11
Chapter 1
Routine maintenance and servicing
Contents
Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 20 Idle speed and mixture check and adjustment . . . . . . . . . . . . . . . . 9
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . 26 Idle speed control valve cleaning and maintenance . . . . . . . . . . . . . 22
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 4 Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . 18 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Door, tailgate and bonnet check and lubrication . . . . . . . . . . . . . . . 16 Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 11 Spark plug renewal and HT component check . . . . . . . . . . . . . . . . . 21
Emission control system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 10
Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 5
Front wheel alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult, Difficult, suitable for Very difficult,
novice with little
experience
1 for beginner with
some experience
2 suitable for competent
DIY mechanic
3 experienced DIY
mechanic
4 suitable for expert DIY
or professional
5
1595Ford Fiesta Remake
Wiring diagrams 1219
12
Notes, internal connection details, and key to symbols
1595Ford Fiesta Remake
1220 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1: Starting, charging, cooling fan, ABS, warning lamps and gauges
1595Ford Fiesta Remake
Wiring diagrams 1221
Diagram 1a: Ignition system carburettor models
12
1222 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1b: Ignition system fuel-injected models
1595Ford Fiesta Remake
Wiring diagrams 1223
Diagram 1c: Typical 1.1/1.3/1.4 CFi fuel injection
12
1224 Wiring diagrams
1595Ford Fiesta Remake
Diagram 1d: 1.6 EFi fuel injection (including RS Turbo)
Wiring diagrams 1225
Diagram 1e: DOHC 16-valve fuel injection
12
1595Ford Fiesta Remake
1226 Wiring diagrams
1595Ford Fiesta Remake
Diagram 2: Exterior lighting side and headlamps
1595Ford Fiesta Remake
Wiring diagrams 1227
Diagram 2a: Exterior lighting stop, reversing, fog and direction indicator lamps
12
1228 Wiring diagrams
1595Ford Fiesta Remake
Diagram 2b: Interior lighting, lights-on warning buzzer, clock and cigar lighter
1595Ford Fiesta Remake
Wiring diagrams 1229
Diagram 3: Ancillary circuits horn (except XR2i/RS models), heater blower and heated front /rear screens
12
1230 Wiring diagrams
1595Ford Fiesta Remake
Diagram 3a: Ancillary circuits horn (R2i and RS models) and wash/wipe
1595Ford Fiesta Remake
Wiring diagrams 1231
Diagram 3b: Ancillary circuits central locking, electric windows and tailgate release (up to 1992)
12
1232 Wiring diagrams
1595Ford Fiesta Remake
Diagram 3c: Ancillary circuits central locking, electric windows and tailgate release (1992-on)
Wiring diagrams 1233
Diagram 4: In-car entertainment
12
1595Ford Fiesta Remake
Reference REF1
Dimensions and weights . . . . . . . . . . . . . . . .REF1 Conversion factors . . . . . . . . . . . . . . . . . . . .REF6
Vehicle identification . . . . . . . . . . . . . . . . . . .REF3 Tools and working facilities . . . . . . . . . . . . . .REF7
General repair procedures . . . . . . . . . . . . . .REF4 MOT test checks . . . . . . . . . . . . . . . . . . . . .REF10
Jacking and vehicle support . . . . . . . . . . . . .REF5 Fault finding . . . . . . . . . . . . . . . . . . . . . . . .REF14
Buying spare parts . . . . . . . . . . . . . . . . . . . .REF5 Glossary of technical terms . . . . . . . . . . . .REF22
Radio/cassette unit anti-theft system . . . . .REF5 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REF27
Dimensions and weights
Note: All figures are approximate, and may vary according to model. Refer to manufacturers 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 REF
Courier models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1395 mm
1595 Ford Fiesta Remake
