light FORD MONDEO 1993 Service Repair Manual

Wiring diagrams 12•33
12
Diagram 9: Exterior lighting – side and headlights (left-hand drive models: non dim-dip)
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12•34 Wiring diagrams
Diagram 10: Exterior lighting – side and headlights (left-hand drive models: daytime running lights)
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Wiring diagrams 12•35
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Diagram 11: Exterior lighting – hazard flasher and direction indicators
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12•36 Wiring diagrams
Diagram 12: Exterior lighting – foglights, stop-lights and reversing lights
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Wiring diagrams 12•37
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Diagram 13: Interior lighting – front and rear courtesy, footwell and luggage compartment lights
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12•38 Wiring diagrams
Diagram 14: Interior lighting – torch, glovebox and engine compartment lights
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Wiring diagrams 12•41
12
Diagram 17 Headlight washer, horn, clock and cigar lighter
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Introduction
A selection of good tools is a fundamental
requirement for anyone contemplating the
maintenance and repair of a motor vehicle.
For the owner who does not possess any,
their purchase will prove a considerable
expense, offsetting some of the savings made
by doing-it-yourself. However, provided that
the tools purchased meet the relevant national
safety standards and are of good quality, they
will last for many years and prove an
extremely worthwhile investment.
To help the average owner to decide which
tools are needed to carry out the various tasks
detailed in this manual, we have compiled
three lists of tools under the following
headings: Maintenance and minor repair,
Repair and overhaul, and Special. Newcomers
to practical mechanics should start off with
the Maintenance and minor repairtool kit, and
confine themselves to the simpler jobs around
the vehicle. Then, as confidence and
experience grow, more difficult tasks can be
undertaken, with extra tools being purchased
as, and when, they are needed. In this way, a
Maintenance and minor repairtool kit can be
built up into a Repair and overhaultool kit over
a considerable period of time, without any
major cash outlays. The experienced do-it-
yourselfer will have a tool kit good enough for
most repair and overhaul procedures, and will
add tools from the Specialcategory when it is
felt that the expense is justified by the amount
of use to which these tools will be put.
Maintenance and minor repair
tool kit
The tools given in this list should be
considered as a minimum requirement if
routine maintenance, servicing and minor
repair operations are to be undertaken. We
recommend the purchase of combination
spanners (ring one end, open-ended the
other); although more expensive than open-
ended ones, they do give the advantages of
both types of spanner.
MCombination spanners:
Metric - 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
19, 21, 22, 24 & 26 mm
MAdjustable spanner - 35 mm jaw (approx)
MTransmission drain plug key (Allen type)
MSet of feeler gauges
MSpark plug spanner (with rubber insert)
MSpark plug gap adjustment tool
MBrake adjuster spanner (where applicable)
MBrake bleed nipple spanner
MScrewdrivers:
Flat blade - approx 100 mm long x 6 mm dia
Cross blade - approx 100 mm long x
6 mm dia
MCombination pliers
MHacksaw (junior)
MTyre pump
MTyre pressure gauge
MOil can
MOil filter removal tool
MFine emery cloth
MWire brush (small)
MFunnel (medium size)
Repair and overhaul tool kit
These tools are virtually essential for
anyone undertaking any major repairs to a
motor vehicle, and are additional to those
given in the Maintenance and minor repairlist.
Included in this list is a comprehensive set of
sockets. Although these are expensive, they
will be found invaluable as they are so
versatile - particularly if various drives are
included in the set. We recommend the half-
inch square-drive type, as this can be used
with most proprietary torque wrenches. If you
cannot afford a socket set, even bought
piecemeal, then inexpensive tubular box
spanners are a useful alternative.
The tools in this list will occasionally need to
be supplemented by tools from the Special
list:
MSockets (or box spanners) to cover range in
previous list
MReversible ratchet drive (for use with
sockets) (see illustration)
MExtension piece, 250 mm (for use with
sockets)
MUniversal joint (for use with sockets)
MTorque wrench (for use with sockets)
MSelf-locking grips
MBall pein hammer
MSoft-faced mallet (plastic/aluminium or
rubber)
MScrewdrivers:
Flat blade - long & sturdy, short (chubby),
and narrow (electrician’s) types
Cross blade - Long & sturdy, and short
(chubby) types
MPliers:
Long-nosed
Side cutters (electrician’s)
Circlip (internal and external)
MCold chisel - 25 mm
MScriber
MScraper
MCentre-punch
MPin punch
MHacksaw
MBrake hose clamp
MBrake bleeding kit
MSelection of twist drillsMSteel rule/straight-edge
MAllen keys (inc. splined/Torx type) (see
illustrations)
MSelection of files
MWire brush
MAxle stands
MJack (strong trolley or hydraulic type)
MLight with extension lead
Special tools
The tools in this list are those which are not
used regularly, are expensive to buy, or which
need to be used in accordance with their
manufacturers’ instructions. Unless relatively
difficult mechanical jobs are undertaken
frequently, it will not be economic to buy
many of these tools. Where this is the case,
you could consider clubbing together with
friends (or joining a motorists’ club) to make a
joint purchase, or borrowing the tools against
a deposit from a local garage or tool hire
specialist. It is worth noting that many of the
larger DIY superstores now carry a large range
of special tools for hire at modest rates.
The following list contains only those tools
and instruments freely available to the public,
and not those special tools produced by the
vehicle manufacturer specifically for its dealer
network. You will find occasional references
to these manufacturers’ special tools in the
text of this manual. Generally, an alternative
method of doing the job without the vehicle
manufacturers’ special tool is given. However,
sometimes there is no alternative to using
them. Where this is the case and the relevant
tool cannot be bought or borrowed, you will
have to entrust the work to a franchised
garage.
MValve spring compressor (see illustration)
MValve grinding tool
MPiston ring compressor (see illustration)
MPiston ring removal/installation tool (see
illustration)
MCylinder bore hone (see illustration)
MBalljoint separator
MCoil spring compressors (where applicable)
MTwo/three-legged hub and bearing puller
(see illustration)
REF•1
Sockets and reversible ratchet driveSpline bit set
Tools and Working Facilities
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REF•6Fault Finding
Engine 1
m mEngine backfires
m mEngine difficult to start when cold
m mEngine difficult to start when hot
m mEngine fails to rotate when attempting to start
m mEngine hesitates on acceleration
m mEngine idles erratically
m mEngine lacks power
m mEngine misfires at idle speed
m mEngine misfires throughout the driving speed range
m mEngine noises
m mEngine rotates but will not start
m mEngine runs-on after switching off
m mEngine stalls
m mEngine starts but stops immediately
m mOil pressure warning light illuminated with engine running
m mStarter motor noisy or excessively-rough in engagement
Cooling system 2
m
mCorrosion
m mExternal coolant leakage
m mInternal coolant leakage
m mOvercooling
m mOverheating
Fuel and exhaust systems 3
m
mExcessive fuel consumption
m mExcessive noise or fumes from exhaust system
m mFuel leakage and/or fuel odour
Clutch 4
m
mClutch fails to disengage (unable to select gears)
m mClutch slips (engine speed increases with no increase
in vehicle speed)
m mJudder as clutch is engaged
m mNoise when depressing or releasing clutch pedal
m mPedal travels to floor - no pressure or very little resistance
Manual transmission 5
m
mJumps out of gear
m mLubricant leaks
m mNoisy in neutral with engine running
m mNoisy in one particular gear
m mVibration
Automatic transmission 6
m
mEngine will not start in any gear, or starts in gears
other than Park or Neutral
m mFluid leakage
m mGeneral gear selection problems
m mTransmission fluid brown, or has burned smell
m mTransmission slips, shifts roughly, is noisy, or
has no drive in forward or reverse gears
m mTransmission will not downshift (kickdown) with
accelerator fully depressed
Driveshafts 7
m mClicking or knocking noise on turns (at slow speed on full-lock)
m mVibration when accelerating or decelerating
Braking system 8
m
mBrake pedal feels spongy when depressed
m mBrakes binding
m mExcessive brake pedal effort required to stop vehicle
m mExcessive brake pedal travel
m mJudder felt through brake pedal or steering wheel when braking
m mNoise (grinding or high-pitched squeal) when brakes applied
m mRear wheels locking under normal braking
m mVehicle pulls to one side under braking
Suspension and steering systems 9
m
mExcessive pitching and/or rolling around corners, or during
braking
m mExcessive play in steering
m mExcessively-stiff steering
m mLack of power assistance
m mTyre wear excessive
m mVehicle pulls to one side
m mWandering or general instability
m mWheel wobble and vibration
Electrical system 10
m
mBattery will not hold a charge for more than a few days
m mCentral locking system inoperative, or unsatisfactory in operation
m mElectric windows inoperative, or unsatisfactory in operation
m mHorn inoperative, or unsatisfactory in operation
m mIgnition warning light fails to come on
m mIgnition warning light remains illuminated with engine running
m mInstrument readings inaccurate or erratic
m mLights inoperative
m mWindscreen/tailgate washers inoperative, or unsatisfactory in
operation
m mWindscreen/tailgate wipers inoperative, or unsatisfactory in
operation
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Engine misfires throughout the driving speed range
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mFuel tank vent blocked or fuel pipes restricted (Chapter 4).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mFaulty ignition coil (Chapter 5).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mUneven or low cylinder compressions (Chapter 2, Part A).
Engine hesitates on acceleration
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
Engine stalls
m mIdle speed control valve faulty (Chapter 4).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mFuel tank vent blocked or fuel pipes restricted (Chapter 4).
Engine lacks power
m
mIncorrect ignition timing (Chapters 5 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mTiming belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mUneven or low cylinder compressions (Chapter 2, Part A).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mBrakes binding (Chapters 1 and 9).
m mClutch slipping (Chapter 8).
m mAutomatic transmission fluid level incorrect (Chapter 1).
Engine runs-on after switching off
m
mIdle speed excessively high (Chapters 4 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mExcessive carbon build-up in engine (Chapter 2, Part A).
m mHigh engine operating temperature (Chapter 3).
Engine backfires
m
mIgnition timing incorrect (Chapters 5 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mTiming belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
Oil pressure warning light illuminated with engine
running
m mLow oil level or incorrect oil grade (Chapter 1).
m mFaulty oil pressure warning light switch (Chapter 2, Part A).
m mWorn engine bearings and/or oil pump (Chapter 2).
m mHigh engine operating temperature (Chapter 3).
m mOil pressure relief valve defective (Chapter 2, Part A).
m mOil pick-up strainer clogged (Chapter 2, Part A).
Engine noises
Pre-ignition (pinking) or knocking during acceleration or under
load
m mIgnition timing incorrect (Chapters 5 and 6).
m mIncorrect grade of fuel (Chapter 4).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mExcessive carbon build-up in engine (Chapter 2, Part A).
Whistling or wheezing noises
m mLeaking inlet manifold gasket (Chapter 2, Part A).
m mLeaking exhaust manifold gasket or downpipe-to-manifold joint
(Chapters 1, 2 Part A, and 4).
m mLeaking vacuum hose (Chapters 1, 4, 6 and 9).
m mBlowing cylinder head gasket (Chapter 2, Part A).
Tapping or rattling noises
m mFaulty hydraulic tappet(s) (Chapter 2, Part A).
m mWorn valve gear or camshaft (Chapter 2, Part A).
m mWorn timing belt or tensioner (Chapter 2, Part A).
m mAncillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).
Knocking or thumping noises
m mWorn big-end bearings (regular heavy knocking, perhaps less
under load) (Chapter 2, Part B).
m mWorn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2, Part B).
m mPiston slap (most noticeable when cold) (Chapter 2, Part B).
m mAncillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).
REF•8Fault Finding
2 Cooling system
Overheating
m mInsufficient coolant in system (Chapter 1).
m mThermostat faulty (Chapter 3).
m mRadiator core blocked or grille restricted (Chapter 3).
m mRadiator electric cooling fan(s) or coolant temperature sensor faulty
(Chapter 3).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mPressure cap faulty (Chapter 3).
m mAuxiliary drivebelt worn or slipping (Chapter 1).
m mIgnition timing incorrect (Chapters 5 and 6).
m mInaccurate coolant temperature gauge sender (Chapter 3).
m mAir-lock in cooling system (Chapter 1).
Overcooling
m
mThermostat faulty (Chapter 3).
m mInaccurate coolant temperature gauge sender (Chapter 3).
External coolant leakage
m
mDeteriorated or damaged hoses or hose clips (Chapter 1).
m mRadiator core or heater matrix leaking (Chapter 3).
m mPressure cap faulty (Chapter 3).
m mWater pump seal leaking (Chapter 3).
m mBoiling due to overheating (Chapter 3).
m mCore plug leaking (Chapter 2, Part B).
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