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Ford 1595 Automobile User Manual

1. 00 AWN VE BUSBRR n KEY TO ITEMS 1 Headlamp Unit LH 2 Headlomp Unit RH 3 Battery 4 Spot Lomp LH 5 Spot Lomp RH 6 Dim Dip Reloy E 51811 7 Dim Dip Relay 8 Dip Beam Reloy D S High Beam Relay VII 18 Number Plote Lomp d ii yyy ge gx Lee FUSE LINK WIRE k 51821 FUSE LINK WIRE 15 Ignition Reloy X 51006 WIRE COLOURS 16 Ignition Switch 19 Instrument Cluster See Internal 3 B Blue Rs Pink Connection Details Page Bk Black 5 Grey 21 Multifunction Switch See Internal Bn Bk 61001 Bn Brown V Violet Connection Detoils Page Gn Green W White 26 Lomp Cluster LH Reor Reg Y yellow 27 Lomp Cluster RH Rear H24507 Diagram 2 Exterior lighting side and headlamps suJeJbeip 9ZeZT 15914 pJ03G6GT Bn 610108 GONDA VE BUSBRR ___ ____ T A ug COLOURS B Blue R Red V Violet Bk Block Pink W White Bn Brown 5 Grey Y Yellow FUSE LINK WIRE B Gn Green 13 Foglamp Switch Rear 2 FUSE LINK WIRE KEY TO ITEMS 15 Ignition Relay X 16 ignition Switch 6 Direction Indicator LH Side Repeater 19 Instrument Cluster See Internal Direction Indicator RH Side Repeater Connection Details Page 1 Foglomp LH Front XR2i Only 8 Foglomp Relay XR2i Only 21 Multifunction Switch See Internal 2 Fogl
2. KEY TO ITEMS WIRE COLOURS Bn 8n 1 Air Temp Sensor 11 Fuel Injection Relay B Blue Rs Pink 2 HEGO Sensor 12 Idle Speed Volve Bk Black 5 Grey 3 Battery 16 Ignition Switch Bn Brown Violet S EEC W Module 1 Inertia Switch Gn Green White 6 Engine Temp Sensor 18 Fuel Injectors Red Y Yellow 51883 SN Conister Purge Valve 28 Phose Sensor 8 Air Flow Meter 23 Speed Sensor 8 Fuel Pump 25 Throttle Sensor EA Bk R 19 Fuel Pump Relay VI Pulse Air Solenoid Valve c x Relay 6 From 1992 gt 2 1 43 S 7 f o 2 da x _ 5 15 51804 51984 Bn Gn gt Bn Y a Bn 6Gn Br Bk Bn R E 9 5 3 Bn Bk 3 3 Bn Y Bn 6n P Bk o Bn Bk Bn Bk G B R Bn Bk Bn Gn 1 B W 1 1 15141 D t a LI k 6 Bn Y b 1m OCTRNE RDJUST 5 i TO SBDS CONNECTOR Bo ug 38 2 2 kN e Ul Sle vs a74 u 4 748 PN UD XJ 4 lt R Bk Gn d FUSE LINK WIRE E Bk R FUSE LINK WIRE Bk Gn Bk gt 3 51001 H24586 BeA CAMARKE C E D oq eo Cp vom d Ho __ t M X Diagram 1e DOHC 16 valve fuel injection GZeZL 5 DCW 15914 pJ03G6GT A Fil F18 F9 m m F8
3. FUSES F26 AND F2 AFTER 1992 Ee rom m t H24518 62 21 DCW 15914 pJ03G6GT KEY TO ITEMS Horn 1 XR2i Only Horn 2 XR2i Only Bottery Wiper Motor Front Wiper Motor Reor Front Wiper Reloy II Washer Pump Horn Relay XR2i Only 16 Ignition Switch 21 Multifunction Switch See Internal Cannection Details Page WIRE COLOURS Blue RAs Pink 1 2 3 4 5 6 8 m Block S Grey S Brown Violet K Green W White Red Y Yellow Bk V Bn W R Y VE BUSBRR VE BUSBRR 51815 A G TAILGATE CONTACT PLATE L ucc wq uw opel ies Aru om w RE 2 PER 6 Le Le RE m 7 E FUSE LINK WIRE DECU FUSE LINK WIRE 51006 3 Bk Diagram Ancillary circuits hom 2 and RS models and wash wipe suJeJbeip OFeZT 15914 pJ03G6GT ignition Switch s 51805 WIRE COLOURS Blue Rs Pink Block S Grey Brown Violet Green White Bk 61001 Y P R Y HE 95 3 5 5208 T RRPPTS 5 2 5 T 3 lt UB A w A Ug A A R Y yi m V A US A Q D 2 lt lt e VE 60388 NE BUSGRR z ELEELE TRILGRTE PLATE 61812 51914 5
4. Refitting 5 Refitting is a reversal of the removal procedure 13 Clock removal and refitting 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 13 2 Carefully prise the clock out of the facia 14 Horn removal and refitting Removal 1 The horn is mounted forward on the left hand 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 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
5. Right hand direction indicators 1595Ford Fiesta Remake 12 12 2 Body electrical systems Additional fuses behind main fuse board No Rating amps Fuses 1992 models onward Main fuse board Fuses 1 to 22 Additional fuses behind main fuse board No Rating amps UC ME Mm Uc 5 25 rrr 26 rcr 27 c ere ee 209 XM aa ded 20 OO pcr 29 edd eae d Pre 1994 models 1994 models onward Relays pre 1992 models Circuit s protected Unused Rear fog lights Tailgate remote release Heated windscreen 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 Note Relay locations and circuits controlled are liable to change from year to year Consult a Ford dealer for specific information No eee ee es es ee ee ee ow ee CO eee eee gt sedem AES EMEN M E RE E UE iE Orr Relays 1992 models onward Circuit s controlled Heated rear window Windscreen wiper delay CFi fuel injection delay relay Not used on UK models Ignition switch Automatic transmission star
6. arrowed to be disconnected 8 Refitting is a reversal of the removal procedure Front direction indicator side repeater 9 Remove the appropriate front wheel arch liner as described in Chapter 11 10 Remove the appropriate sill scuff plate as described in Chapter 11 and release the clip securing the insulation to the panel forward of the lower A pillar 11 Disconnect the supply lead connector and the earth lead then release their grommet from its panel location 12 From outside the vehicle twist the light assembly to release it then withdraw it and its leads 13 Refitting is a reversal of the removal procedure ensuring that the grommet is seated correctly in its panel location Rear light cluster 14 Disconnect the multi plug from the bulbholder then press the retaining lugs on the bulbholder together and remove it see illustration 7 21 Auxiliary light fixture S models C Auxiliary light multi plug B A Bracket retaining nuts B Auxiliary light retaining nut H23333 7 14 Press the retaining lugs on the rear light cluster bulbholder together broken arrows to release the bulbholder 15 Unscrew the four nuts securing the light unit then remove the unit and its seal 16 Refitting is a reversal of the removal procedure Tighten the light unit securing nuts to their specified torque Number plate light 17 Insert a thin flat bladed screwdriver between the light assembly and the bumper and carefully p
7. 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 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 Body electrical systems 12 9 T2 m 6 166 Interior courtesy light pivoted for access to the bulb 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 _ snm 7 7a Release the front direction indicator light retaining spring from its body location 12 10 Body electrical systems 7 7b then pull the light unit out to enable the multi plug
8. A Removal B Refitting 1595Ford Fiesta Remake 16 7 Unscrew the nut from the wiper motor driving shaft 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 PTT Removal 1 Remove the windscreen wiper arms as described in Section 15 12 16 12b Windscreen wiper motor bracket with linkage and motor Inset shows bellows arrangement A 12 14 Body electrical systems H23340 17 3 Windscreen wiper pivot shaft fixture Collar Pivot shaft securing nut Washer Outer rubber bush Inner rubber bush N Carry out the procedure detailed in Sec tion 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 s
9. Body electrical systems 12 15 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 WU 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 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 22 2 U
10. Number plate light Intertor QE macie oec e m e ce Luggage compartment light Instrument warning lights Panel illumination Cigarette lighter illumination Automatic transmission selector illumination Lubricants Grease for windscreen wiper linkage and pivots Torque wrench settings Wiper motor to Wiper motor bracket to bulkhead tailgate Windscreen wiper crank to driving shaft nut Windscreen tailgate wiper arm retaining nut Windscreen wiper pivot shaftnut 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 dur
11. 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 i 10 2 Removing bulbholder from the rear of the instrument cluster bayonet type fitting 1595Ford Fiesta Remake 9 4b Disconnect the speedometer cable from the rear of the instrument cluster 10 Instrument panel components removal and refitting Removal 1 Remove the instrument panel as described in Section 9 Panel illumination and warning light bulbs 2 All bulbholders are a bayonet fit requiring a twist and withdraw removal technique see illustration Bulbs cannot be removed from their holders they are renewed complete Printed circuit 3 Insert a thin flat bladed screwdriver into the multi plug retainer and carefully unclip it having noted its orientation see illustration 4 Remove all panel illumination and warning light bulbholders 5 Using a suitable tool a trim clip removal tool is ide
12. Switeh 17 Oil Pressure Switch gu 2 Fin nn ins FUSE LINK WIRE 51010 USE LI WIRE COLOURS 16 Auta Trans idie Speed Reloy 19 instrument Cluster See internal 3 FUSE LINK WIRE 0581006 _ R Blue Rs Pink Connection Details Page Black S Grey 28 RBS Reioy XII Brown Violet Auto Trans inhibitor Switch Bn Green white 31 Link Only Corburettorc Models Bk 61991 Red Y Yellow Without Rutomotic Transmission 24501 Diagram 1 Starting charging cooling fan ABS warning lamps gauges VON 0 U 2 QN Bn Gn Bn Gn gggo MOM HMM 15914 pJ03G6GT Ooo T e 7 H 51803 51804 2 Xm ut 99 Add 51904 awe 2 Lt WITH ESC H2 MODULE NOJENTO w a8 L a 4 1 1 1 T c D m w x 0 ____ Gn E 51814 51828 1 2 3 4 5 6 7 8 9 1e 12 13 u 51813 gt 4 51887 KEY TO ITEMS Ar Temp Sensor G FUSE LINK WIRE 51206 Bk J 61981 1 3 Battery 4 frank Sensor B Ignition Module 6 Ignition Module WESC 7 Ignition Module ESC H2 B ignition Module ESCPL 13 Ignition Coil Conventional 14 Ignition Coil iste ioutorless IS Engine Temp Sensor 16 ignition Sw
13. a precaution against A or apply any electrical current to it Do not use any air bag which is visibly damaged or which has been tampered with Refitting accidental operation 4 Refitting is a reversal of the removal procedure Warning Do not attempt to open or repair the air bag unit 30 Air bag control module removal and refitting HE 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 Chap ter 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 HE 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 stee
14. 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 f 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 o
15. 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 Body electrical systems 12 3 To Ford specification SAM 1C 911 A Ibf ft 6 to 7 4 to 6 16 to 18 12 to 13 7 to 9 2 10 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 WU 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 th
16. 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 HE 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 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
17. 1008 559 a 6100 KEY TO ITEMS Tailgate Release Switch Tailgate Lock Motor Battery Electric Window Motor LH Electric Window Motor RH Electric Window Switch LH R Y Electric Window Switch AH R Y Door Lock Motor LH Front Door Lock Motor LH Reor n Door Lock Motor RH Front Door Lock Motor RH Reor R B Lek 51918 me ignition Reloy X FUSE LINK WIRE 7 38 ug vg v9g A Ari E nO nS Red Yellow lee Diagram 3b Ancillary circuits central locking electric windows and tailgate release up to 1992 Sweibeip DCW 15914 pJ03G6GT DONDA 5201 ug A 38 A S 38 5 VE_BUSBAR A a A 28 A U9 ug A S A S ug ug A H KEY TO ITEMS Toilgote Release Switch Tailgate Lock Motor Bottery Electric Window Motor LH Electric Window Motor RH Electric Window Switch LH A 8 A 38 A 9 ug A S A S Electric Window Switch RH Door Lock Motor LH Front Door Lock Motor LH Rear Door Lock Motor RH Front Door Lock Motor RH Reor Electric Window Switch RH E e Controls LH Window ignition Relay Y Ignition Switch R B 51918 Multifunction Switch See Internal FUSE LINK WIRE Connection Details Page 51006 WIRE COLOURS FUSE LINK WIRE Blue Rs Pink Black Grey Ix Brown Violet Ma 3
18. 51001 Yellow Diagram 3c Ancillary circuits central locking electric windows and tailgate release 1992 on Ug Ug A TRILGRTE CONTRCT PLRTE ZEeZT 15914 pJ03G6GT Y R a Y Bn Y 6n gt W Bn W Bn Y Bk W Bk Y Bn B 7 Y Bk 7 W Bk 61613 u 4 m 20 m I o m 0 D D D m E D lt D D m A S Y Bn D w Bn Y Bn W Bn Y Bk W Bk 51893 gt 61013 H24514 Zoa A T a 0 Y R lt WR ANTENNA 3 STEREO WITH INTEGRAL 4 WAY BALANCE Y G6n w Gn G S Y R PE Y 6n G W 6n 87 4 51010 FUSE LINK WIRE 51805 FUSE LINK WIRE Diagram 4 In car entertainment KEY TO ITEMS Fader Control 4 Way Speaker LH Front Speaker LH Reor Speaker RH Front Speaker RH Rear Ignition Switch Instrument Cluster See Internal Connection Details Multifunction Switch See internal Connection Details WIRE COLOURS BReg ean C e7T sulejbeip
19. Brown Violet ia 51010 Green W White Bn R Red Y Yellow 1 4 55 KEY TO ITEMS D D H24569 FUSE LINK WIRE FUSE LINK WIRE 51006 re 61001 C D E Diagram 2b Interior lighting lights on waming buzzer clock and cigar lighter 8ZeZT 15914 pJ03G6GT Bk V Bk V Bk V Rlternotor Horn Not XR2i Bottery Heated Rear Window KEY TO ITEMS y 1 S207 mom NET R mo x NEN moo Bk B Bk B Bn Bn Y FUSE LINK WIRE d 51809 9 VE BUSBAR 51887 Bk B Bk B R 8 Bn Ba Y pog FUSE LINK WIRE 51010 51806 FUSE LINK WIRE Bk 61001 Bk B 5 51058 51014 Ba ie R 51008 B lt T 51859 Bk B Bk B Bn Bn Y RE MM lt Los qo o D duo M mc _ ee eee WE qo Sole use Diagram 3 Ancillary circuits hom except XR2i RS models heater blower and heated front rear screens Heoted Rear Window Switch Heated Reor Window Reloy Heated Windscree Heated Windscreen Switch Heated Windscreen Relay XI Heater Blower Motor Heater Blower Motor Switch Ignition Reloy Ignition Switch Multifunction Switch See Internal Connection Details Page WIRE COLOURS Blue Rs Pink Black S Grey Brown Violet Green W White Red Y Yellow Bk B TAILGATE CONTACT PLATE NOTE FUSES F2 AND F28 CHANGE TO
20. 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 565 See Weekly checks Bulbs exterior lights 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 ads 8 Horn removal and refitting Degrees of difficulty Easy suitable for EN novice with little Fairly easy suitable for beginner with X some Specifications Fuses pre 1992 models Main fuse board No Rating amps E ETE E een
21. From 1992 Only 1 3 Bn e ET 51904 lt 4 87 5118 5127 Bn TO 1b C5 51884 ALL MODELS FROM 1991 Bn ALL MODELS FROM 1991 Bn W Bn W Bn Y Y Bn Y W R W ZBK Bn 6n Gn BnG Bn G8n Bnin amp 8n 6n Br Bk Bn Bk Bn Eum H 38 T 61911 Ba Y Ba lt Ba Ba Y Bn Y T m Bn W Bn w Bn W G TR Bk m Bk G FUSEBOX FUSEBOX 5112 5122 Ben 51808 Bn 5114 5125 511 48 4 a ug ug 3 Ad VE BUSBRR 115 S126 utg 318 Bn W Bn W Eee Bk j 5109 5121 q Bk Bk BOW 45 RS OCTRNE RDJUST OR IDLE ADJUST R FUSE LINK WIRE R B pep 9 Bk R c 3 FUSE LINK WIRE 3 Bk Bk B 61001 Bn W Bn W Bk Gn Bk Gn Bk R Bk R Bk R H24504 874 t t i t
22. I 1 1 1 I Lon 9 ___ NL qo Diagram 1c Typical 1 1 1 3 1 4 CFi fuel injection ZeZT DCW 15914 pJ03G6GT 9 R KEY TO ITEMS WIRE COLOURS 1 Air Temp Sensor 11 Fuel Injection Reloy III B Blue Rs Pink 3 Battery From 1990 Bk Black S Grey 5 Module 12 Idle Speed Valve Bn Brown Violet B Engine Temp Sensor 16 ignition Switch Gn Green W White CO Adjuster Potentiometer 1 Inertia Switch R Red Y Yellow 8 Fuel injection Relay II Pre 1990 18 Fuel Injectors S Fuel Pump 28 MAP Sensor 18 Fuel Pump Relay XI 23 Speed Sensor Relay B From 1992 25 Throttle Sensor 35 Boost Control Valve Turbo Only j TURBO TO 1b H3 Bn 5150 Ba _ Ba 5153 LEE 51885 Bk Bn Bk Bn ug ug ug __ 9 3 Bn Bn W Bk gt FUSE LINK WIRE FUSE LINK WIRE Bn W M Bk 61801 OCTANE ADJUST AND IDLE ADJUST 79 0M u 38 VE BUSBAR u9748 R B 51813 51887 Oe cu dF SES Diagram 1d 1 6 EFi fuel injection including RS Turbo 87 8 H s T ao l1 __ __ T Z __ __ gt ___ SE l Lo EINE BULIM 15914 pJ03G6GT
23. S REEL 19 20R 5 28 10A 568 21 10A 56 22 10A 23 24 25 26 15R pai 27 30A 53 B 28 38A 53 2 82 53 h b v ltrt FUSE RATING 25 158 26 27 28 208 2 3 4 No Charge Warning Lamp b Handbrake Warning Lamp c Main Beam Warning Lamp d Instrument illumination e Fuel Gauge f Temperature Gouge 9 Oil Pressure Lamp h Tachometer i Voltage Stabilizer S J ABS Warning Lamp 3 k Choke Warning Lamp 1 1 Dir Ind Warning Lamp LH 12 m Dir ind Warning Lamp RH 13 KEY TO INSTRUMENT CLUSTER 14 Notes internal connection details and key to symbols 1595Ford Fiesta Remake Wiring diagrams 12 19 4 Complex items appear on the diagrams 05 blocks and ore expanded on the internal connections page 5 Brackets show how the circuit may be connected in more than one way 6 Not all items ore fitted to all models CIRCUIT Electric Engine Control System interior Lomp Cigor Lighter Clock And Radio Memory Central Locking Heated Rear Window Dim Dip Lighting LH Side Lamp And Rear Foglamp RH Side Lamp LH Dipped Beam RH Dipped Beam LH Main Beam Rnd RH Spot Lamp RH Main Beam find LH Spot Lame Heater Blower find Reversing Lamp Radiator Cooling Fan Front Foglamps 2 Only Horn Wash wipe Brake Lights And instruments Electric Windows Electric Fuel Pump HEGO Sensor LH Direction indicators RH Direction indicators Free Free Free Tailgate Releas
24. 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
25. al 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 ANERE UOA H23326 10 3 Unclipping the multi plug retainer from the rear of the instrument cluster 12 12 12 Body electrical systems 10 7 Rear view of instrument cluster Retaining tags Multi plug retainer Speedometer cable connection Speedometer gauge retaining screws Tachometer terminals obscured by protective pad Tachometer gauge retaining screws G Fuel and temperature gauge assembly terminals H Fuel and temperature gauge assembly retaining screw gt TI 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 Tachometer 9 Carry out the 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 Fue
26. 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 4S 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 4c then disconnect the multi plug 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 Instrument panel removal and refitting WU Removal 1 Disconnect the battery negative earth lead refer to Chapter 5A
27. ction indicator side repeater bulbholder assembly 1595Ford Fiesta Remake Body electrical systems 12 7 5 2b then unlock the headlight bulb retaining spring and withdraw the bulb 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 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 retainer XR2i models 12 12 8 Body electrical systems 5 21a Disconnect the ear light cluster multi plug from the bulbholder 5 246 then withdraw the assembly to the outside of the vehicle t
28. d 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 H23333 5 8 Remove the front direction indicator light bulbholder by turning it anti clockwise A Light unit C Multi plug B Bulbholder D Retaining spring 5 2a Remove the protective cap 3 Refitting is a reversal of the removal procedure 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 Disconnectthe supply lead connector and 5 13 Removing the dire
29. e Heated Windscreen Heated Windscreen FUSEBOX CHANGES FROM 1992 CIRCUIT Tailgate Release Heated Windscreen Heated Windscreen Power Sunroof KEY TO SYMBOLS PLUG IN CONNECTOR e ERRTH A G1004 BULB DIODE Br SOLDERED JOINT o 21883 FUSE G FUSIBLE LINK 12 24588 DCW 15914 pJ03G6GT NO e NO NR BT __1 ___ lt __ ____ Kf ULL T Ber 2 1 51062 CU i gt 5 Bv un 2 3 _ _ COMES ENSEM Bk B Ll HCS Bot amp DIESEL Mew Mim NN UD Bn Bk t 3 5 dca Bk Y 5 R 4 Fis _ 1 1 3 3 FI3 _ dl Baek n 3 1 a 51839 Base 5 Bk Y lt lt 5 e A Bn Gn 8 i Bn Gn 9 i Bn Bk 4 i Bn Y i i Ba 6 L T u 18 8738 In Bn KEY ITEMS Aiternotor Choke Worning Switch Battery Fuel Gouge Sender Unit Handbrake Warning Switch Low Brake Fluid Sender Unit Cooling Fan Motor Cooling Fan Switch Starter Motor 18 Auto Trans Relay LL RBS Warning Switch LH 12 Auto Trons Throtrle Kicker idle Speed Valve 13 RBS Warning Switch RH 14 Coolant Temperature Sender Unit IS ignition Relay V L Bn W R 16 Ignition
30. e 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 fault finding 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
31. e 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 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 WU 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 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 t
32. he collar recesses 4 Remove the two screws securing the upper steering column shroud from above and the two screws securing it from below the latter accessible only with the lower shroud removed 5 Disconnect the ignition switch wiring multi plug connector Insert a thin bladed screwdriver into the lock tab aperture release the locking tab and remove the loom plate from its location on the left hand side of the steering column 6 Where applicable undo the single screw and withdraw the Passive Anti Theft System PATS transceiver from the ignition switch steering lock barrel 7 Insert the key and turn the ignition switch to position I Depress the lock barrel plunger through the steering column lock housing As the lock barrel plunger is depressed pull on the ignition key to remove the lock barrel see illustration 8 Refitting is a reversal of the removal procedure When relocating the switch to the steering lock the barrel driveshaft must align 4 7 Withdraw the lock barrel after depressing its plunger through the aperture in the steering column lock housing arrowed 1595Ford Fiesta Remake Body electrical systems 12 5 BRIDGE 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 desc
33. he bulbholder together and remove it see illustrations 22 All bulbs are of bayonet type fitting 23 Refitting is a reversal of the removal procedure Rear light cluster Courier models 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 HT 6 3a Remove the selector illumination bulb cover 5 21b then having pressed its retaining lugs withdraw the bulbholder for access to the bulbs 5 29 Release the number plate light securing tab arrowed and separate the bulbholder and light cover Number plate lights 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 3b followed by the bayonet fitting bulb 1595Ford Fiesta Remake 5 24a On Courier models unscrew the two black pla
34. he 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 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 Why 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 20 2 Electrically operated window motor securing bolts A and multi plug connection B 1595Ford Fiesta Remake
35. hims and O ring 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 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 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
36. ing 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 Wattage H4 60 55 was 5 pans obs Oa mi men dera 21 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 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
37. itch WIRE COLOURS 19 Instrument Cluster See Internal Blue Rs Pink Connection Details Page Black S Grey 21 Distributor Brown v Violet 22 Spork Plugs Gceen white 23 Fuel Shut Off Valve Red Y Yellow 24 Suppressor 5185 smu ee eee ee 90 ee BP Bee G3 1 0 1 1 WITH UESC MODULE i i i EO i t i i b b t I i t i i i i i i 1 29929 8 ii MN OBEN RE Diagram 1a Ignition system carburettor models suejbeip DCW 15914 pJ03G6GT sue Awe agen 1 6 EFI TURBO AND 1 8 DOHC 16V TO 19 08 TO 1 8 a y gt 18 22 B Y gt TO 1 22 O8uni LON 1 8 DOHC 16V ONLY ATWO AST HOO u om 1 3 2 1 3 2 4 E 8 5 7 51042 Bk Y lt 5 5 2 5 s 9 19 S 12 18 Bn 9 i Gn 12 i Bn 13 14 um um um om EB UR NS Gm GS MD Xue UAR UU UD UP UD GER GA C GU m UR US m m am M en gt 1008 i gt 5 i gt EE Bn gt i 3 1 a 4 T 6 Bn 1 8 DOHC 16V ONLY 5 i Gn 18 12 2 i
38. l 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 13 Refitting is a reversal of removal procedure given in 11 Speedometer cable removal and refitting WUC 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 11 2 Detaching the speedometer cable at the transmission casing 4 Note the cable routing for use when refitting Pull the soeedometer cable through into the engine compartment and remove it from the car Refitting 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 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 itis withdrawn
39. lbs 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 J between certain
40. make the connections A 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 Warning Under no circumstances may live 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 Short circuit faults are normally caused by a breakdown in wiring insulation which allows a feed wire to touch either another
41. 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 WU 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 Unsc
42. nscrewing the securing pins from the radio cassette player 12 12 16 Body electrical systems 22 3 Radio cassette player extractor tool 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 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 23 Speakers removal and refitting Why 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 23 3 Remove the screws securing the speaker assembly to the front door pe 9 the speaker from the door Disconnect its multi plug as it is withdrawn see illustration Rear speaker 4 The rear speake
43. omp RH Front XR2i Only 9 Reversing Lamp Switch Connection Details Bk 51001 3 Bottery Stop Lomp Switch 26 Lomp Cluster LH Reor 4 Direction Indicotor LH Front Direction Indicator Relay 27 Lomp Cluster RH Rear 5 Direction Indicator RH Front 12 Foglomp Switch Front XR2i Only 30 Auto Trans inhibitor Switch H24508 TAM MAAKE _ Eli Cw Diagram 2a Exterior lighting stop reversing fog and direction indicator lamps 2 21 Ssuejbeip DCW 15914 pJ03G6GT E wo No __ __ T e T _ gt apr 7 SRLOON ONLY ego 1057 BE 51004 Bb 322 89 HLIA Y3ZZN LAOHLIA 3 51922 e 2 ug 2 59 34 8 Bk or A 8 Bk Y Yanan AWN VAN ONLY 8 4 38 S Cigor Lighter Clock Battery Luggage Compartment Lamp Switch Only Luggoge Comportment Lomp Saloon Only Luggage Compartment Lamp Switch Saloon Only Interior Lamp Door Switch Interior Lamp Switch Heater Blower Switch Illumination DDd Auto Trons Selector Illumination Ignition Switch instrument Cluster See Internol 51958 Connection Details 51959 l Multifunction Switch See Internal S Y Connection Details Page SY S Y 28 Lights On Warning Buzzer Only S Bk H o Bn G 0 3i From 1993 O WIRE COLOURS Biue Rs Pink Bn C Black 8 Grey
44. ort it on axle stands see J acking 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 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 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 t
45. 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 itis 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 H23327 Du v on 6 16a Releasing the interior courtesy light from its location removal then insert the switch end of the light to the aperture pivot the light upwards and push home to secure 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 WU 1 Disconnect the battery negative earth lead
46. peedometer cable removal and 11 Switches removal 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 PI 19 Wiper arms removal and refitting 15 Wiper blade check See Weekly checks Difficult suitable for Very difficult suitable for expert DIY mechanic or professional 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
47. r 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 3 1 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 b
48. removal Luggage area contact switch 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 50 Undo the two screws securing the contact switch and withdraw it from its tailgate location 51 Unclip and disconnect the switch multi plug 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 BN renewal ES 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 an
49. rew 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 16 8b withdraw the wiper motor assembly 16 6b then disengage the right hand half of the panel from under its single retaining nut left hand shown and withdraw the motor assembly see illustrations Remove the motor cover then disconnect the multi plug and remove the motor from the vehicle Linkage 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 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 Linkage 15 Prior to refitting grease the ball pivot SOCkets on the linkages then locate them on their appropriate ball pivots and press into 16 12a Windscreen wiper linkage
50. ribed 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 windows early models and the tailgate remote release mechanism where fitted 19 Disconnect the batter
51. ring 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 28252 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 NOTES 1 diagrams ore divided into numbered circuits depending on function e g Diagram 2 Exterior lighting 2 Items ore arranged in relation to o plan view of the vehicle 3 Wires may interconnect between diagrams and ore located by using grid reference e g 2 Al denotes a position on diagram 2 grid location AL INTERNAL CONNECTION DETAILS FUSEBOX FUSE RATING l 3A 2 ISA 3 208 4 38A 5 10A 6 10A LOA 8 10A 9 10A 18 15R 158 12 20A 13 ANGE 14 15A or 15 15A 58 16 20A 4 17 IBA 2S 18 30A n
52. rise 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 Disconnectthe light wiring multi plug then unscrew its retaining nut withdraw the bolt and remove the light unit see illustration SCrews screw C Driving light vertical adjustment screw 1595Ford Fiesta Remake dj il ur A Light assembly retaining D Fog light vertical adjustment 22 Refitting is a reversal of the removal procedure tightening the retaining nut to the specified torque On completion check the auxiliary light beam alignment as described in Section 8 XR2i models 23 Disconnect the battery negative earth lead refer to Chapter 5A Section 1 24 Undo the four Torx retaining screws securing the relevant dual light assembly to its bumper location Note that the retaining and adjusting screws are captive within the light assembly they cannot be removed from the assembly see illustration 25 Withdraw the light assembly from its location then remove the caps protecting the bulbs and disconnect the wiring 26 If required the lights may be removed individually from their housing at this stage Each light is secured to i
53. rs 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 Refitting 6 Refitting is a reversal of the removal procedure 24 Speaker balance control joystick removal and refitting Removal 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 25 Radio aerial removal and refitting WU 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 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
54. 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 Removal Washer pump 1 Chock the rear wheels then jack up the H23342 19 2 Exploded view of windscreen tailgate washer reservoir and pump components A Cap F Tailgate washer B Filter hose C Reservoir G Windscreen D Washer pump washer hose E Pump Seal marked with adhesive tape 1595Ford Fiesta Remake 18 5 Tailgate wiper motor Wiper motor bracket retaining bolts Wiper motor and tailgate contact fingers multi plugs C Earth connection Uo front of the car and support it on axle stands see J acking 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 J acking and
55. s 2 ee ee ee 3 ZU s aoe eae d 4 5 eS ee ee 6 7 Peres tote eee ee ee ere ere 8 eee Tee dua vox eee ee d ee eee ee ee 9 aren ee ed oe ees be eh ee ee oe Pee ees ee 10 DD 11 ETE 12 13 E 14 DD eid ok ob See NES NEN 15 PDT 16 20 cuam eek Da RE 17 LU 18 O d bee fud eee ees 19 ZU ees Sed oe bw ek PG 20 ie ote gk 21 a ee ee ee ee ee ee 22 qd Fairly difficult AJ aS Suitable for competent X experienced DIY A A A DIY mechanic 12 1 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 S
56. s i KEY TO ITEMS i R 3 Battery 4 Cronk Sensor 7 nan 5 ignition Module 5 ignition Module EDIS 1 1 1 3 CFI AND i E M 9 FUSE Link WIRE lt 1088 13 Ignition Conventional 2 14 ignition Coi istr ibu ess 1 4 CFI FROM 1991 WIRE COLOURS 16 Ignition Switch 5 B Blue Rs Pink 13 instrument Cluster See internal Bk 51881 Bk Block 5 Grey Connection Details Page Gn Gn Bn Brown Violet 21 Distributor Gn Green W White 22 Spork Plugs Red Y 24 Suppressor H24583 cp __ c _ I 8 __ 1 I b Diagram 1b Ignition system fuel injected models suJeJbeip 22 21 15914 pJ03G6GT KEY Air Temp Sensor HEGO Sensor Bottery Throttle Control Motor EEC IV Module Engine Temp Sensor Conister Purge Volve Fuel Injection Reloy Pre 1990 Fuel Pump Fuel Pump Reloy VI og ooOoxmmesugtwur TO ITEMS WIRE COLOURS li Power Delay Reloy II B Blue Rs Pink Only From 1990 5 16 Ignition Switch Brown Violet 17 inertio Switch Green White 18 Fuel Injector R Red Y Yellow 20 MAP Sensor 23 Speed Sensor 25 Throttle Sensor 26 Injector Bollost Resistor 36 Pulse fiir Solenoid Valve DIRGNOST iC C CONNECTOR ug g ug ug RENS 5 5116 5128 Bk 5 Relay B
57. 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 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 7 Refitting is a reversal of the removal procedure gt 29 Air bag passenger s side removal and refitting 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 HIK Warning Handle the air bag with extreme care as a 1595Ford Fiesta Remake Body electrical systems 12 17 Warning Before proceeding A 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 Chap ter 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 A mechanism facing downwards as
58. stic nuts securing the rear light cluster assembly 6 Bulbs interior lights renewal WU Instrument panel illumination and warning lights 1 Refer to Section 10 Automatic transmission selector illumination 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 H23334 6 13 Heater fan illumination arrangement that the bulb and bulbholder cannot be separated they are replaced as an assembly 9 Refitting is a reversal of the removal procedure 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
59. 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 n 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 de activated 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 testing or component removal and refitting should be entrusted to a Ford dealer Passive Anti Theft System PATS 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 to
60. ter inhibitor electric fuel pump bridge fitted to carburettor engines without automatic transmission Headlight main beam Dim dip lighting Not used on UK models Not used on UK models Heated windscreen Anti lock braking system Idle speed control automatic transmission two tone horn where fitted Not used on UK models Front foglights XR 21 Headlight dipped beam Dim dip lighting 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 Heated rear window Windscreen wiper delay CFi delay relay or EFi supply relay fuel injection Not used on UK models Ignition switch Automatic transmission starter inhibitor anti theft warning system Headlight main beam Anti lock braking system and or dim dip lighting Not used on UK models Not used on UK models Heated windscreen Anti lock braking system Idle speed control automatic transmission or two tone horn where fitted Fuel pump Front foglights XR2i RS Turbo and RS 1800 Headlight dipped beam Dim dip lighting Not used on UK models 1595Ford Fiesta Remake Bulbs Headlight MONT Direction indicators main Side direction indicator Auxiliary driving and foglights S and XR21 SOHAN i a d oed ee maar de deeds en Rear TOO a dd we Reversing light
61. 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 N removal and refitting SS N 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 27 Anti theft systems general information Anti theft alarm system l This system provides an added form of vehicle security When the system 15 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
62. ts 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 BN beam alignment checking SS and adjustment X 1 Accurate adjustment of the headlight and auxiliary light beams is only possible using optical beam setting equipment and this TA pi WEE NS H23331 7 24 Auxiliary light assembly XR2i models left hand unit shown Driving light horizontal adjustment screw E Bulb protective caps F Foglight bulb connector G Bulb earth leads H Driving light bulb connector H23332 Body electrical systems 12 11 8 2 Exploded view of the headlight unit Sidelight bulb holder Sidelight bulb Headlight bulb retainer Headlight bulb Bulb protective cap Horizontal adjustment screw Vertical adjustment screw Om7m movaOD gt work should therefore be carried out by a Ford dealer or service station with the necessary facilities 2 Temporary adjustment can
63. turn the switch clockwise to secure Reconnect the switch wiring connector and the battery 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 BE 4 46 Withdrawing the luggage area contact plate for access to disconnect the multi plug 1595Ford Fiesta Remake 4 23 Heater fan motor control switch removal 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 Reversing light switch 39 Referto Chapter 7A
64. 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 H23343 19 9 Windscreen tailgate washer reservoir securing bolts arrowed A n engine compartment B In wheelarch wheelarch liner removed 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 supp
65. 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 ofa 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 bu
66. y 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 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 itis 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 902 anticlockwise and withdraw it from the bracket 4 30 Removing the cover from the handbrake warning light switch i 4 206 then disconnect its multiplug and remove the switch 28 Insert the switch into its retainer press it lightly against the brake pedal until all free play is just taken up then

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