Relays FORD SIERRA 1993 2.G Body Electrical System Workshop Manual

Chapter 13
Body electrical system
Anti-theft alarm - location, removal and refitting . . . . . . . . . . . . . . . .51
Auxiliary warning system components - location, testing, removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Brake lamp switch - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Central door locking components - operation, removal and refitting .50
Cigarette lighter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Courtesy lamp and luggage compartment lamp - renewal . . . . . . . .25
Courtesy lamp switch - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Direction indicator and hazard warning flasher switch assembly -
renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Direction indicator/hazard warning flasher relay - renewal . . . . . . . . .6
Electrical door mirror switch - removal and refitting . . . . . . . . . . . . .10
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . . .2
Electric sunroof components - removal and refitting . . . . . . . . . . . . .17
Electric window components - removal and refitting . . . . . . . . . . . . .49
Exterior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Facia panel switches - removal and refitting . . . . . . . . . . . . . . . . . . . .9
Front direction indicator lamp unit - removal and refitting . . . . . . . . .44
Front direction indicator side repeater lamp - removal and refitting . .45
Front foglamps - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .46
Fuses and relays - location and renewal . . . . . . . . . . . . . . . . . . . . . . .3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . .1
Handbrake “on” warning lamp switch - renewal . . . . . . . . . . . . . . . .14
Headlamps - alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Headlamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .41
Headlamp wiper motor - removal and refitting . . . . . . . . . . . . . . . . . .40
Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Horn switch assembly - removal and refitting . . . . . . . . . . . . . . . . . .11
Ignition switch and lock barrel - removal and refitting . . . . . . . . . . . . .4
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . .20Instrument panel components - removal and refitting . . . . . . . . . . . .21
Integral heated rear window/radio aerial amplifier - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Interior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Lighting and wash/wipe switch assembly - renewal. . . . . . . . . . . . . . .7
“Lights-on” warning module - renewal . . . . . . . . . . . . . . . . . . . . . . . .24
Loudspeakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .55
Luggage compartment lamp switch - removal and refitting . . . . . . .13
Map reading lamp - removal and refitting . . . . . . . . . . . . . . . . . . . . .26
Oil pressure warning lamp switch - renewal . . . . . . . . . . . . . . . . . . . .16
Radio aerial (exterior-mounted) - removal and refitting . . . . . . . . . . .53
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . .57
Radio/cassette player power amplifier - removal and refitting . . . . . .56
Rear lamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .43
Rear number plate lamp - removal and refitting . . . . . . . . . . . . . . . . .47
Rear window washer fluid reservoir - removal and refitting . . . . . . . .39
Rear window washer pump - removal and refitting . . . . . . . . . . . . . .38
Rear window wiper motor - removal and refitting . . . . . . . . . . . . . . .37
Reversing lamp switch - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Seat heating pad - removal and refitting . . . . . . . . . . . . . . . . . . . . . .52
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . .30
Trip computer components - removal and refitting . . . . . . . . . . . . . .22
Underbonnet lamp - removal, refitting and bulb renewal . . . . . . . . . .28
Washer nozzles - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .33
Windscreen/headlamp washer fluid reservoir - removal and refitting . .36
Windscreen/headlamp washer pump - removal and refitting . . . . . .35
Windscreen wiper motor and linkage - removal and refitting . . . . . . .34
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Wiper blades - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Wiring diagrams - general information . . . . . . . . . . . . . . . . . . . . . . . .58
13•1
Contents
13Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 volt, negative earth
BulbsFittingsWattage
Halogen headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H460/55
Auxiliary driving lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H355
Front foglamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H355
Side lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base5
Direction indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet21
Brake/tail lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet21/4
Reversing lamp(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet21
Rear foglamp(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet21
Rear number plate lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base5
Luggage compartment lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet10
Underbonnet lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet10
Courtesy lamp(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet10
Map reading lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base5
Vanity mirror illumination lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Festoon3
Glove compartment lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base3
Ashtray lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base1.2
Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base1.2 or 2.5
Instrument illumination lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base1.2 or 2.5
Heater control illumination lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base1
Automatic transmission gear selector lamp . . . . . . . . . . . . . . . . . . . . . .Bayonet1.2
Clock illumination lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bayonet1.4
Cigarette lighter lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass base1.2
Torque wrench settingsNmlbf ft
Trip computer fuel flow sensor unit fuel pipe unions . . . . . . . . . . . . . . .14 to 1710 to 13
General information
The electrical system is of the 12 volt.
negative earth type. Electricity is generated by
an alternator, belt-driven from the crankshaft
pulley. A lead-acid storage battery provides a
reserve of power for starting and when the
demands of the system temporarily exceed
the alternator output.
The battery negative terminal is connected
to “earth” - vehicle metal - and most electrical
system components are wired so that they
only receive a positive feed, the current
returning via vehicle metal. This means that
the component mounting forms part of the
circuit. Loose or corroded mountings can
therefore cause apparent electrical faults.
Many semiconductor devices are used in
the electrical system, both in the “black
boxes” which control vehicle functions and in
other components. Semiconductors are very
sensitive to excessive (or wrong polarity)
voltage, and to extremes of heat. Observe the
appropriate precautions to avoid damage.
Precautions
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 the
“Safety first!” Section at the
beginning of this manual, take note of the
following points when working on the system.
Always remove rings, watches, etc before
working on the electrical system. Even withthe battery disconnected, capacitive
discharge could occur if a component 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 or any
other 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. This also applies when connecting a
battery charger.
Never disconnect the battery terminals, or
alternator multi-plug connector, when the
engine is running.
The battery leads and alternator multi-plug
must be disconnected before carrying out any
electric welding on the car.
Never use an ohmmeter of the type
incorporating a hand cranked generator for
circuit or continuity testing.
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
anti-lock braking systems), particularly where an
electronic control unit (ECU) is involved.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 andconnectors 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 Chapter.
2Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a more complete
understanding of the components included in
the particular circuit concerned. The possible
sources of a fault can be narrowed down by
noting whether 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. 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 also
be used for certain tests), a self-powered test
light (sometimes known as a continuity tester),
an ohmmeter (to measure resistance), 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.
2Electrical fault-finding - general
information
1General information and
precautions
13•2Body electrical system
Specifications

5To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), an
integrity test can be performed on the wiring,
which involves moving 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, but will
not cause the relevant circuit fuse to blow.
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.
Note: A short-circuit that occurs in the wiring
between a circuit’s battery supply and its fuse
will not cause the fuse in that particular circuit
to blow. This part of the circuit is unprotected
- bear this in mind when fault-finding on the
vehicle’s electrical system.
Finding an open-circuit
9To check for an open-circuit, connect one
lead of a circuit tester or voltmeter to either
the negative battery terminal or a known good
earth.
10Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse.
11Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
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 battery 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, but the fuse still
blows with the load(s) connected, 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 and the car body - and
most 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 fault. 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, 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
back to bare metal both the bodyshell and the
wire terminal, or the component’s earth
connection mating surface. 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 terminaland 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.Location
1The main fuses and relays are located in a
box in the engine compartment on the right-
hand side of the bulkhead. The circuits
protected are identified by symbols on the
underside of the fusebox cover. On certain
models, additional relays and fuses are located
in various positions beneath the facia panels. If
uncertain of the location of an auxiliary relay or
fuse, it is suggested that a Ford dealer is
consulted, as the relay and fuse locations vary
substantially depending on model.
Renewal
2Always renew a fuse with one of identical
rating and never renew it more than once
without finding the source of the trouble
(usually a short circuit). Always switch off the
ignition before renewing a fuse or relay, and
when renewing the wiper motor fuse keep the
hands clear of the wiper linkage as it may
return to the parked position. Note that the
fuses are colour-coded as follows:
10ARed
15ABlue
20AYellow
25ANatural
10AGreen
3Access to the fuses and relays in the
fusebox is gained by removing the loose
cover and spring clip (if fitted), pulling the
plastic clip and removing the cover. All fuses
and relays are a push fit (see illustrations).
The fuse/relay plate can be released from the
fusebox for access to the wiring by carefully
levering the plastic lugs around the perimeter
of the plate.
4For details of direction indicator/hazard
warning flasher relay removal and refitting,
refer to the relevant Section of this Chapter.
3Fuses and relays - location and
renewal
Body electrical system 13•3
13
3.3b Fusebox cover removed to expose
fuses and relays (1.8 CVH model shown)3.3a Remove the loose cover for access to
the fusebox cover