FORD FIESTA 1989 Service Repair Manual

12•28 Wiring diagrams
Diagram 2b: Interior lighting, lights-on warning buzzer, clock and cigar\
lighter
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Wiring diagrams 12•29
Diagram 3: Ancillary circuits – horn (except XR2i/RS models), heate\
r blower and heated front /rear screens
12
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12•30 Wiring diagrams
Diagram 3a: Ancillary circuits – horn (R2i and RS models) and wash/\
wipe
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Wiring diagrams 12•31
Diagram 3b: Ancillary circuits – central locking, electric windows and tailgate r\
elease (up to 1992)
12
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12•32 Wiring diagrams
Diagram 3c: Ancillary circuits – central locking, electric windows an\
d tailgate release (1992-on)
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Wiring diagrams 12•33
Diagram 4: In-car entertainment
12
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REF
Dimensions and weights
Note:All figures are approximate, and may vary according to model. Refer to m\
anufacturer’s data for exact figures.
Dimensions
Overall length: 3/5 door hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3743 mm
XR2i, RS Turbo and RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . 3801 mm
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 4052 mm
Width (excluding mirrors): 3/5 door hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1606 mm
XR2i, RS Turbo and RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . 1630 mm
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1650 mm
Overall height: 3/5 door hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1376 mm
XR2i, RS Turbo and RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . 1365 mm
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1812 mm
Wheelbase: Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 2700 mm
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 2446 mm
Front track: 3/5 door hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392 mm
XR2i, RS Turbo and RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . 1406 mm
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1392 mm
Rear track: 3/5 door hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1384 mm
XR2i, RS Turbo and RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . 1376 mm
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1395 mm
Dimensions and weights . . . . . . . . . . . . . . . . REF•1
Vehicle identification . . . . . . . . . . . . . . . . . . . REF•3
General repair procedures . . . . . . . . . . . . . . REF•4
Jacking and vehicle support . . . . . . . . . . . . . REF•5
Buying spare parts . . . . . . . . . . . . . . . . . . . . REF•5
Radio/cassette unit anti-theft system . . . . . REF•5Conversion factors . . . . . . . . . . . . . . . . . . . .
REF•6
Tools and working facilities . . . . . . . . . . . . . . REF•7
MOT test checks . . . . . . . . . . . . . . . . . . . . . REF•10
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . REF•14
Glossary of technical terms . . . . . . . . . . . . REF•22
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF•27
Reference REF•1
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REF•2Conversion factors
Weights
Kerb weight*:3-door hatchback:1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 770 to 780 kg
1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 785 to 850 kg
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 825 to 870 kg
1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 920 to 940 kg
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 990 to 1010 kg
XR2i (1.6 litre) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890 to 910 kg
XR2i (1.8 litre) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 974 kg
RS Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 910 to 930 kg
RS 1800 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 954 to 965 kg
5-door hatchback: 1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 795 to 810 kg
1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 810 to 845 kg
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 845 to 870 kg
1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 840 to 870 kg
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 980 to 1029 kg
Vans: 1.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 775 kg
1.1 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 775 to 790 kg
1.3 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 795 kg
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 920 kg
Payload: 1.0 litre Van models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
310 to 335 kg
1.1 litre Van models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
310 to 335 kg1.3 litre Van models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
330 kgCourier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 515 to 525 kg
Maximum roof rack load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 kg
Maximum towing weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to your Ford dealer for weights and legal requirements concerning anticipated gradients and altitudes.
*Exact kerb weight varies depending on model - refer to VIN plate for de\
tails
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Modifications are a continuing and
unpublicised process in vehicle manufacture,
quite apart from major model changes. Spare
parts manuals and lists are compiled upon a
numerical basis, the individual vehicle identi-
fication numbers being essential to correct
identification of the component concerned. When ordering spare parts, always give as
much information as possible. Quote the vehicle model, year of manufacture, body and
engine numbers as appropriate.
The vehicle identification plate is located on
the top of the front crossmember in the
engine compartment (see illustration). In
addition to many other details, it carries the
Vehicle Identification Number (VIN), maximum
vehicle weight information, and codes for
interior trim and body colours. The
Vehicle Identification Number (VIN) is
given on the vehicle identification plate (see
illustration) . It is also located in a recess in
the floor to the right-hand side of the driver’s
seat, access being gained after lifting the
aperture cover. On later models, the number
is also stamped on a metal tag fixed to the
left-hand side of the facia, which can be read
through the windscreen. The body number and paint code numbers
are located on the vehicle identification plate. The engine number location is dependent
on the engine type. On the HCS engines, it is
stamped on the front left-hand side of the
cylinder block towards the transmission
(facing the radiator) (see illustration). On the
CVH and PTE engines, the location of the
engine number is dependent on the
equipment fitted, but is on the exhaust side of
the engine, facing either towards the timing
belt end or the transmission end (see
illustration) . On the Zetec engines, the
number can be found on the forward-facing
side of the cylinder block, level with the starter
motor, or on the cylinder head just above the
thermostat housing (see illustration).
Buying spare partsREF•3
REF
Vehicle identification
Vehicle identification plate
HCS engine identification numbers
location
A Engine code (side or upper face)
B Serial numberCVH and PTE engine identification number location is on (A) the right-hand side or (B)
the left-hand side, according to model and
equipmentZetec engine identification number on
forward-facing side of cylinder block level with the starter motor (A), or on cylinder
head just above thermostat housing (B)
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1595 Ford Fiesta Remake
REF•4General repair procedures
Whenever servicing, repair or overhaul work
is carried out on the car or its components,
observe the following procedures and
instructions. This will assist in carrying out the
operation efficiently and to a professional
standar d of workmanship.
Joint mating faces and gaskets
When separating components at their
mating faces, never insert screwdrivers or
similar implements into the joint between the
faces in order to prise them apart. This can
cause severe damage which results in oil
leaks, coolant leaks, etc upon reassembly.
Separation is usually achieved by tapping
along the joint with a soft-faced hammer in
or der to break the seal. However, note that
this method may not be suitable where
dowels are used for component location.
Wher e a gasket is used between the mating
faces of two components, a new one must be
fitted on reassembly; fit it dry unless otherwise
stated in the repair procedure. Make sure that
the mating faces are clean and dry, with all
traces of old gasket removed. When cleaning a
joint face, use a tool which is unlikely to score
or damage the face, and remove any burrs or
nicks with an oilstone or fine file.
Make sure that tapped holes are cleaned
with a pipe cleaner, and keep them free of
jointing compound, if this is being used,
unless specifically instructed otherwise. Ensur e that all orifices, channels or pipes
ar e clear, and blow through them, preferably
using compressed air.
Oil seals
Oil seals can be removed by levering them
out with a wide flat-bladed screwdriver or
similar implement. Alternatively, a number of
self-tapping screws may be screwed into the
seal, and these used as a purchase for pliers or
some similar device in order to pull the seal free.
Whenever an oil seal is removed from its
working location, either individually or as part
of an assembly, it should be renewed. The very fine sealing lip of the seal is easily
damaged, and will not seal if the surface it
contacts is not completely clean and free fr om
scratches, nicks or grooves. If the original
sealing surface of the component cannot be
restor ed, and the manufacturer has not made
pr ovision for slight relocation of the seal
r elative to the sealing surface, the component
should be renewed.
Protect the lips of the seal from any surface
which may damage them in the course of
fitting. Use tape or a conical sleeve where
possible. Lubricate the seal lips with oil before
fitting and, on dual-lipped seals, fill the space
between the lips with grease.
Unless otherwise stated, oil seals must be
fitted with their sealing lips toward the
lubricant to be sealed.
Use a tubular drift or block of wood of the
appr opriate size to install the seal and, if the
seal housing is shouldered, drive the seal
down to the shoulder. If the seal housing is unshoulder
ed, the seal should be fitted with
its face flush with the housing top face (unless
otherwise instructed).
Screw threads and fastenings
Seized nuts, bolts and screws are quite a
common occurrence where corrosion has set
in, and the use of penetrating oil or releasing
fluid will often overcome this problem if the
of fending item is soaked for a while before
attempting to release it. The use of an impact
driver may also provide a means of releasing
such stubborn fastening devices, when used
in conjunction with the appropriate
scr ewdriver bit or socket. If none of these
methods works, it may be necessary to resort
to the careful application of heat, or the use of
a hacksaw or nut splitter device. Studs are usually removed by locking two
nuts together on the threaded part, and then
using a spanner on the lower nut to unscrew
the stud. Studs or bolts which have broken off
below the surface of the component in which
they are mounted can sometimes be removed
using a stud extractor. Always ensure that a
blind tapped hole is completely free from oil,
gr ease, water or other fluid before installing
the bolt or stud. Failure to do this could cause
the housing to crack due to the hydraulic
action of the bolt or stud as it is screwed in. When tightening a castellated nut to accept
a split pin, tighten the nut to the specified
tor que, where applicable, and then tighten
further to the next split pin hole. Never slacken
the nut to align the split pin hole, unless stated
in the repair procedure.
When checking or retightening a nut or bolt
to a specified torque setting, slacken the nut
or bolt by a quarter of a turn, and then
r etighten to the specified setting. However,
this should not be attempted where angular
tightening has been used. For some screw fastenings, notably
cylinder head bolts or nuts, torque wrench
settings are no longer specified for the latter
stages of tightening, “angle-tightening” being
called up instead. Typically, a fairly low torque wr ench setting will be applied to the
bolts/nuts in the correct sequence, followed
by one or more stages of tightening through
specified angles.
Locknuts, locktabs and washers
Any fastening which will rotate against a
component or housing during tightening
should always have a washer between it and
the relevant component or housing. Spring or split washers should always be
r enewed when they are used to lock a critical
component such as a big-end bearing
r etaining bolt or nut. Locktabs which are
folded over to retain a nut or bolt should
always be renewed.
Self-locking nuts can be re-used in non-
critical areas, providing resistance can be felt
when the locking portion passes over the bolt
or stud thread. However, it should be noted
that self-locking stiffnuts tend to lose their ef
fectiveness after long periods of use, and
should then be renewed as a matter of course.
Split pins must always be replaced with
new ones of the correct size for the hole. When thread-locking compound is found
on the threads of a fastener which is to be re-
used, it should be cleaned off with a wire
brush and solvent, and fresh compound
applied on reassembly.
Special tools
Some repair procedures in this manual
entail the use of special tools such as a press,
two or three-legged pullers, spring com-
pr essors, etc. Wherever possible, suitable
readily-available alternatives to the manu-
facturer’ s special tools are described, and are
shown in use. In some instances, where no
alter native is possible, it has been necessary
to resort to the use of a manufacturer’s tool, and this has been done for reasons of safety
as well as the efficient completion of the repair
operation. Unless you are highly-skilled and
have a thorough understanding of the
procedur es described, never attempt to
bypass the use of any special tool when the
pr ocedur e described specifies its use. Not
only is there a very great risk of personal
injury , but expensive damage could be
caused to the components involved.
Environmental considerations
When disposing of used engine oil, brake
fluid, antifreeze, etc, give due consideration to
any detrimental environmental effects. Do not,
for instance, pour any of the above liquids
down drains into the general sewage system,
or onto the ground to soak away. Many local
council refuse tips provide a facility for waste
oil disposal, as do some garages. If none of
these facilities are available, consult your local
Envir onmental Health Department, or the
National Rivers Authority, for further advice. With the universal tightening-up of legis-
lation regarding the emission of environmen-
tally-harmful substances from motor vehicles,
most vehicles have tamperproof devices fitted
to the main adjustment points of the fuel
system. These devices are primarily designed
to prevent unqualified persons from adjusting the fuel/air mixture, with the chance of a
consequent increase in toxic emissions. If
such devices are found during servicing or
overhaul, they should, wherever possible, be
r enewed or refitted in accordance with the
manufacturer’ s requirements or current
legislation.
Note: It is
antisocial and
illegal to dump
oil down the
drain. To find
the location of
your local oil
recycling
bank, call this
number free.
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