citroen zx-12

Chapter 12 Body electrical systemsContentsAnti-theft alarm system - general information 24Battery check and maintenance See Chapter 1Battery - removal and refitting See Chapter 5Bulbs (exterior lights) - renewal 5Bulbs (interior lights) - renewal 6Cigarette lighter - removal and refitting 13Clock - removal and refitting 11"Dim-dip" lighting system (UK models only) - general information .. 25Door-open warning display - general information 12Electrical fault finding - general information 2Exterior light units - removal and refitting 7Fuses and relays - general information 3General information and precautions 1Headlight beam alignment - general information 8Horn - removal and refitting 15Instrument panel components - removal and refitting 10Instrument panel - removal and refitting 9"Lights-on" warning buzzer - general information 14Loudspeakers - removal and refitting 22Radio aerial - removal and refitting 23

Degrees of difficulty

Radio/cassette player - removal and refitting 21Reversing light switch (models with manual

transmission) - removal and refitting See Chapter 7ASelector lever position display switch (models with automatic

transmission) - removal, refitting and adjustment .. See Chapter 7BSpeedometer drive cable - removal and refitting 16Starter inhibitor/reversing light switch (models with automatic

transmission) - removal and refitting See Chapter 7BStop-light switch - removal, refitting and adjustment . See Chapter 9Switches - removal and refitting 4Tailgate wiper motor - removal and refitting 19Windscreen/headlight washer system check

and adjustment See Chapter 1Windscreen/tailgate washer system components -

removal and refitting 20Windscreen/tailgate wiper blade check and renewal . See Chapter 1Windscreen wiper motor and linkage - removal and refitting 18Wiper arm - removal and refitting 17Wiring diagrams - explanatory notes 26

Easy, suitable fornovice with littleexperience

Fairly easy, suitablefor beginner withsome experience

Fairly difficult, suitablefor competent DIYmechanic

Difficult, suitable forexperienced DIYmechanic

Very difficult,suitable for expert DIYor professional

SpecificationsSystem type 12-volt, negative earth

Facia f usebox fusesFuse Rating (amps) Circuit(s) protectedF1 30 Heater blower motor, headlamp washers, electric mirrors, air

conditioning relay, headlamp washer timer and heated seatsF2 10 Radio/cassette, instrument panel, stop-lights, front and rear

wash/wipe and "lights-on" buzzerF3 30 Heated rear window relay, electric window relay, indicators and

cooling fan relay(s)F4 25 Central locking and anti-theft alarmF5 25 Heated rear window and heated exterior mirrorF6 10 Hazard warning lightsF7 10 Reversing lights, facia panel lights and instrument panel warning

lightsF8 20 Radio/cassette, interior lights, cigarette lighter, luggage

compartment light, clock and remote central locking receiverF9 30 Electric windows, sunroof, seat adjustment and map reading lightF10 20 HornF11 5 Rear foglightF12 5 Right-hand front and rear sidelights, ashtray and cigarettelighter

illumination, "lights-on" buzzer and switch illuminationF13 5 Left-hand front and rear sidelights, number plate light

Junction box fuses (two-fuse arrangement)F1 - UnusedF2 - UnusedF3 5 Cooling fan relayF4 30 Cooling fan

12•1

12•2 Body electrical systems

Junct ion box f u s e s ( four- fuse a r r a n g e m e n t )F1 15 Front foglightsF2 30 Heater blower motor and air conditioning controlsF3 30 Supplementary cooling fanF4 30 Cooling fanNote: Not all items fitted to all models

Bulbs Fitting WattageHeadlights:

Dip/main beam bulb H4 60/55Individual main beam (where fitted) H1 55

Front foglights H3 55Front sidelights Capless 5Direction indicators Bayonet 21Direction indicator side repeaters Capless 5Interior lights Capless 5Luggage boot light Capless 5Heater control panel illumination Capless 1.2Instrument panel warning lights/illumination Integral with holder 1.2Clock illumination Integral with holder 1.2Stop/tail lights Bayonet 21/5Rear foglight Bayonet 21Reversing lights Bayonet 21

Warning: Before carrying out anywork on the electrical system,read through the precautions

given in "Safety first!" at the beginning ofthis manual, and in Chapter 5.

The electrical system is of 12-volt negativeearth type. Power for the lights and allelectrical accessories is supplied by alead/acid type battery, which is charged bythe alternator.

This Chapter covers repair and serviceprocedures for the various electricalcomponents not associated with engine.Information on the battery, alternator andstarter motor can be found in Chapter 5.

It should be noted that, prior to working onany component in the electrical system, thebattery negative terminal should first bedisconnected, to prevent the possibility ofelectrical short-circuits and/or fires.

Caution: If the radio/cassetteplayer fitted to the vehicle is onewith an anti-theft security code,

as the standard unit is, refer to theinformation given in the preliminarySections of this manual beforedisconnecting the battery.

Note: Refer to the precautions given in"Safety first!" and in Section 1 of this Chapterbefore starting work. The following tests relateto testing of the main electrical circuits, andshould not be used to test delicate electroniccircuits (such as anti-lock braking systems),

particularly where an electronic controlmodule is used.

General1 A typical electrical circuit consists of anelectrical component, any switches, relays,motors, fuses, fusible links or circuit breakersrelated to that component, and the wiring andconnectors which link the component to boththe battery and the chassis. To help topinpoint a problem in an electrical circuit,wiring diagrams are included at the end of thismanual.2 Before attempting to diagnose an electricalfault, first study the appropriate wiringdiagram, to obtain a more completeunderstanding of the components included inthe particular circuit concerned. The possiblesources of a fault can be narrowed down bynoting whether other components related tothe circuit are operating properly. If severalcomponents or circuits fail at one time, theproblem is likely to be related to a shared fuseor earth connection.3 Electrical problems usually stem fromsimple causes, such as loose or corrodedconnections, a faulty earth connection, ablown fuse, a melted fusible link, or a faultyrelay (refer to Section 3 for details of testingrelays). Visually inspect the condition of allfuses, wires and connections in a problemcircuit before testing the components. Usethe wiring diagrams to determine whichterminal 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 (a12-volt bulb with a set of test leads can alsobe used for certain tests); a self-powered testlight (sometimes known as a continuity tester);an ohmmeter (to measure resistance); abattery and set of test leads; and a jumper

wire, preferably with a circuit breaker or fuseincorporated, which can be used to bypasssuspect wires or electrical components.Before attempting to locate a problem withtest instruments, use the wiring diagram todetermine where to make the connections.5 To find the source of an intermittent wiringfault (usually due to a poor or dirtyconnection, or damaged wiring insulation), a"wiggle" test can be performed on the wiring.This involves wiggling the wiring by hand, tosee if the fault occurs as the wiring is moved.It should be possible to narrow down thesource of the fault to a particular section ofwiring. This method of testing can be used inconjunction with any of the tests described inthe following sub-Sections.6 Apart from problems due to poorconnections, two basic types of fault canoccur in an electrical circuit - open-circuit, orshort-circuit.7 Open-circuit faults are caused by a breaksomewhere in the circuit, which preventscurrent from flowing. An open-circuit fault willprevent a component from working, but willnot cause the relevant circuit fuse to blow.8 Short-circuit faults are caused by a "short"somewhere in the circuit, which allows thecurrent flowing in the circuit to "escape" alongan alternative route, usually to earth. Short-circuit faults are normally caused by abreakdown in wiring insulation, which allows afeed wire to touch either another wire, or anearthed component such as the bodyshell. Ashort-circuit fault will normally cause therelevant circuit fuse to blow.

Finding an open-circuit9 To check for an open-circuit, connect onelead of a circuit tester or voltmeter to eitherthe negative battery terminal or a known goodearth.

1 General information andprecautions

2 Electrical fault finding -general information

Body electrical systems 12•3

10 Connect the other lead to a connector inthe circuit being tested, preferably nearest tothe battery or fuse.11 Switch on the circuit, bearing in mind thatsome circuits are live only when the ignitionswitch is moved to a particular position.12 If voltage is present (indicated either bythe tester bulb lighting or a voltmeter reading,as applicable), this means that the section ofthe circuit between the relevant connectorand the battery is problem-free.13 Continue to check the remainder of thecircuit in the same fashion.14 When a point is reached at which novoltage is present, the problem must liebetween that point and the previous test pointwith voltage. Most problems can be traced toa broken, corroded or loose connection.

Finding a short-circuit15 To check for a short-circuit, firstdisconnect the load(s) from the circuit (loadsare the components which draw current froma circuit, such as bulbs, motors, heatingelements, etc).16 Remove the relevant fuse from the circuit,and connect a circuit tester or voltmeter to thefuse connections.17 Switch on the circuit, bearing in mind thatsome circuits are live only when the ignitionswitch is moved to a particular position.18 If voltage is present (indicated either bythe tester bulb lighting or a voltmeter reading,as applicable), this means that there is ashort-circuit.19 If no voltage is present, but the fuse stillblows with the load(s) connected, thisindicates an internal fault in the load(s).

Finding an earth fault20 The battery negative terminal isconnected to "earth" - the metal of theengine/transmission unit and the car body -and most systems are wired so that they onlyreceive a positive feed, the current returningvia the metal of the car body. This means thatthe component mounting and the body formpart of that circuit. Loose or corrodedmountings can therefore cause a range ofelectrical faults, ranging from total failure of acircuit, to a puzzling partial fault. In particular,

lights may shine dimly (especially whenanother circuit sharing the same earth point isin operation), motors (eg wiper motors or theradiator cooling fan motor) may run slowly,and the operation of one circuit may have anapparently-unrelated effect on another. Notethat on many vehicles, earth straps are usedbetween certain components, such as theengine/transmission and the body, usuallywhere there is no metal-to-metal contactbetween components, due to flexible rubbermountings, etc.

21 To check whether a component isproperly earthed, disconnect the battery, andconnect one lead of an ohmmeter to a knowngood earth point. Connect the other lead tothe wire or earth connection being tested. Theresistance reading should be zero; if not,check the connection as follows.22 If an earth connection is thought to befaulty, dismantle the connection, and cleanback to bare metal both the bodyshell and thewire terminal or the component earthconnection mating surface. Be careful toremove all traces of dirt and corrosion, thenuse a knife to trim away any paint, so that aclean metal-to-metal joint is made. Onreassembly, tighten the joint fastenerssecurely; if a wire terminal is being refitted,use serrated washers between the terminaland the bodyshell, to ensure a clean andsecure connection. When the connection isremade, prevent the onset of corrosion in thefuture by applying a coat of petroleum jelly orsilicone-based grease, or by spraying on (atregular intervals) a proprietary ignition sealeror a water-dispersant lubricant.

Fuses1 Most of the fuses are located behind thedriver's side lower facia panel, with a few oddfuses on some models being located in thejunction box on the left-hand side of theengine compartment.2 To gain access to main fusebox, release thethree fasteners by rotating them through 90°,

3 Fuses and relays -general information

then remove the driver's side lower faciapanel. To gain access to those in the junctionbox, unclip the junction box lid, then releasethe retaining clip, and lift the small coversituated inside the box (see illustration 3.7a).3 The fuse number is marked on the fuseboxnext to each fuse; a list of the circuits eachfuse protects is given in the Specifications atthe start of this Chapter. Plastic tweezers arealso clipped into the fusebox, and can beused to remove and fit the fuses (seeillustration).4 To remove a fuse, first switch off the circuitconcerned (or the ignition), then fit thetweezers and pull the fuse out of its terminals.Slide the fuse sideways from the tweezers.The wire within the fuse is clearly visible; if thefuse is blown, it will be broken or melted.5 Always renew a fuse with one of anidentical rating; never use a fuse with adifferent rating from the original, or substituteanything else. Never renew a fuse more thanonce 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 foreasy recognition.6 If a new fuse blows immediately, find thecause before renewing it again; a short toearth as a result of faulty insulation is mostlikely. Where a fuse protects more than onecircuit, try to isolate the defect by switchingon each circuit in turn (if possible) until thefuse blows again. Always carry a supply ofspare fuses of each relevant rating in thevehicle.

Relays7 The majority of relays are located either inthe junction box located on the left-hand sideof the engine compartment (see illustration),or are located behind the driver's lower faciapanel, directly behind the fusebox. Theexceptions 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 theside of the radiator where only one fan isfitted (see illustration).

3.3 Using the plastic tweezers supplied toremove a fuse from the main fusebox

3.7a Engine compartment junction boxrelays. Fuses are located beneath the

small cover (arrowed)

3.7b On models with twin cooling fans, thefan 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 forfurther information, and to the relevant wiringdiagram for details of wiring connections.9 If a circuit or system controlled by a relaydevelops 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 isenergized. If this is the case, the fault lies withthe components or wiring of the system. If therelay is not being energized, then either therelay is not receiving a main supply or aswitching voltage, or the relay itself is faulty.Testing is by the substitution of a known goodunit, but be careful; while some relays areidentical in appearance and in operation,others look similar but perform differentfunctions.10 To renew a relay, first ensure that theignition switch is off. The relay can thensimply be pulled out from the socket, and thenew relay pressed in.

Note: Disconnect the battery negative leadbefore removing any switch, and reconnectthe lead after refitting the switch.

Ignition switch/steering columnlock1 Refer to Chapter 10, Section 21.

4.5b . . . then disconnect the wiringconnectors, and slide off the combination

switch assembly

Steering column combinationswitches2 Remove the steering wheel as described inChapter 10.3 Release the panel fasteners by rotatingthem through a quarter of a turn, and removethe driver's side lower facia panel.4 Slacken and remove the five screws whichsecure the two halves of the steering columnshrouds together, then remove both the upperand lower shroud.5 Undo the three retaining screws, thendisconnect the wiring connectors from therear of the combination switches, and lift theswitch assembly off the steering column (seeillustrations).6 Unscrew the two retaining screws, andslide the relevant switch assembly out ofposition (see illustrations).7 Refitting is a reversal of the removalprocedure.

Instrument panel dimmer switch,exterior mirror switch, alarmswitch and air conditioning switch8 Using a suitable flat-bladed screwdriver,carefully prise the relevant switch panel out ofthe facia, taking great care not to mark eitherthe panel or facia.9 Disconnect the wiring connector from theswitch, then depress the retaining tangs, and

4.6a Undo the two retaining screws . . .

slide the switch out of the panel (seeillustration).10 Slide the switch back into the panel until itclicks into position. Reconnect the wiringconnector, then clip the panel back into thefacia.

Instrument shroud switches11 Release the panel fasteners by rotatingthem through a quarter of a turn, and removethe driver's side lower facia panel.12 Slacken and remove the five screwswhich secure the two halves of the steeringcolumn shrouds together, then remove boththe upper and lower shroud.13 Slacken and remove the four instrumentpanel shroud retaining screws, then removethe shroud, disconnecting the switch wiringconnectors as they become accessible.14 Depress the retaining tangs, and slide therelevant switch out of the shroud (seeillustration).15 Refitting is a reverse of the removalprocedure.

Courtesy light switches16 Open up the door, then prise the rubbergaiter from the courtesy switch.17 Undo the retaining screw, then withdrawthe switch from the pillar, disconnecting itswiring connector as it becomes accessible.Tie a piece of string to the wiring, to prevent itfalling back into the door pillar.

4.6b . . . and slide the relevant switchassembly out from the combination switch

bracket

4.9 Removing the instrument paneldimmer switch

4.14 Removing an instrument shroudswitch

4 Switches - removal and refitting


4.19a Prise the luggage compartment lightswitch out of the trim pane l . . .

18 Refitting is a reverse of the removalprocedure, ensuring that the rubber gaiter iscorrectly seated on the switch.

Luggage compartment lightswitch19 Open up the tailgate, then carefully prisethe switch out from the left-hand trim panel,and disconnect its wiring connector (seeillustrations). Tie a piece of string to thewiring, to prevent it falling back behind thetrim panel.20 Reconnect the wiring connector, and clipthe switch back into position in the trim panel.

Handbrake warning light switch21 Open up the rear ashtray, then depressthe retaining tang and remove the ashtrayfrom the handbrake lever cover panel.Slacken and remove the rear retaining nut andthe two front retaining screws, thenmanoeuvre the cover panel off the handbrakelever.22 Disconnect the wiring connector from thehandbrake switch, then undo the retainingscrew and remove the switch from the side ofthe handbrake lever (see illustration).23 Refitting is a reverse of the removalprocedure.

Electric window switches24 Carefully prise the window switch out ofthe armrest, taking great care not to mark theswitch or the armrest, and disconnect thewiring connector (see illustrations).

4.19b . . . then withdraw the switch anddisconnect its wiring connector

25 On refitting, connect the wiring connector,and clip the switch back into position in thearmrest.

Electric sunroof switch26 Carefully prise the courtesy light out fromthe overhead console, and disconnect it fromits wiring connector. Remove the two consoleretaining screws, then lower the console outof position, and disconnect it from its wiringconnectors.27 Depress the retaining tangs, and slide thesunroof switch out of the console (seeillustration).28 Refitting is a reverse of the removalprocedure.

General1 Whenever a bulb is renewed, note thefollowing 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 metal-to-metal contact between the bulb and itslive(s) and earth. Clean off any corrosionor dirt before fitting a new bulb.

4.22 Handbrake warning light switchretaining screw (arrowed)

(d) Wherever bayonet-type bulbs are fitted(see Specifications) ensure that the livecontacts) bear firmly against the bulbcontact.

(e) Always ensure that the new bulb is of thecorrect rating, and that it is completelyclean before fitting it; this appliesparticularly to headlight/foglight bulbs(see below).

Headlight2 Working in the engine compartment,remove the relevant plastic cover from therear of the headlight unit.3 Disconnect the wiring connectors, thenpress together the ends of the bulb retainingclip, and release it from the rear of the light(see illustrations).

4.24a Carefully prise the window switchout of the armrest. . .

4.24b . . . and disconnect it from its wiring 4.27 Depress the retaining tangs, and slideconnector out the sunroof switch

5.3a Disconnect the wiring connectorsfrom the headlight bulb . . .

5 Bulbs (exterior lights) -renewal


5.3b . . . then release the retaining clip . . . 5.4 . . . and withdraw the bulb from therear of the light unit

4 Withdraw the bulb (see illustration).5 When handling the new bulb, use a tissueor clean cloth, to avoid touching the glasswith the fingers; moisture and grease from theskin can cause blackening and rapid failure ofthis type of bulb.

If the headllight glass isaccidentally touched, wipe itclean using methylated spirit.

5.11 Unhook the retaining spring fromwithin the engine compartment...

5.12 . . . then withdraw the directionindicator from the front of the vehicle, and

release its bulbholder

6 Install the new bulb, ensuring that itslocating tabs are correctly located in the lightcut-outs. Secure the bulb in position with theretaining clip, and reconnect the wiringconnectors.7 Slide the plastic cover back into position,ensuring that it is correctly seated on the rearof the light unit.

Front sidelight8 Working in the engine compartment, twistthe bulbholder anti-clockwise, then withdrawit from the headlight unit (see illustration).Note that on some models, it will benecessary to displace the plastic cover fromthe rear of the unit to gain access to thebulbholder.9 The bulb is of the capless (push-fit) type,and can be removed by simply pulling it out ofthe bulbholder.10 Refitting is the reverse of the removal

5.8 Removing the sidelight bulbholderfrom the rear of the headlight unit

procedure, ensuring that the bulbholder sealis in good condition.

Front direction indicator11 Working in the engine compartment, frombehind the light, unhook the retaining springand withdraw the light unit from the front ofthe vehicle (see illustration).12 Twist the bulbholder in a clockwisedirection to free it from the light, and removethe light unit (see illustration).13 The bulb is a bayonet fit in the holder, andcan be removed by pressing it and twisting inan anti-clockwise direction.14 Refitting is a reverse of the removalprocedure, ensuring that the light unit iscorrectly located and securely retained by itsspring.

Front direction indicator siderepeater15 Push the light unit towards the rear ofthe vehicle, to free its retaining clips,then withdraw it from the wing (seeillustration).16 Pull the bulbholder out of the light unit,then pull the capless (push-fit) bulb out of its'holder (see illustrations).17 Refitting is a reverse of the removalprocedure.

Front foglight18 Undo the two retaining screws, and

5.15 Push the direction indicator siderepeater towards the rear of the vehicle, to

release its retaining clips . . .5.16a . . . then withdraw the light from thewing, and disengage it from its bulbholder

5.16b Side repeater bulb is of the caplesstype, being a push-fit in the holder


5.18 Undo the two retaining screws, andwithdraw the lens unit from the foglight

withdraw the lens unit from the front of thelight (see illustration).19 Release the retaining clip, and withdrawthe bulb from the rear of the unit. Unclip theplastic insulator cover, then disconnect thebulb wiring connector and remove the bulb(see illustrations).20 When handling the new bulb, use a tissueor clean cloth, to avoid touching the glasswith the fingers; moisture and grease from theskin can cause blackening and rapid failure ofthis type of bulb. If the glass is accidentallytouched, wipe it clean using methylated spirit.21 Connect the new bulb to the wiringconnector, and refit the plastic insulator coverto the connector.22 Install the bulb in the rear of the lens,ensuring that its locating tabs are correctlylocated in the cut-outs. Secure the bulb inposition with the retaining clip, ensuring thatthe wiring insulator is correctly locatedunderneath the clip (see illustration).23 Refit the lens to the light unit, taking greatcare not trap the wiring, and securely tightenits retaining screws.

Rear light cluster24 Open up the tailgate, then undo the tworetaining screws and remove the lens from the

5.25 Rear light cluster bulbs

A Direction indicatorB Reversing lightC Stop/tail lightD SidelightE Foglight (where fitted)

5.19a Unclip the plastic insulator cover . . .

rear light cluster, noting its rubber seal (seeillustration).25 The relevant bulb can then be renewed -all bulbs have a bayonet fitting (seeillustration). Note that the stop/tail light bulbhas offset locating pins, to prevent it beinginstalled incorrectly.26 Refitting is the reverse of the removalsequence, noting that the rubber lens sealmust be renewed if damaged.

Number plate light27 Raise the tailgate slightly to improveaccess to the light, then carefully prise out thelight lens to gain access to the bulb.28 The bulb is of the capless (push-fit) type,and is simply pulled out of position.29 Push in the new bulb, and clip the lensback into position.

General1 Refer to Section 5, paragraph 1.

Courtesy lights2 Carefully prise the light unit out of position,then twist the bulbholder in an anti-clockwisedirection, and remove it from the rear of thelight unit (see illustrations).3 The bulb is of the capless (push-fit) type;

5.19b . . . then disconnect the wiringconnector and withdraw the foglight bulb

5.22 Prior to refitting the foglight lens,ensure that the plastic insulator (arrowed)

is correctly positioned underneath theretaining clip

5.24 Rear light cluster lens is retained bytwo screws

6.2a Prise the courtesy light out ofposition . . .

6.2b . . . and twist the bulbholder anti-clockwise to release it from the rear of the

light unit

6 Bulbs (interior lights) - renewal


6.5 Removing the luggage compartmentlight bulbholder

pull the old bulb out of the holder, and pressthe new one into position.4 Refit the bulbholder to the rear of the lightunit, and clip the light unit back into position.

Luggage compartment light5 Refer to the information given above inparagraphs 2 to 5 (see illustration).

Map reading light6 Carefully prise the map reading light unitout of the headlining, then disconnect thewiring connector and remove the light unit(see illustrations).7 Swivel the bulbholder unit fully away fromthe wiring connector, then pull the bulbholder

6.7 Align the bulbholder with the arrow(arrowed) on the light unit, and pull in the

direction of the arrow to remove thebulbholder

6.6a Carefully prise the map reading lightout of the overhead console . . .

lever in the direction of the arrow cast on thelight unit, to disengage the holder from thelight unit (see illustration).8 The bulb is of the capless (push-fit) type;pull the old bulb out of the holder, and pressthe new one into position (see illustration).9 Slide the bulbholder back onto its pivot inthe light unit, then connect the wiringconnector, and clip the light unit back intoposition in the headlining.

Instrument panel lights10 Remove the instrument panel asdescribed in Section 9.11 Twist the relevant bulbholder anti-clockwise, and withdraw it from the rear of thepanel (see illustration).12 All bulbs are integral with their holders. Bevery careful to ensure that the new bulbs areof the correct rating, the same as thoseremoved; this is especially important in thecase of the alternator/no-charge warning light.13 Refit the bulbholder to the rear of theinstrument panel, then refit the instrumentpanel as described in Section 9.

Selector lever position displaybulbs - models with automatictransmission14 Remove the centre console as describedin Chapter 11.15 Twist the relevant bulbholder anti-clockwise, and withdraw it from the rear of thepanel.

6.6b . . . and disconnect it from its wiringconnector

16 The bulbs are of the capless (push-fit)type; pull the old bulb out of the holder, andpress the new one into position.17 Refit the bulbholder to the rear of thepanel, then refit the centre console asdescribed in Chapter 11.

Clock illumination bulb18 Remove the clock as described in Sec-tion 11.19 Twist the bulbholder anti-clockwise, andwithdraw it from the rear of the clock (seeillustration). The bulb is integral with itsholder.20 Refit the bulbholder to the rear of theclock, then refit the clock as described inSection 11.

Cigarette light/ashtrayillumination bulb21 Remove the centre console as describedin Chapter 11.22 Where a radio/cassette player is fitted,remove it as described in Section 21, thenundo the two retaining screws and remove themounting bracket from the radio aperture.Where no radio/cassette player is fitted,carefully prise out the storage box from thecentre of the facia panel.23 Undo the four centre vent panel retainingscrews (two located above the heatercontrols, and two directly below), then unclipthe panel and withdraw it from the facia (seeillustrations 13.3a and 13.3b).

6.8 The map reading light bulb is of thecapless type

6.11 Removing an instrument panel bulbfrom the rear of the panel

6.19 Removing the clock illumination bulb


6.24 Removing the cigarettelighter/ashtray illumination bulb

24 Slide the illumination bulbholder out of thepanel, and renew the bulb (see illustration).The bulbs is of the capless (push-fit) type; pullthe old bulb out of the holder, and press thenew one into position.25 Slide the illumination bulbholder back intoposition, and refit the panel by reversing theremoval procedure.

Heater control panel illuminationbulb26 Carry out the operation described abovein paragraph 22.27 Reaching in through the radio/storage boxaperture, rotate the relevant bulbholder anti-clockwise to free it from the rear of the panel.The bulbs are of the capless (push-fit) type;pull the old bulb out of the holder, and pressthe new one into position.28 Refitting is a reverse of the removalprocedure.

Switch illumination bulbs29 All of the switches are fitted withilluminating bulbs; some are also fitted with abuib to show when the circuit concerned isoperating. These bulbs are an integral part ofthe switch assembly, and cannot be obtainedseparately. Bulb replacement will thereforerequire the renewal of the complete switchassembly.

7 Exterior light units -removal and refitting

Note: Disconnect the battery negative leadbefore removing any light unit, and reconnectthe lead after refitting the light.

Headlight1 Open the bonnet, then slacken and removethe three retaining screws, and remove theplastic cover from the bonnet lock. Slackenthe three retaining screws, and remove theradiator grille (see illustration).2 Remove the direction indicator light asdescribed below.3 Remove the plastic cover(s) from the rear ofthe headlight unit, and disconnect the wiringconnectors from both the headlight and

7.1 Radiator grille is retained by threescrews (arrowed)

sidelight bulbs (and, where fitted, from theheadlight adjustment motor).4 Using pliers, slide out the retaining clip fromthe top headlight mounting point (where fitted)(see illustration).5 Pull the headlight forwards, to release itfrom its two retaining spring clips, and removethe headlight from the vehicle (seeillustrations).6 Refitting is a direct reversal of the removalprocedure. On completion, check theheadlight beam alignment, using theinformation given in Section 8.

Front direction indicator light7 Open the bonnet, and from within theengine compartment, unhook the indicatorlight retaining spring from the vehicle body.8 Withdraw the light unit from the front of thevehicle, and disconnect its wiring connector.

7.4 Using pliers remove the retaining clipfrom the top headlight mounting point

9 Refitting is the reverse of removal.

Front direction side repeater light10 Push the light unit towards the rear of thevehicle, to free its retaining clips, thenwithdraw it from the wing and disconnect itswiring connector.11 On refitting, reconnect the wiringconnector to the light, then clip it back intoposition on the wing.

Front foglight12 Jack up the front of the vehicle, andsupport it on axle stands.13 Trace the wiring back from the rear of thefoglight, and disconnect it at the wiringconnector (see illustration).14 Slacken and remove the foglight retainingnut, and withdraw the light unit from the frontof the bumper (see illustrations).

7.5a Pull the headlight forwards, torelease it from its retaining spring clips . . .

7.5b . . . and withdraw the headlight unitfrom the vehicle

7.13 Disconnect the wiring connector . . . 7.14a . . . then slacken and remove theretaining nut . .


7.14b . . . and withdraw the foglight fromthe front of the bumper

15 Refitting is the reverse of removal.

Rear light cluster

16 Remove the luggage compartment lowerside trim panel as described in Chapter 11,Section 26.17 Slacken and remove the rear light clusterretaining nut, then free the light cluster fromthe rear of the vehicle, and disconnect itswiring connector (see illustrations).18 Refitting is a reversal of the removalprocedure.

Number plate light

19 Raise the tailgate slightly to improveaccess to the light, then carefully prise out thelight lens and disconnect its wiring connector.

9.3a Remove the driver's side lower faciapanel . . .

7.17a Undo the retaining nut situated onthe inside of the luggage compartment...

20 On refitting, reconnect the wiringconnector, and clip the light back into position.

7.17b . . . then remove the rear light unitfrom the rear of the vehicle, anddisconnect its wiring connector

1 Accurate adjustment of the headlight beamis only possible using optical beam-settingequipment, and this work should therefore becarried out by a Citroen dealer or suitably-equipped workshop.2 For reference, the headlights can beadjusted using a suitable-sized Allen key torotate the adjuster assemblies fitted to the topof each light unit. The outer adjuster alters thevertical height of the beam, whilst the inneradjuster alters the horizontal position of thebeam. Prior to adjustment, ensure that thevehicle is unladen, and the adjuster units (seebelow) are both set to position "0".3 Each headlight unit is equipped with a four-position adjuster unit - this can be used toadjust the headlight beam, to compensate forthe relevant load which the vehicle is carrying.The adjuster units are incorporated into thevertical beam adjuster; access to them can begained with the bonnet open. Position "0" isthe standard position, positions " 1 " and "2"for when the vehicle is partly-laden, andposition "3" for when the vehicle is fully-laden.Ensure that both adjusters are set to the sameposition, and be sure to reset to position "0"once the load has been removed.

Removal

1 Disconnect the battery negative terminal.2 Remove the steering wheel as described inChapter 10.3 Release the panel fasteners by rotatingthem through a quarter of a turn, and removethe driver's side lower facia panel. Release theheater duct, and remove it from behind thepanel (see illustrations).4 Slacken and remove the five screws whichsecure the two halves of the steering columnshrouds together, then remove both the upperand lower shroud. Release the steeringcolumn, and lock it in its lowest position.5 Undo the two retaining screws, and free thefusebox from the facia panel (seeillustration).6 Slacken and remove the two bolts securingthe bonnet release lever to the facia, and freethe release lever assembly from the facia.Undo the heater duct retaining screw, locateddirectly beneath the bonnet release lever, thenmanoeuvre the heater duct out from thebehind the facia (see illustration).7 Slacken and remove the four instrumentpanel shroud retaining screws, then removethe shroud, disconnecting the switch wiring

9.6 Undo the two bonnet release leverretaining bolts, and free the lever from itsbracket. Heater duct retaining screw is

9.3b . . . and remove the heater duct frombehind the panel

9.5 Fusebox retaining screws (arrowed)

8 Headlight beam alignment -general information

9 Instrument panel -removal and refitting


9.7a Slacken and remove the instrument 9.7b . . . then disconnect the switch wiringpanel shroud retaining screws (arrowed)... connectors and remove the shroud

9.9a Undo the retaining screws(arrowed)...

9.9b . . . then withdraw the instrumentpanel from the facia . . .

connectors as they become accessible (seeillustrations).8 Reaching in through the lower faciaaperture, reach up behind the instrumentpanel, then depress the retaining tangs anddetach the speedometer cable from the rearof the panel.9 Undo the two lower retaining screws, thenwithdraw the instrument panel assembly fromthe facia. Disconnect the wiring connectorsfrom the rear of the panel, and remove theassembly from the vehicle (see illustrations).

Refitting10 Refitting is a reversal of the removalprocedure. On completion, reconnect thebattery and check the operation of all thepanel warning lights and the instrument panelshroud switches, to ensure that they arefunctioning correctly.

9.9c . . . and disconnect the wiringconnectors (arrowed) from the rear of the

panel

10.2a Slacken and remove the threeinstrument panel cover retaining screws

(arrowed)...

10 Instrument panel components- removal and refitting

General1 Remove the instrument panel as describedin Section 9, then proceed as described underthe relevant sub-heading.

Speedometer2 Slacken and remove the three panel frontcover retaining screws from the rear of the

10.2b . . . then release the retaining clips,and separate the panel and cover

instrument panel. Carefully release the sixretaining clips situated around the outside ofthe cover, then separate the cover andinstrument panel (see illustrations).3 Undo the two retaining screws from thefront of the speedometer face, then undo thetwo retaining bolts from the rear of the panel,and withdraw the speedometer (seeillustrations).4 Refitting is a reverse of the removalprocedure. Do not overtighten the instrumentpanel fasteners, as the plastic is easilycracked.

Tachometer5 Remove the panel front cover as describedin paragraph 2.

10.3a Instrument panel component frontfasteners

A Speedometer screwsB Tachometer screwsC Temperature gauge screwD Fuel gauge screw

10.3b Instrument panel component rearfasteners

A Speedometer boltsB Fuel gauge nuts

C Rear cover screws


10.6 Instrument panel rear cover wiringconnector

10.7 Tachometer rear retaining nuts and 10.11 Temperature gauge retaining nutsprinted circuit board (arrowed)

6 Undo the two screws and remove the coverfrom the rear of panel, disconnecting its wiringconnector as it becomes accessible (seeillustration).7 Undo the four retaining nuts, and removethe circuit board from the rear of thetachometer (see illustration).8 Slacken and remove the three screws fromthe front face of the tachometer, and removethe tachometer from the case.9 Refitting is a reverse of the removalprocedure. Do not overtighten the instrumentpanel fasteners, as the plastic is easily cracked.

Temperature gauge10 Remove the front cover and the rearcover, as described in paragraphs 2 and 6.11 Undo the three retaining nuts from therear, and the single screw from the front, ofthe temperature gauge, and withdraw thegauge from the case (see illustration).12 Refitting is a reverse of the removalprocedure. Do not overtighten the instrumentpanel fasteners, as the plastic is easilycracked.

Fuel gauge13 Remove the front cover as described inparagraph 2.14 Slacken and remove the three nuts fromthe rear, and undo the single retaining screwfrom the front face of the gauge, and withdrawthe gauge from the case.

15 Refitting is a reverse of the removalprocedure. Do not overtighten the instrumentpanel fasteners, as the plastic is easily cracked.

Printed circuit16 Remove all the panel instruments asdescribed above.17 Remove all the bulbholders from the rearof the case, by twisting them in an anti-clockwise direction. Slacken and remove allthe circuit retaining screws, then release theprinted circuit from its retaining pins, andremove it from the rear of the case.18 Refitting is a reversal of the removalprocedure, ensuring that the printed circuit iscorrectly located on all the necessaryretaining pins.

11 Clock - removal and refitting

Removal1 Disconnect the battery negative terminal.2 Using a flat-bladed screwdriver, carefullyprise the clock out of the facia panel, takinggreat care not mark the clock or facia (seeillustration).3 Disconnect the wiring connector, andremove the clock (see illustration).

Refitting4 Reconnect the wiring connector, then clipthe clock into the position in the facia.

5 Reconnect the battery negative terminal,then reset the clock.

Some models covered in this manual areequipped with a door-open warning display inthe instrument panel. If a door is not correctlyshut, the relevant door on the warning panelwill be illuminated.

The system consists of switches which arebuilt into the door lock assemblies and thepanel in the instrument cluster. The panelbulbs are the same as the other instrumentpanel bulbs, and can be renewed asdescribed in Section 6. The switches are anintegral part of each door lock assembly.

13 Cigarette lighter -removal and refitting

Removal1 Remove the centre console as described inChapter 11.2 Where a radio/cassette player is fitted,remove it as described in Section 21, thenundo the two retaining screws and remove themounting bracket from the radio aperture.Where no radio/cassette player is fitted,carefully prise out the storage box from thecentre of the facia panel.

11.2 Carefully prise the clock out of thefacia (note the use of padding under the

screwdriver, to avoid damage).. .

11.3 . . . and disconnect its wiringconnector

13.3a Undo the four retaining screws(arrowed)...

12 Door-open warning display -general information


13.3b . . . then withdraw the centre ventpanel, disconnecting the wiring

connectors from the cigarette lighter13.4a Release the retaining tangs, then

withdraw the metal insert. . .13.4b . . . followed by the plastic outer

section of the cigarette lighter

3 Undo the four centre vent panel retainingscrews (two located above the heatercontrols, and two directly below), then unclipthe panel and withdraw it from the facia.Disconnect the wiring connectors from thecigarette lighter and ashtray illumination bulb,and remove the centre vent panel assemblyfrom the vehicle (see illustrations).4 Remove the lighter element, release theretaining tangs and push out the metal insert,then remove the plastic outer section of thelighter (see illustrations).

Refitting

5 Refitting is a reversal of the removalprocedure.

1 Most vehicles covered in this manual areequipped with a "lights-on" warning system.The purpose of the system is to inform thedriver that the lights have been left on oncethe ignition switch has been turned off; thebuzzer will sound when a door is opened. Thesystem consists of a buzzer unit which islinked to the door courtesy light switches.2 To gain access to the buzzer unit, releasethe three fasteners by rotating them through90°, then remove the driver's side lower faciapanel. The buzzer unit is situated in the relaypanel located directly behind the fusebox. The

buzzer unit is a push-fit in the panel, and caneasily be identified by the slots in its cover(see illustration).3 Refer to Section 4 for information oncourtesy light switch removal.

15 Horn - removal and refitting

Removal1 Jack up the front of the vehicle, andsupport it on axle stands.

Electric horn2 Undo the nut securing the horn to itsmounting bracket, then lower the horn out of

position, and disconnect it from its wiringconnector.

Air horn3 Slacken and remove the nut and boltsecuring the horn mounting bracket to thevehicle body, then remove the horn,disconnecting it from its air supply pipe (seeillustrations).4 Disconnect the wiring connector from the aircompressor, then undo the retaining nut andwithdraw the compressor from underneath thevehicle (see illustrations). Recover the spacerfrom the compressor mounting bolt.

Refitting5 Refitting is a reverse of the removalprocedure.

14.2 "Lights-on" warning buzzer (arrowed)is situated behind the main fusebox

15.3a Slacken and remove the retainingnut and bolt (arrowed)...

15.3b . . . then remove the horn,disconnecting it from its supply pipe

15.4a Disconnect the wiring connector . . . 15.4b . . . then undo the retaining nut andremove the air compressor

14 "Lights-on" warning system- general information


16.4 Unscrew the knurled retaining ring,and separate the upper and lower

speedometer cable sections

General1 The drive cable is in two parts; the lowercable runs from the transmission to a pointjust in front of the left-hand end of thebulkhead, while the upper cable runs fromthat point to the rear of the instrument panel.Each section can be removed individually, asfollows.

Upper cableRemoval2 On left-hand-drive models, remove theinstrument panel as described in Section 9.3 On right-hand-drive models, remove thecomplete facia assembly (see Chapter 11).4 Working in the engine compartment,slacken the knurled retaining ring, andseparate the upper and lower cable sections(see illustration). Tie a length of string to theend of the upper section of the cable.5 From inside the vehicle, withdraw the cablefrom the bulkhead. Once the cable is free,untie the string and leave it in position in thevehicle; the string can then be used to drawthe new cable back into position.

Refitting6 Tie the inner end of the string to the end ofthe cable, then use the string to draw thespeedometer cable through into the engine

17.2a Raise the spindle cover, then undothe retaining n u t . . .

compartment. Once the cable is through,untie the string.7 On left-hand-drive models, position thecable so that approximately 145 mm of thecable protrudes into the engine compartment,then connect the end of the cable to the lowercable section, and securely tighten theretaining ring. Refit the instrument panel asdescribed in Section 9.8 On right-hand-drive models, position thecable so that approximately 100 mm of thecable protrudes into the engine compartment,then connect the end of the cable to the lowercable section, and securely tighten theretaining ring. Refit the facia assembly asdescribed in Chapter 11.

Lower cableRemoval9 Apply the handbrake, then jack up the frontof the vehicle and support it on axle stands.10 Working from underneath the vehicle,withdraw the rubber retaining pin, and detachthe cable from the speedometer drive on thetransmission.11 Working in the engine compartment,slacken the knurled retaining ring, then detachthe lower cable section from the uppersection, and remove it from the vehicle.

Refitting

12 Examine the O-rings fitted to the cablelower-end fitting for signs of damage ordeterioration, and renew if necessary. Apply asmear of clean engine oil to the O-rings, to aidinstallation.

17.2b . . . and remove the wiper arm fromthe 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 inthe speedometer drive, and secure it inposition with the rubber retaining pin. Lowerthe vehicle to the ground.

Removal1 Operate the wiper motor, then switch it offso that the wiper arm returns to the at-restposition.

18.3a Undo the six retaining screws . . .18.3b . . . then carefully ease the wiper

motor/vent panel cover out from behindthe windscreen sealing strip

2 Lift up the wiper arm spindle nut cover, thenslacken and remove the spindle nut. Lift theblade off the glass, and pull the wiper arm offits spindle (see illustrations). If necessary,the arm can be levered off the spindle using asuitable flat-bladed screwdriver.

Refitting3 Ensure that the wiper arm and spindlesplines are clean and dry, then refit the arm tothe spindle, aligning the wiper blade with thetape fitted on removal. Refit the spindle nut,tightening it securely, and clip the nut coverback in position.

Removal1 Disconnect the battery negative terminal.2 Remove the wiper arm as described in theprevious Section.3 Open the bonnet, and slacken and removethe six wiper motor cover/vent panel retainingscrews. Carefully ease the cover out frombehind the windscreen sealing strip, thendisengage its front locating pegs, andmanoeuvre the panel away from the vehicle(see illustrations).

16 Speedometer drive cable -removal and refitting

17 Wiper arm -removal and refitting

18 Windscreen wiper motor andlinkage - removal and refitting

Stick a piece of masking tapealong the edge of the wiperblade, to use as an alignmentaid on refitting.


18.4 Disconnect the wiper motor wiringconnector...

4 Disconnect the wiring connector from thefront of the wiper motor (see illustration).5 Remove the plastic cover from the heaterblower motor intake passage (seeillustration).6 Undo the three wiper motor retaining bolts,then manoeuvre the wiper motor out ofposition, and remove it from the vehicle (seeillustrations).7 If necessary, using a suitable flat-bladedscrewdriver, carefully lever the wiper linkageoff the motor spindle balljoint. Slacken andremove the three motor retaining bolts, andseparate the motor and linkage (seeillustration).

Refitting8 Where necessary, assemble the motor andlinkage, and securely tighten the motor

18.5 . . . and remove the plastic cover fromthe blower motor intake duct

retaining bolts. Clip the linkage onto thespindle balljoint, and check that it is securelyretained.9 Manoeuvre the motor assembly back intoposition, and refit the three retaining bolts,tightening them securely.10 Reconnect the wiring connector to themotor, and refit the cover to the blower motorintake passage.11 Manoeuvre the wiper motor/vent coverback into position, and engage its frontlocating pegs with their mounting rubbers(see illustration). Starting at the centre andworking outwards, carefully ease the top edgeof the cover behind the windscreen sealingstrip. Once the cover is correctly seatedbehind the strip, secure it in position with itssix retaining screws.12 Refit the wiper arm as described in

18.6a Undo the three retaining bolts(arrowed)...

Section 17, and reconnect the batterynegative terminal.

19 Tailgate wiper motor -removal and refitting

Removal1 Remove the wiper arm as described inSection 17.2 Unscrew the knurled retaining ring from thewiper spindle, and lift off the trim cover (seeillustrations).3 Open up the tailgate, then release thefasteners by rotating them through a quarterof a turn, and remove the wiper motor coverfrom the centre of the tailgate (seeillustration).

18.6b . . . then remove the wiper motorfrom the vehicle

18.7 Windscreen wiper motor retainingbolts (arrowed)

18.11 On refitting, ensure the wipermotor/vent cover locating pegs (arrowed)

are correctly located

19.2a Unscrew the knurled retainingring . . .

19.2b . . . . and remove the trim cover fromthe tailgate wiper motor spindle

19.3 Removing the wiper motor coverfrom the rear of the tailgate


19.4a Slacken and remove the threeretaining bolts (arrowed)...

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 theybecome accessible (see illustrations).

Refitting5 Refitting is a reverse of the removalprocedure. Ensure that the tailgate centrallocking servo motor (where fitted) is correctlyengaged with the lock pin, prior to refitting thewiper motor retaining bolts.

20.3 Removing the right-hand wheel archliner

20 Windscreen/tailgate washersystem components -removal and refitting

20.6a Undo the two retaining bolts(arrowed)...

Washer system reservoirNote: To minimise fluid spillage, it isrecommended that the washer reservoir is atleast half-empty prior to removal.1 Jack up the front of the vehicle, andsupport it on axle stands. Remove the right-hand front roadwheel.2 Open the bonnet, and disconnect thewindscreen washer supply pipe from its non-return valve, situated on the right-hand side ofthe bonnet (see illustration).3 Undo the retaining screw from the frontedge of the wheel arch liner, then work aroundthe liner carefully, prising out all its retainingclips, and remove the right-hand wheel arch

20.2 Disconnecting the windscreenwasher supply pipe from its non-return

valve

liner and access cover from the vehicle (seeillustration).4 Push the front direction indicator repeaterlight unit towards the rear of the vehicle, tofree its retaining clips, then withdraw it fromthe wing.

5 Reach up behind the wing, and disconnectthe wiring connector(s) from the washerpump(s).6 Slacken and remove the two reservoirretaining bolts, then pull the top of thereservoir( outwards, to release it from thereservoir filler neck (see illustrations). Lowerthe reservoir out from underneath the wing,disconnecting the supply pipe(s) from thewasher pump(s) as they become accessible.7 Refitting is the reverse of removal, ensuringthat the reservoir is correctly engaged with itsfiller neck.

Washer pump(s)Note: Prior to removing the pump(s), emptythe contents of the reservoir, or be preparedfor fluid spillage.8 Jack up the front of the vehicle, andsupport it on axle stands. Remove the right-hand front roadwheel.9 Remove the wheel arch liner as describedin paragraph 3.10 Disconnect the wiring connector from therelevant pump, then carefully ease the pumpout of its sealing grommet, and manoeuvre itout from behind the wing (see illustrations). If

20.6b . . . and lower the washer reservoirout from behind the wing

20.10a Disconnect the wiringconnector...

20.10b . . . then ease the washer pump outfrom the reservoir


21.2 Remove the rubber plugs . . .

necessary, to improve access to the pump,undo the mounting bolts, and lower thereservoir slightly. Note that, on models with adual pump arrangement, the upper pump istailgate washer pump, and the lower one isthe windscreen washer pump.11 Refitting is a reversal of the removalprocedure.

Windscreen washer jet12 Open the bonnet, then unclip the washerjet from the underside of the bonnet, anddisconnect it from its supply pipe.13 On refitting, ensure that the jet is clippedsecurely in position. If necessary, the jetnozzles can be adjusted using a pin; aim thespray to a point slightly above the centre ofthe wiper swept area.

Tailgate washer jet14 Carefully prise the washer jet out of thetop of the tailgate, and disconnect it from itssupply pipe. Whilst the jet is removed, tapethe supply pipe in position, to ensure that itdoes not fall back into the tailgate.15 On refitting, ensure that the jet is clippedsecurely in position. If necessary, the jetnozzle can be adjusted using a pin; aim thespray to the centre of the wiper swept area.

Non-return valves16 If trouble is experienced at any time withthe flow to the tailgate or windscreen washer

21.3a . . . and undo the two radio/cassette 21.3b Slide the radio/cassette unit out ofunit retaining screws position, and disconnect the aerial

connection and wiring connectors

jets, check that the relevant non-return valveis not blocked. The windscreen washer valveis situated in the supply pipe, next to the right-hand bonnet hinge; the tailgate washer valveis situated at the rear of the vehicle, tuckedaway underneath the top of the tailgatesealing strip.17 To remove a non-return valve, simplydisconnect the hoses from either end of it.18 On refitting, ensure that the valve isinstalled the correct way around, so that itallows fluid to flow only in the direction of thewasher jet(s).

wiring connectors and aerial from the rear ofthe unit (see illustrations).

Refitting4 Refitting is the reverse of the removalprocedure. On completion, reconnect thebattery, and enter the radio security codeusing the information given in "Radio/cassetteunit anti-theft system" at the start of thismanual.

22 Loudspeakers -removal and refitting

21 Radio/cassette player -removal and refitting

Note: The following removal and refittingprocedure is for the range of radio/cassetteunits which Citroen fit as standard equipment.Removal and refitting procedures for non-standard units may differ slightly.

Removal1 Disconnect the battery negative terminal.2 Remove the two rubber plugs from the frontof the unit, to gain access to theradio/cassette unit retaining screws (seeillustration).3 Undo the retaining screws, then withdrawthe unit from the facia, and disconnect the

Removal1 The front speakers are located in the frontdoor trim panels, in front of the door pullhandles. On five-door models, the rearspeakers are located at the bottom of the reardoor trim panel; the rear speakers on three-door models are located in the rear seat sidetrim panels.2 Carefully prise the speaker grille out fromthe trim panel (see illustration).3 Slacken and remove the speaker retainingscrews and, on the front speaker, remove theretaining clip from the mounting peg.Withdraw the speaker from the panel,disconnecting its wiring connector as itbecomes accessible (see illustrations).

22.2 Remove the grille to gain access tothe relevant speaker

22.3a Front speakers are retained by threescrews and a retaining clip (arrowed)

22.3b Rear speakers are retained by fourretaining screws


22.3c Remove the speaker from the panel,and disconnect it from its wiring connector

Refitting4 Refitting is a reverse of the removalprocedure.

Removal

Aerial1 Carefully prise the courtesy light out fromthe overhead console, and disconnect it fromits wiring connector. Remove the two consoleretaining screws, then lower the console outof position, and disconnect it from its wiringconnectors (see illustrations).2 Slacken and remove the nut from the baseof the aerial, and disengage the aerial leadcollar from its stud. The aerial can then belifted away from the outside of the vehicle,noting the rubber seal which is fitted to itsbase (see illustrations).

Aerial lead upper section3 Remove the aerial as described above.4 Unclip the trim panel from the right-handwindscreen pillar, to gain access to the aerialconnection (see illustration). Wherenecessary, release the alarm sensors from theclip on the top of the panel, and remove thepanel. If the aerial connection is not situated

23.1a Undo the two retaining screws(arrowed)...

behind the right-hand trim panel, remove theleft-hand panel.5 Disconnect the upper section of the lead,and tie a piece of string to it. Withdraw theaerial lead through the overhead consoleaperture, and untie the string from its end.Leave the string in position - it can then beused to draw the lead back into position onrefitting.

Aerial lead lower section6 To remove the lower section of the aeriallead, linking the upper section to the rear ofthe radio/cassette unit, it is first necessary toremove the facia panel as described inChapter 11. The lead can then be freed fromall its relevant retaining clips, and removedfrom the vehicle.

Refitting

Aerial7 Ensure that the rubber seal is in goodcondition, then refit it to the aerial base. Refitthe aerial to the roof, ensuring that its locatingpin is correctly located in its hole.8 From inside the vehicle, locate the aeriallead collar on the aerial stud, and refit theretaining nut, tightening it securely.9 Reconnect the wiring connectors to theoverhead console, and locate the console inposition in the headlining. Refit the twoconsole retaining screws, and tighten them

23.1b . . . then lower out the overheadconsole, and disconnect it from its wiring

connectors

securely. Reconnect the courtesy light to itswiring connector, and clip the light back intoposition in the console.

Aerial lead upper section10 Tie the string to the end of the aerial lead,and use the string to draw the lead back intoposition. Untie the string, and reconnect thelead to the lower aerial section.11 Where necessary, ensure that the alarmsensor wire is correctly routed, and refit thesensor to its retaining clip. Clip the panel backinto position, ensuring that the pegs on thebase of the panel are correctly located in thefacia panel.12 Refit the aerial as described above.

Aerial lead lower section13 Refitting is a reversal of the removalprocedure.

Note: This information is applicable only to theanti-theft alarm system fitted by Citroen asstandard equipment.

Some models in the range are fitted with ananti-theft alarm system as standardequipment. The alarm is automatically armedand disarmed when the door locks areoperated using the remote central lockingtransmitter.

23.2a Undo the aerial lead retaining nutfrom inside the vehicle . . .

23.2b . . . then remove the aerial from theroof of the vehicle

23.4 Aerial lead upper-to-lower sectionconnection is located behind the

windscreen pillar trim panel

23 Radio aerial -removal and refitting

24 Anti-theft alarm system - generalinformation


Note that if the doors are operated usingthe key, the alarm will not be armed ordisarmed (as applicable). If for some reasonthe remote central locking transmitter failswhilst the alarm is armed, the alarm can bedisarmed using the key. To do this, open thedoor with the key, then enter the vehicle,noting that the alarm will sound as the door isopened, and switch on the ignition switchwhilst depressing the small button on thealarm switch mounted in the facia. Note thatthe ignition switch must be turned on and thebutton depressed within 10 seconds ofopening the door.

The alarm system has switches on thebonnet, tailgate and each of the doors. It alsohas ultrasonic sensing, which detectsmovement inside the vehicle, via the sensorsmounted on the top of each windscreen pillartrim panel. If required, the ultrasonic sensingfacility of the system can be switched off,whilst retaining the switched side of thesystem. To switch off the ultrasonic sensing,with the ignition switch off, depress the alarmswitch on the facia for approximately 1second, until the switch LED is continuouslylit. Now, when the doors are locked using theremote central locking transmitter, and thealarm is armed, only the switched side of thealarm system is operational. This facility isuseful, as it allows you to leave thewindows/sunroof open, and still arm thealarm. If the windows/sunroof are left openwith the ultrasonic sensing not switched off,the alarm may be falsely triggered by a gust ofwind.

Should the alarm system become faulty, thevehicle should be taken to a Citroen dealer forexamination.

1 To comply with UK regulations, a "dim-dip"lighting system is fitted to all UK models. Thesystem is operates through a dim-dip relay,and a resistor unit situated at the front left-hand corner of the vehicle, above the hornassembly.2 The dim-dip relay is supplied with currentfrom the sidelight circuit, and energised by afeed from the ignition switch. Whenenergised, the unit allows battery voltage topass through the resistor unit to the headlightdipped-beam circuits; this lights theheadlights with approximately one-sixth oftheir normal power, so that the car cannot bedriven using sidelights alone.

The wiring diagrams in this manualrepresent typical examples of those available.To assist you in using the diagrams, here is anexplanation of the various letters and their

use, in conjunction with the wiring diagramkeys (see illustration).

(a) Large numbers - identify the variouscomponents.

(b) Capital letters printed in the middle ofa wire - indicate which harness the wire islocated in.

(c) Small letters located at the connectionpoints - indicates the colour of either thewire itself, or of the marking on the wire. Ifthe letter has a line drawn above it, thenthis shows it indicates the colour of thewire itself; if there is no line above theletter, it indicates the colour of themarking on the wire.

(d) Connecting blocks - the first numberand letter(s) inside the box indicates thesize and colour of the connecting block.The second letter (where applicable) andlast number gives the exact location ofthe relevant wire in that connecting block;the letter indicates which row the wire issituated in, and the number denotes itslocation in that row. For example:

3 BI 2 - shows that the wiring connector isblue in colour, and contains three wiringchannels, the wire shown in the diagrambeing located in the second channel ofthe connector.

15 VA 2 - shows that the wiring connector isgreen in colour, and contains fifteenchannels. The A shows that the wireshown in the diagram is in the upper rowof the connector, and the 2 shows it to bein the second channel of that row.

25 "Dim-dip" lighting system (UKmodels only) -general information

26 Wiring diagrams - explanatorynotes

12•20 Wiring diagrams

Symbols used in wiring diagrams

No.1234

56

7891011121314151617181920

DescriptionSocket connectionPin connectionConnector connectionConnector connection with index (fordifferentiation)Junction not to be dismantled (splice)Junction not to be dismantled (withother connection possibilities)Socket earthingConnector earthingPart body earth connectionSwitch (non-automatic return)Manual switchSelector switchSwitch on at-rest (automatic return)Swithc off at-rest (automatic return)Manual contact switchMechanical contact switchPressure contact switchThermal switchContact delayed on openingContact delayed on closing

No.2122

23242526272829303132333435363738394041

DescriptionFriction contact switchManual contact switch (cigar lighter)with resistanceResistanceRheostatManual rheostatMechanical rheostatTemperature rheostat (thermistor)Pressure rheostatRheostatShuntCoil (relay-solenoid)Warning lightLight bulbDouble-filament light bulbLight-emitting diode (LED)Photo-diodeDiodeFuseThermal circuit breakerScreeningBattery cell

No.424344454647484950

5152535455565758596061

DescriptionSuppressorMotorTwo-speed motorAlternative power generatorSound equipment (horn, loudspeaker)Electronic control unitDelay unitPart framing (with its circuit diagram)Part framing (without its circuitdiagram)Part extractPart extractIndicatorThermocoupleElectrodesOxygen sensorSupply socketNPN transistorPNP transistorConnection indicating lineNo extremity

Wiring diagrams 12•21

Key to wiring diagramsNot all items fitted to all models

No.5101520213540455052535558

5962100101130140141142144152155156157158160170180183211

212

215254255270300302305306307308310311312313314315317318319322326330340350385389391392394

DescriptionFront cigar lighterIgnition distributorAlternatorLH hornRH hornBatteryInstrument clusterIgnition coilSupply connector boxJunction boxWater temperature control unitCentral door locking control unitRemote control door locking receiver(PLIP)Pre-heater (glow plugs) control unitEarth connection boxSpark plugsGlow plugsLights-on warning buzzerAnti-lock braking ECUAir conditioning ECUFuel injection ECUExhaust gas recirculation ECUEngine speed sensorLH front wheel sensor (ABS)RH front wheel sensor (ABS)LH rear wheel sensor (ABS)RH rear wheel sensor (ABS)TDC sensorFlasher unitAdditional air controlAir blower controlLH column switch (lights, indicators,horn)RH column switch (front and rearwipers)Exterior mirror switchAir horn compressorAir con. compressor driving clutchHT coil suppressorIgnition switchBoot light switchDriver's door locking switchPassenger's door locking switchLH rear door closing switchRH rear door closing switchLH front door pillar switchRH front door pillar switchLH rear door pillar switchRH rear door pillar switchReversing light switchHandbrake switchHydraulic fluid level switchThrottle butterfly switchStop-light switchAtmospheric pressure switchStarter motor switchPost-heater switchAirflow meterStarter motorFront ashtray illuminationBoot lightNumber plate LH lightNumber plate RH lightAir con. control illumination

No.429430431432434437441443480481482483484485486487488489490491492493496497498499500501502503504505550551554555570582587588589590591

592

597608650660671680681685694695696697703704705706708712714

DescriptionFuel cut-off solenoid (stop solenoid)Canister discharge solenoidFast idling solenoidIdling actuatorCanister solenoidExhaust gas recirculation solenoidVacuum advance solenoidInjection timing correction solenoidLH rear lightRH rear lightLH front foglightRH front foglightLH rear foglightRH rear foglightLH dipped beamsRH dipped beamsLH front direction indicatorRH front direction indicatorLH rear direction indicatorRH rear direction indicatorLH sidelightRH sidelightLH tail lightRH tail lightLH reversing lightRH reversing lightLH direction indicator repeaterRH direction indicator repeaterLH headlightRH headlightLH stop-lightRH stop-lightLH front speakerRH front speakerLH rear speakerRH rear speakerInjectorRefrigerated air switchFront foglight switchRear foglight switchHazard warning light switchDriver's window switchPassenger's window switch (on driver'sdoor)Passenger's window switch (onpassenger's door)Heated rear window switchHeadlight adjustment device switchFuel gaugeMap reading lightEngine oil pressure switchIgnition moduleAir blower control moduleDigital clockWindscreen wiper motorTailgate wiper motorLH front window motorRH front window motorDriver's door locking motorPassenger's door locking motorLH rear door locking motorRH rear door locking motorTailgate locking motorIdling control stepper motorABS hydraulic pump motor

No.715716720

721742743750751755757758765770772775779

781783786787790798804805806807809813814815

819820822827841843844845849857858859860862876880900902903904907909910912915918962963970971974990

DescriptionLH headlight adjustment device motorRH headlight adjustment device motorEngine cooling fan (single, or LH oftwo)RH engine cooling fanCentral interior lightRear interior lightLH front brake pads sensorRH front brake pads sensorFuel pumpWindscreen washer pumpRear screen washer pumpRadio setThrottle spindle potentiometerMixture adjustment potentiometerPressure switchTDC sensor plug (petrol) or Watertemp, sensor (Diesel)ABS diagnostic socketInjection diagnostic socketHeadlight: LH main and dipped beamsHeadlight: RH main and dipped beamsAir blower motorInjection timing cut-off relayAir conditioning relayCompressor cut-off relay (temperature)Front foglight relaysInjection double relayFront window relayEngine cooling fan relay (fast speed)Engine cooling fan relay (slow speed)Engine cooling fan speed switchoverrelayRear foglight relaysHeated rear window relayCompressor cut-off relay (injection)Dim-dip relay (UK only)Window re-energising relayAir horn compressor relayABS main relayHydraulic fluid motor relayPost-heating cut-off relayCarburettor base heating resistanceDipped beams resistance (dim-dip)Air blower speed resistorCoding resistanceInjector additional resistanceRH rear view mirrorInstrument lighting rheostatOxygen sensorEngine oil level sensorInjection air pressure sensorEngine oil pressure sensorInjection air temperature sensorInjection water temperature sensorWater temp, sensor (control unit)Evaporator temperature sensorWater temperature switch sensorEngine oil temperature sensorWindscreen intermittent wipe timerTailgate intermittent wipe timerCoolant temp, warning thermal switchCooling fan thermal switch (radiator)Water temperature switchHeated rear window


ABAVCLCNCPEFFRHBMTMVPBPCPD

ABSFrontAir conditioningNegative cablePositive cableBoot lightingRear lightsInteriorEngine (and injection)Electric cooling fanDashboardDriver's doorRH rear door

Harness code

PGPJPLPPRDRGRLTJUDUGVDVG

LH rear doorHeadlight adjustment deviceInterior lightPassenger's doorRH rearLH rearDirection indicator side repeaterHeadlight adjustment device switchRH brake pad wearLH brake pad wearRH side tailgateLH side tailgate

BBlGIcJMMvNOrRRoVVi

Colour code

WhiteBlueGreyClear/transparentYellowBrownPurpleBlackOrangeRedPinkGreenLilac

How to use the wiring diagrams

LOCATING REF. NUMBERS

EARTH CONNECTION

CONNECTION TOWARDS ANOTHER FUNCTION

SOCKET CONNECTION

PIN CONNECTION

PIN PROTECTOR COLOUR

OUTLET INDICATION(not necessary for the function)

COLOUR MARK ON WIRE

CONNECTOR CONNECTION

REF. FIGURE ON THE WIRE

WIRE COLOUR(letter with a horizontal bar over it)

PART SHOWN(without interior drawing)

WIRING HARNESS REF. LETTER(see ' identification of wiring")

SYMBOL FOR THE PART FUNCTION

PART SHOWN(with inner drawing)

PART NUMBER(see "identification")

PART, WIRE OR HARNESS NOT EXISTING(in this model)

CONNECTION NOT TO BE DISMANTLED (splice...)


Inst

rum

ent

pan

el (

low

- to

mid

-sp

ecifi

catio

n m

od

els)


Inst

rum

ent

pan

el (

mid

-to

hig

h-s

pec

ifica

tion

mo

del

s)


Eng

ine

elec

tric

al s

yste

ms

-112

4 cc

and

136

0 ca

rbur

etto

r (H

1A/T

U1K

and

K2D

/TU

3 2K

)S

tart

ing

and

ch

arg

ing

sys

tem

s


Engine electrical systems - 1124 cc fuel injection (HDZ/TU1M L/Z)


Eng

ine

elec

tric

al s

yste

ms

- 13

60 c

c fu

el in

ject

ion

(K

DX

/TU

3MC

L/Z

)


Eng

ine

elec

tric

al s

yste

ms

- 15

80 c

c cc

no

n-c

atal

yst

(BA

4/X

U5M

3K

an

d X

U5M

4K

)


En

gin

e el

ectr

ical

sys

tem

s -

1580

cc

cata

lyst

(B

DY

/XU

5M 3

Z),

au

tom

atic

tran

smis

sio

n


Eng

ine

elec

tric

al s

yste

ms

- 17

61 c

c (L

FZ

/XU

7PJL

/Z)


Engine electrical systems - 1905 cc non-catalyst (D6E/XU9JA K)


Eng

ine

elec

tric

al s

yste

ms

- 19

05 c

c ca

taly

st (

DK

Z/X

U9J

A Z

), m

anu

al t

ran

smis

sio

n


Engin

e e

lect

rica

l sy

stem

s -

199

8 c

c 1

6-va

lve

(R

FY

/XU

10J4

LZ)


Ext

erio

r lig

htin

g

Wiring diagrams 12*35

Interior lighting


Wash/wipe systems


Heated rear window, electric mirror


Anti-lock braking system


Engine cooling fan and heater blower


Electric windows and central locking

Wir

ing

dia

gra

m fo

r en

gin

e(1

.9 li

tre—

XU

9JA

Z)

Wir

ing

dia

gra

m fo

r ci

gar

ette

lighte

ran

d in

terior l

ight

Wir

ing

dia

gra

m fo

r fro

nt a

ndre

arsc

reen

wip

ers

Wirin

g d

iag

ram

for f

uel

inje

ctio

n s

yste

m (1

.6 li

tre

with

ou

t cat

alyt

icco

nve

rter

)

Wirin

g d

iagra

m fo

r fu

el in

ject

ion

and

igni

tion

sys

tem

(1.6

litr

e w

ith

cata

lytic

co

nve

rter

)

Wir

ing

dia

gra

m fo

r fu

el in

ject

ion

and

igniti

on

sys

tem

(1,9

litr

e)W

irin

g d

iag

ram

radio

inst

alla

tion

Wir

ing

dia

gra

m fo

r in

stru

men

t pan

el(T

rim le

vel D

— 1

.6 a

nd 1

,9 li

tre)

Wirin

g d

iagra

m in

stru

men

t pan

el(T

rim le

vel C

—1.

6IIt

re)

Wir

ing

dia

gra

m fo

r AB

SW

irin

g d

iag

ram

for h

eate

d re

arsc

reen

an

d a

dju

stab

le m

irro

rs

Wiri

ng

dia

gra

m fo

rsig

nal

s a

nd

lighti n

g(1

.6lit

re e

ng

ine)

citroen zx-12

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