12• 1
Chapter 12 B od y elec elec tr triic a l s ys tems Contents Air bag (dri driver ver’s ’s s ide) - removal removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . . 28 Air ba g (pa (pa ss enge r’s side) - remova remova l a nd refitti refitting ng . . . . . . . . . . . . . . . 29 Air bag clock spri spring - removal removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . . . 31 Air bag control module - removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . 30 Anti nti-th -theft eft systems - general infor information mation . . . . . . . . . . . . . . . . . . . . . . 27 Ba tter ttery, y, bulbs bulbs a nd fuses . . . . . . . . . . . . . . . . . . . .See “Weekly checks” Bulbs (exter (exteriior lilights) - renewa renewa l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bulbs (i (inter nteriior lilights) - renewa renewa l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cigarette lilighter - removal and refitti refitting ng . . . . . . . . . . . . . . . . . . . . . . 12 Clock - removal and refi refitti tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electri El ectricc w indow regul regulato ato r motor - removal and refitti refitting ng . . . . . . . . . . 20 Electri El ectrica ca l fault fault-f -fiindin nding g - general infor information mation . . . . . . . . . . . . . . . . . . . 2 Exteri Ext erior or lilight units units - removal removal and refitti refitting ng . . . . . . . . . . . . . . . . . . . . . 7 Fuses Fu ses a nd rel relays ays - general general inf inform ormati ation on . . . . . . . . . . . . . . . . . . . . . . . 3 General inf nform ormati ation on and precautions precautions . . . . . . . . . . . . . . . . . . . . . . . . 1 Headlight and auxiliary light beam alignment - checking and adjustment adju stment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Horn Hor n - removal and refitti refitting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instru nstrument ment panel - removal and refitti refitting ng . . . . . . . . . . . . . . . . . . . . . . 9 Instru nstrument ment panel components - removal removal and refitti refitting ng . . . . . . . . . . . 10 “Lights-on” “Li ghts-on” w arni arning ng module - removal removal and refitti refitting ng . . . . . . . . . . . . . 26 Rad io a eri erial al - removal removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rad io/ca ssette player - removal removal and refitti refitting ng . . . . . . . . . . . . . . . . . . 22 Sc reen was her fl flui uid d level check . . . . . . . . . . . . . .S ee “Weekly checks” Spea ker ba lanc e co ntr ntrol ol joystick joystick - removal and ref refiitti tting ng . . . . . . . . . 24 Spea ker kerss - removal removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Speed ometer cab le - removal removal and refitti refitting ng . . . . . . . . . . . . . . . . . . . . 11 Switches - removal and refi refitti tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tail ailga ga te remote rel releas eas e motor - removal removal and ref refiitti tting ng . . . . . . . . . . . 21 Tail ailga ga te wiper motor assemb ly - removal removal and ref refiitti tting ng . . . . . . . . . . . 18 Windscreen wiper motor and link linkag ag e - removal and refitti refitting ng . . . . . . 16 Windscreen wiper pivot pivot sha ft - removal removal and ref refiitti tting ng . . . . . . . . . . . . 17 Win inds ds creen/ creen/ta ta ilgate w as her sys tem co mponents - removal and refiitti ref tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Wiper arms - removal removal and ref refiitti tting ng . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wiper blad blad e check . . . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Degrees Degr ees of diff diffic icult ulty y Easy, sui suitab tab le for novice with little experience
1
Fairly easy, suitable for beginner with some som e experience experience
Specifications
2
Fairlydifficult, suitab le for compe tent suitab DIY mec mecha hani nicc
3
Difficult, suitable for experienced DIY mechanic
4
Verydiffic difficult, ult, suitable for expert DIY or professional
5
1 2• 2• 2 B o d y e le le c t ri ric a l s y s t e ms ms Additional fuses behind main fuse board: No
Rating (amps)
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Fuses - 1992 models onward Main fuse board: Fuses Fu ses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional fuses behind main fuse board: No Rating (amps) 2 3* 3* 2 3* 3** 24 * 2 4* 4** 25 26 27 2 8* 8* 28* 28 ** 29
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U nu nu se se d R e a r f o g lilig h ts ts U nu nu se se d R e a r fo g li lig h ts ts Ta il ilg a t e re re m o te te re re le le a s e , a n t ii-t he he ft ft w a rn rn in in g s y s te te m He a t ed ed w in in ds ds c re re e n He a t ed ed w in in ds ds c re re e n F ul ull-le n g th th s un un ro ro o f Automati utomaticc transmi transmission ssion starter inhi nhibi bitor tor Air b a g
* Pre-1994 Pre- 1994 mod model elss ** 1994 models onward
Relays (pre-1992 models) elayy locations and circuits circui ts control c ontrolled led are are liable liable to change from fr om year year to year. C onsult a Ford deal dealer, er, for spec specific ific informat information. ion. Note: R ela No Circuit(s) controlled I II III IV V VI
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He a te te d re re a r w in in d o w Win d sc sc re re e n w ip ip er er d e la la y C F i (f ue ue l in je je c t io io n ) d e la la y re re la la y No t us us e d on on UK UK m o de de ls ls Ig ni n it io io n s w itit ch ch Autom utomati aticc transmi transmission ssion starter inhi nhibi bitor tor/ /el electr ectriic fuel fuel pum pump p (bri (bridge dge fitted to carburettor engines without automatic transmission) He a d li lig h t m a in in b ea ea m D im im -d -d ip ip li lig h t in in g No t us us e d on on UK UK m o de de ls ls No t u s e d o n U K m od od e ls ls He a te te d w in in ds ds c re re en en
1 2• 2• 2 B o d y e le le c t ri ric a l s y s t e ms ms Additional fuses behind main fuse board: No
Rating (amps)
23 2 4/ 4/2 5 26 2 7/ 7/2 8
- . 10 15 30
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U nu nu s e d R e a r f o g lilig h ts ts Ta il ilg a t e re re mo mo t e re le le a s e He a t e d w in in d s c re re e n
Fuses - 1992 models onward Main fuse board: Fuses Fu ses 1 to 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional fuses behind main fuse board: No Rating (amps) 2 3* 3* 2 3* 3** 24 * 2 4* 4** 25 26 27 2 8* 8* 28* 28 ** 29
- . . 10 - . . 10 15 30 30 20 30 10
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Unchanged from from pre-1 pre-199 992 2 models models
Circuit(s) protected
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U nu nu se se d R e a r f o g lilig h ts ts U nu nu se se d R e a r fo g li lig h ts ts Ta il ilg a t e re re m o te te re re le le a s e , a n t ii-t he he ft ft w a rn rn in in g s y s te te m He a t ed ed w in in ds ds c re re e n He a t ed ed w in in ds ds c re re e n F ul ull-le n g th th s un un ro ro o f Automati utomaticc transmi transmission ssion starter inhi nhibi bitor tor Air b a g
* Pre-1994 Pre- 1994 mod model elss ** 1994 models onward
Relays (pre-1992 models) elayy locations and circuits circui ts control c ontrolled led are are liable liable to change from fr om year year to year. C onsult a Ford deal dealer, er, for spec specific ific informat information. ion. Note: R ela No Circuit(s) controlled I II III IV V VI
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He a te te d re re a r w in in d o w Win d sc sc re re e n w ip ip er er d e la la y C F i (f ue ue l in je je c t io io n ) d e la la y re re la la y No t us us e d on on UK UK m o de de ls ls Ig ni n it io io n s w itit ch ch Autom utomati aticc transmi transmission ssion starter inhi nhibi bitor tor/ /el electr ectriic fuel fuel pum pump p (bri (bridge dge fitted to carburettor engines without automatic transmission) He a d li lig h t m a in in b ea ea m D im im -d -d ip ip li lig h t in in g No t us us e d on on UK UK m o de de ls ls No t u s e d o n U K m od od e ls ls He a te te d w in in ds ds c re re en en
Bo dy el electri ectrica ca l sys tems 12 12•• 3 Bulbs
Wattage
Headlight (halogen) Headlight (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sideliight (fr Sidel (front) ont) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dirrecti Di ection on indi indicators cators (main (main)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side dire directi ction on indi indicator cator repeater repeaterss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxi uxilliary drivi driving ng a nd foglights foglights (S (S a nd XR2i XR2i)) . . . . . . . . . . . . . . . . . . . . . . Stop/tail Stop/ tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fogli foglight ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reversi Rever sing ng li light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number pl plate ate li light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inter nteriior lilight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lu g g a g e c o m p a rt rt me me n t lig h t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instr nstrumen umentt warning warning li lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pa nel illumi uminati nation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigarette Ci garette lilighter illumi uminati nation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automati utomaticc transmission transmission selector selector ilillumi uminati nation on . . . . . . . . . . . . . . . . . . . . .
H4, 60/55 H4, 5 21 5 H3,, 55 H3 21/5 21 21 10 10 5 1.3 or 2.6 2.6 1.3 or 2.6 2.6 1.4 2
Lubricants Greas e for windsc windsc reen wiper wiper lilinkage a nd pivots pivots . . . . . . . . . . . . . . . . . .
To Ford specifi specifica ti tion on SAM-1 SAM-1C-91 C-9111-A A
Torque wrench settings
Nm
Wip e r m o t o r t o b ra c ke t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wip e r m o t o r b ra c ke t t o b u lkh e a d /t a ilg a t e . . . . . . . . . . . . . . . . . . . . . . . Win d s c re e n w ip e r c ra n k t o d riv in g s h a ft n u t . . . . . . . . . . . . . . . . . . . . . Win d s c re e n /t a ilg a t e w ip e r a rm re t a in in g n u t . . . . . . . . . . . . . . . . . . . . . Win d s c re e n w ip e r p iv o t s h a ft n ut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Win d s c re e n /t a ilg a t e w a s h e r re s e rv o ir s e c urin g b o lt s . . . . . . . . . . . . . . . He a d lig h t re t a in in g b o lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ta il lig h t s e c u rin g n u t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Au x ilia ry lig h t re t a in in g n u t (S mo mo d e ls ) . . . . . . . . . . . . . . . . . . . . . . . . . . Ho rn b ra c ke t re t a in in g b o lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S t a rt e r in h ib it o r s w it c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 to 9 6 to 8 22 t o 24 17 t o 18 9 t o 12 2. 5 t o 3. 5 5. 4 t o 7. 0 1. 5 t o 2. 5 6. 8 t o 9. 2 24 t o 33 9 t o 14
1 Gener General al in infor forma mati tion on an and d precautions
module cover in the centre of the steering wheel. A “clock spring” ensures that a good
lbf ft 6 to 7 4 to 6 16 t o 18 12 t o 13 7 to 9 2 to 3 4 to 5 1 to 2 5 to 7 18 t o 24 7 t o 10
electrical short-circ uits and/or electrical and/or fires. If a radio/cassette player player wi th anti-theft ity code is fitt fitted, ed, refer ref er to the
1 2• 4 B o d y e le c t ric a l s y s t e ms wiring diagrams are included at the end of this manual. 2 Before 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 conce rned. The po ssible sources of a fault ca n be na rrowed dow n 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-spo t. 4 The b a sic to ols req uired for electrica l faultfinding 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 in c o r p o ra t e d , w h ic h c a n b e u s e d t o b y p a s s suspect wires or electrical components. Before attempting to locate a problem with test instruments, use the wiring diagram to determine where to make the c onnections.
Warning: Under no circ umstances may live measuring instruments such as ohmmeters, voltmeters or a bulb
current flowing in the circuit to “escape” along an alternative route, usually to earth. Shortcircuit faults are normally caused by a brea kdow n in wiring insula tion, w hich a llows a feed wire to touch either another wire, or an earthed component such as the bodyshell. A short-circuit fault will normally cause the releva nt circuit fuse to blow.
Finding an open-circuit 9 To c heck 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 goo d ea rth. 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 connecto r nearest the c ircuit sw itch on the co mponent 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 betwe en that po int and the previous tes t point with voltage. Most problems can be traced to a broken, co rroded or loos e co nnection.
Finding a short-circuit 15 To
c hec k
for
a
s hort-circuit,
first
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 o r the rad iato r cooling fa n 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, e tc. 21 To c heck whether a co mponent 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 co nnection b eing 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, u s e s e r ra t e d w a s h e r s b e t w e e n t h e t e r m in a l and the bodyshell, to ensure a clean and sec ure c onnection. When the c onnection is remade, prevent the onset of corrosion in the future by applying a coat of petroleum jelly or silicone-bas ed g rease, o r by spraying on (at
Bo dy electrica l sys tems 12• 5
3.1a Method of fuse/relay board retention
A Retaining screws B Retaining lugs
C S upport
the inside fac e of the cover to remove a nd fit the fuses (see illustrations). 2 To remove a fuse, use the tw eezers provided to pull it out of the holder. Slide the fuse sidew ays from the twee zers. The wire within the fuse is clearly visible, and it will be broken if the fuse is b low n. 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 s tam ped o n top of the fuse. 4 With the exception of the indicator flasher relay, the remainder of the relays are fitted to the reverse side o f the ma in fuse/relay boa rd. Acce ss is a s d escribed in paragraph 1. 5 The various relays ca n be removed from their respec tive locations o n the fuse b oa rd by ca refully pulling them from the so ckets. 6 The d irec tion indica tor flashe r relay is attached to the multi-function switch unit on the steering column. Access to the relay is made by undoin nd
3.1b Withdrawing the fuse/relay board downwards into the driver’s footwell
3 Remove the lower steering column shroud by undoing its four retaining screws, then deta ch the c hoke w arning light sw itch/pull control assembly from the lower shroud by unscrewing its retaining collar (ba yonet-type fixing), using a suitable tool to locate in the collar recess es. 4 Remove the two s crews s ecuring 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 Disconnec t the ignition sw itch wiring multiplug 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 ap plica ble, undo the s ingle sc rew and withdraw the P a ssive Anti-Theft Sys tem (P ATS ) tra ns c eiver from the ign ition sw itch/st eering loc k ba rrel.
3.1c Component layout on the fuse/relay board. See S peci fic ations for relay identification
with the switch shaft as it is pushed into position. Check the switch for satisfactory operation on completion.
S tee ring column multi -func ti on s wi tc h 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 sc rew is loca ted directly forward of the hazard warning light switch. Remove the switch ass embly. 11 Refitting is a reversal of the removal
1 2• 6 B o d y e le c t ric a l s y s t e ms
4.20a Prise the centre console switch up from its location . . .
4.20b . . . then disconnect its multiplug and remove the switch
4.23 Heater fan motor control switch removal
windows (early models) and the tailgate remote releas e me chanism, w here fitted. 19 Disconnect the battery negative (earth) lead (refer to C ha pter 5A, S ect ion 1). 20 To remo ve a sw itch, ca refully prise it from its location using a thin flat-bladed screwdriver, then disconnect the multi-plug (see illustrations). 21 To refit, conn ec t the multi-plug then pus h home to sec ure.
28 Insert the switch into its retainer, press it
piece of string to it, so that it can be retrieved if it drops do wn into the do or pillar. 37 Disconnect the wiring from the switch. 38 Refitting is a reversa l of remo val.
Heater fan motor control swi tch 22 Disconnect the battery negative (earth) lead (refer to C ha pter 5A, S ect ion 1). 23 Pull the heater fan motor control knob off, then move the air distribution and temperature controls fully to the right. Unclip and remove the heater slide fac ia to wa rds the left-hand side of the vehicle, removing the s l id e c o n t r o l k no b s o n ly a s n e c e s s a r y, a n d disconnecting its bulbholder (bayonet type) as it is w ithdraw n (see illustration). 24 Squeeze the two release tabs together on the heater fan motor control switch, and
lightly against the brake pedal until all free play is just taken up, then turn the switch c l o c kw i s e t o s e c u r e . R e c o n n e c t t h e s w i t c h wiring c onnector a nd the b attery.
Handbrake warning lig ht s wi tc h 29 P u s h t h e c a r p e t m o u n d i n g d o w n a s necessary to gain access to the switch, loca ted on the handb rake lever. 30 Remove the cover, then disconnect the warning light switch wiring multi-plug (see illustration). Undo the two screws securing the switch to the handbrake lever assembly and remove the sw itch. 31 Refit by reversing the removal procedure.
Low brak e fluid level warni ng light switch 32 This is incorpo rate d into the b rake fluid reservoir cap, and senses fluid level in the reservoir. It cannot be renewed separately from the ca p.
Reversing lig ht switch 39 Refer to Chapter 7A, Section 6.
S tar ter inhibi tor s wi tc h (automatic transmis si on) 40 Disconnect the battery negative (earth) lea d (refer to C hap ter 5A, S ection 1). 41 The s tarter inhibitor sw itch is loc a ted on the transmission housing, and prevents the engine from being started with the selector lever in any position except “P” or “N”. Access to the switch is gained after raising and supporting the vehicle at the front end on a x l e s t a n d s ( s e e “Jacking and vehicle support”). 42 Detach the switch multi-plug, then unscrew and remove the switch from the transmission, together with its O-ring. As the sw itch is removed , ca tch a ny fluid s pilla ge in a
Bo dy electrica l sys tems 12• 7 50 Undo the two screws s ecuring the contac t switch and withdraw it from its tailgate location. 51 Unclip and disconnect the switch multiplug, and disconnect the earth wiring. Remove the sw itch. 52 Refit in the reverse order of removal. Make sure that the pins a nd their conta cts are clean. On c ompletion, c heck the operation of the rear wipers, courtesy light, heated rear window a nd the tailga te relea se/central locking system.
E lectric window switches (199 2 models onward)
5.2a Remove the protective cap . . .
5.2b . . . then unlock the headlight bulb retaining spring and withdraw the bulb
3 Refitting is a reversal of the removal
the earth lead, then release their grommet from its panel location. 13 From outside the vehicle, twist the light as sembly to relea se it, then withdraw it a nd its leads (see illustration). 14 Refitting is a reversal of the removal procedure, ensuring that the grommet is seated correctly in its panel location.
53 On later models the electric window switches are located in the upper surfaces of the door stowage pockets. Removal and refitting is the same as for the earlier centre console mounted switches described previously in this S ection.
procedure.
Front sidelight 4 The bulbholder is loca ted o n the s ide of the
5 Bulbs (exterior lights) renewal
1
Note: Ensure that all exterior lig hts are
switched off before disc onnecting the wiring connectors to any exterior lig ht bulbs. Note that if a bulb fails, and has just been in use, it will still be extremely hot, particularly in the case of a headlight bulb.
Headlight 1 From within the engine compartment, disco nnect the m ulti-plug from the ba ck of the headlight. 2 Remove the rubber bulb protective cap,
headlight unit, and is removed by twisting anti-clockwise a nd withdraw ing from within the engine compa rtment. 5 Withdraw the push-fit bulb from its holder. 6 Refitting is a reversal of the removal procedure.
Fr ont direc tion indicator 7 Remove the direction indicator light unit by relea sing the retaining spring from its b ody location, then pulling the light assembly forwards. Disconnect its multi-plug as it is withdrawn. 8 Turn the bulbho lder anti-clockwise a nd remove it (see illustration). The b ulb is a ba yonet type fitting in its ho lder. 9 Refitting is a reversal of the removal
Aux iliary li g hts S models 15 Undo the screw at the base of the light, then withdraw the lens a nd reflector a ssemb ly from the light ho using. 16 Disconnect the wiring then release the bulb retainer and remove the bulb. 17 Refitting is a reversal of the removal procedure.
XR2i models 18 Remove the auxiliary light assembly from its b umper loca tion, a s desc ribed in S ection 7.
1 2• 8 B o d y e le c t ric a l s y s t e ms
5.21a Disconnect the ear light cluster multi-plug from the bulbholder . . .
5.21b . . . then having pressed its retaining lugs, withdraw the bulbholder for access to the bulbs
5.24a On Courier models, unscrew the two black plastic nuts securing the rear light cluster assembly . . .
6 Bulbs (interior lights) renewal
2
Ins trument panel illumination and warning lig hts 1 Refer to Section 10.
Automati c trans mi s s ion s elector illumination 2 Using a thin flat-bladed screwdriver, prise 5.24b . . . then withdraw the assembly to the outside of the vehicle the bulbholder together and remove it (see illustrations). 22 All bulbs a re of ba yonet type fitting. 23 Refitting is a reversal of the removal procedure.
R ear lig ht cluster (Courier
5.29 Release the number plate light securing tab (arrowed) and separate the bulbholder and light cover
Number plate lig hts 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
up the selector cover and remove it. 3 P ull the bulb a ss embly to releas e it from the selecto r lever, then remo ve its c over. The b ulb is a ba yonet fit in its ho lder (see illustrations). 4 Refitting is a reversal of the removal procedure.
Hazard warning switch 5 The ha za rd wa rning light s witch, a n integra l part of the steering column multi-function
Bo dy electrica l sys tems 12• 9
6.13 Heater fan illumination arrangement
6.16a Releasing the interior (courtesy) light from its location
that the bulb and bulbholder cannot be separated - they are replaced as an assembly. 9 Refitting is a reversal of the removal procedure.
remova l, then insert the s witch end of the light to the aperture, pivot the light upwa rds a nd push home to se cure.
C ig arette lig hter illumination
Luggage compartment (courtesy) lig ht
10 Remove the cigarette lighter, as desc ribed
18 Carefully prise the luggage compartment
in S ection 12. 11 P ull the bulbholder from its loc at ion in the illuminate d surround, then pull the bulb out of the b ulbho lder. 12 Refitting is a reversal of the removal procedure.
(courtesy) light assembly out of its location, using a thin fla t-blad ed sc rewdriver. Twist the bulbholder anti-clockwise to remove. 19 The b ulb is remove d b y pulling it from its bulbholder. 20 Refitting is a reversal of the removal procedure.
Heater faci a illumination 13 Pull the heater fan motor control knob off, then move the air distribution and temperature controls fully to the right. Unclip and remove the heater slide fac ia towa rds the left-hand side of the vehicle, removing the slide control knobs only as necessary, and disconnecting its bulbholder (bayonet type) as it is withdraw n (see illustration). 14 The b ulb is remove d b y pulling it from its
7 Exterior light units removal and refitting
2
6.16b Interior (courtesy) light pivoted for access to the bulb
7.2 Disconnecting the multi-plug from the back of the headlight and out of its location (see illustration). 5 Refitting is a reversal of the removal forwards
1 Disconnect the battery negative (earth) lead
procedure, ensuring that the lower headlight mounting guide is inserted correctly, and that the retaining spring engages fully (see
(refer to Chapter 5A, Section 1), before
illustration)
1 2• 10 B o d y e le c t ric a l s y s t e ms 22 Refitting is a reversal of the removal procedure, tightening the retaining nut to the specified torque. On completion, check the auxiliary light beam alignment as described in Sec tion 8.
XR2i models 23 Disconnect the battery negative (earth)
7.7b . . . then pull the light unit out to enable the multi-plug (arrowed) to be disconnected
7.14 Press the retaining lugs on the rear light cluster bulbholder together (broken arrows) to release the bulbholder
8 Refitting is a reversal of the removal
15 Unscrew the four nuts securing the light
procedure.
unit, then remove the unit and its seal. 16 Refitting is a reversal of the removal proc ed ure. Tighten the light unit sec uring nuts to their specified torque.
Fr ont directi on indicator side repeater 9 Remove the appropriate front wheel arch liner as described in Chapter 11. 10 Remove the appropriate sill scuff plate as desc ribed in Cha pter 11, a nd releas e the clip securing the insulation to the panel forward of the lower A-pillar. 11 Disco nnect the supply lead connecto r and the earth lead, then release their grommet from its panel location. 12 From outside the vehicle, twist the light as sembly to releas e it, then withdraw it a nd its leads. 13 Refitting is a reversal of the removal procedure, ensuring that the grommet is seated correctly in its panel location.
R ear light cluster 14 Disconnect
the multi-plug from the bulbholder, then press the retaining lugs on
Number plate light 17 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. 18 Detach the connections on the underside of the light assembly. 19 Refitting is a reversal of the removal procedure.
A uxiliary lig hts S models
lea d (refer to C hap ter 5A, S ection 1). 24 Undo the four Torx retaining sc rews sec uring the relevant d ual light as sem bly to its bumper location. Note that the retaining and adjusting screws are captive within the light assembly - they cannot be removed from the assembly (see illustration). 25 Withdraw the light assembly from its loca tion, then remove the ca ps protecting the bulbs and disconnect the wiring. 26 If required, the lights may be removed individually from their housing at this stage. Each light is secured to its housing unit by a combination of two types of clips - foglight retention differs from driving light retention. 27 The a djusting/reta ining c lips a re remove d by undoing the adjustment screws on the front o f the ho using unit, then turning the c lips using pliers or similar tool, before withdraw ing. To remo ve a retaining-only clip, lift the lug on the side of the clip using a screwdriver, then turn the clip using pliers or simila r tool, before w ithdraw ing. 28 Refitting is a reversal of the removal procedure. On completion, check the auxiliary light be am alignment a s d esc ribed in Sec tion 8.
8 Headlight and auxiliary light beam alignment - checking and ad justment
20 Disconnect the battery negative (earth) lead (refer to Cha pter 5A, S ect ion 1). 21 Disconnect the light wiring multi-plug then
1A
2
ad justment of the hea dlight a nd
Bo dy electrica l sys tems 12• 11
8.2 Exploded view of the headlight unit
A B C D E F G
S idelig ht bulb holder Sidelight bulb Headlight bulb retainer Headlight bulb Bulb protective cap Horizontal adjustment screw Vertical adjustment screw
work should therefore be carried out by a Ford dealer or service station with the necessary facilities. 2 Temporary ad justment ca n be mad e when the headlight has been removed and refitted, or to compensate for normal adjustment whene ver a hea vy load is being ca rried. Turn the adjustment screws at the rear of the headlight unit to make the adjustment (see illustration). 3 Before making any adjustments to the headlight settings, it is important that the tyre pressures are correct, and that the vehicle is sta nding o n level ground. B ounce the front of the vehicle a few times to settle the suspension. Ideally, so mebod y of no rmal size should sit in the driver’s seat during the adjustment, and the vehicle should have a full
9.4a Instrument cluster securing screws (arrowed) a djustment only of the foglights . Adjustment is ma de via Torx-hea d ca ptive sc rews o n the front of the housings (see illustration 7.24). 6 Whenever temporary adjustments are made, the settings must be reset as soon as possible once the vehicle is in normal use.
9.4b Disconnect the speedometer cable from the rear of the instrument cluster . . .
10 Instrument panel components removal and refitting
1
Removal 1 Remove the instrument panel as desc ribed
9 Instrument panel removal and refitting
2
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 2 Disconnect the speedometer cable at the transmission casing (see Section 11). 3 Remove the two screws securing the instrument panel bezel from its underside. Remove the b ezel. 4 Remove the four screws securing the instrument panel to its location, then carefully
in Section 9.
Panel illumination and warning light bulbs 2 All bulbho lders a re a ba yonet fit, req uiring a “twist and withdraw” removal technique (see illustration). Bulbs cannot be removed from their holders -they are renewed complete.
Printed circuit 3 Insert a thin flat-bladed sc rewdriver into the multi-plug retainer and carefully unclip it, having noted its orientation (see illustration). 4 Remove all panel illumination and warning light bulbholders. 5 Using a suitable too l (a trim c lip remova l
1 2• 12 B o d y e le c t ric a l s y s t e ms
10.7 Rear view of instrument cluster
A B C D E
R etaining tag s Multi-plug retainer S peedometer cable connection S peedometer g aug e retaining sc rews Tachometer terminals (obscured by protective pad) F Tachometer gauge retaining screws G Fuel and temperature gauge ass embly terminals H Fuel and temperature gauge ass embly retaining s crew retaining tags, taking care to avoid damaging or losing the warning light graphic strips (see illustration). 8 Remo ve its two Torx-hea d reta ining screws, then detach and withdraw the speed ometer from the front of the a sse mbly.
11.2 Detaching the speedometer cable at the transmission casing 4 Note the cable routing for use when refitting. P ull the spee domete r ca ble through into the engine compartment, and remove it from the car.
out the procedure given in paragraphs 6 and 7. 10 Carefully prise the printed circuit from the tachometer terminals, using a similar method to that described in paragraph 5, releasing it from its retainers a s nec essa ry. 11 Remo ve its two Torx-hea d reta
14 Horn removal and refitting
1
Refitting 5 Refitting is the reversal of removal. Ensure
Removal
that the cable is routed as noted before removal, secured with the relevant clips and cable-ties, and that the grommet is properly located in the bulkhead.
1 The horn is mounte d forw a rd on the left-
12 Cigarette lighter removal and refitting
1
Tachometer 9 Carry
13.2 Carefully prise the clock out of the facia
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 2 Remove the cigarette lighter element (hea ted s ection). 3 Carefully prise the element barrel out from
hand side of the engine compartment, near the ba ttery. 2 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 3 Remove the wiring loom connection from the horn(s). 4 Both single and dual horns are mounted to a bracket which is secured to the bodywork by a single bolt. Remove the bolt and withdraw the horn(s) and bracket from the vehicle. The horn(s) ma y be sep a rated from the bracket, as required, by removing the reta ining nut(s).
Refitting
Bo dy electrica l sys tems 12• 13
16.6a Remove all retaining screws from the right-hand half of the bulkhead panel (upper centre screw shown) . . .
16 Windscreen wiper motor and linkage - removal and refitting
2
Removal Wiper motor 1 Operate the wiper motor, then switch it off so that it returns to its rest position. 2 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 3 Dependent on model, disconnect and remove the air cleaner components as necessary to allow access to remove the bulkhead panel. 4 Remove the co oling sys tem expansion tank as desc ribed in Chapter 3. 5 Release the wiring loom, any connectors, ca ble-ties and hoses from the right-hand ha lf of the bulkhead panel, then remove its rubber seal.
16.6b . . . then disengage the right-hand half of the panel from under its single retaining nut (left-hand shown)
16.7 Unscrew the nut from the wiper motor driving shaft
a n d w i t h d r a w t h e m o t o r a s s e m b l y (see illustrations). Remove the motor cover, then disconnect the multi-plug and remove the moto r from the vehicle.
Linkage 9 Pull the rubber seal off the bulkhead panel. 10 Bring the windscreen wiper linkage to an ac ces sible po sition, using the ignition s witch as a means of stopping the wiper motor returning to the pa rked pos ition. 11 Disconnect the battery negative (earth) lea d (refer to Cha pter 5A, S ection 1). 12 Prise the linkages off their ball pivots as required, using a suitably-sized open-ended sp a nner. The cra nk has a dua l (vertically stacked) ball pivot with a bellows separating the two linkag es (see illustrations). 13 If the running faces of the ball pivots are damaged, the pivot shaft(s) or crank must be renewed.
Refitting
16.8a With the crank removed from the driving shaft taper, undo the three wiper motor retaining bolts (arrowed) pos ition us ing a suitably-sized s oc ket. The bellows between the two linkages on the crank must also be greased using the specified lubricant. Refit the bulkhead panel rubber seal on completion.
1 2• 14 B o d y e le c t ric a l s y s t e ms
17.3 Windscreen wiper pivot shaft fixture
A B C D E
C ollar Pivot shaft securing nut Was her Outer rubber bush Inner rubber bush
2 Carry out the procedure detailed in Section 16, parag raphs 2 to 6. 3 Remove the collars from the pivot sha fts, unscrew the pivot shaft securing nuts and remove the was hers and o uter rubber bushes (see illustration). 4 Undo the two wiper motor brac ket securing bolts and remove the bracket assembly from the vehicle, disconnecting the multi-plug from the motor as the assembly is withdrawn (see illustration). 5 Remove the inner rubber bush from the pivot sha ft being renewed, and disconnect its linkage as described in paragraph 12 of the previous Section. 6 Remove the c irclip, w as hers, shims and Oring, keeping them in order for refitting, and withdraw the pivot shaft from the wiper motor bracket assembly.
Refitting
17.4 Removing the wiper motor bracket and linkage assembly (wiper motor removed) 4 Remove
the tailgate trim panel as described in Chapter 11. 5 Disconnect the wiper motor multi-plug and earth lead, then undo the three bolts securing the wiper motor bracket, and remove the assembly from the vehicle (see illustration). 6 The wiper motor ma y be s epa rated from its bracket by undoing the three mounting bolts sec uring it. Note wa sher/spa cer a nd rubber insulator fitment.
Refitting 7 Refitting is a reversal of the removal procedure, ensuring that the wiper motor shaft locates through its collar on the exterior pa nel surfa ce . Tighten a ll bo lts to their specified torque.
19 Windscreen/tailgate washer system components removal and refitting
1
18.5 Tailgate wiper motor
A Wiper motor bracket retaining bolts B Wiper motor and tailgate “contact fingers” multi- plug s C Earth connection front of the car and support it on axle stands (see “J acking and vehicle support”). 2 Withdraw the washer pump from the reservoir, collecting the fluid in a suitable container as the pump is removed. Note the sea l fitment (see illustration). 3 Having noted hose fitment to pump connectors, remove the multi-plug and hoses, then remove the pump from the vehicle. 4 Examine the pump seal. If it is perished or otherwise d ama ged, it should be replac ed.
Reservoir 5 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 6 Chock the rear wheels then jack up the front of the car and support it on axle stands (see “J acking and vehicle support”). Remove the left-hand front roadwheel. 7 Remove the wheelarch liner as described in
Bo dy electrica l sys tems 12• 15 23 Release
19.16 Routing of washer hoses in the engine compartment
A Windscreen washer hose B Tailgate washer hose C Tailg ate washer hose one-way valve
Windscreen washer jets and hoses 10 Disconnect the battery negative (earth) lea d (refer to C hap ter 5A, S ection 1). 11 With the bo nnet raised and supported on its stay, release the fasteners securing its insulation panel (where fitted). Remove the insulation pa nel. 12 Ca refully press in the reta ining lugs on the wa sher jets using a flat-bladed screwd river, then raise the washer jets from the exterior surfac e of the bonnet and s eparate them from their hos es 13 The windscreen w as her jet hose may have been fitted with a one-way (non-return) valve. If this is the case, the main hose run sections can be removed from either side of the valve as required. 14 Chock the rear wheels then jack up the front of the car and support it on axle stands (see “Jacking and vehicle support”)
the left-hand side of the headlining by removing the retaining clips/gra b hand les/co a t hooks, as a pplica ble. 24 In the engine compartment, disconnect the ta ilga te wa sher hos e from its valve. The forward hose run may be removed, if required, in a manner similar to that described in parag raphs 15 and 16 abo ve, releas ing it from its clips in the engine compartment. 25 R e m o v e t h e t a i l g a t e w a s h e r h o s e grommet, then withdraw the hose through the bulkhead into the pa sseng er compa rtment. 26 Releas e the ho se from its A-pillar and roof frame locations. Release the grommet (hose protector) from its ta ilga te a nd b ody loca tions, and withdraw the hose from the vehicle.
on the ignition and activate the motor, to engage and pull the motor fully into the regulator mecha nism. 5 Ensure that the multi-plug connection is loca ted o n top o f the motor (as if the window regulator is in position in the door), before securing the motor to the regulator mec hanism w ith its two Torx-hea d bo lts. 6 Switch off the ignition and disconnect the multi-plug. 7 Refit the window regulator to the vehicle, in accordance with Chapter 11.
21 Tailgate remote release motor - removal and refitting
Refitting 27 Refitting is a reversal of removal. Always renew the pump-to-reservoir seal washer, and ensure that all connections are securely made. When reconnecting the pump hoses, ensure that the hose marked with tape is connected to the correspondingly marked connection on the pump. 28 On completion, top-up the washer reservoir (“see Weekly checks”) a n d c h e c k that the operation of the washers is satisfactory. If necessary, adjust the windscreen washer jets by inserting a pin into the centre of the jet and directing the flow at the top pa rt of the windscreen.
20 Electric window regulator motor - removal and refitting
3
Removal 1 Remove the window regulator from the
2
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 2 Remove the tailgate inner trim panel as described in Chapter 11. 3 R e m o v e t h e t w o m o t o r s e c u r in g s c r e w s , then twist the operating rod retaining clip and withdraw the operating rod from it. 4 Disconnect the wiring and remove the motor assembly. 5 The moto r may be sepa rated from its bracket by removing tw o further screws .
Refitting 6 Refitting is a reversal of the removal procedure.
22 Radio/cassette player removal and refitting
3
1 2• 16 B o d y e le c t ric a l s y s t e ms
25 Radio aerial removal and refitting
2
Note: The roof-mounted aerial mast section should be removed prior to using an automatic carwash. This is achieved by unscrewing it from the aerial base.
Removal 1 Disconnect the battery negative (earth) lead 22.3 Radio/cassette player extractor tool
23.3 Remove the screws securing the speaker assembly to the front door
illustration). If possible, it is preferable to
the speaker from the door. Disconnect its multi-plug a s it is w ithdraw n (see illustration).
obtain purpose-made rods from an audio specialist, as these have cut-outs which snap firmly into the clips so that the radio can be pulled out. Pull the unit squarely from its aperture, or it may jam. sufficiently 4 With the rad io/ca ss ette withdrawn, disconnect the feed, earth, aerial and speaker leads . 5 Remove the tools from the unit by gently wigg ling and pulling.
6 Refitting is a reversal of removal. When the leads are reconnected to the rear of the unit, press it into position to the point where the retaining clips are felt to engage. Reactivate the unit in accordance with the code and the instructions given in the Ford Audio Ope rating Manua l supplied with the ve hicle.
removal and refitting
4 The rear spea kers a re suspended benea th the parcel shelf supports and are secured in position by locating tags and screws. 5 Remove the s ecuring s crews then lower the speaker, disengaging its locating tags from the pa rcel shelf support (see illustrations). Disconnec t its multi-plug a s it is w ithdraw n.
Refitting
Refitting
23 Speakers -
Rear speaker
3
6 Refitting is a reversal of the removal procedure.
24 Speaker balance control joystick - removal and refitting
1
(refer to Chapter 5A, Section 1). 2 Unscrew the aerial mast section, then remove the base section as follows. Insert a thin fla t-bla ded sc rewdriver into the slot in the interior (co urtesy) light as semb ly and ca refully lever the assembly out. 3 Through the resultant opening, the ae rial base securing screw is accessible. Remove the screw and detach the aerial base from the roof of the vehicle, having noted the aerial lea d fitment.
Refitting 4 Refitting is a reversal of the removal procedure, ensuring that the aerial base sits squarely on the roof. Insert the switch end of the light assembly to its aperture first, then pivot the light upwards and push home to secure.
26 “Lights-on” warning module - removal and refitting
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1). 2 Using a thin flat-bladed screwdriver, carefully
Removal
1
Bo dy electrica l sys tems 12• 17
27 Anti-theft systems ge neral information
Anti -the ft alarm s ys tem 1 This sys tem provides an a dde d form of vehicle security. When the system is activated, the alarm will sound if the vehicle is broken into through a ny one of the do ors, the bonnet, or tailga te. The a larm w ill also b e triggered if the ignition system is turned on or the radio/ca ss ette disco nnected whilst the system is activated. 2 This sys tem is a ctivated/de-ac tivate d whenever one of the front doors is locked/unlocked b y the key. The s yste m operates on all doors, the bonnet and tailgate whene ver ea ch d oo r is individua lly locked (or, in the ca se o f central locking, w hen the central locking is engaged). In addition, the ignition/sta rting s yst em is a lso immob ilised when the system is activated. 3 A further security feature included is that even though the battery may be disconnected whilst the system is activated, the alarm activation continues as soon as the battery is reconnected. Because of this feature, it is important to ensure that the system is deactivated before disconnecting the battery at any time, such as when working on the vehicle. 4 The system incorporates a diagnostic mod e to enable Ford technicians to quickly identify any faults in the system. In the event of a system malfunction, any testing or component removal and refitting should be entrusted to a Ford d ealer.
Pass ive Anti-Theft System
the cover facing away from your body. If in doubt concer ning any proposed work involving the air bag or its control circuitry, consult a Ford dealer or other qualified speci alist.
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1).
Warning: B efore proceeding , wait a minimum of 15 minutes, as a precaution ag ainst accidental firi ng of the air bag . This period ensures that any stored energy in the back-up capacitor is diss ipated. 2 Undo the screws, and remove the steering column lower shroud. 3 Undo the two external screws and the two internal screws and remove the steering column upper shroud. 4 Turn the stee ring w heel as ne ces sa ry so that one of the air bag module retaining bolts becomes accessible from the rear of the steering wheel. Undo the bolt, then turn the steering wheel again until the second bolt is ac ces sible. Undo this bolt also. 5 Withdraw the air bag module from the steering wheel far enough to access the wiring multi-plug. Some force may be needed to free the mod ule from the a dd itional steering wheel spoke retainers. 6 Disconnect the multi-plug from the rear of the module, and remove the module from the vehicle.
Warning: Position the air bag module in a s afe place, with the mechanism facing downwards as a precaution ag ainst accidental operation. Warning : Do not attempt to
Warning: B efore proceeding , wait a minimum of 15 minutes, as a precaution ag ainst accidental firi ng of the air bag . This period ensures that any stored energy in the back-up capacitor is diss ipated. 2 Remove the facia as described in Chapter 11. 3 Undo the air bag module retaining nuts a nd remove the unit from the facia.
Warning: Position the air bag module in a s afe place, w ith the mechanism facing downwards as a precaution ag ainst accidental operation. Warning : Do not attempt to open or repair the air bag unit, or apply any electrical cur rent to it. Do not use any air bag w hich is vis ibly damag ed or which has been tampered wi th.
Refitting 4 Refitting is a reversal of the removal procedure.
30 Air bag control module removal and refitting
4
Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5A, Section 1).
Warning: B efore proceeding , wait a minimum of 15 minutes, as a precaution ag ainst accidental firing of the air bag unit. This per iod ensures that any stored in the back-up capacitor is
1 2• 18 B o d y e le c t ric a l s y s t e ms wiring passes reassembly.
through,
as
an
aid
to
Refitting 3 Position the clock spring on the steering wheel, routing the wiring as noted on removal, and sec ure w ith the retaining s crews. 4 The clock spring must now be c entred a s follows. 5 Depress the locking pin, and rotate the clock spring outer rotor fully anti-clockwise until it is tight (see illustration). 6 Now turn the outer rotor approximately 3.75 turns clockwise, then release the locking pin. Ensure that the locking pin engages when it is released. 7 Check that the relative position of the direction indicator cancelling cam to the cable connector on the clock spring assembly is as shown (see illustration 31.5). 8 Refit the steering wheel as described in Cha pter 10.
31.5 Centring the air bag clock spring. Depress locking pin (A) and rotate outer rotor (B) anti-clockwise (“X” indicates relative position of the direction indicator cancelling cam to the cable connector - see text)
Wiring dia grams 12• 19
1 2 • 2 0 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1: Starting, charging, cooling fan, ABS, warning lamps and gauges
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1a: Ignition system – carburettor models
W i r i n g d i a g r a m s 1 2 • 2 1
1 2 • 2 2 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1b: Ignition system – fuel-injected models
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1c: Typical 1.1/1.3/1.4 CFi fuel injection
W i r i n g d i a g r a m s 1 2 • 2 3
1 2 • 2 4 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1d: 1.6 EFi fuel injection (including RS Turbo)
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 1e: DOHC 16-valve fuel injection
W i r i n g d i a g r a m s 1 2 • 2 5
1 2 • 2 6 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 2: Exterior lighting – side and headlamps
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 2a: Exterior lighting – stop, reversing, fog and direction indicator lamps
W i r i n g d i a g r a m s 1 2 • 2 7
1 2 • 2 8 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 2b: Interior lighting, lights-on warning buzzer, clock and cigar lighter
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 3: Ancillary circuits – horn (except XR2i/RS models), heater blower and heated front /rear screens
W i r i n g d i a g r a m s 1 2 • 2 9
1 2 • 3 0 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 3a: Ancillary circuits – horn (R2i and RS models) and wash/wipe
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 3b: Ancillary circuits – central locking, electric windows and tailgate release (up to 1992)
W i r i n g d i a g r a m s 1 2 • 3 1
1 2 • 3 2 W i r i n g d i a g r a m s
1 5 9 5 F o r d F i e s t a R e m a k e
Diagram 3c: Ancillary circuits – central locking, electric windows and tailgate release (1992-on)
