engine FORD MONDEO 1993 Service Repair Manual

the specified mileage (or time) since the last
service has been reached.
4To reset the service interval system and
turn off the light, a switch inside the glovebox
must be depressed for a minimum of 4
seconds with the ignition switched on. This
should be carried out by a Ford dealer if the
vehicle is still in the warranty period.
Component renewal
5The following paragraphs describe brief
removal procedures for the auxiliary warning
system components. Disconnect the battery
negative (earth) lead before commencing
work (refer to Chapter 5, Section 1). Refitting
procedures are a reversal of removal.
Display warning bulb
6Remove the control assembly.
7Prise off the cover, and pull out the relevant
bulb and bulbholder.
Low air temperature warning sender
unit
8Remove the front bumper.
9Unclip the sender unit and disconnect the
multi-plug (see illustration).
Engine oil level sensor
10Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
11Place a container beneath the oil level
sensor, to catch any spilt oil.12Unscrew the screws and remove the
cover from the sensor.
13Disconnect the multi-plug.
14Unscrew and remove the sensor, and
remove the seal (see illustration).
Door ajar sensor
15Remove the door lock as described in
Chapter 11, Section 14.
16Unclip the sensor and disconnect the
multi-plug.
Low coolant warning switch
17Refer to Chapter 3, Section 6.
Low washer fluid switch
18Disconnect the multi-plug from the
washer fluid reservoir.
19Drain or syphon out the fluid from the
reservoir.
20Using a screwdriver, lever out the switch
from the reservoir (see illustration).
Service indicator reset switch
21Remove the glove compartment lid as
described in Chapter 11, Section 32.
22Carefully lever out the switch using a
small screwdriver.
23Remove the rear cover and disconnect
the wiring (see illustration).
Control assembly
24Remove the instrument panel surround,
referring to Section 10.25Unscrew the mounting screws,
disconnect the multi-plugs and remove the
assembly.
Bulb failure module
26Remove the lower facia panel from under
the steering wheel.
27Unclip the bulb failure module and
disconnect the multi-plug.
Note: From November 1993, for added
security, a complex Bosch immobiliser system
was fitted to some models. For further details,
refer to your Ford dealer.
1All UK models are fitted with an anti-theft
alarm system, incorporating movement
sensors and an ignition immobiliser. The
system is activated when the vehicle is
locked.
2The system includes a start inhibitor circuit,
which makes it impossible to start the engine
with the system armed.
3The movement sensors consist of two
ultrasonic units, located in the “B” pillars,
incorporating transmitters and receivers (see
illustrations). The receivers check that the
echo frequency matches the original
frequency. If there is any significant
difference, the system triggers the alarm.
20 Anti-theft alarm system- general
information
12•18 Body electrical system
19.9 Low air temperature sender unit
removal
1 Clip 2 Sender unit 3 Multi-plug19.14 Engine oil level sensor removal
1 Cover 2 Multi-plug 3 Sensor 4 Seal19.20 Removing the low washer fluid
switch
19.23 Service indicator switch removal
1 Lever out the switch 2 Cover 3 Wiring20.3A Disconnecting a movement sensor
multi-plug20.3B Removing a movement sensor
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switches mounted in the engine compartment
with a control cable connected to the throttle
valve actuator, driver-operated switches,
brake and clutch pedal switches, an indicator
light, and a road speed sensor.
4The driver-operated switches are mounted
on the steering wheel, and allow the driver to
control the various functions.
5The vehicle speed sensor uses the
speedometer cable drive pinion to generate
pulses which are fed to the speed control unit.
6The stop-light switch, brake pedal switch
and (when applicable) clutch pedal switch are
used to disable the cruise control system. The
stop-light switch is activated when the brake
pedal is applied gently, and the brake pedal
switch is activated when the brake pedal is
applied forcibly.
7An indicator light on the instrument panel is
illuminated when the system is in operation.
8The following paragraphs describe brief
removal procedures for the cruise control
system components. The battery negative
(earth) lead should be disconnected before
commencing work (refer to Chapter 5, Sec-
tion 1). Refitting is a reversal of removal.
Speed control switch
9Remove the steering column upper and
lower shrouds, with reference to Chapter 10.
10Remove the air bag module as described
in Section 29.11Disconnect the multi-plugs, then unscrew
the screws and remove the switch.
Disable switches
12Remove the lower facia panel from under
the steering column.
13Disconnect the multi-plugs from the
clutch switch, brake pedal switch and stop-
light switch.
14To remove the clutch and brake pedal
switches, twist them anti-clockwise. To
remove the stop-light switch, twist it
clockwise (see illustration).
15Refitting is the reverse of removal. To
ensure correct operation of the brake pedal
switches, reset the switch by fully extending
its plunger (see illustration).Depress the
pedal until the distance between it and the
mounting bracket is as shown in Chapter 9,
illustration 25.6. Hold the pedal in this
position, clip the switch securely into position
and gently raise the pedal to the at-rest
position. This will automatically set the
position of the switch.
Speed control actuator
16Remove the air cleaner as described in
Chapter 4.
17Disconnect the actuator cable from the
throttle linkage on the throttle housing, by
releasing the inner cable end fitting from the
segment and unclipping the outer cable from
the bracket.
18Unscrew the actuator mounting bolt, thenslide the actuator out of the mounting pin
holes.
19Disconnect the multi-plug and remove the
assembly.
20Depress the actuating cable cap locking
arm, and remove the cap by turning it anti-
clockwise (see illustration).
21Gently raise the cable retaining lug by a
maximum of 0.5 mm, and push the cable end
out of the slot in the pulley.
22When refitting, make sure that the cable
end locks into the slot in the pulley.
23To locate the cable cap onto the actuator
pulley, keep the cable taut and in the pulley
groove, and pull the throttle linkage end of the
cable to draw the cable cap onto the pulley.
24To refit the cable cap, keep the cable taut
and the pulley still, then refit the cable cap
tabs into the actuator slots; turn the cap
clockwise until the locking arm locates on the
locking stop. Note:Incorrect assembly of the
cable onto the pulley may result in a high idle
speed. Check that the throttle lever is in its
idle position after refitting the actuator.
Removal
Washer reservoir and pump
1Unscrew the bolts, and release the clips to
remove the radiator lower cover.
2Unscrew the mounting bolts, and pull the
reservoir forwards slightly (see illustration).
For better access, it may be necessary to
remove the front bumper.
3Disconnect the multi-plugs for the
windscreen washer pump and fluid level
sensor (see illustration).
4Disconnect the hoses from the windscreen
washer pump and (where applicable) from the
headlamp washer pump. Anticipate some loss
of fluid by placing a container beneath the
reservoir.
5Withdraw the reservoir from the vehicle.
6Pull the level sensor, the windscreen
washer pump, and (where applicable) the
22 Windscreen/tailgate washer
system components -
removal and refitting
12•20 Body electrical system
21.14 Removal of the speed control
disable switches
1 Clutch switch 3 Stop-light switch
2 Brake pedal switch21.15 Resetting the brake pedal and stop-
light switches21.20 Removing the actuator cable
locking arm
22.2 Washer reservoir mounting bolts
(arrowed)22.3 Disconnecting the washer pump and
level sensor multi-plugs
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12•26 Wiring diagrams
Diagram 2: Engine management – sensor inputs (manual transmission models)
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Wiring diagrams 12•27
12
Diagram 3: Engine management – solenoid outputs and fuel pump (manual transmission models)
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12•28 Wiring diagrams
Diagram 4: Engine management – ignition, tachometer, cooling fan and diagnostic connectors (manual transmission models)
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Wiring diagrams 12•29
12
Diagram 5: Engine management – sensor inputs (automatic transmission models)
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12•30 Wiring diagrams
Diagram 6: Engine management – solenoid outputs, ignition and fuel pump (automatic transmission models)
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Wiring diagrams 12•31
12
Diagram 7: Engine management – cooling fan, solenoid valve unit and diagnostic connectors (automatic transmission models)
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12•38 Wiring diagrams
Diagram 14: Interior lighting – torch, glovebox and engine compartment lights
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REF•3
MImpact screwdriver
MMicrometer and/or vernier calipers (see
illustrations)
MDial gauge (see illustration)
MUniversal electrical multi-meter
MCylinder compression gauge
(see illustration)
MClutch plate alignment set (see illustration)
MBrake shoe steady spring cup removal tool
(see illustration)
MBush and bearing removal/installation set
(see illustration)
MStud extractors (see illustration)
MTap and die set (see illustration)
MLifting tackle
MTrolley jack
Buying tools
For practically all tools, a tool factor is the
best source, since he will have a very
comprehensive range compared with the
average garage or accessory shop. Having
said that, accessory shops often offer
excellent quality tools at discount prices, so it
pays to shop around.
Remember, you don’t have to buy the most
expensive items on the shelf, but it is always
advisable to steer clear of the very cheap
tools. There are plenty of good tools around atreasonable prices, but always aim to purchase
items which meet the relevant national safety
standards. If in doubt, ask the proprietor or
manager of the shop for advice before making
a purchase.
Care and maintenance of tools
Having purchased a reasonable tool kit, it is
necessary to keep the tools in a clean and
serviceable condition. After use, always wipe
off any dirt, grease and metal particles using a
clean, dry cloth, before putting the tools away.
Never leave them lying around after they have
been used. A simple tool rack on the garage
or workshop wall for items such as
screwdrivers and pliers is a good idea. Store
all normal spanners and sockets in a metal
box. Any measuring instruments, gauges,
meters, etc, must be carefully stored where
they cannot be damaged or become rusty.
Take a little care when tools are used.
Hammer heads inevitably become marked,
and screwdrivers lose the keen edge on their
blades from time to time. A little timely
attention with emery cloth or a file will soon
restore items like this to a good serviceable
finish.
Working facilities
Not to be forgotten when discussing tools isthe workshop itself. If anything more than
routine maintenance is to be carried out, some
form of suitable working area becomes
essential.
It is appreciated that many an owner-
mechanic is forced by circumstances to
remove an engine or similar item without the
benefit of a garage or workshop. Having done
this, any repairs should always be done under
the cover of a roof.
Wherever possible, any dismantling should
be done on a clean, flat workbench or table at
a suitable working height.
Any workbench needs a vice; one with a
jaw opening of 100 mm is suitable for most
jobs. As mentioned previously, some clean
dry storage space is also required for tools, as
well as for any lubricants, cleaning fluids,
touch-up paints and so on, which become
necessary.
Another item which may be required, and
which has a much more general usage, is an
electric drill with a chuck capacity of at least 8
mm. This, together with a good range of twist
drills, is virtually essential for fitting
accessories.
Last, but not least, always keep a supply of
old newspapers and clean, lint-free rags
available, and try to keep any working area as
clean as possible.
Bush and bearing removal/installation setStud extractor setTap and die set
Tools and Working Facilities
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