Chapter 1 Routine maintenance and servicing

11.07.2015 Views
1595Ford Fiesta Remake12•2 Body electrical systemsAdditional fuses behind main fuse board:No Rating (amps) Circuit(s) protected23 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unused24/25 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lights26 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate remote release27/28 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated windscreenFuses - 1992 models onwardMain fuse board:Fuses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unchanged from pre-1992 modelsAdditional fuses behind main fuse board:No Rating (amps) Circuit(s) protected23* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unused23** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lights24* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unused24** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lights25 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate remote release, anti-theft warning system26 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated windscreen27 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated windscreen28* 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-length sunroof28** 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission starter inhibitor29 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air bag* Pre-1994 models** 1994 models onwardRelays (pre-1992 models)Note: Relay locations and circuits controlled are liable to change from year to year. Consult a Ford dealer, for specific information.NoCircuit(s) controlledI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear windowII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper delayIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CFi (fuel injection) delay relayIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition switchVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission starter inhibitor/electric fuel pump (bridgefitted to carburettor engines without automatic transmission)VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight main beamVIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dim-dip lightingIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsXI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated windscreenXII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-lock braking systemA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle speed control (automatic transmission) two-tone horn (where fitted)B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front foglights (XR2i)D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight dipped beamE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dim-dip lightingRelays (1992 models onward)Note: Relay locations and circuits controlled are liable to change from year to year. Consult a Ford dealer, for specific information.NoCircuit(s) controlledI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear windowII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper delayIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CFi delay relay or EFi supply relay (fuel injection)IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition switchVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission starter inhibitor, anti-theft warning systemVII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight main beamVIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-lock braking system and/or dim-dip lightingIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK modelsXI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated windscreenXII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-lock braking systemA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle speed control (automatic transmission) or two-tone horn (where fitted)B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pumpC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front foglights (XR2i, RS Turbo and RS 1800)D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight dipped beamE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dim-dip lightingF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used on UK models

Body electrical systems 12•3BulbsWattageHeadlight (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4, 60/55Sidelight (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Direction indicators (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Side direction indicator repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Auxiliary driving and foglights (S and XR2i) . . . . . . . . . . . . . . . . . . . . . . H3, 55Stop/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/5Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Instrument warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 or 2.6Panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 or 2.6Cigarette lighter illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4Automatic transmission selector illumination . . . . . . . . . . . . . . . . . . . . . 2LubricantsGrease for windscreen wiper linkage and pivots . . . . . . . . . . . . . . . . . .To Ford specification SAM-1C-911-ATorque wrench settings Nm lbf ftWiper motor to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 9 6 to 7Wiper motor bracket to bulkhead/tailgate . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6Windscreen wiper crank to driving shaft nut . . . . . . . . . . . . . . . . . . . . . 22 to 24 16 to 18Windscreen/tailgate wiper arm retaining nut . . . . . . . . . . . . . . . . . . . . . 17 to 18 12 to 13Windscreen wiper pivot shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 7 to 9Windscreen/tailgate washer reservoir securing bolts . . . . . . . . . . . . . . . 2.5 to 3.5 2 to 3Headlight retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 to 7.0 4 to 5Tail light securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.5 1 to 2Auxiliary light retaining nut (S models) . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 to 9.2 5 to 7Horn bracket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 33 18 to 24Starter inhibitor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 14 7 to 101 General information andprecautionsGeneral informationThe electrical system is of 12-volt negativeearth type. Power for the lights and allelectrical accessories is supplied by alead/acid battery, which is charged by theengine-driven alternator.This Chapter covers repair and serviceprocedures for the various electricalcomponents not associated with the engine.Information on the battery, ignition system,alternator, and starter motor can be found inChapter 5A and B.All models from 1994 onwards are fittedwith a driver’s air bag, which is designed toprevent serious chest and head injuries to thedriver during an accident. A similar bag for thefront seat passenger is also available. Thecombined sensor and electronics for the airbag is located next to the steering columninside the vehicle, and contains a back-upcapacitor, crash sensor, decelerometer,safety sensor, integrated circuit andmicroprocessor. The air bag is inflated by agas generator, which forces the bag out of themodule cover in the centre of the steeringwheel. A “clock spring” ensures that a goodelectrical connection is maintained with the airbag at all times - as the steering wheel isturned in each direction, the spring winds andunwinds.An anti-theft alarm system is available onlater models, and is triggered if the vehicle isbroken into through the doors, bonnet, ortailgate. The alarm will also be triggered if theignition or audio equipment is tampered with.Additionally, from the 1994 model yearonwards, a Passive Anti-Theft System (PATS)is fitted. This system, (which worksindependently of the standard alarm) preventsthe engine from being started unless aspecific code, programmed into the ignitionkey, is recognised by the PATS transceiver.PrecautionsWarning: Before carrying outany work on the electricalsystem, read through theprecautions given in “Safetyfirst!” at the beginning of this manual andin Chapter 5A, Section 1.Caution: Prior to working on anycomponent in the electrical system, thebattery negative lead should first bedisconnected, to prevent the possibility ofelectrical short-circuits and/or fires. If aradio/cassette player with anti-theftsecurity code is fitted, refer to theinformation given in the reference sectionsof this manual before disconnecting thebattery.2 Electrical fault-finding -general information2Note: Refer to the precautions given in“Safety first!” and in Section 1 of this Chapterbefore starting work. The following tests relateto testing of the main electrical circuits, andshould not be used to test delicate electroniccircuits (such as engine managementsystems), particularly where an electroniccontrol unit is used. Also refer to theprecautions given in Chapter 5A, Section 1.General1 A typical electrical circuit consists of anelectrical component, any switches, relays,motors, fuses, fusible links or circuit breakersrelated to that component, and the wiring andconnectors which link the component to boththe battery and the chassis. To help topinpoint a problem in an electrical circuit,121595Ford Fiesta Remake

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Page 105 and 106: 4A•1Chapter 4 Part A:Fuel system

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Page 153 and 154: Exhaust and emission control system



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Page 175 and 176: 9•1Chapter 9Braking systemContent

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Page 253 and 254: Wiring diagrams 12•21Diagram 1a:

Page 255 and 256: Wiring diagrams 12•23Diagram 1c:

Page 257 and 258: Wiring diagrams 12•25Diagram 1e:

Page 259 and 260: Wiring diagrams 12•27Diagram 2a:

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Page 267 and 268: REF•2 Conversion factorsWeightsKe

Page 269 and 270: REF•4 General repair proceduresWh

Page 271 and 272: REF•6 Conversion FactorsLength (d

Page 273 and 274: REF•8 Tools and working facilitie

Page 275 and 276: REF•10 MOT test checksThis is a g

Page 277 and 278: REF•12 MOT test checksExhaust sys

Page 279 and 280: REF•14 Fault findingEngine Engine

Page 281 and 282: REF•16 Fault findingEngine (conti

Page 283 and 284: REF•18 Fault findingAutomatic tra

Page 285 and 286: REF•20 Fault findingElectrical sy

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Chapter 1 Routine maintenance and servicing

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