Ford Fiesta (1989-1995). Manual - part 53

the special tool (see illustration), then strike
the main body of the tool with a soft-faced
hammer to extract the lower hinge pin from its
location.
6 With the help of an assistant to support the
door, remove the upper hinge pin from its
location, in a similar manner to that used for
the lower hinge pin, and then remove the door
assembly.

Refitting

7 To refit, align the door hinge sections to the
hinge sections on the body, and insert both
hinge pins as far as possible, by hand.
Ensuring that the hinge pins have entered all
three sections of hinge, tap them gently
through, with a soft-faced hammer, until their
retaining clips can be fitted. New retaining
clips should be used.

8 Reconnect the multi-plug and insert it to its
body location on the A- pillar, ensuring that it
seats correctly.
9 Refit the door check arm to its body
location. Press the door aperture weatherseal
back into position on its flange.
10 There should be no need to adjust the
door striker, or check door alignment.

21 Side door inner trim panel -

removal and refitting

1

Removal

1 Using a screwdriver with a broad flat blade,
carefully prise up and remove the interior
weatherstrip from its location at the top of the
door trim panel. Be careful not to kink or bend
it as it is being removed. On front doors, pull

the end of the weatherstrip out from under the
door mirror trim.
2 Detach the door interior release handle
bezel by removing its retaining screw (see
illustration).
3 Using a small thin screwdriver, release the
window regulator handle (where fitted) by
releasing its spring clip from behind and pulling
it from the regulator shaft (see illustration).
Remove its bezel also. On models with electric
front window switches in the door trim panel,
disconnect the switch wiring multi-plugs as the
trim panel is withdrawn.
4 Detach the armrest/doorpull assembly from
the door. Some models are fitted with an
armrest/doorpull secured by three screws,
two of which are concealed behind a
removable panel. Certain lower specification
vehicles have the door pull secured with only
two screws. (see illustrations)
5 On front doors, remove the three screws
securing the door stowage pocket/speaker
grille moulding, then pull the moulding upper
edge away from the door, and disengage the
hook fixings on its base from their locations
(see illustration).
6 Using a trim clip tool, release the retaining
clips around the base and the sides of the
panel, then raise it to free it from the door. If a
trim clip tool is unavailable, two thin flat-
bladed screwdrivers carefully inserted
between the trim panel and the door may
suffice. Place the screwdrivers on each side
of the clips and then apply gentle leverage.

11•10 Bodywork and fittings

21.4b  Undoing armrest/doorpull retaining

screws

21.4a  Detaching armrest/doorpull

removable panel

21.3  Window regulator handle. Inset

shows removal

A Spring clip
B Rotate the tag to remove the knob

21.2  Removing the door interior release

handle bezel (armrest/doorpull shown

removed)

1595Ford Fiesta Remake

20.5  Door hinge pin removal using Ford special tools

A  Hinge pin          B  Removal tool          C  Soft-faced hammer

Refitting

7 To refit, first align the trim panel to the door,
secure its upper edge into its hook fastenings,
then press into position to engage the trim
clips. Where electric window switches are
fitted, reconnect the switch wiring multi-plugs
before fitting the panel.
8 If necessary, refit the clip to the window
regulator handle, then refit the handle to the
regulator shaft by pushing it on. The clip
should engage positively, in the annular
groove on the shaft.
9 Refit the door stowage pocket/speaker
grille moulding, armrest/doorpull and door
interior release handle bezel, as applicable, by
reversing the method of removal.
10 Refit the interior weatherstrip to its
location, tapping it down into position, being
careful not to bend or kink it. On front doors, it
will be necessary to slide its forward edge
under the door mirror trim before tapping into
position.

22 Side door lock, lock cylinder

and handles - removal and
refitting

2

Exterior handle

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 Disconnect the handle operating rod from
the latch assembly, by twisting the clip and
withdrawing the rod, as applicable.
4 Remove the two screws securing the
handle then, from the outside, withdraw 
the handle and rod, guiding the rod out
through the door skin as necessary (see
illustrations). The handle and rod may be
disconnected as required.

Refitting

5 Refitting is a reversal of the removal
procedure. On completion, re-secure the PVC
sheet then refit the inner trim panel as
described in Section 21.

Door lock barrel

Removal

6 Remove the door inner trim panel, as
described in Section 21.
7 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.
8 Drill out the rivets securing the door glass
guide above the lock barrel, and remove it.
9 Disconnect the lock barrel operating rod
from the latch assembly, by twisting the clip
and withdrawing the rod.
10 Release the lock barrel retaining clip by
withdrawing it upwards, then from the
outside, withdraw the lock barrel and rod,
guiding the rod out through the door skin. The
lock barrel and rod may be disconnected as
required.

Refitting

11 Refitting is a reversal of the removal
procedure. Ensure that the lock barrel gasket
is located correctly between the lock barrel
outer surround and the door skin, and that the

door glass guide is riveted securely. Check
that the window operates smoothly and
correctly, by temporarily refitting the regulator
handle or operating the electric window
motor.
12 On completion, re-secure the PVC sheet
then refit the inner trim panel as described in
Section 21.

Door latch and interior release
handle

Removal

13 Remove the door inner trim panel, as
described in Section 21.
14 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.
15 On rear doors fitted with central locking,
undo the two screws securing the rod guard
and remove it (see illustration).
16 Disconnect the operating rods from the
latch assembly as necessary. On rear doors
with central locking, disconnect and release
the motor loom multi-plug assembly, and
withdraw the motor side of the loom back into
the door cavity. Undo the three screws
securing the motor assembly, disengage its
operating rod and remove it from the vehicle
(see illustration).

Bodywork and fittings 11•11

22.4b  Removing the door exterior handle,

guiding its operating rod out through the

door skin (front door)

22.4a  Door exterior handle and lock barrel

securing arrangements (front door)

A Handle screw locations
B Lock barrel retaining clip

21.5  Disengaging the hook fixings on the

base of the door stowage pocket/speaker

grille moulding

22.16  Central locking motor retaining

screws (A), and loom multi-plug 

assembly (B) on rear door

22.15  Rod guard securing screws

(arrowed) on rear doors with central

locking only

11

1595Ford Fiesta Remake

17 On front doors, vehicles fitted with central
locking have a latch with an integral motor. If
central locking is fitted, prise up and twist the
rearward clips securing the motor loom to the
door, to free the loom, disconnect the multi-
plugs and withdraw the loom (motor side)
back into the door cavity.
18 Remove the interior release handle
surround, then prise up the forward end of the
handle unit. Release the handle from its
rearward location by sliding it forward to
disengage the hooks (see illustration).
19 Detach the door interior release cable
from its retaining clips on the door panel.
20 Remove the latch securing screws from
the upper rear edge of the door, and with-
draw the latch and interior release mechanism
from the vehicle (see illustration).
21 Remove the cable cover from the latch
assembly, then detach the cable from the
latch.
22 Peel the sponge pad from the reverse side
of the interior release handle, and remove the
outer cable from its abutment in the body of
the handle. Remove the inner cable core by
aligning the core with the slot by its end fixing,
then slide the end fixing out.

Refitting

23 Refitting is a reversal of the removal
procedure. On completion, re-secure the PVC
sheet then refit the inner trim panel as
described in Section 21.

23 Tailgate support strut -

removal and refitting

1

Removal

1 Open the tailgate and support it securely,
using a length of timber, or have an assistant
hold it open.
2 Detach the support strut by raising the
retaining clip and pulling the strut away from
its ball stud fixing on the tailgate. Do not raise
the clip more than 4.0 mm, or the support
strut will be damaged.
3 Repeat the operation on the other end of
the support strut.

Refitting

4 To refit, align the thicker (cylinder) end of
the support strut to the ball stud fixing on the
tailgate, then push until it snaps into
engagement.
5 Repeat the operation with the thinner
(piston) end of the support strut to the ball
stud fixing on the body.

24 Tailgate -

removal and refitting

1

Removal

1 Open the tailgate and mark around the
hinge positions on the tailgate panel itself.
2 Remove the central blanking plug from the
upper portion of the tailgate to expose the
washer jet, and disconnect the washer hose
from the jet base, as applicable. Free the
washer hose grommet and withdraw the hose
from the tailgate.
3 Disconnect the support strut from the
tailgate, as described in Section 23.
4 With the aid of an assistant, undo the four
bolts securing the tailgate to the vehicle body
and remove the tailgate.

Refitting

5 To refit, align the hinges on the body with
the marks made on the tailgate panel, then
refit and tighten the four bolts to secure. Refit
the support strut as described in Section 23.
6 The remainder of the refitting operation is a
reversal of the removal procedure.
7 Close the tailgate and check the alignment.
Adjust as necessary to obtain an even gap
between the tailgate and all adjacent panels.

25 Tailgate spoiler - 

removal and refitting

2

Removal

1 Drill out the rivets securing the outer edges
of the spoiler to the tailgate.

2 Open the tailgate and remove the four
blanking plugs covering the spoiler retaining
nuts. Undo the nuts and remove the spoiler.

Refitting

3 To refit, first align the spoiler mounting
studs to their tailgate fixing holes, then rivet
the outer edges of the spoiler to the tailgate.
4 Refit the four retaining nuts and tighten to
the specified torque.
5 Refit the blanking plugs.

26 Tailgate inner trim panel -

removal and refitting

1

Removal

1 Open the tailgate then, using a screwdriver,
remove the seven plastic retaining screws
from the trim panel.
2 Remove the square plastic clip from the
trim panel.
3 Disengage the clips from the panel edge
nearest the window, and manoeuvre the panel
to release the hooks on the other panel edge.
Withdraw the trim panel from the vehicle.

Refitting

4 Refitting is a reversal of removal.

27 Tailgate lock components -

removal and refitting

2

Note: For vehicles equipped with remote
tailgate release, removal and refitting
procedures for the tailgate remote release
motor are contained in Chapter 12.

Removal

1 Remove the tailgate inner trim panel as
described in Section 26.
2 Remove the two Torx screws securing the
tailgate latch, then pull it down, disconnect its
operating rod and remove the latch from the
vehicle (see illustration).
3 Remove the bolt securing the lock barrel

11•12 Bodywork and fittings

27.2  Tailgate latch and its Torx securing

screws (arrowed)

22.20  Removing the latch securing screws

(arrowed)

22.18  Detaching the interior door release

handle

1595Ford Fiesta Remake

retainer to the tailgate, then withdraw the
retainer (see illustration).
4 Remove the lock assembly from the tailgate
by partially withdrawing the lock, twisting it so
that the lock rod can be removed, then fully
withdrawing.

Refitting

5 To refit, first ensure that the lock gasket is
in position, then partially insert the lock into
the tailgate and reconnect the lock rod. Fully
insert the lock and refit its retainer and
securing bolt.
6 Using an electrician’s thin screwdriver,
prise up the lever on the latch and fit the lock
rod to it, ensuring that it fully engages.
7 Align the latch with its location and refit its
two securing screws.
8 Check for correct lock operation before
refitting the tailgate interior trim panel as
described in Section 26.

28 Rear doors (Courier models)

- removal and refitting

1

Removal

1 Open the door and disconnect the wiring
leading to it; all connectors are accessible
from the openings inside the door frame.

2 Unclip the door check arm, and unscrew
the bottom hinge’s cap securing bolt (see
illustration).
3 Lift the door off its hinges and withdraw it.

Refitting

4 Refitting is the reverse of the removal
procedure; apply grease to the hinge pins,
and tighten the cap bolt securely.
5 The door hinges can be unbolted from the
door and frame; either remove the door first,
or support it carefully and remove the hinge
with it in place.

29 Rear door inner trim panels

(Courier models) - 
removal and refitting

1

Removal

1 Remove the interior handle bezel by
pushing it away from the door’s hinges until it
can be withdrawn.
2 Using either a trim clip releasing tool or a
screwdriver with a broad flat blade, and
protecting the paintwork and trim with a layer
of rag, extract the clips securing the panel and
withdraw it.

Refitting

3 Refitting is the reverse of the removal
procedure.

30 Rear door lock, catches and

handles (Courier models) -
removal and refitting

1

Interior handle

Removal

1 Remove the inner trim panel, as described
in Section 29.
2 Remove its four retaining screws, and
withdraw the complete latch assembly (see
illustrations).
3 Disconnect the link rod and remove the
single retaining screw to withdraw the interior
handle.

Refitting

4 Refitting is the reverse of the removal
procedure.

Exterior handle and lock
assembly

Removal

5 Remove the inner trim panel, as described
in Section 29.
6 Remove its four retaining screws, and
withdraw the complete latch assembly.
7 Using pliers, rotate the exterior handle
locking ring anti-clockwise to release it, then
withdraw the handle with the inner and outer
gaskets (see illustrations).
8 The lock assembly is secured by a circlip to
the handle.

Bodywork and fittings 11•13

30.2a  Courier rear door latch assembly

retaining screws (arrowed)

28.2  Unscrewing the bottom hinge’s cap

securing bolt on Courier rear door

27.3  Tailgate lock retention arrangement

A Lock barrel retainer securing bolt
B Lock barrel retainer

30.7b  . . . to release Courier rear door

exterior handle

30.7a  Release locking ring and withdraw

gaskets . . .

30.2b  Latch assembly released -

disconnect cables to withdraw

11

1595Ford Fiesta Remake