Citroen zx-12
Citroen zx-12
Citroen zx-12
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
Front foglights Heater blower motor and air conditioning controls Supplementary cooling fan Cooling fan Fitting H4 H1 H3 Capless Bayonet Capless Capless Capless Capless Integral with holder Integral with holder Bayonet Bayonet Bayonet Wattage 60/55 55 55 5 21 5 5 5 1.2 1.2 1.2 21/5 21 21
an
electronic
control
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 faultfinding 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. Shortcircuit faults are normally caused by a breakdown in wiring insulation, which allows a feed wire to touch either another wire, or an earthed component such as the bodyshell. A short-circuit fault will normally cause the relevant circuit fuse to blow.
Finding an open-circuit
9 To check for an open-circuit, connect one lead of a circuit tester or voltmeter to either the negative battery terminal or a known good earth.
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).
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 (c) Cooling fan relay(s) - in the rear of the fan shroud on models with twin fans, or at the side of the radiator where only one fan is fitted (see illustration).
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
4.5a Undo the three retaining screws (arrowed)... 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.
4.5b . . . then disconnect the wiring connectors, and slide off the combination switch assembly
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 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
4.6b . . . and slide the relevant switch assembly out from the combination switch bracket
4.19a Prise the luggage compartment light switch out of the trim p a n e l . . . 18 Refitting is a reverse of the removal procedure, ensuring that the rubber gaiter is correctly seated on the switch.
4.19b . . . then withdraw the switch and disconnect its wiring connector 25 On refitting, connect the wiring connector, and clip the switch back into position in the armrest.
4.22 Handbrake warning light switch retaining screw (arrowed) (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).
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. (c) Always check the bulb contacts and holder, ensuring that there is clean metalto-metal contact between the bulb and its live(s) and earth. Clean off any corrosion or dirt before fitting a new bulb.
4.27 Depress the retaining tangs, and slide out the sunroof switch
5.4 . . . and withdraw the bulb from the rear of the light unit 4 Withdraw the bulb (see illustration). 5 When handling the new bulb, use a tissue or clean cloth, to avoid touching the glass with the fingers; moisture and grease from the skin can cause blackening and rapid failure of this type of bulb. If the headllight glass is accidentally touched, wipe it clean using methylated spirit. 6 Install the new bulb, ensuring that its locating tabs are correctly located in the light cut-outs. Secure the bulb in position with the retaining clip, and reconnect the wiring connectors. 7 Slide the plastic cover back into position, ensuring that it is correctly seated on the rear of the light unit.
5.8 Removing the sidelight bulbholder from the rear of the headlight unit procedure, ensuring that the bulbholder seal is in good condition.
5.11 Unhook the retaining spring from within the engine compartment...
Front sidelight
8 Working in the engine compartment, twist the bulbholder anti-clockwise, then withdraw it from the headlight unit (see illustration). Note that on some models, it will be necessary to displace the plastic cover from the rear of the unit to gain access to the bulbholder. 9 The bulb is of the capless (push-fit) type, and can be removed by simply pulling it out of the bulbholder. 10 Refitting is the reverse of the removal
5.12 . . . then withdraw the direction indicator from the front of the vehicle, and release its bulbholder
Front foglight
18 Undo the two retaining screws, and
5.15 Push the direction indicator side repeater towards the rear of the vehicle, to release its retaining clips . . .
5.16a . . . then withdraw the light from the wing, and disengage it from its bulbholder
5.16b Side repeater bulb is of the capless type, being a push-fit in the holder
5.18 Undo the two retaining screws, and withdraw the lens unit from the foglight withdraw the lens unit from the front of the light (see illustration). 19 Release the retaining clip, and withdraw the bulb from the rear of the unit. Unclip the plastic insulator cover, then disconnect the bulb wiring connector and remove the bulb (see illustrations). 20 When handling the new bulb, use a tissue or clean cloth, to avoid touching the glass with the fingers; moisture and grease from the skin can cause blackening and rapid failure of this type of bulb. If the glass is accidentally touched, wipe it clean using methylated spirit. 21 Connect the new bulb to the wiring connector, and refit the plastic insulator cover to the connector. 22 Install the bulb in the rear of the lens, ensuring that its locating tabs are correctly located in the cut-outs. Secure the bulb in position with the retaining clip, ensuring that the wiring insulator is correctly located underneath the clip (see illustration). 23 Refit the lens to the light unit, taking great care not trap the wiring, and securely tighten its retaining screws.
5.19b . . . then disconnect the wiring connector and withdraw the foglight bulb
rear light cluster, noting its rubber seal (see illustration). 25 The relevant bulb can then be renewed all bulbs have a bayonet fitting (see illustration). Note that the stop/tail light bulb has offset locating pins, to prevent it being installed incorrectly. 26 Refitting is the reverse of the removal sequence, noting that the rubber lens seal must be renewed if damaged.
General
1 Refer to Section 5, paragraph 1.
Courtesy lights
2 Carefully prise the light unit out of position, then twist the bulbholder in an anti-clockwise direction, and remove it from the rear of the light unit (see illustrations). 3 The bulb is of the capless (push-fit) type;
5.25 Rear light cluster bulbs A B C D E Direction indicator Reversing light Stop/tail light Sidelight Foglight (where fitted)
6.2b . . . and twist the bulbholder anticlockwise to release it from the rear of the light unit
6.5 Removing the luggage compartment light bulbholder pull the old bulb out of the holder, and press the new one into position. 4 Refit the bulbholder to the rear of the light unit, and clip the light unit back into position.
6.6a Carefully prise the map reading light out of the overhead console . . . lever in the direction of the arrow cast on the light unit, to disengage the holder from the light unit (see illustration). 8 The bulb is of the capless (push-fit) type; pull the old bulb out of the holder, and press the new one into position (see illustration). 9 Slide the bulbholder back onto its pivot in the light unit, then connect the wiring connector, and clip the light unit back into position in the headlining.
6.6b . . . and disconnect it from its wiring connector 16 The bulbs are of the capless (push-fit) type; pull the old bulb out of the holder, and press the new one into position. 17 Refit the bulbholder to the rear of the panel, then refit the centre console as described in Chapter 11.
6.11 Removing an instrument panel bulb from the rear of the panel
6.24 Removing the cigarette lighter/ashtray illumination bulb 24 Slide the illumination bulbholder out of the panel, and renew the bulb (see illustration). The bulbs is of the capless (push-fit) type; pull the old bulb out of the holder, and press the new one into position. 25 Slide the illumination bulbholder back into position, and refit the panel by reversing the removal procedure.
7.1 Radiator grille is retained by three screws (arrowed) sidelight bulbs (and, where fitted, from the headlight adjustment motor). 4 Using pliers, slide out the retaining clip from the top headlight mounting point (where fitted) (see illustration). 5 Pull the headlight forwards, to release it from its two retaining spring clips, and remove the headlight from the vehicle (see illustrations). 6 Refitting is a direct reversal of the removal procedure. On completion, check the headlight beam alignment, using the information given in Section 8.
7.4 Using pliers remove the retaining clip from the top headlight mounting point 9 Refitting is the reverse of removal.
Front foglight
12 Jack up the front of the vehicle, and support it on axle stands. 13 Trace the wiring back from the rear of the foglight, and disconnect it at the wiring connector (see illustration). 14 Slacken and remove the foglight retaining nut, and withdraw the light unit from the front of the bumper (see illustrations).
7.5a Pull the headlight forwards, to release it from its retaining spring clips . . .
Headlight
1 Open the bonnet, then slacken and remove the three retaining screws, and remove the plastic cover from the bonnet lock. Slacken the three retaining screws, and remove the radiator grille (see illustration). 2 Remove the direction indicator light as described below. 3 Remove the plastic cover(s) from the rear of the headlight unit, and disconnect the wiring connectors from both the headlight and
7.14b . . . and withdraw the foglight from the front of the bumper 15 Refitting is the reverse of removal.
7.17a Undo the retaining nut situated on the inside of the luggage compartment... 20 On refitting, reconnect the wiring connector, and clip the light back into position.
7.17b . . . then remove the rear light unit from the rear of the vehicle, and disconnect its wiring connector
9.3b . . . and remove the heater duct from behind the panel
9.6 Undo the two bonnet release lever retaining bolts, and free the lever from its bracket. Heater duct retaining screw is
9.7a Slacken and remove the instrument panel shroud retaining screws (arrowed)...
9.7b . . . then disconnect the switch wiring connectors and remove the shroud
9.9b . . . then withdraw the instrument panel from the facia . . . connectors as they become accessible (see illustrations). 8 Reaching in through the lower facia aperture, reach up behind the instrument panel, then depress the retaining tangs and detach the speedometer cable from the rear of the panel. 9 Undo the two lower retaining screws, then withdraw the instrument panel assembly from the facia. Disconnect the wiring connectors from the rear of the panel, and remove the assembly from the vehicle (see illustrations).
9.9c . . . and disconnect the wiring connectors (arrowed) from the rear of the panel
10.2a Slacken and remove the three instrument panel cover retaining screws (arrowed)...
Refitting
10 Refitting is a reversal of the removal procedure. On completion, reconnect the battery and check the operation of all the panel warning lights and the instrument panel shroud switches, to ensure that they are functioning correctly. 10.2b . . . then release the retaining clips, and separate the panel and cover instrument panel. Carefully release the six retaining clips situated around the outside of the cover, then separate the cover and instrument panel (see illustrations). 3 Undo the two retaining screws from the front of the speedometer face, then undo the two retaining bolts from the rear of the panel, and withdraw the speedometer (see illustrations). 4 Refitting is a reverse of the removal procedure. Do not overtighten the instrument panel fasteners, as the plastic is easily cracked.
10.3a Instrument panel component front fasteners A B C D Speedometer screws Tachometer screws Temperature gauge screw Fuel gauge screw
General
1 Remove the instrument panel as described in Section 9, then proceed as described under the relevant sub-heading.
Speedometer
2 Slacken and remove the three panel front cover retaining screws from the rear of the
Tachometer
5 Remove the panel front cover as described in paragraph 2.
10.3b Instrument panel component rear fasteners A Speedometer bolts B Fuel gauge nuts C Rear cover screws
10.6 Instrument panel rear cover wiring connector 6 Undo the two screws and remove the cover from the rear of panel, disconnecting its wiring connector as it becomes accessible (see illustration). 7 Undo the four retaining nuts, and remove the circuit board from the rear of the tachometer (see illustration). 8 Slacken and remove the three screws from the front face of the tachometer, and remove the tachometer from the case. 9 Refitting is a reverse of the removal procedure. Do not overtighten the instrument panel fasteners, as the plastic is easily cracked.
10.7 Tachometer rear retaining nuts and printed circuit board 15 Refitting is a reverse of the removal procedure. Do not overtighten the instrument panel fasteners, as the plastic is easily cracked.
10.11 Temperature gauge retaining nuts (arrowed) 5 Reconnect the battery negative terminal, then reset the clock.
Printed circuit
16 Remove all the panel instruments as described above. 17 Remove all the bulbholders from the rear of the case, by twisting them in an anticlockwise direction. Slacken and remove all the circuit retaining screws, then release the printed circuit from its retaining pins, and remove it from the rear of the case. 18 Refitting is a reversal of the removal procedure, ensuring that the printed circuit is correctly located on all the necessary retaining pins.
Temperature gauge
10 Remove the front cover and the rear cover, as described in paragraphs 2 and 6. 11 Undo the three retaining nuts from the rear, and the single screw from the front, of the temperature gauge, and withdraw the gauge from the case (see illustration). 12 Refitting is a reverse of the removal procedure. Do not overtighten the instrument panel fasteners, as the plastic is easily cracked.
Fuel gauge
13 Remove the front cover as described in paragraph 2. 14 Slacken and remove the three nuts from the rear, and undo the single retaining screw from the front face of the gauge, and withdraw the gauge from the case.
Refitting
4 Reconnect the wiring connector, then clip the clock into the position in the facia.
11.2 Carefully prise the clock out of the facia (note the use of padding under the screwdriver, to avoid damage)...
13.3b . . . then withdraw the centre vent panel, disconnecting the wiring connectors from the cigarette lighter 3 Undo the four centre vent panel retaining screws (two located above the heater controls, and two directly below), then unclip the panel and withdraw it from the facia. Disconnect the wiring connectors from the cigarette lighter and ashtray illumination bulb, and remove the centre vent panel assembly from the vehicle (see illustrations). 4 Remove the lighter element, release the retaining tangs and push out the metal insert, then remove the plastic outer section of the lighter (see illustrations).
13.4a Release the retaining tangs, then withdraw the metal insert... buzzer unit is a push-fit in the panel, and can easily be identified by the slots in its cover (see illustration). 3 Refer to Section 4 for information on courtesy light switch removal.
13.4b . . . followed by the plastic outer section of the cigarette lighter position, and disconnect it from its wiring connector.
Air horn
3 Slacken and remove the nut and bolt securing the horn mounting bracket to the vehicle body, then remove the horn, disconnecting it from its air supply pipe (see illustrations). 4 Disconnect the wiring connector from the air compressor, then undo the retaining nut and withdraw the compressor from underneath the vehicle (see illustrations). Recover the spacer from the compressor mounting bolt.
Removal
1 Jack up the front of the vehicle, and support it on axle stands.
Refitting
5 Refitting is a reversal of the removal procedure.
Electric horn
2 Undo the nut securing the horn to its mounting bracket, then lower the horn out of
Refitting
5 Refitting is a reverse of the removal procedure.
14.2 "Lights-on" warning buzzer (arrowed) is situated behind the main fusebox
15.3a Slacken and remove the retaining nut and bolt (arrowed)...
15.3b . . . then remove the horn, disconnecting it from its supply pipe
15.4b . . . then undo the retaining nut and remove the air compressor
16.4 Unscrew the knurled retaining ring, and separate the upper and lower speedometer cable sections
17.2a Raise the spindle cover, then undo the retaining n u t . . . compartment. Once the cable is through, untie the string. 7 On left-hand-drive models, position the cable so that approximately 145 mm of the cable protrudes into the engine compartment, then connect the end of the cable to the lower cable section, and securely tighten the retaining ring. Refit the instrument panel as described in Section 9. 8 On right-hand-drive models, position the cable so that approximately 100 mm of the cable protrudes into the engine compartment, then connect the end of the cable to the lower cable section, and securely tighten the retaining ring. Refit the facia assembly as described in Chapter 11.
17.2b . . . and remove the wiper arm from the spindle 13 Attach the lower cable to the upper cable, and securely tighten the retaining ring. 14 Ensuring that the cable is correctly routed, slide the lower end of the cable into position in the speedometer drive, and secure it in position with the rubber retaining pin. Lower the vehicle to the ground.
Refitting
3 Ensure that the wiper arm and spindle splines are clean and dry, then refit the arm to the spindle, aligning the wiper blade with the tape fitted on removal. Refit the spindle nut, tightening it securely, and clip the nut cover back in position.
Refitting
6 Tie the inner end of the string to the end of the cable, then use the string to draw the speedometer cable through into the engine
18.3b . . . then carefully ease the wiper motor/vent panel cover out from behind the windscreen sealing strip
18.4 Disconnect the wiper motor wiring connector... 4 Disconnect the wiring connector from the front of the wiper motor (see illustration). 5 Remove the plastic cover from the heater blower motor intake passage (see illustration). 6 Undo the three wiper motor retaining bolts, then manoeuvre the wiper motor out of position, and remove it from the vehicle (see illustrations). 7 If necessary, using a suitable flat-bladed screwdriver, carefully lever the wiper linkage off the motor spindle balljoint. Slacken and remove the three motor retaining bolts, and separate the motor and linkage (see illustration).
18.5 . . . and remove the plastic cover from the blower motor intake duct retaining bolts. Clip the linkage onto the spindle balljoint, and check that it is securely retained. 9 Manoeuvre the motor assembly back into position, and refit the three retaining bolts, tightening them securely. 10 Reconnect the wiring connector to the motor, and refit the cover to the blower motor intake passage. 11 Manoeuvre the wiper motor/vent cover back into position, and engage its front locating pegs with their mounting rubbers (see illustration). Starting at the centre and working outwards, carefully ease the top edge of the cover behind the windscreen sealing strip. Once the cover is correctly seated behind the strip, secure it in position with its six retaining screws. 12 Refit the wiper arm as described in
18.6a Undo the three retaining bolts (arrowed)... Section 17, and reconnect the battery negative terminal.
Refitting
8 Where necessary, assemble the motor and linkage, and securely tighten the motor
18.11 On refitting, ensure the wiper motor/vent cover locating pegs (arrowed) are correctly located
19.2b . . . . and remove the trim cover from the tailgate wiper motor spindle
19.3 Removing the wiper motor cover from the rear of the tailgate
19.4b . . . then withdraw the motor, disconnecting the wiring connectors (arrowed) as they become accessible 4 Undo the three wiper motor retaining bolts, then withdraw the motor from the tailgate, disconnecting its wiring connectors as they become accessible (see illustrations).
20.2 Disconnecting the windscreen washer supply pipe from its non-return valve liner and access cover from the vehicle (see illustration). 4 Push the front direction indicator repeater light unit towards the rear of the vehicle, to free its retaining clips, then withdraw it from the wing. 5 Reach up behind the wing, and disconnect the wiring connector(s) from the washer pump(s). 6 Slacken and remove the two reservoir retaining bolts, then pull the top of the reservoir( outwards, to release it from the reservoir filler neck (see illustrations). Lower the reservoir out from underneath the wing, disconnecting the supply pipe(s) from the washer pump(s) as they become accessible. 7 Refitting is the reverse of removal, ensuring that the reservoir is correctly engaged with its filler neck.
Refitting
5 Refitting is a reverse of the removal procedure. Ensure that the tailgate central locking servo motor (where fitted) is correctly engaged with the lock pin, prior to refitting the wiper motor retaining bolts.
Washer pump(s)
Note: Prior to removing the pump(s), empty the contents of the reservoir, or be prepared for fluid spillage. 8 Jack up the front of the vehicle, and support it on axle stands. Remove the righthand front roadwheel. 9 Remove the wheel arch liner as described in paragraph 3. 10 Disconnect the wiring connector from the relevant pump, then carefully ease the pump out of its sealing grommet, and manoeuvre it out from behind the wing (see illustrations). If
20.6b . . . and lower the washer reservoir out from behind the wing
20.10b . . . then ease the washer pump out from the reservoir
21.3b Slide the radio/cassette unit out of position, and disconnect the aerial connection and wiring connectors wiring connectors and aerial from the rear of the unit (see illustrations).
necessary, to improve access to the pump, undo the mounting bolts, and lower the reservoir slightly. Note that, on models with a dual pump arrangement, the upper pump is tailgate washer pump, and the lower one is the windscreen washer pump. 11 Refitting is a reversal of the removal procedure.
jets, check that the relevant non-return valve is not blocked. The windscreen washer valve is situated in the supply pipe, next to the righthand bonnet hinge; the tailgate washer valve is situated at the rear of the vehicle, tucked away underneath the top of the tailgate sealing strip. 17 To remove a non-return valve, simply disconnect the hoses from either end of it. 18 On refitting, ensure that the valve is installed the correct way around, so that it allows fluid to flow only in the direction of the washer jet(s).
Refitting
4 Refitting is the reverse of the removal procedure. On completion, reconnect the battery, and enter the radio security code using the information given in "Radio/cassette unit anti-theft system" at the start of this manual.
Removal
1 The front speakers are located in the front door trim panels, in front of the door pull handles. On five-door models, the rear speakers are located at the bottom of the rear door trim panel; the rear speakers on threedoor models are located in the rear seat side trim panels. 2 Carefully prise the speaker grille out from the trim panel (see illustration). 3 Slacken and remove the speaker retaining screws and, on the front speaker, remove the retaining clip from the mounting peg. Withdraw the speaker from the panel, disconnecting its wiring connector as it becomes accessible (see illustrations).
Removal
1 Disconnect the battery negative terminal. 2 Remove the two rubber plugs from the front of the unit, to gain access to the radio/cassette unit retaining screws (see illustration). 3 Undo the retaining screws, then withdraw the unit from the facia, and disconnect the
Non-return valves
16 If trouble is experienced at any time with the flow to the tailgate or windscreen washer
22.3a Front speakers are retained by three screws and a retaining clip (arrowed)
22.3c Remove the speaker from the panel, and disconnect it from its wiring connector
23.1a Undo the two retaining screws (arrowed)... behind the right-hand trim panel, remove the left-hand panel. 5 Disconnect the upper section of the lead, and tie a piece of string to it. Withdraw the aerial lead through the overhead console aperture, and untie the string from its end. Leave the string in position - it can then be used to draw the lead back into position on refitting.
23.1b . . . then lower out the overhead console, and disconnect it from its wiring connectors securely. Reconnect the courtesy light to its wiring connector, and clip the light back into position in the console.
Refitting
4 Refitting is a reverse of the removal procedure.
Removal
Aerial
1 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 (see illustrations). 2 Slacken and remove the nut from the base of the aerial, and disengage the aerial lead collar from its stud. The aerial can then be lifted away from the outside of the vehicle, noting the rubber seal which is fitted to its base (see illustrations).
Refitting
Aerial
7 Ensure that the rubber seal is in good condition, then refit it to the aerial base. Refit the aerial to the roof, ensuring that its locating pin is correctly located in its hole. 8 From inside the vehicle, locate the aerial lead collar on the aerial stud, and refit the retaining nut, tightening it securely. 9 Reconnect the wiring connectors to the overhead console, and locate the console in position in the headlining. Refit the two console retaining screws, and tighten them
23.2a Undo the aerial lead retaining nut from inside the vehicle . . .
23.2b . . . then remove the aerial from the roof of the vehicle
23.4 Aerial lead upper-to-lower section connection is located behind the windscreen pillar trim panel
Symbols used in wiring diagrams No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Socket connection Pin connection Connector connection Connector connection with index (for differentiation) Junction not to be dismantled (splice) Junction not to be dismantled (with other connection possibilities) Socket earthing Connector earthing Part body earth connection Switch (non-automatic return) Manual switch Selector switch Switch on at-rest (automatic return) Swithc off at-rest (automatic return) Manual contact switch Mechanical contact switch Pressure contact switch Thermal switch Contact delayed on opening Contact delayed on closing No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Description Friction contact switch Manual contact switch (cigar lighter) with resistance Resistance Rheostat Manual rheostat Mechanical rheostat Temperature rheostat (thermistor) Pressure rheostat Rheostat Shunt Coil (relay-solenoid) Warning light Light bulb Double-filament light bulb Light-emitting diode (LED) Photo-diode Diode Fuse Thermal circuit breaker Screening Battery cell No. 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Description Suppressor Motor Two-speed motor Alternative power generator Sound equipment (horn, loudspeaker) Electronic control unit Delay unit Part framing (with its circuit diagram) Part framing (without its circuit diagram) Part extract Part extract Indicator Thermocouple Electrodes Oxygen sensor Supply socket NPN transistor PNP transistor Connection indicating line No extremity
Key to wiring diagrams Not all items fitted to all models No. 5 10 15 20 21 35 40 45 50 52 53 55 58 59 62 100 101 130 140 141 142 144 152 155 156 157 158 160 170 180 183 211 212 215 254 255 270 300 302 305 306 307 308 310 311 312 313 314 315 317 318 319 322 326 330 340 350 385 389 391 392 394 Description Front cigar lighter Ignition distributor Alternator LH horn RH horn Battery Instrument cluster Ignition coil Supply connector box Junction box Water temperature control unit Central door locking control unit Remote control door locking receiver (PLIP) Pre-heater (glow plugs) control unit Earth connection box Spark plugs Glow plugs Lights-on warning buzzer Anti-lock braking ECU Air conditioning ECU Fuel injection ECU Exhaust gas recirculation ECU Engine speed sensor LH front wheel sensor (ABS) RH front wheel sensor (ABS) LH rear wheel sensor (ABS) RH rear wheel sensor (ABS) TDC sensor Flasher unit Additional air control Air blower control LH column switch (lights, indicators, horn) RH column switch (front and rear wipers) Exterior mirror switch Air horn compressor Air con. compressor driving clutch HT coil suppressor Ignition switch Boot light switch Driver's door locking switch Passenger's door locking switch LH rear door closing switch RH rear door closing switch LH front door pillar switch RH front door pillar switch LH rear door pillar switch RH rear door pillar switch Reversing light switch Handbrake switch Hydraulic fluid level switch Throttle butterfly switch Stop-light switch Atmospheric pressure switch Starter motor switch Post-heater switch Airflow meter Starter motor Front ashtray illumination Boot light Number plate LH light Number plate RH light Air con. control illumination No. 429 430 431 432 434 437 441 443 480 481 482 483 484 485 486 487 488 489 490 491 492 493 496 497 498 499 500 501 502 503 504 505 550 551 554 555 570 582 587 588 589 590 591 592 597 608 650 660 671 680 681 685 694 695 696 697 703 704 705 706 708 712 714 Description Fuel cut-off solenoid (stop solenoid) Canister discharge solenoid Fast idling solenoid Idling actuator Canister solenoid Exhaust gas recirculation solenoid Vacuum advance solenoid Injection timing correction solenoid LH rear light RH rear light LH front foglight RH front foglight LH rear foglight RH rear foglight LH dipped beams RH dipped beams LH front direction indicator RH front direction indicator LH rear direction indicator RH rear direction indicator LH sidelight RH sidelight LH tail light RH tail light LH reversing light RH reversing light LH direction indicator repeater RH direction indicator repeater LH headlight RH headlight LH stop-light RH stop-light LH front speaker RH front speaker LH rear speaker RH rear speaker Injector Refrigerated air switch Front foglight switch Rear foglight switch Hazard warning light switch Driver's window switch Passenger's window switch (on driver's door) Passenger's window switch (on passenger's door) Heated rear window switch Headlight adjustment device switch Fuel gauge Map reading light Engine oil pressure switch Ignition module Air blower control module Digital clock Windscreen wiper motor Tailgate wiper motor LH front window motor RH front window motor Driver's door locking motor Passenger's door locking motor LH rear door locking motor RH rear door locking motor Tailgate locking motor Idling control stepper motor ABS hydraulic pump motor No. 715 716 720 721 742 743 750 751 755 757 758 765 770 772 775 779 781 783 786 787 790 798 804 805 806 807 809 813 814 815 819 820 822 827 841 843 844 845 849 857 858 859 860 862 876 880 900 902 903 904 907 909 910 912 915 918 962 963 970 971 974 990 Description LH headlight adjustment device motor RH headlight adjustment device motor Engine cooling fan (single, or LH of two) RH engine cooling fan Central interior light Rear interior light LH front brake pads sensor RH front brake pads sensor Fuel pump Windscreen washer pump Rear screen washer pump Radio set Throttle spindle potentiometer Mixture adjustment potentiometer Pressure switch TDC sensor plug (petrol) or Water temp, sensor (Diesel) ABS diagnostic socket Injection diagnostic socket Headlight: LH main and dipped beams Headlight: RH main and dipped beams Air blower motor Injection timing cut-off relay Air conditioning relay Compressor cut-off relay (temperature) Front foglight relays Injection double relay Front window relay Engine cooling fan relay (fast speed) Engine cooling fan relay (slow speed) Engine cooling fan speed switchover relay Rear foglight relays Heated rear window relay Compressor cut-off relay (injection) Dim-dip relay (UK only) Window re-energising relay Air horn compressor relay ABS main relay Hydraulic fluid motor relay Post-heating cut-off relay Carburettor base heating resistance Dipped beams resistance (dim-dip) Air blower speed resistor Coding resistance Injector additional resistance RH rear view mirror Instrument lighting rheostat Oxygen sensor Engine oil level sensor Injection air pressure sensor Engine oil pressure sensor Injection air temperature sensor Injection water temperature sensor Water temp, sensor (control unit) Evaporator temperature sensor Water temperature switch sensor Engine oil temperature sensor Windscreen intermittent wipe timer Tailgate intermittent wipe timer Coolant temp, warning thermal switch Cooling fan thermal switch (radiator) Water temperature switch Heated rear window
CONNECTION NOT TO BE DISMANTLED (splice...) PART, WIRE OR HARNESS NOT EXISTING (in this model) PART NUMBER (see "identification") PART SHOWN (with inner drawing) SYMBOL FOR THE PART FUNCTION
REF. FIGURE ON THE WIRE CONNECTOR CONNECTION COLOUR MARK ON WIRE OUTLET INDICATION (not necessary for the function) PIN PROTECTOR COLOUR PIN CONNECTION SOCKET CONNECTION
Exterior lighting
Interior lighting
Wash/wipe systems
Wiring diagram for fuel injection system (1.6 litre without catalytic converter)
Wiring diagram for fuel injection and ignition system (1.6 litre with catalytic converter)
Wiring diagram for fuel injection and ignition system (1,9 litre) Wiring diagram radio installation
Wiring diagram for instrument panel (Trim level D 1.6 and 1,9 litre)
Wiring diagram for heated rear screen and adjustable mirrors Wiring diagram for ABS