I also have a big front mount (grs) which is also in a fiesta. Like I said my fans have been coming on earlier and for longer periods because of the decrease in amount of air available to the rad for cooling. The fans which come with these intercoolers are not always that much kop and couild be causing the burning of wires. I would replace the fan switch and fan and check all wiring to the fan and if that don't sort well I am stumped