Chapter 1 Routine maintenance and servicing

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