), and
retaining spring arrangement (B)
7.5 Refitting the headlight. Mounting
guides (A) to fit to panel (B)
1595Ford Fiesta Remake
7.7a Release the front direction indicator
light retaining spring from its body
location . . .
12•10 Body electrical systems
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
7.7b . . . then pull the light unit out to
enable the multi-plug (arrowed) to be
disconnected
7.14 Press the retaining lugs on the rear
light cluster bulbholder together (broken
arrows) to release the bulbholder
8 Refitting is a reversal of the removal
procedure.
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.
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).
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).
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
7.24 Auxiliary light assembly (XR2i models) - left-hand unit shown
7.21 Auxiliary light fixture (S models)
A Bracket retaining nuts
B Auxiliary light retaining nut
C Auxiliary light multi-plug
A Light assembly retaining
screws
B Fog light vertical adjustment
screw
C Driving light vertical adjustment
screw
1595Ford Fiesta Remake
D Driving light horizontal
adjustment screw
E Bulb protective caps
F Fog light bulb connector
G Bulb earth leads
H Driving light bulb connector
Body electrical systems 12•11
8.2 Exploded view of the headlight unit
A
B
C
D
E
F
G
Sidelight bulb holder
Sidelight bulb
Headlight bulb retainer
Headlight bulb
Bulb protective cap
Horizontal adjustment screw
Vertical adjustment screw
work should therefore be carried out by a
Ford dealer or service station with the
necessary facilities.
2 Temporary 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
9.4a Instrument cluster securing screws
(arrowed)
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.
9.4b Disconnect the speedometer cable
from the rear of the instrument cluster . . .
10 Instrument panel
components removal and refitting
1
Removal
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
5 Refitting is a reversal of removal. On
completion check the function of all electrical
components.
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
12
9.4c . . . then disconnect the multi-plug
10.2 Removing a bulbholder from the rear
of the instrument cluster (bayonet type
fitting)
1595Ford Fiesta Remake
10.3 Unclipping the multi-plug retainer
from the rear of the instrument cluster
12•12 Body electrical systems
10.7 Rear view of instrument cluster
A
B
C
D
E
Retaining tags
Multi-plug retainer
Speedometer cable connection
Speedometer gauge retaining screws
Tachometer terminals (obscured by
protective pad)
F Tachometer gauge retaining screws
G Fuel and temperature gauge assembly
terminals
H Fuel and temperature gauge assembly
retaining screw
11.2 Detaching the speedometer cable at
the transmission casing
4 Note the cable routing for use when
refitting. Pull the speedometer cable through
into the engine compartment, and remove it
from the car.
14 Horn removal and refitting
1
Refitting
retaining tags, taking care to avoid damaging
or losing the warning light graphic strips (see
illustration).
8 Remove its two Torx-head retaining
screws, then detach and withdraw the
speedometer from the front of the assembly.
5 Refitting is the reversal of removal. Ensure
that the cable is routed as noted before
removal, secured with the relevant clips and
cable-ties, and that the grommet is properly
located in the bulkhead.
12 Cigarette lighter removal and refitting
1
Tachometer
9 Carry out the procedure given in
paragraphs 6 and 7.
10 Carefully prise the printed circuit from the
tachometer terminals, using a similar method
to that described in paragraph 5, releasing it
from its retainers as necessary.
11 Remove its two Torx-head retaining
screws, then unclip and withdraw the
tachometer from the front of the assembly.
Fuel and temperature gauge
assembly
12 Removal and refitting procedures are
similar in method to those for the tachometer,
but only one Torx-head screw retains the
assembly.
Refitting
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the cigarette lighter element
(heated section).
3 Carefully prise the element barrel out from
the illuminated surround, disconnecting its
multi-plug as it is withdrawn.
4 Hinge the illuminated surround out
carefully, removing its bulb feed connector as
it is withdrawn.
Refitting
5 Refitting is a reversal of the removal
procedure.
13 Clock removal and refitting
13 Refitting is a reversal of removal.
11 Speedometer cable removal and refitting
13.2 Carefully prise the clock out of the
facia
2
Removal
1 Remove the instrument panel as described
in Section 9.
2 Unscrew the speedometer cable from the
pinion/speed sensor on the transmission (see
illustration).
3 Release the cable-ties and retaining clips in
the engine compartment, and withdraw the
cable grommet from the bulkhead.
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Using a thin flat-bladed screwdriver,
carefully prise the clock out of the facia (see
illustration). Use a piece of card or similar to
prevent damage to the facia. Withdraw the
clock so that its multi-plug may be
disconnected, then remove it from the vehicle.
Refitting
3 Refitting is a reversal of removal. Reset the
clock on completion.
1595Ford Fiesta Remake
Removal
1 The horn is mounted forward on the lefthand side of the engine compartment, near
the battery.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Remove the wiring loom connection from
the horn(s).
4 Both single and dual horns are mounted to
a bracket which is secured to the bodywork
by a single bolt. Remove the bolt and
withdraw the horn(s) and bracket from the
vehicle. The horn(s) may be separated from
the bracket, as required, by removing the
retaining nut(s).
Refitting
5 Refitting is a reversal of removal.
15 Wiper arms removal and refitting
1
Removal
1 With the wiper(s) “parked” (ie in the normal
at-rest position), mark the positions of the
blade(s) on the screen, using a wax crayon or
strips of masking tape.
2 Lift up the plastic cap from the bottom of
the wiper arm, and loosen the nut one or two
turns.
3 Lift the wiper arm, and release it from the
taper on the spindle by moving it from side to
side.
4 Completely remove the nut and washer,
then withdraw the wiper arm from the
spindle.
Refitting
5 Refitting is a reversal of the removal
procedure. Make sure that the arm is fitted in
the previously-noted position.
Body electrical systems 12•13
16.6a Remove all retaining screws from
the right-hand half of the bulkhead panel
(upper centre screw shown) . . .
16 Windscreen wiper motor and
linkage - removal and refitting
2
16.6b . . . then disengage the right-hand
half of the panel from under its single
retaining nut (left-hand shown)
16.7 Unscrew the nut from the wiper
motor driving shaft
and withdraw the motor assembly (see
illustrations). Remove the motor cover, then
disconnect the multi-plug and remove the
motor from the vehicle.
Linkage
Removal
Wiper motor
1 Operate the wiper motor, then switch it off
so that it returns to its rest position.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Dependent on model, disconnect and
remove the air cleaner components as
necessary to allow access to remove the
bulkhead panel.
4 Remove the cooling system expansion tank
as described in Chapter 3.
5 Release the wiring loom, any connectors,
cable-ties and hoses from the right-hand half
of the bulkhead panel, then remove its rubber
seal.
6 The right-hand half of the bulkhead panel is
secured by screws and a single nut. The nut is
located behind the panel at the bonnet hinge
end. Release the right-hand half of the panel
and, having ensured that it is free to move,
remove it (see illustrations).
7 Unscrew the nut from the driving shaft, and
pull the crank off the driving shaft taper (see
illustration).
8 Undo the three wiper motor retaining bolts
9 Pull the rubber seal off the bulkhead panel.
10 Bring the windscreen wiper linkage to an
accessible position, using the ignition switch
as a means of stopping the wiper motor
returning to the parked position.
11 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
12 Prise the linkages off their ball pivots as
required, using a suitably-sized open-ended
spanner. The crank has a dual (vertically
stacked) ball pivot with a bellows separating
the two linkages (see illustrations).
13 If the running faces of the ball pivots are
damaged, the pivot shaft(s) or crank must be
renewed.
Refitting
Wiper motor
14 Refitting is a reversal of the removal
procedure, tightening all nuts and bolts to the
specified torque. Refit the expansion tank as
described in Chapter 3.
16.8a With the crank removed from the
driving shaft taper, undo the three wiper
motor retaining bolts (arrowed)
position using a suitably-sized socket. The
bellows between the two linkages on the
crank must also be greased using the
specified lubricant. Refit the bulkhead panel
rubber seal on completion.
17 Windscreen wiper pivot
shaft - removal and refitting
2
Linkage
15 Prior to refitting, grease the ball pivot
sockets on the linkages, then locate them on
their appropriate ball pivots and press into
Removal
1 Remove the windscreen wiper arms as
described in Section 15.
12
16.8b . . . and withdraw the wiper motor
assembly
16.12a Windscreen wiper linkage
A Removal
B Refitting
1595Ford Fiesta Remake
16.12b Windscreen wiper motor bracket
with linkage and motor. Inset shows
bellows arrangement (A)
12•14 Body electrical systems
17.3 Windscreen wiper pivot shaft fixture
A
B
C
D
E
Collar
Pivot shaft securing nut
Washer
Outer rubber bush
Inner rubber bush
2 Carry out the procedure detailed in Section 16, paragraphs 2 to 6.
3 Remove the collars from the pivot shafts,
unscrew the pivot shaft securing nuts and
remove the washers and outer rubber bushes
(see illustration).
4 Undo the two wiper motor bracket securing
bolts and remove the bracket assembly from
the vehicle, disconnecting the multi-plug
from the motor as the assembly is withdrawn
(see illustration).
5 Remove the inner rubber bush from the
pivot shaft being renewed, and disconnect its
linkage as described in paragraph 12 of the
previous Section.
6 Remove the circlip, washers, shims and Oring, keeping them in order for refitting, and
withdraw the pivot shaft from the wiper motor
bracket assembly.
Refitting
7 Refitting is a reversal of the removal
procedure, greasing the pivot shaft with the
specified lubricant before inserting it to its
location. Refer to paragraph 15 in the previous
Section before refitting the linkage. Reference
must also be made to the Specifications for
details of tightening torques.
8 Refit the windscreen wiper arms in
accordance with Section 15. Refit the
expansion tank as described in Chapter 3.
18 Tailgate wiper motor
assembly removal and refitting
17.4 Removing the wiper motor bracket
and linkage assembly (wiper motor
removed)
4 Remove the tailgate trim panel as
described in Chapter 11.
5 Disconnect the wiper motor multi-plug and
earth lead, then undo the three bolts securing
the wiper motor bracket, and remove the
assembly from the vehicle (see illustration).
6 The wiper motor may be separated from its
bracket by undoing the three mounting bolts
securing it. Note washer/spacer and rubber
insulator fitment.
Refitting
7 Refitting is a reversal of the removal
procedure, ensuring that the wiper motor
shaft locates through its collar on the exterior
panel surface. Tighten all bolts to their
specified torque.
19 Windscreen/tailgate washer
system components removal and refitting
1
Removal
Washer pump
1 Chock the rear wheels then jack up the
18.5 Tailgate wiper motor
A Wiper motor bracket retaining bolts
B Wiper motor and tailgate “contact fingers”
multi- plugs
C Earth connection
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
2 Withdraw the washer pump from the
reservoir, collecting the fluid in a suitable
container as the pump is removed. Note the
seal fitment (see illustration).
3 Having noted hose fitment to pump
connectors, remove the multi-plug and hoses,
then remove the pump from the vehicle.
4 Examine the pump seal. If it is perished or
otherwise damaged, it should be replaced.
Reservoir
5 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
6 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the left-hand front roadwheel.
7 Remove the wheelarch liner as described in
Chapter 11.
8 Withdraw the windscreen/tailgate washer
pump from the reservoir with its hoses and
multi-plug attached, collecting the fluid in a
suitable container. Note the seal fitment.
9 Release the hoses and wiring from the
reservoir guide and remove the three reservoir
securing bolts (see illustration). Remove the
reservoir.
1
Removal
1 Operate the wiper, then switch it off so that
it returns to its rest position. Note that the
wiper motor will only operate with the tailgate
shut, as the spring-tensioned connector pins
must be in contact with the contact plates.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Remove the wiper arm with reference to
Section 15.
19.2 Exploded view of windscreen/tailgate
washer reservoir and pump components
A Cap
F Tailgate washer
B Filter
hose
G Windscreen
C Reservoir
washer hose
D Washer pump
E Pump seal
(marked with
adhesive tape)
1595Ford Fiesta Remake
19.9 Windscreen/tailgate washer reservoir
securing bolts (arrowed)
A In engine compartment
B In wheelarch (wheelarch liner removed)
Body electrical systems 12•15
19.16 Routing of washer hoses in the
engine compartment
A Windscreen washer hose
B Tailgate washer hose
C Tailgate washer hose one-way valve
Windscreen washer jets and hoses
10 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
11 With the bonnet raised and supported on
its stay, release the fasteners securing its
insulation panel (where fitted). Remove the
insulation panel.
12 Carefully press in the retaining lugs on the
washer jets using a flat-bladed screwdriver,
then raise the washer jets from the exterior
surface of the bonnet and separate them from
their hoses
13 The windscreen washer jet hose may have
been fitted with a one-way (non-return) valve.
If this is the case, the main hose run sections
can be removed from either side of the valve
as required.
14 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
15 Disconnect the windscreen washer hose
(marked with adhesive tape) from the washer
pump (see illustration 19.2). Withdraw the
hose from the reservoir guide, and into the
engine compartment.
16 Release the hose from its clips in the
engine compartment, including the bonnet
hinge clip, release the hose grommet from the
bonnet (where fitted) and withdraw the hoses
from the bonnet (see illustration).
23 Release the left-hand side of the
headlining by removing the retaining
clips/grab handles/coat hooks, as applicable.
24 In the engine compartment, disconnect
the tailgate washer hose from its valve. The
forward hose run may be removed, if required,
in a manner similar to that described in
paragraphs 15 and 16 above, releasing it from
its clips in the engine compartment.
25 Remove the tailgate washer hose
grommet, then withdraw the hose through the
bulkhead into the passenger compartment.
26 Release the hose from its A-pillar and roof
frame locations. Release the grommet (hose
protector) from its tailgate and body locations,
and withdraw the hose from the vehicle.
on the ignition and activate the motor, to
engage and pull the motor fully into the
regulator mechanism.
5 Ensure that the multi-plug connection is
located on top of the motor (as if the window
regulator is in position in the door), before
securing the motor to the regulator
mechanism with its two Torx-head bolts.
6 Switch off the ignition and disconnect the
multi-plug.
7 Refit the window regulator to the vehicle, in
accordance with Chapter 11.
21 Tailgate remote release
motor - removal and refitting
Refitting
27 Refitting is a reversal of removal. Always
renew the pump-to-reservoir seal washer, and
ensure that all connections are securely
made. When reconnecting the pump hoses,
ensure that the hose marked with tape is
connected to the correspondingly marked
connection on the pump.
28 On completion, top-up the washer
reservoir (“see Weekly checks”) and check
that the operation of the washers is
satisfactory. If necessary, adjust the
windscreen washer jets by inserting a pin into
the centre of the jet and directing the flow at
the top part of the windscreen.
20 Electric window regulator
motor - removal and refitting
3
Removal
1 Remove the window regulator from the
vehicle, as described in Chapter 11.
2 To remove the motor from the regulator
mechanism, undo and remove the two Torx
head bolts securing it, then carefully separate
by unscrewing (see illustration).
Refitting
3 Carefully screw the motor shaft into the
regulator mechanism.
4 Temporarily connect the multi-plug, switch
2
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the tailgate inner trim panel as
described in Chapter 11.
3 Remove the two motor securing screws,
then twist the operating rod retaining clip and
withdraw the operating rod from it.
4 Disconnect the wiring and remove the
motor assembly.
5 The motor may be separated from its
bracket by removing two further screws.
Refitting
6 Refitting is a reversal of the removal
procedure.
22 Radio/cassette player removal and refitting
3
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Unscrew the four hexagonal head securing
pins from the corners of the unit with an Allen
key (see illustration).
3 In order to release the radio retaining clips,
two U-shaped rods must be inserted into the
special holes on each side of the radio (see
Tailgate washer jet and hose
17 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
18 On XR2i models, remove the tailgate
spoiler as described in Chapter 11.
19 Remove the central blanking plug from
the upper interior surface of the tailgate, to
expose the washer jet base.
20 Depress the washer jet retaining lug using
a flat-bladed screwdriver, then push the
washer jet out through the panel. From the
outside, fully withdraw the washer jet and
disconnect it from its hose. Note washer jet
seal fitment.
21 Remove the left-hand sun visor.
22 Remove the left-hand A-pillar trim as
described in Chapter 11.
12
20.2 Electrically operated window motorsecuring bolts (A), and multi-plug
connection (B)
1595Ford Fiesta Remake
22.2 Unscrewing the securing pins from
the radio/cassette player
12•16 Body electrical systems
25 Radio aerial removal and refitting
2
Note: The roof-mounted aerial mast section
should be removed prior to using an
automatic carwash. This is achieved by
unscrewing it from the aerial base.
Removal
22.3 Radio/cassette player extractor tool
23.3 Remove the screws securing the
speaker assembly to the front door
illustration). If possible, it is preferable to
obtain purpose-made rods from an audio
specialist, as these have cut-outs which snap
firmly into the clips so that the radio can be
pulled out. Pull the unit squarely from its
aperture, or it may jam.
4 With the radio/cassette sufficiently
withdrawn, disconnect the feed, earth, aerial
and speaker leads.
5 Remove the tools from the unit by gently
wiggling and pulling.
the speaker from the door. Disconnect its
multi-plug as it is withdrawn (see illustration).
Refitting
Refitting
6 Refitting is a reversal of removal. When the
leads are reconnected to the rear of the unit,
press it into position to the point where the
retaining clips are felt to engage. Reactivate
the unit in accordance with the code and the
instructions given in the Ford Audio Operating
Manual supplied with the vehicle.
6 Refitting is a reversal of the removal
procedure.
Rear speaker
4 The rear speakers are suspended beneath
the parcel shelf supports and are secured in
position by locating tags and screws.
5 Remove the securing screws then lower the
speaker, disengaging its locating tags from
the parcel shelf support (see illustrations).
Disconnect its multi-plug as it is withdrawn.
24 Speaker balance control
joystick - removal and refitting
1
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Unscrew the aerial mast section, then
remove the base section as follows. Insert a
thin flat-bladed screwdriver into the slot in the
interior (courtesy) light assembly and carefully
lever the assembly out.
3 Through the resultant opening, the aerial
base securing screw is accessible. Remove
the screw and detach the aerial base from the
roof of the vehicle, having noted the aerial
lead fitment.
Refitting
4 Refitting is a reversal of the removal
procedure, ensuring that the aerial base sits
squarely on the roof. Insert the switch end of
the light assembly to its aperture first, then
pivot the light upwards and push home to
secure.
26 “Lights-on” warning module
- removal and refitting
Removal
23 Speakers removal and refitting
3
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
Front speaker
2 Remove the side door inner trim panel as
described in Chapter 11.
3 Remove the four screws securing the
speaker assembly to the door and withdraw
23.5a Remove the rear speaker securing
screws . . .
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Using a thin flat-bladed screwdriver, carefully
prise the joystick assembly out of the facia. Use
a piece of card or similar to prevent damage to
the facia. Withdraw the assembly so that its
multi-plug may be disconnected, then remove it
from the vehicle (see illustration).
Refitting
3 To refit, first connect its multi-plug then
push home to secure.
4 Reconnect the battery negative lead.
23.5b . . . then disengage the locating
tags (A) from their location on the parcel
shelf support (B)
1595Ford Fiesta Remake
1
Removal
The “lights-on” warning feature is fitted to
certain models from 1993 onwards. The
warning module, which resembles an ordinary
relay, is located behind the facia, between the
steering column and radio/cassette player. It
can be removed by reaching up behind the
facia and unclipping it from its mounting.
Refitting
Refitting is a reversal of removal.
24.2 Carefully prise the speaker balance
control joystick from its location
Body electrical systems 12•17
the cover facing away from your body. If in
doubt concerning any proposed work
involving the air bag or its control circuitry,
consult a Ford dealer or other qualified
specialist.
27 Anti-theft systems general information
Anti-theft alarm system
Removal
1 This system provides an added form of
vehicle security. When the system is
activated, the alarm will sound if the vehicle is
broken into through any one of the doors, the
bonnet, or tailgate. The alarm will also be
triggered if the ignition system is turned on or
the radio/cassette disconnected whilst the
system is activated.
2 This system is activated/de-activated
whenever one of the front doors is
locked/unlocked by the key. The system
operates on all doors, the bonnet and tailgate
whenever each door is individually locked (or,
in the case of central locking, when the central
locking is engaged). In addition, the
ignition/starting system is also immobilised
when the system is activated.
3 A further security feature included is that
even though the battery may be disconnected
whilst the system is activated, the alarm
activation continues as soon as the battery is
reconnected. Because of this feature, it is
important to ensure that the system is deactivated before disconnecting the battery at
any time, such as when working on the
vehicle.
4 The system incorporates a diagnostic mode
to enable Ford technicians to quickly identify
any faults in the system. In the event of a
system malfunction, any testing or
component removal and refitting should be
entrusted to a Ford dealer.
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
Warning: Before proceeding,
wait a minimum of 15 minutes,
as a precaution against
accidental firing of the air bag.
This period ensures that any stored energy
in the back-up capacitor is dissipated.
2 Undo the screws, and remove the steering
column lower shroud.
3 Undo the two external screws and the two
internal screws and remove the steering
column upper shroud.
4 Turn the steering wheel as necessary so
that one of the air bag module retaining bolts
becomes accessible from the rear of the
steering wheel. Undo the bolt, then turn the
steering wheel again until the second bolt is
accessible. Undo this bolt also.
5 Withdraw the air bag module from the
steering wheel far enough to access the
wiring multi-plug. Some force may be needed
to free the module from the additional steering
wheel spoke retainers.
6 Disconnect the multi-plug from the rear of
the module, and remove the module from the
vehicle.
Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards
as a precaution against
accidental operation.
Passive Anti-Theft System
(PATS)
Warning: Do not attempt to
open or repair the air bag unit,
or apply any electrical current to
it. Do not use any air bag which
is visibly damaged or which has been
tampered with.
5 From 1994 model year onwards, a Passive
Anti-Theft System (PATS) is fitted. This
system, (which works independently of the
standard alarm system) is a vehicle
immobiliser which prevents the engine from
being started unless a specific code,
programmed into the ignition key, is
recognised by the PATS transceiver.
6 The PATS transceiver, fitted around the
ignition switch, decodes a signal from the
ignition key as the key is turned from position
“O” to position “II”. If the coded signal
matches that stored in the memory of the
PATS module, the engine will start. If the
signal is not recognised, the engine will crank
on the starter but will not fire.
28 Air bag (driver’s side) removal and refitting
4
Warning: Handle the air bag
with extreme care as a
precaution against personal
injury, and always hold it with
Refitting
7 Refitting is a reversal of the removal
procedure.
29 Air bag (passenger’s side) removal and refitting
4
Warning: Handle the air bag
with extreme care as a
precaution against personal
injury, and always hold it with
the cover facing away from your body. If in
doubt concerning any proposed work
involving the air bag or its control circuitry,
consult a Ford dealer or other qualified
specialist.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
1595Ford Fiesta Remake
Warning: Before proceeding,
wait a minimum of 15 minutes,
as a precaution against
accidental firing of the air bag.
This period ensures that any stored energy
in the back-up capacitor is dissipated.
2 Remove the facia as described in Chapter 11.
3 Undo the air bag module retaining nuts and
remove the unit from the facia.
Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards
as a precaution against
accidental operation.
Warning: Do not attempt to
open or repair the air bag unit,
or apply any electrical current to
it. Do not use any air bag which
is visibly damaged or which has been
tampered with.
Refitting
4 Refitting is a reversal of the removal
procedure.
30 Air bag control module removal and refitting
4
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
Warning: Before proceeding,
wait a minimum of 15 minutes,
as a precaution against
accidental firing of the air bag
unit. This period ensures that any stored
energy in the back-up capacitor is
dissipated.
2 Remove the module access cover from the
rear of the glovebox.
3 Press the module wiring multi-plug locking
tag upwards then pivot the retaining strap
over and disconnect the multi-plug.
4 Remove the facia as described in Chapter 11.
5 Undo the three retaining bolts and remove
the module from its location.
Refitting
6 Refitting is a reversal of the removal
procedure.
31 Air bag clock spring removal and refitting
4
Removal
1 Remove the steering wheel as described in
Chapter 10.
2 Undo the three retaining screws, and
remove the clock spring from the steering
wheel. As the unit is withdrawn, note which
aperture in the steering wheel the air bag
12
12•18 Body electrical systems
wiring passes through, as an aid to
reassembly.
Refitting
3 Position the clock spring on the steering
wheel, routing the wiring as noted on removal,
and secure with the retaining screws.
4 The clock spring must now be centred as
follows.
5 Depress the locking pin, and rotate the
clock spring outer rotor fully anti-clockwise
until it is tight (see illustration).
6 Now turn the outer rotor approximately
3.75 turns clockwise, then release the locking
pin. Ensure that the locking pin engages when
it is released.
7 Check that the relative position of the
direction indicator cancelling cam to the cable
connector on the clock spring assembly is as
shown (see illustration 31.5).
8 Refit the steering wheel as described in
Chapter 10.
31.5 Centring the air bag clock spring. Depress locking pin (A) and rotate outer rotor (B)
anti-clockwise (“X” indicates relative position of the direction indicator cancelling cam to
the cable connector - see text)
1595Ford Fiesta Remake
Wiring diagrams 12•19
12
Notes, internal connection details, and key to symbols
1595Ford Fiesta Remake
12•20 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1: Starting, charging, cooling fan, ABS, warning lamps and gauges
1595Ford Fiesta Remake
Wiring diagrams 12•21
Diagram 1a: Ignition system – carburettor models
12
12•22 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1b: Ignition system – fuel-injected models
1595Ford Fiesta Remake
Wiring diagrams 12•23
Diagram 1c: Typical 1.1/1.3/1.4 CFi fuel injection
12
12•24 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1d: 1.6 EFi fuel injection (including RS Turbo)
1595Ford Fiesta Remake
Wiring diagrams 12•25
Diagram 1e: DOHC 16-valve fuel injection
12
12•26 Wiring diagrams
1595Ford Fiesta Remake
Diagram 2: Exterior lighting – side and headlamps
1595Ford Fiesta Remake
Wiring diagrams 12•27
Diagram 2a: Exterior lighting – stop, reversing, fog and direction indicator lamps
12
12•28 Wiring diagrams
1595Ford Fiesta Remake
Diagram 2b: Interior lighting, lights-on warning buzzer, clock and cigar lighter
1595Ford Fiesta Remake
Wiring diagrams 12•29
Diagram 3: Ancillary circuits – horn (except XR2i/RS models), heater blower and heated front /rear screens
12
12•30 Wiring diagrams
1595Ford Fiesta Remake
Diagram 3a: Ancillary circuits – horn (R2i and RS models) and wash/wipe
1595Ford Fiesta Remake
Wiring diagrams 12•31
Diagram 3b: Ancillary circuits – central locking, electric windows and tailgate release (up to 1992)
12
12•32 Wiring diagrams
1595Ford Fiesta Remake
Diagram 3c: Ancillary circuits – central locking, electric windows and tailgate release (1992-on)
1595Ford Fiesta Remake
Wiring diagrams 12•33
Diagram 4: In-car entertainment
12