Peugeot 205 (954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc). Manual - part 24

13 With the bonnet open, remove the plastic
grille and unscrew the front facia mounting
nuts (see illustration).
14 Withdraw the facia panel at the same time
disconnecting the relevant switches and cigar
lighter. Reconnect the switch wiring
immediately to ensure correct refitting.

1988 models onward

15 Disconnect the battery negative lead.
16 Remove the screws and withdraw the
right-hand lower facia panel (see illustration).
17 Prise out the instrument panel rheostat,
and disconnect the wires.
18 Remove the screws and withdraw the
lower steering column shroud.

19 Prise out the coin box and the triangular
cover (see illustrations).
20 Pull off the heater control knobs.
21 Remove the screws in the outer control
knob apertures and withdraw the heater
control surround (see illustration).
22 Remove the screws and withdraw the
central vent assembly (see illustrations).
23 Remove the radio (Chapter 12) or
oddments compartment, as applicable.
24 Remove the screws and withdraw the trim
quadrants from each side of the facia.
25 Remove the ashtray and disconnect the
wiring from the cigar lighter (see illustration).
Identify the wiring.

26 Unclip the clock surround (see
illustration).
27 Insert lengths of welding rod, or similar,
into the holes at the top of the switch
surround to release the upper clips, then undo
the lower screws and remove the surround
(see illustrations).
28 Prise the steering column grommet from
the floorpan.
29 Unscrew the mounting nuts and lower the
steering column to the floor (see illustration).
30 Prise the small vents from each side of the
centre console.
31 Pull back the carpet and remove the
screws (see illustration).

11•12 Bodywork and fittings

26.13 Facia front mounting nut

26.16 Removing a right-hand lower facia

panel securing screw

26.19a Prise out the coin box . . .

26.22b . . . and lower screws

26.25 Removing the ashtray

26.26 Removing the clock surround

26.19b . . . and triangular cover

26.21 . . . Withdraw the heater control

surround

26.22a Removing the central vent

assembly upper . . .

32 Prise the small tray from the centre
console (see illustration).
33 Remove the screws, and slide the
surround up the gear lever (see illustration).
34 Remove the upper and lower nuts, and
withdraw the centre console (see
illustrations).
35 Unclip the felt cover from under the facia.
36 Remove the screws and withdraw the
front facia panel. Disconnect the wiring from
the switches (see illustration).
37 Remove the heater control panel retaining
screws.
38 If necessary, remove the side vents.
39 Remove the instrument panel (Chapter 12)

and choke cable, where applicable (Chap-
ter 4A).
40 Remove the left lower facia mounting
screw.
41 Unclip the glovebox and remove the
lighting switch. Also remove the light.
42 Remove the remaining mounting screws
and nuts, and withdraw the facia sufficiently
to disconnect the wiring. Access to the front
mounting nuts is gained by removing the
wiper arms and the plastic guard from the
plenum chamber in the engine compartment.
Identify each wire for location.
43 Unclip the fuse and relay panel, and
withdraw the facia panel from the car.

Refitting

All models

44 Refitting is a reversal of removal, but on
completion check the operation of all
electrical components.

Bodywork and fittings 11•13

26.27a Method of releasing the switch

surround upper clips

26.27b Remove the lower screws and

withdraw the surround

26.29 Steering column mounting nuts

(arrowed)

26.34a Removing the centre console

upper nuts . . .

26.34b . . . and lower nut

26.36 Front facia panel screws (arrowed)

26.31 Prise out the console vent and

remove the screw

26.32 Removing the centre console tray

26.33 Remove the screws and slide the

surround up the gear lever

11•14

Notes

Chapter 12
Body electrical system

General

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-volt negative earth

Fuses (early models)

No Circuit protected

Rating (amp)

Reverse light, cooling fan relay, tachometer (GTI) . . . . . . . . . . . . .

Accessories, indicators, fuel gauge, warning lights, heater blower
motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition switch, wash/wipe system, stop-lights, tachometer (non-
GTI option), radio, heated rear window, electric window relay
(option), clock illumination (GTI). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Central door locking (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette lighter, clock, interior lights, glovebox illumination, radio . .

Electric front windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated rear window, horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side/tail lights/warning light, instrument panel illumination, number
plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(In-line) fuel pump (GTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air compressor and horn (1.9 GTI models) - removal and refitting  . . 21
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Bulbs (exterior lights) - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bulbs (interior lights) - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Central door locking system - general information  . . . . . . . . . . . . . . 19
Clock - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dim-dip lighting system - general information  . . . . . . . . . . . . . . . . . 13
Electrical fault finding - general information  . . . . . . . . . . . . . . . . . . . 2
Front direction indicator light unit - removal and refitting  . . . . . . . . . 11
Fuses and relays - general information  . . . . . . . . . . . . . . . . . . . . . . . 3
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight beam alignment - checking and adjusting  . . . . . . . . . . . . 12
Headlight unit - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 10

Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Instrument panel - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 5
Radio - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Speedometer cable - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Screen washer fluid level check  . . . . . . . . . . . . . .See “Weekly checks”
Switches - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate heated window - general information  . . . . . . . . . . . . . . . . . 18
Tailgate wiper motor - removal and refitting  . . . . . . . . . . . . . . . . . . . 16
Vehicle immobiliser - general information  . . . . . . . . . . . . . . . . . . . . . 23
Washer system - general information  . . . . . . . . . . . . . . . . . . . . . . . . 17
Windscreen wiper motor and linkage - removal and refitting  . . . . . . 15
Wiper arms - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiper blade check  . . . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”

12•1

Specifications

Contents

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

Degrees of difficulty

Fuses (1986 to 1988 GTI and CTI models)

No Circuit protected

Rating (amp)

Reversing lights, tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction indicators, heater blower motor, oil pressure gauge, oil
temperature gauge, heated seats, fuel gauge, coolant temperature
gauge, low battery charge warning, oil pressure warning, brake
system warning, coolant temperature warning, low coolant
level warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen wiper/washer, stop-lights, headlight washer, radio,
accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette lighter, clock, interior lights, boot light, central door
locking, radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrically-operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail light (RH), number plate light . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel illumination, side lights . . . . . . . . . . . . . . . . . . . .

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (1988 to 1989 models, except GTI and CTI)

No Circuit protected

Rating (amp)

Reversing lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction indicators, heater blower motor, ignition warning light . .

Fuel gauge, stop-lights, front and rear wash/wipe, tachometer,
headlight wash, radio, storage tray light, warning lights (coolant
temperature, oil pressure, coolant level, handbrake, choke) . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette lighter, clock, interior lights, boot light, central door
locking, radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horns, heated rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrically-operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail lights, number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel illumination, side lights . . . . . . . . . . . . . . . . . . . .

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (1988 to 1989 GTI and CTI models)

No Circuit protected

Rating (amp)

Reversing lights, tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction indicators, heater blower motor, oil pressure gauge, oil
temperature gauge, heated seats, fuel gauge, coolant temperature
gauge, low battery charge warning, oil pressure warning, brake
system warning, coolant temperature warning, low coolant level
warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front and rear wash/wipe, stop-lights, headlight washer, radio,
accessories, storage tray light, map reading light . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette lighter, clock, interior lights, boot light, central door
locking, radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horns, heated rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrically-operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear foglight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail light, number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel illumination, side lights . . . . . . . . . . . . . . . . . . . .

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12•2 Body electrical system

Fuses (1989 to 1991 - all models)

No Circuit protected

Rating (amp)

Reversing lights, tachometer, fuel gauge, warning lights (low
battery charge, coolant temperature, oil pressure, low coolant
level, brake system, choke). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction indicators, gauges (fuel, oil temperature, . . . . . .coolant
temperature, oil pressure), heater blower . . .motor, warning lights
(low battery charge, coolant temperature, oil pressure, low coolant
level, brake system, choke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Map reading light, stop-lights, windscreen and tailgate wash/wipe,
tachometer, radio, glovebox light, electric windows, heated rear
window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette lighter, clock, interior lights, luggage compartment light,
central locking, radio, power feed to tow bar . . . . . . . . . . . . . . . . .

Horn, heated rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail lights, number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel illumination, side lights . . . . . . . . . . . . . . . . . . . .

Electric fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (1991 models onward)

No Circuit protected

Rating (amp)

Direction indicators, gauges (fuel, oil temperature, coolant
temperature, oil pressure), heater blower motor, warning lights
(low battery charge, coolant temperature, oil pressure, low
coolant level, brake system, choke, ABS) . . . . . . . . . . . . . . . . . . . .

Map reading light, stop-lights, windscreen and tailgate wash/wipe,
tachometer, radio, glovebox light, heated rear window . . . . . . . . .

Driving lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clock, interior lights, luggage compartment light, central locking,
radio, power feed to tow bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horn, heated rear window, cigarette lighter . . . . . . . . . . . . . . . . . .

Electric windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel illumination, side lights . . . . . . . . . . . . . . . . . . . .

Electric fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses in engine compartment

Circuit protected

Rating (amp)

ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power supply to ABS electronic control unit . . . . . . . . . . . . . . . . . . . . .

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bulbs

Wattage

Headlights:

Non-GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45/40

GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H4 (60/55)

Front parking lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front driving light (GTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H3 (55)

Tail/stop-lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5/21

Reverse light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear foglights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Body electrical system 12•3

12•4 Body electrical system

General information and
precautions

General information

The electrical system is of 12-volt negative

earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid battery which is charged by the
alternator.

This Chapter covers repair and service

procedures for the various electrical
components and systems generally not
associated with the engine. Information on the
battery, ignition system, alternator, and starter
motor can be found in the relevant Parts of
Chapter 5.

Precautions

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.
Caution: Prior to working on any
component in the electrical system, the
battery negative lead should first be
disconnected, to prevent the possibility of
electrical short-circuits and/or fires. If a
radio/cassette player with anti-theft
security code is fitted, refer to the
information given in the reference sections
of this manual before disconnecting the
battery.

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, particularly where an electronic
control unit 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 complete understanding
of the components included in the particular
circuit concerned. The possible sources of a
fault can be narrowed down by noting if other
components related to the circuit are
operating properly. If several components or

circuits fail at one time, the problem is likely to
be related to a shared fuse or earth
connection.
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. 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); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
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.
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.

Finding an open-circuit

9 To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
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 connector nearest the circuit
switch on the component 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
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 during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).

Finding an earth fault

20 The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission and the vehicle body -
and many systems are wired so that they only
receive a positive feed, the current returning
via the metal of the car body. This means that
the component mounting and the body form
part of that circuit. Loose or corroded
mountings can therefore cause a range of
electrical faults, ranging from total failure of a
circuit, to a puzzling partial failure. In
particular, lights may shine dimly (especially
when another circuit sharing the same earth
point is in operation), motors (eg wiper motors
or the radiator cooling fan motor) may run
slowly, and the operation of one circuit may
have an apparently-unrelated effect on
another. Note that on many vehicles, earth
straps are used between certain components,
such as the engine/transmission and the
body, usually where there is no metal-to-
metal contact between components, due to
flexible rubber mountings, etc.
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
both the bodyshell and the wire terminal (or
the component earth connection mating
surface) back to bare metal. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
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.

Fuses and relays - general
information

Fuses

1 The fuse board is located above the
glovebox on the left-hand side of the facia.
2 Blade type fuses are used and symbols by
the fuses denote the circuit protected.
3 On GTI models an in-line fuse for the fuel
pump is located near the rear of the fuse
board. The fuse board also incorporates a
connector which can be adjusted to supply
the radio with negative or positive current
according to the polarity of the radio fitted. On
later models, additional fuses are located
behind the left-hand side of the radiator, on
the left-hand side of the bulkhead, and near
the horn on 1.9 GTI models.
4 To remove a fuse, first switch off the ignition
then open the glovebox. Depress the spring
clip and lower the fuse board. Pull the fuse out
of its terminals; the wire within the fuse should
be visible; if the fuse is blown the wire will be
broken or melted (see illustration).

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 fuses are also colour-coded for easy
recognition.
6 Persistent blowing of a particular fuse
indicates a fault in the circuit(s) protected.
Where more than one circuit is involved,
switch on one item at a time until the fuse
blows, so showing in which circuit the fault
lies.
7 Besides a fault in the electrical component
concerned, a blown fuse can also be caused
by a short-circuit in the wiring to the
component. Look for trapped or frayed wires
allowing a live wire to touch vehicle metal, and
for loose or damaged connectors.
8 The fuse board is retained at the rear by
two plastic ball and socket joints which can
be snapped apart to remove the assembly.

Relays

9 A relay is an electrically-operated switch,
which is used for the following reasons:

a) A relay can switch a heavy current

remotely from the circuit in which the
current is flowing, allowing the use of
lighter gauge wiring and switch contacts.

b) A relay can receive more than one control

input, unlike a mechanical switch.

c) A relay can have a timer function - for

example an intermittent wiper delay.

10 If a circuit which includes a relay develops
a fault, remember that the relay itself could be
faulty. Testing is by substitution of a known
good relay. Do not assume that relays which
look similar are necessarily identical for
purposes of substitution.
11 Relays are incorporated in most circuits
and are mounted on the fuse board or within
the engine compartment.

12 Make sure that the ignition is switched off,
then pull the relay from its socket. Push the
new relay firmly in to refit. Refer to the wiring
diagram key for a list of relays.

Switches - removal and
refitting

Steering column combination
switches

1 Disconnect the battery negative lead.
2 Remove the steering wheel and column
shrouds, with reference to Chapter 10.
3 Disconnect the wiring harness plug.
4 Remove the relevant screws and withdraw
the switch from the column platform (see
illustration).
5 Refitting is a reversal of removal.

Facia switches (pre-1988
models)

6 Disconnect the battery negative lead.
7 Carefully prise out the switch against the
tension of the plastic retaining tabs (see
illustration).
8 Disconnect the wiring or multi-plug, noting
the fitted location, and remove the switch.
9 Refitting is a reversal of removal.

Body electrical system 12•5

4.7 Heated rear window switch and cigar

lighter removed from facia

3.4 Removing a fuse

4.4 Combination switch screws (arrowed)

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