Ford Fiesta (1989-1995). Instruction - part 59

2 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from the motor as the assembly is withdrawn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, shims 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

1

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.

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 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

1

Removal

Washer pump

1 Chock the rear wheels then jack up the

front of the car and support it on axle stands
(see “Jacking 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 “Jacking and 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.

12•14 Body electrical systems 

19.9  Windscreen/tailgate washer reservoir

securing bolts (arrowed)

A In engine compartment
B In wheelarch (wheelarch liner removed)

19.2  Exploded view of windscreen/tailgate

washer reservoir and pump components

A Cap
B Filter
C Reservoir
D Washer pump
E Pump seal

F Tailgate washer

hose

G Windscreen

washer hose
(marked with
adhesive tape)

18.5  Tailgate wiper motor

A Wiper motor bracket retaining bolts
B Wiper motor and tailgate “contact fingers”

multi- plugs

C Earth connection

17.4  Removing the wiper motor bracket

and linkage assembly (wiper motor

removed)

17.3  Windscreen wiper pivot shaft fixture

A Collar
B Pivot shaft securing nut
C Washer
D Outer rubber bush
E Inner rubber bush

1595Ford Fiesta Remake

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 support it on axle stands
(see “Jacking 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 the 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

3

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

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 

2

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

3

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

Body electrical systems  12•15

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

22.2  Unscrewing the securing pins from

the radio/cassette player

20.2  Electrically operated window motor-

securing bolts (A), and multi-plug

connection (B)

12

1595Ford Fiesta Remake

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
Instruction supplied with the vehicle.

23 Speakers - 

removal and refitting

3

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

the speaker from the door. Disconnect its
multi-plug as it is withdrawn (see illustration).

Rear speaker

4 The rear speakers 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 

1

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.

25 Radio aerial - 

removal and refitting

2

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 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

- removal and refitting

1

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.

12•16 Body electrical systems 

24.2  Carefully prise the speaker balance

control joystick from its location

23.5b  . . . then disengage the locating 

tags (A) from their location on the parcel

shelf support (B)

23.5a  Remove the rear speaker securing

screws . . .

23.3  Remove the screws securing the

speaker assembly to the front door

22.3  Radio/cassette player extractor tool

1595Ford Fiesta Remake

27 Anti-theft systems - 

general information

Anti-theft alarm system

1 This system provides an added form of
vehicle security. When the system is
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 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). In 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, any 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
“O” to 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

4

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 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.

29 Air bag (passenger’s side) -

removal and refitting

4

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 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
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

4 Refitting is a reversal of the removal
procedure.

30 Air bag control module -

removal and refitting

4

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

4

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

Body electrical systems  12•17

12

1595Ford Fiesta Remake