Ford Fiesta (1989-1995). Instruction - part 24

6 Unscrew the nut securing the cooling fan
shroud to the radiator, noting the insulating
washer arrangement, then lift the fan shroud
and motor assembly from the vehicle (see
illustration).
7 To separate the fan from the motor shaft,
first remove its retaining clip and washer, then
withdraw the fan (see illustration). A new clip
will be needed upon reassembly. Remove the
three nuts securing the motor to the shroud
and separate the two components.

Turbo models

8 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
9 Undo the two retaining screws and move
the HT lead bracket clear of the working area,
disconnecting the HT leads as required.
10 Disconnect the fan motor wiring multi-
plug and the two auxiliary lamp wiring multi-
plugs. Unclip the wiring from any local
retaining clips.
11 Remove the front bumper as described in
Chapter 11.
12 Undo the two lower fan shroud retaining
bolts, release the shroud upper locating
tongue from the radiator and withdraw the
assembly from the front of the car.
13 To separate the fan from the motor shaft,
pull off the fan guard from the shroud, flatten
back the raised lockwasher tab, and unscrew
clockwise (a left-hand thread is employed)
the nut securing the fan to the motor shaft.
Remove the fan then undo the three nuts
securing the motor to the shroud and
separate the two components.

Refitting

All models

14 Refitting is a reversal of the removal
procedure. On non-Turbo models, ensure that
the locating tags on the base of the shroud
locate correctly in their slots in the body
crossmember. On Turbo models, if the fan
was removed, use a new lockwasher when
refitting. On all models, ensure that the wiring
connections are cleanly and securely made,
and locate the loom in the retaining clips.

6

Cooling system electrical
switches and sensors -
testing, removal and refitting

2

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Coolant temperature gauge
sender

Testing

1 If the coolant temperature gauge is
inoperative, check the fuses first (see Chap-
ter 12).
2 If the gauge indicates overheating at any
time, consult the “Fault finding” section at the
end of this instruction, to assist in tracing
possible cooling system faults.

3 If the gauge indicates overheating shortly
after the engine is started from cold,
disconnect the temperature gauge sender’s
wiring multi-plug. The sender is located below
the thermostat housing on HCS engines,
adjacent to the thermostat housing on CVH
and PTE engines, and on the forward-facing
side of the thermostat housing on Zetec
engines. If the gauge reading now drops,
renew the sender. If the reading remains high,
the wire to the gauge may be shorted to earth,
or the gauge is faulty.
4 If the gauge fails to indicate after the engine
has been warmed up (approximately 
10 minutes) and the fuses are known to be
sound, switch off the engine. Disconnect the
sender’s wiring multi-plug, and use a jumper
wire to ground the connector to a clean earth
point (bare metal) on the engine. Switch on
the ignition without starting the engine. 
If the gauge now indicates Hot, renew the
sender.
5 If the gauge still does not work, the circuit
may be open, or the gauge may be faulty. See
Chapter 12 for additional information.

Removal

6 Refer to the relevant Part of Chapter 4 and
remove the air cleaner or air inlet hoses,
according to engine type as necessary, to
gain access to the sender unit.
7 Drain the cooling system (see Chapter 1).
8 On Zetec engines, disconnect the
expansion tank coolant hose and the radiator
top hose from the thermostat housing’s water
outlet.
9 Disconnect the wiring multi-plug from the
sender unit.
10 Unscrew the sender and withdraw it.

Refitting

11 Clean as thoroughly as possible the
sender unit location, then apply a light coat of
sealant to the sender’s threads. Screw in the
sender, tighten it to the specified torque, and
reconnect the wiring multi-plug.
12 Reconnect the hoses, and refit any
components disconnected for access. Refill
or top-up the cooling system (see “Weekly
Checks”

or Chapter 1) and run the 

engine. Check for leaks and proper gauge
operation.

Engine coolant temperature
sensor

Testing

13 Disconnect the battery negative (earth)
lead (see Chapter 5A, Section 1).
14 Locate the coolant temperature sensor,
which will be found below the inlet manifold
on HCS engines, on the side or centre of the
inlet manifold on CVH and PTE engines, or on
top of the thermostat housing on Zetec
engines. Once located, refer to the relevant
Part of Chapter 4 and remove the air cleaner
or air inlet hoses, according to engine type as
necessary, to improve access to the sensor
unit.
15 Disconnect the wiring multi-plug from the
sensor.
16 Using an ohmmeter, measure the
resistance between the sensor terminals.
Depending on the temperature of the sensor
tip, the resistance measured will vary, but
should be within the broad limits given in the
Specifications of this Chapter. If the sensor’s
temperature is varied - by removing it (see
below) and placing it in a freezer for a while, or
by warming it gently - its resistance should
alter accordingly.
17 If the results obtained show the sensor to
be faulty, renew it.
18 On completion, reconnect the wiring
multi-plug and refit any components removed
for access, then reconnect the battery.

Removal

19 Disconnect the battery negative (earth)
lead (see Chapter 5A, Section 1).
20 Locate the sensor as described
previously, and remove any components as
necessary for access.
21 Drain the cooling system (see Chapter 1).
22 Disconnect the wiring multi-plug from the
sensor.
23 Unscrew the sensor and withdraw it.

Refitting

24 Clean as thoroughly as possible the
sensor location, then apply a light coat of
sealant to the sensor’s threads. Refit and
tighten the sensor to the specified torque

Cooling, heating and ventilation systems  3•5

5.7  Nuts securing fan motor to shroud (A),

and shroud to body crossmember locating

tags (B). Inset shows fan to motor shaft

retaining clip (arrowed)

5.6  Radiator cooling fan shroud securing

nut (arrowed)

3

1595Ford Fiesta Remake

wrench setting, and reconnect the multi-plug.
25 Refit any components disconnected for
access then refill the cooling system (see
Chapter 1).

Radiator electric cooling fan
thermostatic switch

Testing

26 Refer to the procedures contained in
Section 5.

Removal

27 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
28 Drain the cooling system (see Chapter 1).
29 Disconnect the wiring multi-plug from the
thermostatic switch, and then unscrew the
switch from the thermostat housing or
radiator side tank, as applicable. Remove the
sealing washer.

Refitting

30 Refitting is a reversal of removal, but fit a
new sealing washer and tighten the switch
securely. Refill the cooling system as
described in Chapter 1, then reconnect the
battery.

7

Radiator and expansion tank
- removal, inspection and
refitting

2

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Radiator

Removal (all models except Turbo)

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Remove the radiator cooling fan assembly
as described in Section 5.
4 Release the hose clips and disconnect the
hoses from the radiator. Additionally, on

automatic transmission models, disconnect
the transmission fluid cooling pipe
connections fitting blanking plugs to prevent
excessive fluid loss (see illustration).
5 On Zetec engine models, disconnect the
wiring multi-plug from the cooling fan
thermostatic switch
6 Remove the radiator securing bolts and lift
the radiator out of its locating slots in the body
crossmember. Note rubber insulators fitted to
the locating lugs on the base of the radiator
(see illustrations).
7 With the radiator removed, it can be
inspected for leaks and damage. If it needs
repair, have a radiator specialist or dealer
service department perform the work, as
special techniques are required.
8 Insects and dirt can be removed from the
radiator with a garden hose or a soft brush.
Don’t bend the cooling fins as this is done.

Removal (Turbo models)

9 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
10 Drain the cooling system (see Chapter 1).
11 Remove the radiator cooling fan assembly
as described in Section 5.
12 Release the hose clips and disconnect the
hoses from the radiator.
13 Disconnect the turbocharger coolant feed
by slackening its clamp and pulling the hose
(at the radiator rear right-hand side) off the
turbocharger’s metal pipe.
14 Remove the intercooler, as described in
Chapter 4C.
15 Remove its three retaining screws, and
withdraw the exhaust manifold heat shield.

16 Lift the radiator out of its locating slots in
the body crossmember. Note rubber
insulators fitted to the locating lugs on the
base of the radiator.
17 Clean and inspect the radiator with
reference to paragraphs 7 and 8 above.

Refitting (all models)

18 Refitting is a reversal of removal, but
check the rubber insulators, and if necessary
renew them. Refill the cooling system with
reference to Chapter 1. On automatic
transmission models check, and if necessary
top-up, the automatic transmission fluid level
(Chapter 1).

Expansion tank

Removal

19 Partially drain the cooling system, so that
the coolant level drops below the expansion
tank. Refer to Chapter 1 for details.
20 Before disconnecting the coolant hoses
from the expansion tank, it is advisable to
clamp them just short of their connections to
the expansion tank, to prevent spillage of
coolant and the ingress of air when they are
detached.
21 Loosen off the coolant hose clips at the
expansion tank, and detach the hoses from it.
If they are not clamped, secure them so that
their ends are raised, to minimise coolant
spillage.
22 Remove the single bolt retaining the
expansion tank, and slide the other side of the
tank free from its retaining bracket (see
illustrations).

3•6 Cooling, heating and ventilation systems

7.22b  . . . and release the expansion tank

from its retaining bracket

7.22a  Remove the single bolt retaining the

expansion tank . . .

7.6b  Rubber insulator on radiator locating

lug

7.6a  Radiator securing bolt, insulator and

washer

7.4  Automatic transmission fluid cooling

pipe connections (arrowed) at the radiator

1595Ford Fiesta Remake

If leakage is the reason for
removing the radiator, bear
in mind that minor leaks can
often be cured using a

radiator sealant with the radiator in
situ.

Refitting

23 Refit in the reverse order of removal. Top-
up the cooling system as described in
“Weekly Checks”.

8

Water pump (HCS engines) -
removal and refitting

2

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Slacken the water pump pulley retaining
bolts, then remove the auxiliary drivebelt as
described in Chapter 1 (see illustration).
4 Remove the retaining bolts, and remove the
drivebelt pulley from the water pump.
5 Loosen off the coolant hose securing clips,
and disconnect the hoses from the water
pump.
6 Unscrew the retaining bolts, and withdraw
the water pump from the engine (see
illustration).
7 No provision is made for the repair of the
water pump; if it is noisy or defective in any
way, it must be renewed.

Refitting

8 Clean all traces of gasket from the engine
and the water pump mating faces. Ensure that
the mating faces are clean and dry. Note 
that the water pump gasket fitted during
production is integral with the timing cover
gasket, and this will need to be cut away
using a sharp knife, keeping as close to the
timing cover as possible.
9 Refitting is a reversal of the removal
procedure. Use a new gasket, lightly smeared
with jointing compound, and tighten the
retaining bolts to the specified torque.
10 Refit and adjust the auxiliary drivebelt as
described in Chapter 1.
11 Refill the cooling system as described in
Chapter 1, and reconnect the battery.

9

Water pump (CVH and PTE
engines) - 
removal and refitting

4

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Remove the timing belt and tensioner (see
Chapter 2B). If the belt is fouled with coolant,
it must be renewed as a matter of course.
4 Loosen off the coolant hose retaining clip,
and detach the coolant hose from the water
pump.
5 Unscrew and remove the four bolts
securing the water pump to the front end face
of the cylinder block, and then withdraw the
pump from the vehicle (see illustration).

Refitting

6 Clean the engine water pump mating faces.
Ensure that the mating faces are clean and
dry.
7 No provision is made for the repair of the
water pump; if it is noisy or defective in any
way, it must be renewed.
8 Refitting is a reversal of the removal
procedure. Tighten the retaining bolts to the
specified torque, and ensure that the coolant
hose connection to the water pump is
securely made.

9 Refit the timing belt and tensioner as
described in Chapter 2B.
10 Refill the cooling system as described in
Chapter 1, and reconnect the battery.

10 Water pump (Zetec engines)

- removal and refitting

4

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Remove the timing belt and tensioner (see
Chapter 2C). If the belt is fouled with coolant,
it must be renewed as a matter of course.
4 Disconnect the radiator bottom hose from
the pump union.
5 Unbolt and remove the water pump (see
illustrations). If the pump is to be renewed,
unbolt the timing belt guide pulleys, and
transfer them to the new pump.

Refitting

6 Clean the mating surfaces carefully; the
gasket must be renewed whenever it is
disturbed.
7 On refitting, use grease to stick the new
gasket in place, refit the pump, and tighten
the pump bolts to the specified torque.
8 The remainder of refitting is a reversal of the

Cooling, heating and ventilation systems  3•7

9.5  CVH engine timing belt tensioner

retaining bolts (A) and water pump

securing bolts (B)

8.6  HCS engine water pump removal

8.3  HCS engine water pump pulley

retaining bolts (arrowed)

10.5b  . . . and remove the Zetec engine

water pump

10.5a  Unscrew the bolts (arrowed) . . .

3

1595Ford Fiesta Remake

removal procedure. Refit the timing belt and
tensioner as described in Chapter 2C, noting
that a new tensioner spring and retaining pin
must be fitted if the timing belt has been
removed for the first time. Tighten all
fasteners to the specified torque, and refill the
system with coolant as described in Chap-
ter 1.

11 Heater/ventilation

components - 
removal and refitting

3

Heater controls

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Refer to Chapter 12 and remove the radio.
3 Pull off the heater fan motor control knob,
then move the air distribution and
temperature controls fully to the right. Unclip
and remove the heater slide facia towards the
left-hand side of the vehicle, removing the
slide control knobs only as necessary, and
disconnecting its bulbholder (bayonet type) as
it is withdrawn.
4 Squeeze the two release tabs together on
the heater fan motor control switch, and
remove it, disconnecting its multi-plug as it is
withdrawn.
5 Disconnect the heater control cables from
the heater casing assembly by releasing the
outer cable abutments and disengaging the

cable inner cores from their flap operating
mechanisms (see illustration).
6 Undo the three heater control panel
securing screws, and remove the control
panel (with its cables attached) from behind
the facia (see illustration).
7 Disconnect the heater control cables from
their control panel levers, as required, by
releasing their outer cable clamping covers
and inner cable core securing clips (see
illustrations).
8 If renewing a heater control panel, note that
the new unit, is supplied with control cables
and assembly aids fitted (see illustration).
The assembly aids ensure correct heater
control adjustments during fitting, and must
be removed thereafter.

9 Refitting is a reversal of the removal
procedure, adjusting the heater control cables
to complete. The adjustment is made
automatically by moving the heater slide
control levers from their left-hand stop to their
right-hand stop. When moving the control
levers, a considerable amount of resistance
may be encountered, which must be
overcome.

Heater fan motor and resistor
assembly

10 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
11 Depending on engine type, refer to the
relevant Part of Chapter 4 and remove the air
cleaner if necessary, to gain access to the
bulkhead panel in the engine compartment.
12 Remove the expansion tank as described
in Section 7.
13 Undo the retaining bolt and remove the
jack and wheelbrace.
14 Disconnect the modules on the bulkhead
panel. Release the wiring loom and any
connectors, cable-ties and hoses from the
bulkhead panel, and remove its rubber seal.
15 Remove the bulkhead panel. The panel is
secured by screws, with a nut at either end
(behind the panel), and is removed in two
sections.
16 Detach and remove the cover from the
heater fan motor assembly (see illustration).
17 Disconnect the wiring from the heater fan

3•8 Cooling, heating and ventilation systems

11.16  Removing the cover from the heater

fan motor assembly

11.8  Heater control panel. Assembly 

aids (A) fitted to heater casing flap valve

end of cables

11.7c  Releasing inner cable core from

heater control lever

11.7b  . . . and removing it

11.7a  Releasing outer cable clamping

cover . . .

11.6  Heater control panel securing 

screws (A), and fan motor control 

switch (B)

11.5  Disengaging heater control cable

from its flap operating mechanism on the

heater casing

1595Ford Fiesta Remake