zx-12.pdf

12•1

Chapter 12 Body electrical systems

Contents

Anti-theft alarm system - general information 24

Battery check and maintenance See Chapter 1

Battery - removal and refitting See Chapter 5

Bulbs (exterior lights) - renewal 5

Bulbs (interior lights) - renewal 6

Cigarette lighter - removal and refitting 13

Clock - removal and refitting 11

"Dim-dip" lighting system (UK models only) - general information .. 25

Door-open warning display - general information

Radio/cassette player - removal and refitting

Reversing light switch (models with manual

transmission) - removal and refitting See Chapter 7A

Selector lever position display switch (models with automatic

transmission) - removal, refitting and adjustment .. See Chapter 7B

Speedometer drive cable - removal and refitting

Starter inhibitor/reversing light switch (models with automatic

transmission) - removal and refitting See Chapter 7B

Stop-light switch - removal, refitting and adjustment . See Chapter 9

Switches - removal and refitting

Electrical fault finding - general information

Exterior light units - removal and refitting

Tailgate wiper motor - removal and refitting

Fuses and relays - general information

Windscreen/headlight washer system check

and adjustment

General information and precautions

See Chapter 1

Headlight beam alignment - general information

Windscreen/tailgate washer system components -

removal and refitting 20

Windscreen/tailgate wiper blade check and renewal . See Chapter 1

Windscreen wiper motor and linkage - removal and refitting

Horn - removal and refitting

Instrument panel components - removal and refitting

Instrument panel - removal and refitting

"Lights-on" warning buzzer - general information

Wiper arm - removal and refitting

Loudspeakers - removal and refitting

Wiring diagrams - explanatory notes

Radio aerial - removal and refitting

Degrees of difficulty

Easy, suitable for

novice with little

experience

Fairly easy, suitable

for beginner with

some experience

Fairly difficult, suitable

for competent DIY

mechanic

Difficult, suitable for

experienced DIY

mechanic

Very difficult,

suitable for expert DIY

or professional

Specifications

System type

12-volt, negative earth

Facia f usebox fuses

Fuse Rating (amps)

Circuit(s) protected

Heater blower motor, headlamp washers, electric mirrors, air

conditioning relay, headlamp washer timer and heated seats

Radio/cassette, instrument panel, stop-lights, front and rear

wash/wipe and "lights-on" buzzer

Heated rear window relay, electric window relay, indicators and

cooling fan relay(s)

Central locking and anti-theft alarm

Heated rear window and heated exterior mirror

Hazard warning lights

Reversing lights, facia panel lights and instrument panel warning

lights

Radio/cassette, interior lights, cigarette lighter, luggage

compartment light, clock and remote central locking receiver

Electric windows, sunroof, seat adjustment and map reading light

F10 20

Horn

F11 5

Rear foglight

F12 5

Right-hand front and rear sidelights, ashtray and cigarettelighter

illumination, "lights-on" buzzer and switch illumination

F13 5

Left-hand front and rear sidelights, number plate light

Junction box fuses (two-fuse arrangement)

Unused

Cooling fan relay

Cooling fan

12•2 Body electrical systems

Junction box fuses (four-fuse arrangement)

Front foglights

Heater blower motor and air conditioning controls

Supplementary cooling fan

Cooling fan

Note: Not all items fitted to all models

Bulbs

Fitting

Wattage

Headlights:

Dip/main beam bulb

60/55

Individual main beam (where fitted)

Front foglights

Front sidelights

Capless

Direction indicators

Bayonet

Direction indicator side repeaters

Capless

Interior lights

Capless

Luggage boot light

Capless

Heater control panel illumination

Capless

1.2

Instrument panel warning lights/illumination

Integral with holder

1.2

Clock illumination

Integral with holder

1.2

Stop/tail lights

Bayonet

21/5

Rear foglight

Bayonet

Reversing lights

Bayonet

1 General information and

precautions

particularly where an electronic control

module is used.

General

1 A typical electrical circuit consists of an

electrical component, any switches, relays,

motors, fuses, fusible links or circuit breakers

related to that component, and the wiring and

connectors which link the component to both

the battery and the chassis. To help to

pinpoint a problem in an electrical circuit,

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 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.

3 Electrical problems usually stem from

simple causes, such as loose or corroded

connections, a faulty earth connection, a

blown fuse, a melted fusible link, or a faulty

relay (refer to Section 3 for details of testing

relays). Visually inspect the condition of all

fuses, wires and connections in a problem

circuit before testing the components. Use

the wiring diagrams to determine which

terminal connections will need to be checked,

in order to pinpoint the trouble-spot.

4 The basic tools required for electrical fault-

finding include a circuit tester or voltmeter (a

12-volt bulb with a set of test leads can also

be used for certain tests); 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.

5 To find the source of an intermittent wiring

fault (usually due to a poor or dirty

connection, or damaged wiring insulation), a

"wiggle" test can be performed on the wiring.

This involves wiggling the wiring by hand, to

see if the fault occurs as the wiring is moved.

It should be possible to narrow down the

source of the fault to a particular section of

wiring. This method of testing can be used in

conjunction with any of the tests described in

the following sub-Sections.

6 Apart from problems due to poor

connections, two basic types of fault can

occur in an electrical circuit - open-circuit, or

short-circuit.

7 Open-circuit faults are caused by a break

somewhere in the circuit, which prevents

current from flowing. An open-circuit fault will

prevent a component from working, but will

not cause the relevant circuit fuse to blow.

8 Short-circuit faults are caused by a "short"

somewhere in the circuit, which allows the

current flowing in the circuit to "escape" along

an alternative route, usually to earth. Short-

circuit faults are normally caused by a

breakdown in wiring insulation, which allows a

feed wire to touch either another wire, or an

earthed component such as the bodyshell. A

short-circuit fault will normally cause the

relevant circuit fuse to blow.

Warning: Before carrying out any

work on the electrical system,

read through the precautions

given in "Safety first!" at the beginning of

this manual, and in Chapter 5.

The electrical system is of 12-volt negative

earth type. Power for the lights and all

electrical accessories is supplied by a

lead/acid type battery, which is charged by

the alternator.

This Chapter covers repair and service

procedures for the various electrical

components not associated with engine.

Information on the battery, alternator and

starter motor can be found in Chapter 5.

It should be noted that, prior to working on

any component in the electrical system, the

battery negative terminal should first be

disconnected, to prevent the possibility of

electrical short-circuits and/or fires.

Caution: If the radio/cassette

player fitted to the vehicle is one

with an anti-theft security code,

as the standard unit is, refer to the

information given in the preliminary

Sections of this manual before

disconnecting the battery.

2 Electrical fault finding -

general information

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),

Finding an open-circuit

9 To 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.

Body electrical systems 12•3

10 Connect the other lead to a connector in

the circuit being tested, preferably nearest to

the battery or fuse.

11 Switch on the circuit, bearing in mind that

some circuits are live only when the ignition

switch is moved to a particular position.

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 battery is problem-free.

13 Continue to check the remainder of the

circuit in the same fashion.

14 When a point is reached at which no

voltage is present, the problem must lie

between that point and the previous test point

with voltage. Most problems can be traced to

a broken, corroded or loose connection.

Finding a short-circuit

15 To check for a short-circuit, first

disconnect the load(s) from the circuit (loads

are the components which draw current from

a circuit, such as bulbs, motors, heating

elements, etc).

16 Remove the relevant fuse from the circuit,

and connect a circuit tester or voltmeter to the

fuse connections.

17 Switch on the circuit, bearing in mind that

some circuits are live only when the ignition

switch is moved to a particular position.

18 If voltage is present (indicated either by

the tester bulb lighting or a voltmeter reading,

as applicable), this means that there is a

short-circuit.

19 If no voltage is present, but the fuse still

blows with the load(s) connected, this

indicates an internal fault in the load(s).

Finding an earth fault

20 The battery negative terminal is

connected to "earth" - the metal of the

engine/transmission unit 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.

21 To 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.

22 If 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 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 terminal

and the bodyshell, to ensure a clean and

secure connection. When the connection is

remade, prevent the onset of corrosion in the

future by applying a coat of petroleum jelly or

silicone-based grease, or by spraying on (at

regular intervals) a proprietary ignition sealer

or a water-dispersant lubricant.

then remove the driver's side lower facia

panel. To gain access to those in the junction

box, unclip the junction box lid, then release

the retaining clip, and lift the small cover

situated inside the box (see illustration 3.7a).

3 The fuse number is marked on the fusebox

next to each fuse; a list of the circuits each

fuse protects is given in the Specifications at

the start of this Chapter. Plastic tweezers are

also clipped into the fusebox, and can be

used to remove and fit the fuses (see

illustration) .

4 To remove a fuse, first switch off the circuit

concerned (or the ignition), then fit the

tweezers and pull the fuse out of its terminals.

Slide the fuse sideways from the tweezers.

The wire within the fuse is clearly visible; if the

fuse is blown, it will be broken or melted.

5 Always renew a fuse with one of an

identical rating; never use a fuse with a

different rating from the original, or substitute

anything else. Never renew a fuse more than

once without tracing the source of the trouble.

The fuse rating is stamped on top of the fuse;

note that the fuses are also colour-coded for

easy recognition.

6 If a new fuse blows immediately, find the

cause before renewing it again; a short to

earth as a result of faulty insulation is most

likely. Where a fuse protects more than one

circuit, try to isolate the defect by switching

on each circuit in turn (if possible) until the

fuse blows again. Always carry a supply of

spare fuses of each relevant rating in the

vehicle.

Relays

7 The majority of relays are located either in

the junction box located on the left-hand side

of the engine compartment (see illustration) ,

or are located behind the driver's lower facia

panel, directly behind the fusebox. The

exceptions to this are as follows:

(a) Sunroof relay - located behind the

overhead console

(b) Tailgate wiper motor relay - fitted to the

wiper motor bracket

shroud on models with twin fans, or at the

side of the radiator where only one fan is

fitted (see illustration).

3 Fuses and relays -

general information

Fuses

1 Most of the fuses are located behind the

driver's side lower facia panel, with a few odd

fuses on some models being located in the

junction box on the left-hand side of the

engine compartment.

2 To gain access to main fusebox, release the

three fasteners by rotating them through 90°,

3.3 Using the plastic tweezers supplied to

remove a fuse from the main fusebox

3.7a Engine compartment junction box

relays. Fuses are located beneath the

small cover (arrowed)

3.7b On models with twin cooling fans, the

fan relay(s) are located in the rear of the

fan shroud

12•4 Body electrical systems

4.5a Undo the three retaining screws

(arrowed)...

4.5b ... then disconnect the wiring

connectors, and slide off the combination

switch assembly

4.6a Undo the two retaining screws ...

8 Refer to the appropriate Chapters for

further information, and to the relevant wiring

diagram for details of wiring connections.

9 If a circuit or system controlled by a relay

develops a fault and the relay is suspect,

operate the system; if the relay is functioning,

it should be possible to hear it click as it is

energized. If this is the case, the fault lies with

the components or wiring of the system. If the

relay is not being energized, then either the

relay is not receiving a main supply or a

switching voltage, or the relay itself is faulty.

Testing is by the substitution of a known good

unit, but be careful; while some relays are

identical in appearance and in operation,

others look similar but perform different

functions.

10 To renew a relay, first ensure that the

ignition switch is off. The relay can then

simply be pulled out from the socket, and the

new relay pressed in.

Steering column combination

switches

2 Remove the steering wheel as described in

Chapter 10.

3 Release the panel fasteners by rotating

them through a quarter of a turn, and remove

the driver's side lower facia panel.

4 Slacken and remove the five screws which

secure the two halves of the steering column

shrouds together, then remove both the upper

and lower shroud.

5 Undo the three retaining screws, then

disconnect the wiring connectors from the

rear of the combination switches, and lift the

switch assembly off the steering column (see

illustrations) .

6 Unscrew the two retaining screws, and

slide the relevant switch assembly out of

position (see illustrations) .

7 Refitting is a reversal of the removal

procedure.

slide the switch out of the panel (see

illustration) .

10 Slide the switch back into the panel until it

clicks into position. Reconnect the wiring

connector, then clip the panel back into the

facia.

Instrument shroud switches

11 Release the panel fasteners by rotating

them through a quarter of a turn, and remove

the driver's side lower facia panel.

12 Slacken and remove the five screws

which secure the two halves of the steering

column shrouds together, then remove both

the upper and lower shroud.

13 Slacken and remove the four instrument

panel shroud retaining screws, then remove

the shroud, disconnecting the switch wiring

connectors as they become accessible.

14 Depress the retaining tangs, and slide the

relevant switch out of the shroud (see

illustration).

15 Refitting is a reverse of the removal

procedure.

Courtesy light switches

16 Open up the door, then prise the rubber

gaiter from the courtesy switch.

17 Undo the retaining screw, then withdraw

the switch from the pillar, disconnecting its

wiring connector as it becomes accessible.

Tie a piece of string to the wiring, to prevent it

falling back into the door pillar.

4 Switches - removal and refitting

Instrument panel dimmer switch,

exterior mirror switch, alarm

switch and air conditioning switch

8 Using a suitable flat-bladed screwdriver,

carefully prise the relevant switch panel out of

the facia, taking great care not to mark either

the panel or facia.

9 Disconnect the wiring connector from the

switch, then depress the retaining tangs, and

Note: Disconnect the battery negative lead

before removing any switch, and reconnect

the lead after refitting the switch.

Ignition switch/steering column

lock

1 Refer to Chapter 10, Section 21.

4.6b ... and slide the relevant switch

assembly out from the combination switch

bracket

4.9 Removing the instrument panel

dimmer switch

4.14 Removing an instrument shroud

switch

Body electrical systems 12•5

4.19a Prise the luggage compartment light

switch out of the trim panel...

4.19b ... then withdraw the switch and

disconnect its wiring connector

4.22 Handbrake warning light switch

retaining screw (arrowed)

18 Refitting is a reverse of the removal

procedure, ensuring that the rubber gaiter is

correctly seated on the switch.

Luggage compartment light

switch

19 Open up the tailgate, then carefully prise

the switch out from the left-hand trim panel,

and disconnect its wiring connector (see

illustrations) . Tie a piece of string to the

wiring, to prevent it falling back behind the

trim panel.

20 Reconnect the wiring connector, and clip

the switch back into position in the trim panel.

Handbrake warning light switch

21 Open up the rear ashtray, then depress

the retaining tang and remove the ashtray

from the handbrake lever cover panel.

Slacken and remove the rear retaining nut and

the two front retaining screws, then

manoeuvre the cover panel off the handbrake

lever.

22 Disconnect the wiring connector from the

handbrake switch, then undo the retaining

screw and remove the switch from the side of

the handbrake lever (see illustration) .

23 Refitting is a reverse of the removal

procedure.

Electric window switches

24 Carefully prise the window switch out of

the armrest, taking great care not to mark the

switch or the armrest, and disconnect the

wiring connector (see illustrations) .

25 On refitting, connect the wiring connector,

and clip the switch back into position in the

armrest.

Electric sunroof switch

26 Carefully prise the courtesy light out from

the overhead console, and disconnect it from

its wiring connector. Remove the two console

retaining screws, then lower the console out

of position, and disconnect it from its wiring

connectors.

27 Depress the retaining tangs, and slide the

sunroof switch out of the console (see

illustration).

28 Refitting is a reverse of the removal

procedure.

(d) Wherever bayonet-type bulbs are fitted

(see Specifications) ensure that the live

contacts) bear firmly against the bulb

contact.

(e) Always ensure that the new bulb is of the

correct rating, and that it is completely

clean before fitting it; this applies

particularly to headlight/foglight bulbs

(see below).

Headlight

2 Working in the engine compartment,

remove the relevant plastic cover from the

rear of the headlight unit.

3 Disconnect the wiring connectors, then

press together the ends of the bulb retaining

clip, and release it from the rear of the light

(see illustrations) .

5 Bulbs (exterior lights) -

renewal

General

1 Whenever a bulb is renewed, note the

following points:

(a) Disconnect the battery negative lead

before starting work.

(b) Remember that, if the light has just been

in use, the bulb may be extremely hot.

holder, ensuring that there is clean metal-

to-metal contact between the bulb and its

live(s) and earth. Clean off any corrosion

or dirt before fitting a new bulb.

4.24a Carefully prise the window switch

out of the armrest...

4.24b ... and disconnect it from its wiring 4.27 Depress the retaining tangs, and slide

connector

out the sunroof switch

5.3a Disconnect the wiring connectors

from the headlight bulb ...

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