Ford Fiesta (1989-1995). Instruction - part 54

Refitting

9 Refitting is the reverse of the removal
procedure.

Upper and lower door catches

Removal

10 Remove the inner trim panel, as described
in Section 29.
11 Remove its four retaining screws, and
withdraw the complete latch assembly.
Disconnect the upper and lower catch cables

from the latch assembly operating
mechanism.
12 Unbolt the catch and withdraw it from the
door  (see illustration). If the cables are
available separately (seek the advice of a Ford
dealer) they can be disconnected from each
catch by releasing the retaining clip.

Refitting

13 Refitting is the reverse of the removal
procedure; check the adjustment of the catch
before finally tightening the bolts.
14 The striker plates can be adjusted on their
slotted mounting bolt locations, if required.

31 Door window regulator -

removal and refitting 

3

Instruction front regulator

Removal

1 Remove the door inner trim panel, as
described in Section 21.
2 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not

tear the sheet; cut closely around the clips, as
required.
3 Remove the door window glass, as
described in Section 32.
4 Drill the heads off the regulator securing
rivets and manoeuvre the regulator assembly
from the door (see illustration). Lay the
regulator body in the bottom of the door, then
withdraw the gear mechanism and cable
followed by the rigid “pillar”.

Refitting

5 Refit the regulator by reversing the method
of removal, ensuring that it is securely riveted
to the door.
6 Refit the door window glass, as described
in Section 32.
7 Re-secure the PVC sheet then refit the door
inner trim panel as described in Section 21.

Electric front regulator

Removal

Note: For motor removal and refitting
procedure, refer to Chapter 12.
8 Remove the door inner trim panel, as
described in Section 21.
9 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
10 Remove the door window glass, as
described in Section 32.
11 Disconnect the multi-plug on the regulator
motor body, and remove the three nuts
securing the motor/winding mechanism
section of the assembly to the door.
12 Drill the heads off the regulator securing
rivets and manoeuvre the regulator assembly
from the door. Lay the regulator body in the
bottom of the door, then withdraw the gear
mechanism and cable followed by the rigid
“pillar”.

Refitting

13 To refit, first position the regulator
assembly in the door, and refit the three nuts
securing the motor/winding mechanism
section.
14 Re-rivet the pillar section of the regulator
assembly securely to door.
15 Reconnect the multi-plug to the regulator
motor body.
16 Refit the door window glass, as described
in Section 32.
17 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.

Rear regulator

Removal

18 Remove the door inner trim panel, as
described in Section 21.
19 Locally detach the PVC sheet from the
door to allow access into the door cavity. Do
not tear the sheet; cut closely around the
clips, as required.
20 Drill the heads off the four regulator
securing rivets, and remove the two lower

11•14 Bodywork and fittings

31.4  Window regulator assembly (instruction, front)

30.12 Courier rear door lower catch

removal

1595Ford Fiesta Remake

A Window glass lifting

channel

B Regulator assembly
C Rivets
D Screws

window glass guide securing screws (see
illustration).
21 Support the window glass then, having
pushed the regulator into the door cavity,
disconnect the regulator arm from it. Remove
the regulator assembly.

Refitting

22 Refitting is a reversal of the removal
procedure, ensuring that the window regulator
is securely riveted to the door. Check the
operation of the window regulator, by
temporarily refitting the regulator handle and,
if necessary, adjust the window glass guide to
ensure that the window glass does not stick
or judder.
23 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.

32 Door window glass - 

removal and refitting

3

Front side door glass

Removal

1 Remove the door inner trim panel, as
described in Section 21.
2 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
3 Remove the door belt weatherseal
moulding as described in Section 10.
4 Remove the two screws securing the
window glass lifting channel to the regulator
assembly, through either their upper or lower
access holes. Support the glass as the screws
are removed.
5 Remove the window glass by tilting it
forwards towards the hinge end of the door,
then withdraw it towards the latch end.

Refitting

6 To refit, position the window glass into the
door by reversing the method of removal.
7 Loosely refit the two screws to hold the
window glass lifting channel to the regulator

assembly, but do not tighten them at this
stage.
8 Raise the window glass fully, then tighten
the retaining screws through their upper
access holes. This ensures correct positioning
of the window glass in its aperture.
9 Refit the door belt weatherseal moulding as
described in Section 10.
10 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.

Rear side door sliding glass

Removal

11 Remove the door window regulator, as
described in Section 31, then fully lower the
window glass into the door.
12 Remove the door belt weatherseal
mouldings in a similar manner to that
described in Section 10.
13 Remove the remaining two window glass
guide securing screws from their location at
the top of the door, and disengage the top 
of the guide.
14 Manoeuvre the fixed rear quarter window
glass forwards and out from its location, along
with the window glass guide. Lift out the
plastic strip.
15 Manoeuvre the door window glass up and
out of the door, from the exterior side of the
door.

Refitting

16 Refitting is a reversal of the removal
procedure, ensuring that the fixed rear quarter
window seats correctly in its location, and that
the window glass guide holds the window
glass correctly (refer to Section 31).

Rear side door fixed quarter
glass

17 The fixed rear quarter window glass is
removed and refitted in conjunction with the
rear side door sliding glass described
previously in this Section.

Rear door glass (Courier
models)

18 The rear door window glass on Courier
models is removed and refitted using the
same technique as for the fixed side window
glass described in Section 33.

33 Side window glass - 

removal and refitting

3

Fixed side window glass

Removal

1 The lip of the weatherseal surrounding the
window glass must be released from the top
and sides of the body aperture flange, using a
suitable tool, before exerting pressure from
the inside of the vehicle to remove the glass.
Any surrounding interior trim should be
removed. It is important that an assistant

helps and holds the glass from the outside as
it is pressed out from the inside.
2 With the assembly removed from the
vehicle, detach the weatherseal from the
window glass.
3 If the weatherseal is to be re-used it should
be cleaned. Do not use petrol, white spirit or
other similar substances, as they may cause
rapid rubber deterioration. Ensure that the
glass groove in the weatherseal is free from
any sealant or glass fragments.
4 Ensure that the body aperture flange is free
from any sealant also.

Refitting

5 Commence refitting by attaching the
weatherseal to the window glass, ensuring
that it is seated correctly.
6 Insert a length of nylon or terylene cord into
the body aperture flange groove of the
weatherseal, so that the cord ends emerge at
the top centre of the window, and overlap by
approximately 150.0 mm.
7 Offer the assembly to the body aperture,
and engage the lower lips of the weatherseal
over the body aperture flange. Ensure that the
engagement of the weatherseal lips is not
hampered in any way, and that the cord ends
are protruding inside the vehicle.
8 With an assistant applying a gentle even
pressure on the window glass from the
outside, pull one end of the cord at right-
angles to the glass. This will pull the inner lip
of the weatherseal over the body aperture
flange.
9 When the cord has been pulled halfway
around the aperture, repeat the procedure
with the other end of the cord. The cord
should release when the window glass is fully
fitted.
10 Refit any disturbed interior trim as
necessary.

Hinged side window glass

Removal

11 With an assistant standing outside ready
to take the window, unscrew the single screw
securing each hinge, then open the window
and unscrew the two screws securing the
catch to the body. Withdraw the window.
12 The weatherstrip can now be removed
and refitted, if required.

Refitting

13 To refit the window, have your assistant
stand outside and offer up the window so that
both hinge leaves enter their sockets, then
loosely refit the catch securing screws. Refit
the hinge securing screws, then adjust the
catch position to ensure that the window is
clamped evenly on to the weatherstrip over
the whole mating surface when the catch is
fastened. Tighten all screws securely.

Sliding side window and glass

Removal

14 To remove the complete sliding window
assembly on Courier Kombi models requires
special cutting equipment and supplies of

Bodywork and fittings 11•15

31.20 Regulator retaining rivets (A) and

lower window glass guide securing 

screws (B) on rear door

11

1595Ford Fiesta Remake

suitable adhesive; it is recommended that this
task be left to a Ford dealer or similar expert.
15 To remove the window glass, remove their
retaining screws and withdraw the lock
assemblies, slide the front glass as far to the
rear as possible, then prise up and withdraw
the front glass guide; it will be necessary to
pull the last part of the guide from under the
glass.
16 Withdraw the vertical seal and two
support blocks from between the two glasses,
slide the seal to the front of the frame, and
withdraw it. Slide each glass in turn 
to the front of the frame and withdraw it, 
then prise up and withdraw the rear glass
guide.

Refitting

17 On refitting, check that the glass guides
are undamaged; renew them if necessary.
Ensure that the lock assemblies are removed
from both glasses.
18 Press the rear glass guide into place. Refit
first the rear glass, fitting it to the front of the
frame and sliding it to the rear, then the front
glass, in the same way.
19 To refit the vertical seal, sandwich it
between two strips of thin sheet metal and
install it, with its support blocks, first in the
front part of the frame, then push it into place.
This will require some effort as the glass is
reached, due to the distortion caused by the
location notch on the block. When the seal is
fully in place, withdraw the metal strips, and
check that the seal’s lips have not folded back
on themselves.
20 When refitting the front glass guide, locate
it first around the frame’s detent catch, then
slide it under the glass using soapy water as a
lubricant.
21 Refit the lock assemblies, clean the
glasses, and check the operation of the
windows and locks.

34 Windscreen and tailgate

window glass - 
removal and refitting

4

Note: The DIY mechanic is advised to leave
windscreen/tailgate window glass removal
and refitting to an expert. For those with the
necessary tools and equipment, the 
following paragraphs are a guide to the
procedure.

Removal

1 Remove the windscreen/tailgate wiper arms
as described in Chapter 12.
2 If removing the windscreen, remove both A-
pillar trims, and release the front of the
headlining by removing the sun visors and
courtesy light. If a heated windscreen is fitted,
disconnect its electrical contacts at the
windscreen. If removing the tailgate window
glass, disconnect the wiring to the heating
element.

3 As a precautionary measure to prevent
damage to the paintwork, cover the
surrounding bodywork with an old blanket or
similar.
4 Using a suitable tool, release the
weatherseal from the top and sides of the
body aperture flange before exerting pressure
from the inside of the vehicle to remove the
assembly. It is strongly advised that an
assistant outside the vehicle is ready to
receive the glass as it is pushed out.
5 With the assembly removed from the
vehicle, detach the weatherseal from the
windscreen/tailgate glass.

Refitting

6 With reference to the procedures described
for the fixed side window glass in Section 33,
clean the weatherseal, then refit in
accordance with the rest of that Section.
7 Any trim and equipment removed during
preparation should now be refitted.

35 Sunroof panel - 

removal and refitting

1

Removal

1 Open the sunroof fully using the handwheel.
2 Detach the sunroof from its rearward
mounting point by pressing in the red locking
bar on the handwheel, then raise it and
remove.

Refitting

3 To refit, engage the hinges in their
locations, in the forward edge of the sunroof
opening, then lower the sunroof. Allow the
handwheel to click into its safety lock.
4 Check that the safety lock mechanism
retains the panel securely.
5 Close the sunroof fully using the
handwheel.

36 Sunroof panel seal - 

renewal

1

1 Remove the sunroof panel, as described in
Section 35, then lay the panel on a soft cloth.
2 Remove the two hinge plate assemblies
from the panel by undoing the hinge plate
retaining screws.
3 Pull the seal from the panel edge, noting the
position of its join.
4 Starting from the position of the original
join, press the seal into position, ensuring that
it sits evenly right around. Adjust as necessary
so that the ends butt tightly together.
5 Refit the two hinge plate assemblies to the
panel.
6 Refit the sunroof panel, as described in
Section 35.

37 Sunroof weatherseal -

removal and refitting

1

Removal

1 Remove the sunroof panel, as described in
Section 35.
2 Starting from the joint on the rearward
opening edge, pull the seal up and remove.

Refitting

3 Refitting is a reversal of the removal
procedure, ensuring that the weatherseal
does not deform at the corners, or split at the
joint.

38 Full-length sunroof - 

general information

1 The full-length sunroof is electrically-
operated, the operating system consisting of
the motor and the roof-mounted switch. The
circuit is fed via fuses 18 and 28 from the
ignition switch; switch illumination is via 
fuse 6.
2 All components are mounted in the roof of
the passenger compartment, above the
headlining at the front of the vehicle.
3 To open the sunroof, press the switch
lightly on the upper side; to close it, check
first that the opening is completely
unobstructed, and press the switch on the
lower side.
4 Maintenance is confined to checking for
freedom of action and a snug fit when shut.
Check that the seals are in good clean
condition and not scratched or damaged.
5 Owners must note the following to ensure
that the maximum trouble-free life from this
feature:

a) It is normal for the motor to slow down as

the sunroof approaches full opening.

b) If the sunroof stops before it is fully

opened in cold weather, this may be due
to the material being too hard to fold
correctly; do not force the sunroof open if
this is suspected.

c) If the material does not fold correctly on

opening at any time, close the sunroof
again, correct the folds by hand, and try
again.

d) Never open or close the sunroof with the

vehicle travelling at more than 70 mph
(120 km/h), and never allow passengers to
travel standing up or with any part of their
bodies in the opening.

e) Ensure that any collected water, snow or

ice is removed from the sunroof before
opening it. Check that the deflector is
clear of water, particularly after washing
the vehicle; sponge it dry if necessary.

f) Never place heavy objects on the sunroof

or its surrounds.

g) The sunroof should be cleaned frequently

11•16 Bodywork and fittings

1595Ford Fiesta Remake

to avoid the material being stained by dirt.
Use a sponge, soft brush or soft cloth and
a neutral detergent, rinsing with a gentle
flow of clean water from directly above
until all traces of dirt and detergent are
removed. Never use a high-pressure jet,
pressure washer or similar, and do not
aim the jet from a hose at the joints of the
sunroof with the body (or water will enter
the passenger compartment). Never use
alcohol, petrol, thinners or similar
products to clean the material.

h) If the vehicle is parked in heavy rain, or if it

is parked outside for long periods, a
proprietary car cover or tarpaulin should
be used to protect the roof and body. Do
not leave the sunroof open for long
periods; the material will stiffen in its folds,
with a consequent risk of tearing when the
sunroof is eventually operated again.

6 If the system fails with the sunroof open, it
can be closed in emergency by switching off
the ignition, prising out the access plug in
front of the switch, and using the crank
provided to rotate the motor shaft clockwise
until the roof is closed.
7 If the switch is thought to be at fault, it can
be removed after first disconnecting the
battery negative (earth) lead (refer to Chap-
ter 5, Section 1) ; the switch can then be
eased from its housing until the wires can be
disconnected. Refitting is the reverse of the
removal procedure.
8 If any other failure or problem is
encountered, the general inaccessibility of the
system’s components means that servicing
and fault-finding is beyond the capabilities of
most owners; the vehicle should be taken to a
Ford dealer for attention.

39 Front seat and slide

assembly - 
removal and refitting

1

Removal

Warning: On vehicles fitted with
mechanical seat belt pre-
tensioning stalks, be careful
when handling the seat, as the

tensioning device (“grabber”) contains a
powerful spring, which could cause injury
if released in an uncontrolled fashion. The
tensioning mechanism should be
immobilised by inserting a safety “transit
clip” available from Ford parts stockists.
You are strongly advised to seek the
advice of a Ford dealer as to the correct
use of the “transit clip” and the safety
implications before proceeding.
1 On pre-1994 models, slide the seat fully
rearwards to expose the two front slide
assembly to floorpan bolts. Remove all four
bolts securing the slides to the floorpan, and
remove the seat from the vehicle.
2 On later models, pull off the trim cover from
the outer slide.

3 On vehicles fitted with mechanical seat belt
pre-tensioning stalks, fit the safety “transit
clip”.
4 Slide the seat fully rearwards, remove the
inner slide trim cover then unscrew and
remove the front slide assembly to floorpan
bolts.
5 Now slide the seat fully forward, and
unscrew the rear slide securing bolts each
side. Lift the seat and remove it from the
vehicle.

Refitting

6 Position the seat in the vehicle, and align
the slide assemblies with their mounting bolt
locations in the floorpan. Refit the front
securing bolts first, followed by the 
rear securing bolts, to ensure that the seat
runs smoothly in its slide mechanism. Tighten
the bolts to the specified torque. On later
models, remove the “transit clip” (where
applicable) and refit the trim covers.

40 Rear seat - 

removal and refitting

1

Backrest and catch

Removal

1 To remove the backrest, release the
backrest catch/catches, then fold the
backrest forwards.
2 Remove the hinge-to-backrest securing
screws, then remove the backrest (see
illustration).
3 The hinges may be removed at this stage if
required, by undoing the hinge-to-body
securing screws.
4 If desired, the rear seat backrest catch may
be removed by removing the catch retaining
bolts (see illustration).

Refitting

5 If removed, refit the backrest catch and
secure with the retaining bolts.
6 To install the backrest, align the hinges to
the body and backrest, then loosely refit the
securing screws.

7 Fold the backrest into its upright position
and engage the backrest catch/catches.
Adjust the alignment of the components then,
when correct, tighten the securing screws to
their specified torques.
8 Check for correct catch engagement.

Cushion

Removal

9 To remove the cushion, remove the three
screws securing the forward edge of the seat
cushion to the raised floorpan section.
10 Push down and back on the cushion, to
disengage the hook and catch on the rear
underside of the seat.
11 Remove the seat from the vehicle after
guiding the seat belt clips through the slits in
the seat cushion.

Refitting

12 Refitting the cushion is a reversal of the
removal procedure.

Seat assembly (Courier Kombi
models)

Removal

13 The seats are secured by two bolts at
each forward hinge, visible once the seat has
been folded forwards. Unbolt the hinges and
withdraw the seat assembly.

Refitting

14 Refitting is the reverse of the removal
procedure.

41 Seat belts - 

removal and refitting

3

Removal

Front seat belt (five-door models)

1 Remove the cover from the upper anchor
position and remove the anchor bolt.
2 Remove the lower anchor bolt from its
location on the floor by the base of the B-
pillar. Prevent the retractor unit from reeling in
too great a quantity of seat belt by attaching a
clothes peg, or similar item, to the seat belt.

Bodywork and fittings 11•17

40.4  Rear seat backrest catch retaining

bolts (arrowed)

40.2  Rear seat hinge arrangement

A Hinge-to-backrest screw locations
B Hinge-to-body screw locations (removed

after backrest detached)

11

1595Ford Fiesta Remake