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Battery check Ford Fiesta 2002 - 2008 Diesel 1.6 TDCi

OnDemand step-by-step maintenance & repair BETA

Ford Fiesta 2002 - 2008  | 1.6 TDCi Battery check

  • time 5 minutes
  • difficulty 1
Locate the battery
Check the Negative (-) terminal clamp is tight
Check the Positive (+) terminal clamp is tight. CAUTION If using a spanner to tighten the terminal, be careful not to short the spanner on the bodywork
Check the battery is generally secure, and if loose, tighten the battery retainer
To tighten, a 10mm socket is needed. Not too tight as you may damage the battery casing. If you have to replace the battery or alternator, click below
- Close + Open

Battery removal & replacement

Battery removal

1 The battery is located on the left-hand side of the engine compartment, on a platform above the transmission.
2 Loosen the clamp nut, then detach the earth lead from the battery negative (earth) terminal post (see illustration) . This is the terminal to disconnect before working on, or dis-connecting, any electrical component on the car. Position the lead away from the battery.
Loosen the clamp nut, and disconnect the battery negative lead . . .
3 Remove or pivot up the plastic cover from the positive terminal, then loosen the positive lead clamp nut (see illustration) . Detach the positive lead from the terminal, and position it away from the battery.
. . . and similarly, the positive lead
4 Undo the two nuts securing the battery top clamp bar, and lift it off (see illustrations) . On certain models, two vacuum hoses may be clipped to the clamp bar – if so, detach them before removal.
Undo the two nuts . . .
. . . and lift off the battery top clamp
5 Lift out the battery, keeping it as level as possible (see illustration) . Take care, as the battery is heavy.
Lift out the battery

Battery refitting

6 Refitting is a reversal of removal. Reconnect the battery negative lead last. Make sure the battery terminals and clamps are clean before refitting, and that the clamp nuts are tightened securely.

Battery tray removal

7 If required, once the battery has been removed, the battery tray and its support bracket can also be removed, as follows.

Petrol models

8 Open the bonnet, lift the grille panel clip at each side, then lift the grille out to release the lower mounting tabs and remove it (see illustrations) .
Lift up the clip at each end...
...then lift the grille panel out of its lower mountings, and remove it
9 Remove the three headlight securing screws (see illustration) . On models manufactured from 08/2005-onwards, access to the lower screw is gained by releasing the front bumper upper centre clips and pulling the bumper slightly forward.
Remove the three headlight screws
10 Pull the unit forwards slightly, disconnect the wiring plug from the side, and remove the unit completely (see illustrations) .
Pull the headlight forwards...
...and disconnect the wiring plug
11 Remove the two screws securing the powertrain control module (PCM) to its mounting bracket, then slide the module forwards and free it – there is no need to disconnect the wiring connector from it (see illustrations) .
Working through the headlight aperture, remove the upper . . .
. . . and lower PCM securing screws . . .
. . . then unclip and slide the module forwards

All models

12 Unclip and slide the battery junction box upwards out of the slot on the back of the battery tray. There is no need to disconnect any wiring from it, just lay it to one side. If required, however, the box can be unplugged and removed completely, if the main wire to the battery terminal is also disconnected (see illustrations) .
Unclip and lift out the battery junction box . . .
. . . if required, the box can be unplugged and removed
13 The battery tray is secured by three bolts at the base. Undo the bolts, and lift the battery tray off its support bracket (see illustrations) .
Remove the three bolts in the base of the battery tray . . .
. . . and lift the tray out
14 The battery tray support bracket is secured by three bolts in total – two into the inner wing, and a third hidden under the junction box wiring. Remove the bolts, and lift out the support bracket (see illustrations) .
Two of the battery tray support bracket bolts go into the inner wing . . .
. . . while the third is hidden under the junction box wiring
Removing the battery tray support bracket

Battery tray refitting

15 Refitting is a reversal of removal.
- Close + Open

Alternator replacement

1 Loosen the clamp nut, then detach the earth lead from the battery negative (earth) terminal post. Position the lead well away from the battery.

Duratec 8V engine

2 Remove the auxiliary drivebelt.
3 Unbolt the power steering fluid pipe support bracket (one bolt) from the power steering pump.
4 Remove the two alternator upper mounting bolts (see illustration) .
Alternator upper mounting bolts (just below power steering pump)
5 Jack up the front of the car, and support it on axle stands.
6 Access to the alternator is limited. Although not essential, to improve access, remove the radiator cooling fan and frame as follows:
7 Disconnect the cooling fan wiring plug from the fan motor and resistor, and unclip the wiring harness as necessary (see illustration) .
Disconnect the cooling fan wiring plug
8 Remove the cooling fan motor and frame by releasing the two plastic catches either side at the top, then lift the motor and frame up to disengage the lower slide-in clips. Once released, the frame can be removed (see illustrations) .
Release the cooling fan frame catches each side...
...then remove the frame and fan as an assembly
9 Prise out the plastic plug and unscrew the nut beneath to disconnect the battery supply cable, then pull off the separate wiring connector also fitted (see illustrations) . Note the fitted positions and routing of the wiring.
Prise out the plastic cover plug . . .
. . . and disconnect the battery cable from the alternator
Disconnecting the alternator wiring plug
10 Support the alternator, then remove the lower mounting bolt and slide the alternator forwards to remove it from its mounting bracket (see illustrations) .
Remove the lower mounting bolt in front of the alternator . . .
. . . then slide the unit out forwards, and remove it

Refitting

11 Refitting is a reversal of removal, noting the following points:
  1. Only fit the mounting bolts hand-tight to begin with.
  2. Ensure that the wiring is reconnected correctly, and that the retaining nuts are tight.
  3. Tighten the lower mounting bolt to 45 Nm (33 Ibf ft).
  4. Tighten the two upper bolts to 45 Nm (33 Ibf ft), starting with the one nearest the pulley.
  5. Refit and tension the auxiliary drivebelt.

Duratec 16V engine

12 Remove the auxiliary drivebelt. Note that the radiator grille and right-hand headlight must be removed (described within the drivebelt removal procedure).
13 Prise up the plastic cap and disconnect the alternator battery cable, then disconnect the field wiring multi-plug behind it (see illustrations) . Note the fitted positions and routing of the wiring.
Disconnecting the battery positive cable from the alternator terminal
Disconnecting the field winding wiring
14 Lift the power steering fluid reservoir off its mounting clips on the inner wing, and place it to one side without disconnecting any hoses.
15 Remove the alternator upper mounting nut and stud, and loosen the upper mounting bolt next to it as far as possible – the bolt cannot be removed at this stage.
16 Support the alternator, remove the alternator lower mounting bolt (see illustration) , then twist the alternator so that the upper bolt can be removed, and manoeuvre the alternator out through the headlight aperture.
Alternator lower mounting bolt

Refitting

17 Refitting is a reversal of removal, noting the following points:
  1. Fit the upper mounting bolt before offering the alternator in through the headlight aperture.
  2. Only fit the mounting bolts/stud and nut hand-tight to begin with.
  3. Tighten the lower mounting bolt to 45 Nm (33 Ibf ft), followed by the upper nut and bolt.
  4. Ensure that the wiring is reconnected correctly, and that the retaining nuts are tight.
  5. Fit a new auxiliary drivebelt.

Diesel engine

18 The alternator is located on the left-hand rear of the engine. First, remove the auxiliary drivebelt.
19 On the 1.6 litre diesel engine, carry out the following:
  1. Loosen the clip and disconnect the intercooler-to-inlet manifold air hose from the inlet air shutoff throttle housing. Position the hose to one side.
  2. Loosen the clips and remove the intercooler inlet air hose from the turbo air cooler and transfer pipe.
  3. Unbolt and remove the turbocharger heat shield.
  4. Unbolt and remove the auxiliary drivebelt tensioner.
20 Prise up the plastic cap and disconnect the alternator battery cable, then disconnect the field wiring multi-plug next to it (see illustration) . Note the fitted positions and routing of the wiring.
Prise out the cover, then disconnect the alternator wiring and plug
21 Where applicable, disconnect the wiring plug from the air conditioning compressor, then remove the four mounting bolts and tie the compressor to one side, without disturbing any of the hose connections.
22 Remove the alternator left-hand mounting bolts (see illustration) .
Alternator left-hand mounting bolts
23 Support the alternator, then remove the right-hand mounting bolts (see illustrations) . On some 1.4 litre models, one of the right-hand bolts is shared with one of the auxiliary drivebelt idler pulleys – if it’s the lower one, the idler pulley bolt is hidden under a plastic cover, which must be prised off. Undo the bolts, and remove the alternator from the engine.
Alternator right-hand mounting bolt locations . . .
. . one of the bolts will be shared with a drivebelt pulley

Refitting

24 Refitting is a reversal of removal, noting the following points:
  1. Tighten the mounting bolts to the specified torque, including those for the air conditioning compressor, where applicable.
  2. Ensure that the wiring is reconnected correctly, and that the retaining nuts are tight.
  3. Refit the auxiliary drivebelt.
Air conditioning compressor mounting bolts 25 Nm (18 Ibf ft)
Alternator mounting bolts 45 Nm (33 Ibf ft)
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