warning lights FORD FIESTA 1989 Service Repair Manual

squeezed (see illustration) . If you are using
non-Ford specification antifreeze, and so
have to renew the coolant every two years or
so, it’s a good idea to renew the hoses at that
time, regardless of their apparent condition.
3 Make sure that all hose connections are
tight. A leak in the cooling system will usually
show up as white- or rust-coloured deposits
on the areas adjoining the leak; if the spring
clamps that are used to secure the hoses in
this system appear to be slackening, they
should be renewed to prevent the possibility
of leaks.
4 Some other hoses are secured to their
fittings with clamps. Where clamps are used,
check to be sure they haven’t lost their
tension, allowing the hose to leak. If clamps
aren’t used, make sure the hose has not
expanded and/or hardened where it slips over
the fitting, allowing it to leak.
5 Check all fluid reservoirs, filler caps, drain
plugs and fittings etc, looking for any signs
of leakage of oil, transmission and/or brake
hydraulic fluid, coolant and power steering
fluid. If the vehicle is regularly parked in the
same place, close inspection of the ground
underneath it will soon show any leaks. As
soon as a leak is detected, its source must
be traced and rectified. Where oil has been
leaking for some time, it is usually necessary
to use a steam cleaner, pressure washer or
similar, to clean away the accumulated
dirt, so that (when the engine is run again)
the exact source of the leak can be
identified.
Vacuum hoses
6 It’s quite common for vacuum hoses,
especially those in the emissions system, to be
colour-coded, or to be identified by coloured stripes moulded into them. Various systems
require hoses with different wall thicknesses,
collapse resistance and temperature
resistance. When renewing hoses, be sure the
new ones are made of the same material.
7
Often the only effective way to check a
hose is to remove it completely from the
vehicle. If more than one hose is removed, be
sure to label the hoses and fittings to ensure
correct installation.
8 When checking vacuum hoses, be sure to
include any plastic T-fittings in the check.
Inspect the fittings for cracks, and check the
hose where it fits over the fitting for distortion,
which could cause leakage.
9 A small piece of vacuum hose (quarter-inch
inside diameter) can be used as a
stethoscope to detect vacuum leaks. Hold
one end of the hose to your ear, and probe
around vacuum hoses and fittings, listening
for the “hissing” sound characteristic of a
vacuum leak. Warning: When probing with the
vacuum-hose stethoscope, be
very careful not to come into
contact with moving engine
components such as the auxiliary
drivebelt, radiator electric cooling fan, etc.
Fuel hoses
Warning: There are certain
precautions which must be
taken when inspecting or
servicing fuel system
components. Work in a well-ventilated
area, and do not allow open flames
(cigarettes, appliance pilot lights, etc.) or
bare light bulbs near the work area. Mop
up any spills immediately, and do not store
fuel-soaked rags where they could ignite.
10 Check all fuel hoses for deterioration and
chafing. Check especially for cracks in areas
where the hose bends, and also just before
fittings, such as where a hose attaches to the
fuel filter.
11 High-quality fuel line, usually identified by
the word “Fluoroelastomer” printed on the
hose, should be used for fuel line renewal.
Never, under any circumstances, use
unreinforced vacuum line, clear plastic tubing
or water hose for fuel lines.
12 Spring- type clamps are commonly used
on fuel lines. These clamps often lose their
tension over a period of time, and can be
“sprung” during removal. Replace all
spring- type clamps with screw clamps
whenever a hose is replaced.
Metal lines
13 Sections of metal piping are often used
for fuel line between the fuel filter and the
engine. Check carefully to be sure the piping
has not been bent or crimped, and that cracks
have not started in the line.
14 If a section of metal fuel line must be
renewed, only seamless steel piping should
be used, since copper and aluminium piping
don’t have the strength necessary to
withstand normal engine vibration. 15
Check the metal brake lines where they
enter the master cylinder and ABS hydraulic
unit (if used) for cracks in the lines or loose
fittings. Any sign of brake fluid leakage calls
for an immediate and thorough inspection of
the brake system.
6 Engine compartment wiring check
1
1With the vehicle parked on level ground,
apply the handbrake firmly and open the
bonnet. Using an inspection light or a small
electric torch, check all visible wiring within
and beneath the engine compartment.
2 What you are looking for is wiring that is
obviously damaged by chafing against sharp
edges, or against moving suspension/
transmission components and/or the auxiliary
drivebelt, by being trapped or crushed
between carelessly-refitted components, or
melted by being forced into contact with the
hot engine castings, coolant pipes, etc. In
almost all cases, damage of this sort is
caused in the first instance by incorrect
routing on reassembly, after previous work
has been carried out.
3 Depending on the extent of the problem,
damaged wiring may be repaired by rejoining
the break or splicing-in a new length of wire,
using solder to ensure a good connection,
and remaking the insulation with adhesive
insulating tape or heat-shrink tubing, as
appropriate. If the damage is extensive, given
the implications for the vehicle’s future
reliability, the best long-term answer may well
be to renew that entire section of the loom,
however expensive this may appear.
4 When the actual damage has been
repaired, ensure that the wiring loom is re-
routed correctly, so that it is clear of other
components, and not stretched or kinked, and
is secured out of harm’s way using the plastic
clips, guides and ties provided.
5 Check all electrical connectors, ensuring
that they are clean, securely fastened, and
that each is locked by its plastic tabs or wire
clip, as appropriate. If any connector shows
external signs of corrosion (accumulations of
white or green deposits, or streaks of “rust”),
or if any is thought to be dirty, it must be
unplugged and cleaned using electrical
contact cleaner. If the connector pins are
severely corroded, the connector must be
renewed; note that this may mean the renewal
of that entire section of the loom - see your
local Ford dealer for details.
6 If the cleaner completely removes the
corrosion to leave the connector in a
satisfactory condition, it would be wise to
pack the connector with a suitable material
which will exclude dirt and moisture,
preventing the corrosion from occurring
again; a Ford dealer may be able to
recommend a suitable product.
7 Check the condition of the battery
Every 10 000 miles or 12 months1•13
5.2 Hoses, like drivebelts, have a habit of
failing at the worst possible time - to
prevent the inconvenience of a blown radiator or heater hose, inspect them
carefully as shown here
1
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13Detach the fuel injectors from the fuel rail,
then remove the upper and lower seal from
each injector (see illustration) . All seals must
be renewed (even if only one injector is to be
renewed).
14 Prior to refitting the injectors, ensure that
all mating surfaces are perfectly clean.
Lubricate the new injector seals with clean
engine oil to ease their assembly to the
injectors.
15 Refitting is a reversal of the removal
procedure. Refer to the Specificationsat the
start of this Chapter for the tightening torques.
When refitting the fuel rail, ensure that the
injectors are correctly located. Ensure that the
mating surfaces of the throttle housing are
perfectly clean before assembling.
16 On completion, restart the engine and
check the various fuel connections for any
signs of leaks.
Fuel pressure regulator
17 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that
fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
18 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1). 19
Release the fuel return pipe securing clip,
and detach the pipe from the regulator.
20 Pull free the vacuum pipe from the
regulator connector (see illustration).
21 Unscrew the two retaining bolts and
remove the regulator. Remove the old sealing
ring for renewal.
22 Refit in the reverse order of removal.
Lubricate the new seal ring with clean engine oil
to ease assembly. When the regulator is refitted
and the fuel and vacuum lines are reconnected,
turn the ignition on and off five times (without
cranking the engine) and check for any sign of
fuel leaks before restarting the engine.
Idle speed control valve
Note: The idle speed control valve may be
mounted on the air cleaner, on the engine
compartment bulkhead, or on the side of the
inlet manifold according to valve make and
year of manufacture. Valves manufactured by
Weber are mounted on the air cleaner and
require periodic maintenance (see Chapter 1).
Bulkhead and inlet manifold mounted valves
are manufactured by Hitachi and are
maintenance free.
23 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
24 Disconnect the valve’s wiring multiplug
(see illustration) .
25 Where applicable disconnect the air
hose(s) from the valve.
26 Undo the two or four bolts (according to
type), and remove the valve from the air
cleaner, bulkhead or inlet manifold. 27
Refitting is a reversal of the removal
procedure. Ensure that the mating faces are
clean before reassembling.
28 When the valve is refitted, restart the
engine and check that there are no induction
leaks. Run the engine until its normal
operating temperature is reached, and check
that the idle speed is stable. Stop the engine,
connect up a tachometer in accordance with
its maker’s instructions, then restart the
engine and check that the idle speed is as
specified with all electrical items (lights, heater
blower motor, etc) switched off, then on. The
idle speed should remain the same. Switch off
the electrical items, turn the engine off and
detach the tachometer to complete the test.
Throttle housing
29 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
30 Disconnect the ignition HT lead
connectors from the spark plugs, and release
the leads from their locating grooves in the air
inlet duct. Position them out of the way.
31 Remove the air inlet components as
described in Section 4.
32 Unscrew the retaining nuts and the bolt,
and detach the accelerator cable support
bracket at the throttle housing.
33 Disconnect the wiring connector from the
throttle position sensor.
34 Unscrew the four retaining bolts, and
remove the throttle housing and its mating
face gasket (see illustration 14.7) .
35 Refit in the reverse order of removal.
Check that the mating faces are clean, and fit
a new gasket.
EEC IV engine management
module
Note: The module is fragile. Take care not to
drop it, or subject it to any other kind of
impact. Do not subject it to extremes of
temperature, or allow it to get wet. Refer to
Part B, Section 14 for illustrations of the
following procedure.
36 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
37 Unscrew and remove the two nuts
securing the module cover in the engine
compartment, then carefully draw the cover
away from its location. Unscrew the module
multi-plug retaining bolt and disconnect
the multi-plug from the module.
38 The aid of an assistant will be required at
this stage, to support and withdraw the
module from inside the passenger
compartment as its mounting bracket retaining
tags are compressed and released from the
engine compartment. Do not allow the module
to drop into the passenger compartment as
irreparable damage is likely to result. The
module may be separated from its mounting
bracket by undoing the securing bolts.
39 Refitting is a reversal of the removal
procedure, ensuring that the module
mounting bracket retaining tags are felt to
snap into position
4C•6 Fuel system - electronic fuel injection engines
14.24 Disconnect the multi-plug from the idle speed control valve. Upper valve
retaining bolt (arrowed)14.20 Fuel pressure regulator showingvacuum pipe (A) and fuel return pipe
connection (B)
14.13 Remove the seals from the injectors14.12b . . . and withdraw the fuel rail and injectors
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1 General information,precautions and battery
disconnection
General information
The engine electrical system consists
mainly of the charging and starting systems.
Because of their engine-related functions,
these components are covered separately
from the body electrical devices such as the
lights, instruments, etc (which are covered in
Chapter 12). Information on the ignition
system is covered in Part B of this Chapter.
The electrical system is of the 12-volt
negative earth type. The battery is of the low maintenance or
“maintenance-free” (sealed for life) type and is
charged by the alternator, which is belt-driven
from the crankshaft pulley. The starter motor is of the pre-engaged
type incorporating an integral solenoid. On
starting, the solenoid moves the drive pinion
into engagement with the flywheel ring gear
before the starter motor is energised. Once
the engine has started, a one-way clutch
prevents the motor armature being driven by
the engine until the pinion disengages from
the flywheel.
Precautions
Further details of the various systems are
given in the relevant Sections of this Chapter.
While some repair procedures are given, the
usual course of action is to renew the
component concerned. The owner whose
interest extends beyond mere component
renewal should obtain a copy of the
“Automobile Electrical & Electronic Systems
Manual” , available from the publishers of this
manual. It is necessary to take extra care when
working on the electrical system to avoid
damage to semi-conductor devices (diodes
and transistors), and to avoid the risk of
personal injury. In addition to the precautions
given in “Safety first!” at the beginning of this
manual, observe the following when working
on the system:
Always remove rings, watches, etc before
working on the electrical system. Even with
the battery disconnected, capacitive
discharge could occur if a component’s live
terminal is earthed through a metal object.
This could cause a shock or nasty burn. Do not reverse the battery connections.
Components such as the alternator, electronic
control units, or any other components having
semi-conductor circuitry could be irreparably
damaged. If the engine is being started using jump
leads and a slave battery, connect the
batteries positive-to-positive and negative-to-
negative (see “Jump starting” ). This also
applies when connecting a battery charger.
Never disconnect the battery terminals, the
alternator, any electrical wiring or any test instruments when the engine is running.
Do not allow the engine to turn the
alternator when the alternator is not
connected. Never “test” for alternator output by
“flashing” the output lead to earth.
Never use an ohmmeter of the type
incorporating a hand-cranked generator for
circuit or continuity testing.
Always ensure that the battery negative lead
is disconnected when working on the
electrical system. Before using electric-arc welding
equipment on the car, disconnect the battery,
alternator and components such as the fuel
injection/ignition electronic control unit to
protect them from the risk of damage.
Battery disconnection
Several systems fitted to the vehicle require
battery power to be available at all times, either
to ensure that their continued operation (such as
the clock) or to maintain control unit memories
(such as that in the engine management
system’s ECU) which would be wiped if the
battery were to be disconnected. Whenever the
battery is to be disconnected therefore, first note
the following, to ensure that there are no
unforeseen consequences of this action:
a) First, on any vehicle with central locking, it is a wise precaution to remove the key
from the ignition, and to keep it with you,
so that it does not get locked in, if the
central locking should engage accidentally
when the battery is reconnected.
b) On cars equipped with an engine
management system, the system’s ECU will
lose the information stored in its memory -
referred to by Ford as the “KAM” (Keep-
Alive Memory) - when the battery is
disconnected. This includes idling and
operating values, and any fault codes
detected - in the case of the fault codes, if
it is thought likely that the system has
developed a fault for which the
corresponding code has been logged, the
vehicle must be taken to a Ford dealer for
the codes to be read, using the special
diagnostic equipment necessary for this.
Whenever the battery is disconnected, the
information relating to idle speed control
and other operating values will have to be
re-programmed into the unit’s memory.
The ECU does this by itself, but until then,
there may be surging, hesitation, erratic idle
and a generally inferior level of
performance. To allow the ECU to relearn
these values, start the engine and run it as
close to idle speed as possible until it
reaches its normal operating temperature,
then run it for approximately two minutes at
1200 rpm. Next, drive the vehicle as far as
necessary - approximately 5 miles of varied
driving conditions is usually sufficient - to
complete the relearning process.
c) If the battery is disconnected while the alarm system is armed or activated, the
alarm will remain in the same state when the battery is reconnected. The same
applies to the engine immobiliser system
(where fitted).
d) If a Ford “Keycode” audio unit is fitted,
and the unit and/or the battery is
disconnected, the unit will not function
again on reconnection until the correct
security code is entered. Details of this
procedure, which varies according to the
unit and model year, are given in the
“Ford Audio Systems Operating Guide”
supplied with the vehicle when new, with
the code itself being given in a “Radio
Passport” and/or a “Keycode Label” at
the same time. Ensure you have the
correct code before you disconnect the
battery. For obvious security reasons, the
procedure is not given in this manual. If
you do not have the code or details of the
correct procedure, but can supply proof
of ownership and a legitimate reason for
wanting this information, the vehicle’s
selling dealer may be able to help.
Devices known as “memory-savers” (or
“code-savers”) can be used to avoid some of
the above problems. Precise details vary
according to the device used. Typically, it is
plugged into the cigarette lighter, and is
connected by its own wires to a spare battery;
the vehicle’s own battery is then disconnected
from the electrical system, leaving the
“memory-saver” to pass sufficient current to
maintain audio unit security codes and ECU
memory values, and also to run permanently-
live circuits such as the clock, all the while
isolating the battery in the event of a short-
circuit occurring while work is carried out.
Warning: Some of these devices
allow a considerable amount of
current to pass, which can mean
that many of the vehicle’s
systems are still operational when the
main battery is disconnected. If a
“memory-saver” is used, ensure that the
circuit concerned is actually “dead” before
carrying out any work on it!
2 Electrical fault finding - general information
Refer to Chapter 12.
3 Battery -testing and charging
1
Standard and low maintenance
battery - testing
1If the vehicle covers a small annual mileage,
it is worthwhile checking the specific gravity
of the electrolyte every three months to
determine the state of charge of the battery.
Use a hydrometer to make the check and
compare the results with the following table.
5A•2 Starting and charging systems
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Ambient Ambient
temperature temperature
abovebelow
25°C (77°F) 25°C (77°F)
Fully-charged 1.210 to 1.230 1.270 to 1.290
70% charged 1.170 to 1.190 1.230 to 1.250
Fully-discharged 1.050 to 1.070 1.110 to 1.130
Note that the specific gravity readings
assume an electrolyte temperature of
15°C (60°F); for every 10°C (18°F) below 15°C
(60°F) subtract 0.007. For every 10°C (18°F)
above 15°C (60°F) add 0.007.
2 If the battery condition is suspect, first
check the specific gravity of electrolyte in
each cell. A variation of 0.040 or more
between any cells indicates loss of electrolyte
or deterioration of the internal plates.
3 If the specific gravity variation is 0.040 or
more, the battery should be renewed. If the
cell variation is satisfactory but the battery is
discharged, it should be charged as
described later in this Section.
Maintenance-free battery -
testing
4 In cases where a “sealed for life”
maintenance-free battery is fitted, topping-up
and testing of the electrolyte in each cell is not
possible. The condition of the battery can
therefore only be tested using a battery
condition indicator or a voltmeter.
5 If testing the battery using a voltmeter,
connect the voltmeter across the battery and
compare the result with those given in the
Specifications under “charge condition”. The
test is only accurate if the battery has not
been subjected to any kind of charge for the
previous six hours. If this is not the case,
switch on the headlights for 30 seconds, then
wait four to five minutes before testing the
battery after switching off the headlights. All
other electrical circuits must be switched off,
so check that the doors and tailgate are fully
shut when making the test.
6 If the voltage reading is less than 12.2 volts,
then the battery is discharged, whilst a
reading of 12.2 to 12.4 volts indicates a
partially discharged condition.
7 If the battery is to be charged, remove it
from the vehicle (Section 4) and charge it as
described later in this Section.
Standard and low maintenance
battery - charging
Note: The following is intended as a guide
only. Always refer to the manufacturer’s
recommendations (often printed on a label
attached to the battery) before charging a
battery.
8 Charge the battery at a rate of 3.5 to
4 amps and continue to charge the battery at
this rate until no further rise in specific gravity
is noted over a four hour period.
9 Alternatively, a trickle charger charging at
the rate of 1.5 amps can safely be used
overnight.
10 Specially rapid “boost” charges which are
claimed to restore the power of the battery in 1 to 2 hours are not recommended, as they
can cause serious damage to the battery
plates through overheating.
11
While charging the battery, note that the
temperature of the electrolyte should never
exceed 37.8°C (100°F).
Maintenance-free battery -
charging
Note: The following is intended as a guide
only. Always refer to the manufacturer’s
recommendations (often printed on a label
attached to the battery) before charging a
battery.
12 This battery type takes considerably
longer to fully recharge than the standard
type, the time taken being dependent on the
extent of discharge, but it can take anything
up to three days.
13 A constant voltage type charger is
required, to be set, when connected, to 13.9
to 14.9 volts with a charger current below
25 amps. Using this method, the battery
should be usable within three hours, giving a
voltage reading of 12.5 volts, but this is for a
partially discharged battery and, as
mentioned, full charging can take
considerably longer.
14 If the battery is to be charged from a fully
discharged state (condition reading less than
12.2 volts), have it recharged by your Ford
dealer or local automotive electrician, as the
charge rate is higher and constant supervision
during charging is necessary.
4 Battery -
removal and refitting
1
Note: Refer to the precautions in Section 1
before starting work.
Removal
1 The battery is located forward on the left-
hand side of the engine compartment, on a
platform welded to the vehicle structure.
2 Undo the retaining nut, then detach the
earth leads from the stud of the battery
negative (earth) terminal post. This is the
terminal to disconnect before working on, or
disconnecting, any electrical component on
the vehicle.
3 Pivot up the plastic cover from the positive
terminal, then unscrew the positive lead
retaining nut on the terminal. Detach the
positive lead from the terminal.
4 Release the clamp securing the battery to
its platform and remove it. Lift the battery
from its location, keeping it in an upright
position to avoid the possibility of corrosive
electrolyte spilling onto the paintwork.
5 Clean the battery terminal posts, clamps
and the battery casing. If the bulkhead is
rusted as a result of battery acid spilling onto
it, clean it thoroughly and re-paint with
reference to Chapter 1. 6
If you are renewing the battery, make sure
that you get one that’s identical, with the
same dimensions, amperage rating, cold
cranking rating, etc. Dispose of the old battery
in a responsible fashion. Most local authorities
have facilities for the collection and disposal
of such items - batteries contain sulphuric
acid and lead, and should not be simply
thrown out with the household rubbish!
Refitting
7 Refitting is a reversal of removal. Smear the
battery terminals with a petroleum-based jelly
prior to reconnecting. Always connect the
positive terminal clamp first and the negative
terminal clamp last.
5 Charging system - testing
2
Note:Refer to the precautions in Section 1
before starting work.
1 If the ignition warning light fails to
illuminate when the ignition is switched on,
first check the alternator wiring connections
for security. If satisfactory, check that the
warning light bulb has not blown, and that
the bulbholder is secure in its location in the
instrument panel. If the light still fails to
illuminate, check the continuity of the
warning light feed wire from the alternator to
the bulbholder. If all is satisfactory, the
alternator is at fault and should be renewed
or taken to an auto-electrician for testing and
repair.
2 If the ignition warning light illuminates when
the engine is running, stop the engine and
check that the drivebelt is correctly tensioned
(see Chapter 1) and that the alternator
connections are secure. If all is so far
satisfactory, have the alternator checked by
an auto-electrician for testing and repair.
3 If the alternator output is suspect even
though the warning light functions correctly,
the regulated voltage may be checked as
follows.
4 Connect a voltmeter across the battery
terminals and start the engine.
5 Increase the engine speed until the
voltmeter reading remains steady; the
reading should be approximately 13.5 to
14.6 volts.
6 Switch on as many electrical accessories
(eg, the headlights, heated rear window and
heater blower) as possible, and check that the
alternator maintains the regulated voltage at
around 13 to 14 volts.
7 If the regulated voltage is not as stated, the
fault may be due to worn brushes, weak brush
springs, a faulty voltage regulator, a faulty
diode, a severed phase winding or worn or
damaged slip rings. The alternator should be
renewed or taken to an auto-electrician for
testing and repair.
Starting and charging systems 5A•3
5A
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12
1595Ford Fiesta Remake
Fuses - pre-1992 models
Main fuse board:
No Rating (amps) Circuit(s) protected
1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . Electronic engine control system
2 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Interior light, cigarette lighter, clock and radio memory
3 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Central locking system
4 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated rear window element
5 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Dim-dip lighting
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand side lights and rear fog light
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand side lights
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand dipped beam
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand dipped beam
10 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand main beam and right-hand auxiliary driving light
11 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand main beam and left-hand auxiliary driving light
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heater fan motor and reversing light
13 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Radiator cooling fan motor
14 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Front foglights (XR2i only)
15 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Horn
16 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Wiper motor and windscreen/tailgate washer pump
17 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Brake stop lights, instrument illumination and instrument warning
18 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electrically operated windows
19 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Electric fuel pump
20 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Oxygen sensor (vehicles with catalytic converter)
21 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Left-hand direction indicators
22 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Right-hand direction indicators
Chapter 12
Body electrical systems
Air bag (driver’s side) - removal and refitting . . . . . . . . . . . . . . . . . . 28
Air bag (passenger’s side) - removal and refitting . . . . . . . . \
. . . . . . . 29
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 31
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 30
Anti-theft systems - general information . . . . . . . . . . . . . . . . . . . . . . 27
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . . .See
“Weekly checks”
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cigarette lighter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 12
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electric window regulator motor - removal and refitting . . . . . . . . . . 20
Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . 2
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses and relays - general information . . . . . . . . . . . . . . . . . . . . . . . 3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight and auxiliary light beam alignment - checking and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 8
Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel components - removal and refitting . . . . . . . . . . . 10
“Lights-on” warning module - removal and refitting . . . . . . . . . . . . . 26
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . 22
Screen washer fluid level check . . . . . . . . . . . . . .See
“Weekly checks”
Speaker balance control joystick - removal and refitting . . . . . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate remote release motor - removal and refitting . . . . . . . . . . . 21
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 18
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Windscreen wiper pivot shaft - removal and refitting . . . . . . . . . . . . 17
Windscreen/tailgate washer system components - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 19
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
12•1
Specifications Contents
Easy,suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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Additional fuses behind main fuse board:
NoRating (amps) Circuit(s) protected
23 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . Unused
24/25 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
26 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Tailgate remote release
27/28 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
Fuses - 1992 models onward
Main fuse board:
Fuses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . Unchanged from pre-1992 models
Additional fuses behind main fuse board:
No Rating (amps) Circuit(s) protected
23* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Unused
23** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
24* - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Unused 24** 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Rear fog lights
25 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Tailgate remote release, anti-theft warning system
26 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
27 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Heated windscreen
28* 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Full-length sunroof
28** 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Automatic transmission starter inhibitor
29 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Air bag
* Pre-1994 models
** 1994 models onward
Relays (pre-1992 models)
Note: Relay locations and circuits controlled are liable to change from year t\
o year. Consult a Ford dealer, for specific information.
No Circuit(s) controlled
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated rear window
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Windscreen wiper delay
III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . CFi (fuel injection) delay relay
IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Ignition switch
VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Automatic transmission starter inhibitor/electric fuel pump (bridge fitted to carburettor engines without automatic transmission)
VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight main beam
VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated windscreen
XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Idle speed control (automatic transmission) two-tone horn (where fitt\
ed)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Front foglights (XR2i)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight dipped beam
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
Relays (1992 models onward)
Note: Relay locations and circuits controlled are liable to change from year t\
o year. Consult a Ford dealer, for specific information.
No Circuit(s) controlled
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated rear window
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Windscreen wiper delay
III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . CFi delay relay or EFi supply relay (fuel injection)
IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Ignition switch
VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Automatic transmission starter inhibitor, anti-theft warning system
VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight main beam
VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system and/or dim-dip lighting
IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Heated windscreen
XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Anti-lock braking system
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Idle speed control (automatic transmission) or two-tone horn (where f\
itted)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Fuel pump
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Front foglights (XR2i, RS Turbo and RS 1800)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Headlight dipped beam
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Dim-dip lighting
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . Not used on UK models
12•2 Body electrical systems
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BulbsWattage
Headlight (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . H4, 60/55
Sidelight (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 5
Direction indicators (main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Side direction indicator repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Auxiliary driving and foglights (S and XR2i) . . . . . . . . . . . . . . . . . . . . . . H3, 55
Stop/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 21/5
Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 21
Reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 21
Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 10
Interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 10
Luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
1.3 or 2.6
Panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 1.3 or 2.6
Cigarette lighter illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Automatic transmission selector illumination . . . . . . . . . . . . . . . . . . . . . 2
Lubricants
Grease for windscreen wiper linkage and pivots . . . . . . . . . . . . . . . . . . To Ford specification SAM-1C-911-A
Torque wrench settingsNm lbf ft
Wiper motor to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 8 to 9 6 to 7
Wiper motor bracket to bulkhead/tailgate . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 4 to 6
Windscreen wiper crank to driving shaft nut . . . . . . . . . . . . . . . . . . . . . 22 to 24 16 to 18
Windscreen/tailgate wiper arm retaining nut . . . . . . . . . . . . . . . . . . . . . 17 to 18 12 to 13
Windscreen wiper pivot shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 7 to 9
Windscreen/tailgate washer reservoir securing bolts . . . . . . . . . . . . . . . 2.5 to 3.5 2 to 3
Headlight retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 5.4 to 7.0 4 to 5
Tail light securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1.5 to 2.5 1 to 2
Auxiliary light retaining nut (S models) . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 to 9.2 5 to 7
Horn bracket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 33 18 to 24
Starter inhibitor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 9 to 14 7 to 10
Body electrical systems 12•3
12
1595Ford Fiesta Remake
1 General information and
precautions
General information
The electrical system is of 12-volt negative
earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid battery, which is charged by the
engine-driven alternator.
This Chapter covers repair and service
procedures for the various electrical
components not associated with the engine.
Information on the battery, ignition system,
alternator, and starter motor can be found in
Chapter 5A and B.
All models from 1994 onwards are fitted
with a driver’s air bag, which is designed to
prevent serious chest and head injuries to the
driver during an accident. A similar bag for the
front seat passenger is also available. The
combined sensor and electronics for the air
bag is located next to the steering column
inside the vehicle, and contains a back-up
capacitor, crash sensor, decelerometer,
safety sensor, integrated circuit and
microprocessor. The air bag is inflated by a
gas generator, which forces the bag out of the module cover in the centre of the steering
wheel. A “clock spring” ensures that a good
electrical connection is maintained with the air
bag at all times - as the steering wheel is
turned in each direction, the spring winds and
unwinds.
An anti-theft alarm system is available on
later models, and is triggered if the vehicle is
broken into through the doors, bonnet, or
tailgate. The alarm will also be triggered if the
ignition or audio equipment is tampered with.
Additionally, from the 1994 model year
onwards, a Passive Anti-Theft System (PATS)
is fitted. This system, (which works
independently of the standard alarm) prevents
the engine from being started unless a
specific code, programmed into the ignition
key, is recognised by the PATS transceiver.
Precautions
Warning: Before carrying out
any work on the electrical
system, read through the
precautions given in “Safety
first!” at the beginning of this manual and
in Chapter 5A, Section 1.
Caution: Prior to working on any
component in the electrical system, the
battery negative lead should first be
disconnected, to prevent the possibility of electrical short-circuits and/or fires. If a
radio/cassette player with anti-theft
security code is fitted, refer to the
information given in the reference sections
of this manual before disconnecting the
battery.
2 Electrical fault-finding
-
general information
2
Note: Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before starting work. The following tests relate
to testing of the main electrical circuits, and
should not be used to test delicate electronic
circuits (such as engine management
systems), particularly where an electronic
control unit is used. Also refer to the
precautions given in Chapter 5A, Section 1.
General
1 A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
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wiring diagrams are included at the end of this
manual.
2Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a complete understanding
of the components included in the particular
circuit concerned. The possible sources of a
fault can be narrowed down by noting if other
components related to the circuit are
operating properly. If several components or
circuits fail at one time, the problem is likely to
be related to a shared fuse or earth
connection.
3 Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay (refer to Section 3 for details of testing
relays). Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked
in order to pinpoint the trouble-spot.
4 The basic tools required for electrical fault-
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used for certain tests); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
Warning: Under no
circumstances may live
measuring instruments such as
ohmmeters, voltmeters or a bulb
and test leads be used to test any of the
air bag circuitry or components. Any
testing in these areas must be left to a
Ford dealer as there is a danger of
activating the system if the correct
procedures are not followed.
5 To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6 Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7 Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working.
8 Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.
Finding an open-circuit
9
To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
10 Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse. At this point, battery
voltage should be present, unless the lead
from the battery or the fuse itself is faulty
(bearing in mind that some circuits are live
only when the ignition switch is moved to a
particular position).
11 Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
the circuit between the relevant connector
and the switch is problem-free.
13 Continue to check the remainder of the
circuit in the same fashion.
14 When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.
Finding a short-circuit
15 To check for a short-circuit, first
disconnect the load(s) from the circuit (loads
are the components which draw current from
a circuit, such as bulbs, motors, heating
elements, etc).
16 Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17 Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19 If no voltage is present during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).
Finding an earth fault
20 The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission and the vehicle body -
and many systems are wired so that they only
receive a positive feed, the current returning
via the metal of the car body. This means that
the component mounting and the body form
part of that circuit. Loose or corroded mountings can therefore cause a range of
electrical faults, ranging from total failure of a
circuit, to a puzzling partial failure. In
particular, lights may shine dimly (especially
when another circuit sharing the same earth
point is in operation), motors (eg wiper
motors or the radiator cooling fan motor) may
run slowly, and the operation of one circuit
may have an apparently-unrelated effect on
another. Note that on many vehicles, earth
straps are used between certain
components, such as the engine/
transmission and the body, usually where
there is no metal-to-metal contact between
components, due to flexible rubber
mountings, etc.
21
To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5A, Section 1) and connect one
lead of an ohmmeter to a known good earth
point. Connect the other lead to the wire or
earth connection being tested. The resistance
reading should be zero; if not, check the
connection as follows.
22 If an earth connection is thought to be
faulty, dismantle the connection, and clean
both the bodyshell and the wire terminal (or
the component earth connection mating
surface) back to bare metal. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer
or a water-dispersant lubricant.
3 Fuses and relays -
general information
Note: It is important to note that the ignition
switch and the appropriate electrical circuit
must always be switched off before any of the
fuses (or relays) are removed and renewed.
1 The main fuse and relay board is located
below the facia panel to the right of the
steering wheel. The fuses can be inspected
and if necessary renewed, by removing the
hinged access cover. The remaining
additional fuses and relays (depending on
model) may be accessed by removing the two
fuse board retaining screws, releasing the
retaining lugs on either side of the main fuse
plate and withdrawing the fuse/relay board
downwards into the driver’s footwell. Each
fuse location is numbered - refer to the fuse
chart in the Specifications at the start of this
Chapter to check which circuits are protected
by each fuse. Plastic tweezers are attached to
12•4 Body electrical systems
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the inside face of the cover to remove and fit
the fuses (see illustrations) .
2 To remove a fuse, use the tweezers
provided to pull it out of the holder. Slide the
fuse sideways from the tweezers. The wire
within the fuse is clearly visible, and it will be
broken if the fuse is blown.
3 Always renew a fuse with one of an
identical rating. Never renew a fuse more than
once without tracing the source of the trouble.
The fuse rating is stamped on top of the fuse.
4 With the exception of the indicator flasher
relay, the remainder of the relays are fitted to
the reverse side of the main fuse/relay board.
Access is as described in paragraph 1.
5 The various relays can be removed from
their respective locations on the fuse board by
carefully pulling them from the sockets.
6 The direction indicator flasher relay is
attached to the multi-function switch unit on
the steering column. Access to the relay is
made by undoing the retaining screws and
removing the steering column shrouds. The
relay can then be withdrawn from the switch.
7 If a system controlled by a relay becomes
inoperative and the relay is suspect, listen to
the relay as the circuit is operated. If the relay
is functioning, it should be possible to hear it
click as it is energised. If the relay proves
satisfactory, the fault lies with the
components or wiring of the system. If the
relay is not being energised, then it is not
receiving a main supply voltage or a switching
voltage, or the relay is faulty.
4 Switches -
removal and refitting
2
Ignition switch (loom plate and
lock barrel)
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the manual choke control knob,
where fitted, by depressing the lug securing it,
and pulling it from its shaft. The lug is found
on the side of the control knob shank. 3
Remove the lower steering column shroud
by undoing its four retaining screws, then
detach the choke warning light switch/pull
control assembly from the lower shroud by
unscrewing its retaining collar (bayonet-type
fixing), using a suitable tool to locate in the
collar recesses.
4 Remove the two screws securing the upper
steering column shroud from above, and the
two screws securing it from below, the latter
accessible only with the lower shroud
removed.
5 Disconnect the ignition switch wiring multi-
plug connector. Insert a thin-bladed
screwdriver into the lock tab aperture, release
the locking tab and remove the loom plate
from its location on the left-hand side of the
steering column.
6 Where applicable, undo the single screw
and withdraw the Passive Anti-Theft System
(PATS) transceiver from the ignition
switch/steering lock barrel.
7 Insert the key and turn the ignition switch to
position ”I”. Depress the lock barrel plunger
through the steering column lock housing. As
the lock barrel plunger is depressed, pull
on the ignition key to remove the lock barrel
(see illustration) .
8 Refitting is a reversal of the removal
procedure. When relocating the switch to the
steering lock, the barrel driveshaft must align with the switch shaft as it is pushed into
position. Check the switch for satisfactory
operation on completion.
Steering column multi-function
switch
9
Carry out the operations described in
paragraphs 1 to 4 above.
10 Disconnect the wiring multi-plugs from
the multi-function switch assembly, then
remove the single screw securing the switch
assembly to the steering column lock
housing. This retaining screw is located
directly forward of the hazard warning light
switch. Remove the switch assembly.
11 Refitting is a reversal of the removal
procedure.
Facia centre panel switches
(below heater controls)
12 These switches individually control the
front and rear foglights, heated windscreen
and heated rear window element. Where
these features are not fitted to the vehicle,
blanking plates are installed instead of
switches.
13 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
14 Remove the radio/cassette player as
described in Section 22.
15 Remove the ashtray, then undo the three
screws from the base of the centre panel.
Withdraw the centre panel, disconnecting the
cigarette lighter connections as it is
withdrawn.
16 Push the required switch/switches out
from behind, disconnect the multi-plug and
remove the switch.
17 Refitting is a reversal of the removal
procedure.
Centre console switches
18 The switches mounted on the centre
console control the electrically operated
Body electrical systems 12•5
3.1c Component layout on the fuse/relay board. See Specifications for relay
identification
3.1b Withdrawing the fuse/relay board downwards into the driver’s footwell3.1a Method of fuse/relay board retention
A Retaining screws C Support
B Retaining lugs
4.7 Withdraw the lock barrel after
depressing its plunger through the
aperture in the steering column lock
housing (arrowed)12
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the bulbholder together and remove it (see
illustrations) .
22 All bulbs are of bayonet type fitting.
23 Refitting is a reversal of the removal
procedure.
Rear light cluster (Courier
models)
24 Working inside the load compartment,
unscrew the two black plastic nuts securing
the light cluster assembly. Withdraw the
assembly to the outside of the vehicle,
disconnecting the wiring from the bulbholder
(see illustrations) .
25 All bulbs are of bayonet type fitting.
26 Refitting is a reversal of the removal
procedure.
Number plate lights
27 Insert a thin flat-bladed screwdriver
between the light assembly and the bumper,
and carefully prise the light out. Use a rag, or
a piece of card, between the screwdriver and
the bumper, to prevent damage to the
bumper.
28 Detach the connections on the underside
of the light assembly.
29 Release the tab securing the light cover to
the bulbholder, and remove the cover (see
illustration) .
30 The bulb is a bayonet type fitting in its
holder.
31 Refitting is a reversal of the removal
procedure.
6 Bulbs (interior lights) -
renewal
2
Instrument panel illumination
and warning lights
1 Refer to Section 10.
Automatic transmission selector
illumination
2Using a thin flat-bladed screwdriver, prise
up the selector cover and remove it.
3 Pull the bulb assembly to release it from the
selector lever, then remove its cover. The bulb
is a bayonet fit in its holder (see illustrations).
4 Refitting is a reversal of the removal
procedure.
Hazard warning switch
5 The hazard warning light switch, an integral
part of the steering column multi-function
switch assembly, has a bulb cover which pulls
off. The bulb is removed by pulling it from its
location.
6 Refitting is a reversal of the removal
procedure.
Clock illumination
7 Carefully prise the clock out of its facia
location, as described in Section 13.
8 Twist the bulbholder and withdraw it from
the rear of the clock (see illustration). Note
12•8Body electrical systems
6.8 Withdrawing the clock illumination
bulb and its integral holder from the rear of
the clock6.3b . . . followed by the (bayonet fitting) bulb6.3a Remove the selector illumination bulbcover . . .
5.29 Release the number plate light
securing tab (arrowed) and separate the bulbholder and light cover5.24b . . . then withdraw the assembly to
the outside of the vehicle
5.24a On Courier models, unscrew the twoblack plastic nuts securing the rear light cluster assembly . . .5.21b . . . then having pressed its retaininglugs, withdraw the bulbholder for access to the bulbs5.21a Disconnect the ear light clustermulti-plug from the bulbholder . . .
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