engine FORD MONDEO 1993 Service Repair Manual

11.3B . . . and disconnect the multi-plug
uniform gap all round. Adjust the rear height
of the bonnet by repositioning it on the
hinges. Adjust the front height by
repositioning the lock (see Section 10) and
turning the rubber buffers on the engine
compartment front cross panel up or down to
support the bonnet (see illustration).
Removal
1With the bonnet open, disconnect the
battery negative (earth) lead (Chapter 5,
Section 1).
2Working inside the vehicle, remove the trim
from the “B” pillar, and pull off the doorweatherstrips from the bottom of the door
apertures.
3Remove the clips and screws, and
withdraw the lower side trim, to give access to
the bonnet release lever (see illustration).
4Release the outer cable from the lever
bracket.
5Unscrew and remove the lever mounting
screws, and turn the lever clockwise through
a quarter-turn to disconnect it from the cable.
6Remove the radiator grille (Section 7). Also
remove the backing panel from the engine
compartment front crossmember.
7Release the inner and outer cables from the
lock.
8Withdraw the cable from the engine
compartment, feeding it through the front
crossmember, and removing the grommet
from the bulkhead.
Refitting
9Refitting is a reversal of the removal
procedure.
Removal
1Remove the radiator grille (Section 7).
2Release the inner and outer cables from the
bonnet lock.
3Mark the position of the lock on the
crossmember, then unscrew the mounting
nuts and withdraw the lock.
Refitting and adjustment
4Refitting is a reversal of the removal
procedure, starting by positioning the lock as
noted before removal.
5If the front of the bonnet is not level with the
front wings, the lock may be moved up or
down within the mounting holes. After making
an adjustment, raise or lower the rubber
buffers to support the bonnet correctly.
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2Carefully prise out the plastic cover with a
small screwdriver. Remove the screw, and
11 Door inner trim panel -
removal and refitting
10 Bonnet lock - removal,
refitting and adjustment
9 Bonnet release cable and
lever - removal and refitting
11•6 Bodywork and fittings
8.8 Removing the bonnet8.9 Buffer for adjustment of the bonnet
front height9.3 Bonnet release lever
11.2B . . . remove the screw . . .11.2A Prise out the plastic cover . . .
11.2C . . . and withdraw the bezel from the
inner door handle11.3A Remove the window operating
switch . . .
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Chapter 12 Body electrical system
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 30
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 29
Air bag unit (driver’s side) - removal and refitting . . . . . . . . . . . . . . . 28
Anti-theft alarm system - general information . . . . . . . . . . . . . . . . . . 20
Auxiliary warning system - general information and
component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery - check, maintenance and charging . . . . . . . . See Chapter 1
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . See Chapter 5
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compact disc player - removal and refitting . . . . . . . . . . . . . . . . . . . 25
Cruise control system - general information . . . . . . . . . . . . . . . . . . . 21
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses, relays and timer module - testing and renewal . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight beam alignment - checking and adjustment . . . . . . . . . . 8
Headlight levelling motor - removal and refitting . . . . . . . . . . . . . . . 9Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel components - removal and refitting . . . . . . . . . . . 11
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Radio/cassette player - coding, removal and refitting . . . . . . . . . . . 23
Radio/cassette player power amplifier - removal and refitting . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Speedometer drive cable - removal and refitting . . . . . . . . . . . . . . . 12
Stop-light switch - removal and refitting . . . . . . . . . . . See Chapter 9
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 17
TCS inhibition switch - removal and refitting . . . . . . . . See Chapter 9
Trip computer module - removal and refitting . . . . . . . . . . . . . . . . . 18
Windscreen/tailgate washer system and wiper blade
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Windscreen/tailgate washer system components - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses (auxiliary fusebox in engine compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse No Rating Colour Circuit(s) protected
1 80 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply to main fusebox
2 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fans
3 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Diesel engine glow plugs and/or ABS braking system
4 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system, or ignition and daytime running lights
5 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (left-hand side)
6 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (right-hand side)
7 30 Light green . . . . . . . . . . . . . . . . . . . . . . ABS braking system
8 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air conditioning compressor/heated seats or air conditioning
compressor/daytime running lights
9 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . ECU (petrol), Cold start solenoid (Diesel)
10 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . Ignition switch
11 3 Violet . . . . . . . . . . . . . . . . . . . . . . . . . . ECU memory
12 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Horn and hazard flasher warning system
13 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Oxygen sensor
14 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
15 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (right-hand side)
16 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (left-hand side)
17 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (right-hand side)
18 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (left-hand side)
12•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
12
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Fuses (main fusebox in passenger compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse Rating Colour Circuit(s) protected
19 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Heated door mirrors
20 10 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Front/rear wiper motor (circuit breaker)
21 30 Light green . . . . . . . . . . . . . . . . . . . . . . Front electric windows (only)
21 40 Orange . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear electric windows
22 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . ABS module
23 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Reversing lights
24 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Stop-lights
25 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Central locking system/double-locking/anti-theft alarm
26 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Foglights
27 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter
28 30 Light green . . . . . . . . . . . . . . . . . . . . . . Headlight washer system
29 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated rear window
30 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and auxiliary warning system
31 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel illumination
32 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Radio
33 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (left-hand side)
34 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and digital clock
35 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (right-hand side)
36 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air bag
37 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heater blower
38 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive damping
Relays (auxiliary fusebox in engine compartment)
Relay Colour Circuit(s) protected
R1 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime running lights (left-hand-drive, but not all countries) or dim-
dip lights (UK)
R2 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (high speed)
R3 Blue (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning cut-out
R3 Brown (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning in conjunction with Diesel engine
R4 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen heater time delay
R5 Dark green (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R5 Black (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R6 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter solenoid
R7 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns
R8 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
R9 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlights
R10 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlights
R11 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU power supply (petrol), cold start (Diesel)
Relays (main fusebox in passenger compartment)
Relay Colour Circuit(s) protected
R12 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior, courtesy and footwell lights
R13 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear window
R14 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater blower
R15 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper motor
R16 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition
Auxiliary relays (not in the fuseboxes)
Relay Colour Circuit(s) protected Location
R17 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel glow plug Battery tray
R18 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “One-touch down” Driver’s door
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver’s window relay
R19 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control cut-off Central fuse box bracket the
below instrument panel
R20 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system Bulb module bracket
R21 Orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear screen wiper interval Bulb module bracket
R22 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglights (left-hand-drive only) Interface module bracket
R23 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction indicators Steering column
R24 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (left-hand side) Door lock module bracket
R25 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (right-hand side) Door lock module bracket
R26 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated seats Door lock module bracket
12•2 Body electrical system
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BulbsWattage Type
Headlight main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Headlight dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Foglights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Direction indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Side repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Stop-lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Reversing lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Rear fog/tail lights (Saloon and Estate) . . . . . . . . . . . . . . . . . . . . . . . . . . 21/4 Bayonet
Rear tail light (Saloon and Hatchback) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bayonet
Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Festoon
Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wedge
Interior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Festoon
Reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Torque wrench settingsNm lbf ft
Windscreen wiper motor bolts:
Into old motor (see text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Into new motor (see text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Body electrical system 12•3
12
Warning: Before carrying out any
work on the electrical system,
read through the precautions
given in “Safety first!” at the beginning of
this manual.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
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 5.
All models 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 (see illustration).
The sensor and electronic unit 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 (see
illustration). 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.
All UK models are fitted with an alarm
system incorporating a movement sensor and
ignition immobiliser. On Saloon and
Hatchback models, the alarm system horn is
located on the left-hand side of the luggage
1 General information
1.3A Air bag system components
1 Air bag module (driver’s)
2 Clock spring3 Diagnostic and sensor unit
4 Air bag indicator light5 Air bag module
(passenger’s)
1.3B Air bag sensor and electronic unit
1 Crash sensor
2 Safety sensor
3 Voltage back-up
4 Application Specific Integrated Circuit
5 Microprocessor
procarmanuals.com

compartment, but on Estate models, it is on
the right-hand side.
Some models are fitted with a headlight
levelling system, which is controlled by a knob
on the facia. On position “0”, the headlights
are in their base position, and on position “5”,
the headlights are in their maximum inclined
angle.
It should be noted that, when portions of
the electrical system are serviced, the cable
should be disconnected from the battery
negative terminal, to prevent electrical shorts
and fires.
Caution: When disconnecting the
battery for work described in the
following Sections, refer to
Chapter 5, Section 1.
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,
anti-lock braking systems, etc), particularly
where an electronic control module is used.
Also refer to the precautions given in Chapter
5, Section 1.
General
1A 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,
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.
3Electrical 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.
4The basic tools required for electrical fault-
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can alsobe 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.
5To 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.
6Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7Open-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.
8Short-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
9To 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.
10Connect 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).
11Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12If 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.
13Continue to check the remainder of the
circuit in the same fashion.
14When 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
15To 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).
16Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19If 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
20The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission unit 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.
21To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5, 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.
22If 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
2 Electrical fault finding -
general information
12•4 Body electrical system
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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
such as Holts Damp Start, or a water-
dispersant lubricant such as Holts Wet Start.
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. In
the event of the fuse/relay unit having to be
removed, the battery earth lead must be
disconnected. When reconnecting the battery,
reference should be made to Chapter 5.
1Fuses are designed to break a circuit when
a predetermined current is reached, in order
to protect components and wiring which
could be damaged by excessive current flow.
Any excessive current flow will be due to a
fault in the circuit, usually a short-circuit (see
Section 2). The main fusebox, which also
carries some relays, is located inside the
vehicle below the facia panel on the
passenger’s side, and is accessed by a lever
behind the glovebox (see illustration).
2A central timer module is located on the
bottom of the main fusebox. This module
contains the time control elements for the
heated rear window, interior lights and
intermittent wiper operation. The module also
activates a warning buzzer/chime when the
vehicle is left with the lights switched on, or if
a vehicle fitted with automatic transmission is
not parked in position “P”.
3The auxiliary fusebox is located on the front
left-hand side of the engine compartment,
and is accessed by unclipping and removing
the cover. The auxiliary fusebox also contains
some relays (see illustration). Each circuit is
identified by numbers on the main fusebox
and on the inside of the auxiliary fusebox
cover. Reference to the fuse chart in the
Specifications at the start of this Chapter will
indicate the circuits protected by each fuse.
Plastic tweezers are attached to the main
fusebox and to the inside face of the auxiliary
fuse and block cover, to remove and fit the
fuses and relays.
4To 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 (see illustration).
5Always renew a fuse with one of an
identical rating. Never substitute a fuse of a
higher rating, or make temporary repairs using
wire or metal foil; more serious damage, or
even fire, could result. The fuse rating is
stamped on top of the fuse. Never renew a
fuse more than once without tracing the
source of the trouble.
6Spare fuses of various current ratings areprovided in the cover of the auxiliary fusebox.
Note that if the vehicle is to be laid up for a
long period, fuse 34 in the main fusebox
should be removed, to prevent the ancillary
electrical components from discharging the
battery.
7Relays are electrically-operated switches,
which are used in certain circuits. The various
relays can be removed from their respective
locations by carefully pulling them from the
sockets. Each relay in the fuseboxes has a
plastic bar on its upper surface to enable the
use of the tweezers. The locations and
3 Fuses, relays and timer
module- testing and renewal
Body electrical system 12•5
12
3.4 The fuses can be checked visually to
determine if they are blown
3.1 Main fusebox layout
1 Fuse/relay removal tweezers 2 Diode 3 Multi-plug connections
3.3 Auxiliary fusebox layout
1 Fuses 1 to 3 3 Relays R2, R5 and R6 5 Relay sockets for relays R1 and R4
2 Fuses 4 to 8, 11 to 14 4 Relays R7 to R11 6 Diode
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Engine compartment light
1With the bonnet open, pull the wedge-type
bulb from the bulbholder.
2Fit the new bulb using a reversal of the
removal procedure.
Interior lights
3Switch off the interior light by locating the
switch in its middle position.
4Using a small screwdriver, carefully prise
out the light or bulb cover, as applicable (see
illustration).
5Lift up the reflector, then release the
festoon-type bulb from the contact springs
(see illustration).
6Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.
Reading light
7With the reading light switched off, prise
out the light using a small screwdriver.
8Hinge back the contact plate, and release
the festoon-type bulb from the contact
springs.9Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.
Instrument panel illumination and
warning lights
10Remove the instrument panel as
described in Section 10.
11Twist the bulbholder anti-clockwise to
remove it (see illustration).
12Fit the new bulbholder using a reversal of
the removal procedure.
Foglight warning indicator
13Using a screwdriver, prise out the
indicator from the facia, and disconnect the
multi-plug.
14Twist the bulbholder anti-clockwise with
the screwdriver, and remove it (see
illustration).
15Fit the new bulb using a reversal of the
removal procedure.
Hazard warning light
16Pull the cover directly up from the switch,
then remove the bulb (see illustrations).
17Fit the new bulb using a reversal of the
removal procedure.
Glovebox light
18Open the glovebox, then pull out the
wedge-type bulb from the light located under
the upper edge.
Heater fan switch illumination
19Pull off the switch knob, then depress and
twist the bulb to remove it.
Automatic transmission selector
panel illumination
20Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
21Remove the ashtray.
22Select Neutral, then prise out the panel
from the centre console.
23Disconnect the multi-plug from the
overdrive control switch.
24Disconnect the bulbholder and pull out
the wedge-type bulb.
25Fit the new bulb using a reversal of the
removal procedure.
Interior door handle illumination
26Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
27Remove the door interior trim panel as
described in Chapter 11.
28Using a knife, cut free the foam
watershield for access to the rear of the
interior door handle.
29Pull out the bulbholder and remove the
bulb.
Clock illumination
30Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
31Remove the clock as described in Sec-
tion 13.
6 Bulbs (interior lights) - renewal
Body electrical system 12•11
12
6.14 Removing the bulb from the foglight
warning indicator6.16A Pull off the hazard warning light
cover . . .6.16B . . . and remove the bulb
6.4 Prise out the interior light with a
screwdriver6.5 Lifting the reflector from the interior
light6.11 Removing a bulb from the rear of the
instrument panel
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6Similarly remove the fuel gauge and
temperature gauge by unscrewing the single
screws.
7Remove all the pin contacts.
8Using a small punch, push in the multi-plug
securing pins, and remove the multi-plugs.
9Carefully lift the printed circuit from the
location dowels on the housing, taking care
not to damage it.
Refitting
10Refitting is a reversal of the removal
procedure.
Removal
1Remove the windscreen wiper arms as
described in Section 15.
2With the bonnet closed, release the grille
panel upper edge from just in front of the
windscreen, by prising off the caps and
unscrewing the upper retaining screws.
3Open the bonnet, and support with the
stay.
4Pull off the sealing strip from the cross
panel at the rear of the engine compartment.
5Unscrew the lower screws, and remove the
grille panel halves from in front of thewindscreen, withdrawing first one side and
then the other.
6Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
7Reach in behind the bulkhead. Squeeze the
collar on the upper end of the speedometer
cable, where it is attached to the intermediate
cable from the rear of the speedometer head.
Disconnect the cable, and withdraw it from
the bulkhead inner panel, together with the
rubber grommet (see illustrations).
8Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
9Unscrew the nut and disconnect the
speedometer cable from the vehicle speed
sensor on the transmission, then withdraw the
cable from within the engine compartment.
Use two spanners to loosen the nut - one to
counterhold the sensor, and the other to
unscrew the cable nut (see illustrations).Refitting
10Refitting is a reversal of the removal
procedure.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).2Using a small screwdriver, prise the clock
out of the facia (see illustration). To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the clock, and withdraw the clock (see
illustration).
Refitting
4Refitting is a reversal of the removal
procedure. Reset the clock on completion.
Removal
1Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
2Unscrew the bolts, and release the clips
securing the radiator lower cover to the front
of the vehicle.
3Disconnect the wiring from the horn
terminal.
4Unscrew the mounting bolt, and withdraw
the horn with its mounting bracket from under
the vehicle (see illustration).
Refitting
5Refitting is a reversal of the removal
procedure.
14 Horn - removal and refitting
13 Clock- removal and refitting
12 Speedometer drive cable -
removal and refitting
Body electrical system 12•15
12
12.9B . . . and disconnect the
speedometer cable from the vehicle speed
sensor13.2 Prising the clock out of the facia13.3 Disconnecting the multi-plug from
the rear of the clock
12.7A Squeeze the collar . . .12.7B . . . and disconnect the
speedometer main cable from the
intermediate cable12.9A Unscrew the cable nut . . .
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Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1). If the windscreen
wiper arms are to be removed, close the bonnet.
2With the wiper(s) “parked” (ie in the normal
at-rest position), mark the positions of the
blade(s) on the screen, using a wax crayon or
strips of masking tape.
3Lift up the plastic cap from the bottom of
the wiper arm, and loosen the nut one or two
turns (see illustration).
4Lift the wiper arm, and release it from the
taper on the spindle by moving it to one side.5Completely remove the nut, and withdraw the
wiper arm from the spindle (see illustration).
Refitting
6Refitting is a reversal of the removal
procedure. Make sure that the arm is fitted in
the previously-noted position.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the wiper arms as described in
Section 15.
3With the bonnet closed, release the grillepanel upper edge from just in front of the
windscreen, by prising off the caps and
unscrewing the upper retaining screws (see
illustrations).
4Open the bonnet, and support it with the
stay.
5Pull off the bonnet sealing strip from the
cross panel at the rear of the engine
compartment (see illustration).
6Unscrew the lower screws, and remove the
grille panel halves from in front of the
windscreen, withdrawing one side then the
other side (see illustrations).
7Unscrew the mounting bolts securing the
wiper motor and linkage to the bulkhead. On
right-hand-drive models, the linkage is on the
right-hand side of the bulkhead (see
illustration); on left-hand-drive models, it is
on the left-hand side.
16 Windscreen wiper motor and
linkage - removal and refitting
15 Wiper arms-
removal and refitting
12•16 Body electrical system
14.4 Horn and mounting bracket (arrowed)15.3 Loosening the wiper arm retaining
nut15.5 Removing the wiper arm from the
spindle
16.6A Unscrew the lower screws . . .16.6B . . . and remove the grille panel from
in front of the windscreen16.7 Wiper motor mounting bolt locations
(right-hand-drive)
16.3A Prise off the cap . . .16.3B . . . and remove the upper retaining
screws16.5 Removing the bonnet sealing strip
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8Disconnect the wiper motor multi-plug.
9Withdraw the wiper motor, complete with
the linkage, from the bulkhead (see
illustration).
10Mark the position of the motor arm on the
mounting plate, then unscrew the centre nut
(see illustration).
11Unscrew the motor mounting bolts, and
separate the motor from the linkage assembly.
Refitting
12Refitting is a reversal of the removal
procedure. There are two tightening torques
for the motor mounting bolts - the lower one
for bolts that are being re-inserted into an old
motor, and the higher ones for bolts that are
being inserted into a new motor. Make sure
that the wiper motor is in its “parked” position
before fitting the motor arm, and check that
the wiper linkage is in line with the motor arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the tailgate wiper arm as
described in Section 15.
3Remove the tailgate inner trim panel by
unscrewing the retaining screws.
4Release the multi-plug from the clip, then
disconnect it (see illustration).5Disconnect the wiper motor earth lead.
6Unscrew the mounting bolts, and remove
the wiper motor from inside the tailgate (see
illustrations).
7Unbolt and remove the mounting plate. If
necessary, remove the mounting rubbers for
renewal (see illustrations).
Refitting
8Refitting is a reversal of the removal
procedure. Make sure that the wiper motor is
in its “parked” position before fitting the wiper
arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Using a small screwdriver, prise the trip
computer module out of the facia. To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the trip computer module, and withdraw the
unit.
4If necessary, the bulb can be removed by
twisting it anti-clockwise.
Refitting
5Refitting is a reversal of the removal
procedure.1Some models are fitted with an auxiliary
warning system, which monitors brake lights,
sidelights, dipped beam and tail lights,
external temperature, and door/tailgate/
bootlid opening. An engine oil level warning
light on the instrument panel is also part of the
system.
2The auxiliary warning system module and
graphic warning display are combined into
one unit.
Service interval reminder
3The system also includes a service interval
reminder warning light, which is illuminated if
19 Auxiliary warning system -
general information and
component renewal
18 Trip computer module-
removal and refitting
17 Tailgate wiper motor
assembly - removal and refitting
Body electrical system 12•17
12
17.6B . . . and remove the tailgate wiper
motor assembly (Hatchback shown -
Estate similar)17.7A Tailgate wiper motor assembly and
mounting plate17.7B A mounting rubber removed from
the mounting plate
17.6A Unscrew the mounting bolts . . .
16.9 Removing the wiper motor and
linkage16.10 Wiper motor arm and mounting
plate located on the motor17.4 Disconnecting the tailgate wiper
motor multi-plug
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