tailgate FORD MONDEO 1993 Service User Guide

Removal
Lock barrel
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2With the boot lid open, remove the luggage
space trim from the right-hand rear corner.
3Remove the screws, and prise out the rear
light trim cover from the guides.
4Release the door-ajar sensor from the clip
near the lock.
5Slide the outer cable from the lock bracket.
Raise the inner cable until it is aligned with the
slot in the barrel lever, and disconnect it.
6Pull out the lock locating spring clip.
7Detach the cable mounting bracket from
the barrel, and remove the barrel.
Lock
8Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
9With the boot lid open, prise out the clips
and remove the trim from inside the boot lid.
10Release the door-ajar sensor from the clip
near the lock.
11Using a Torx key, unscrew the lock
mounting screws, and withdraw the lock for
access to the cables.
12Disconnect both the inner and outer
cables from the lock bracket.13Prise open the plastic lip, and remove the
central locking control rod.
14Withdraw the lock assembly.
Refitting
Lock barrel and lock
15Refitting is a reversal of the removal
procedure.
Removal
Hatchback
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1). Open the tailgate.
2The tailgate may be unbolted from the
hinges and the hinges left in position, or the
hinges may be detached from the roof panel
by unscrewing the mounting nuts. In the latter
case, carefully pull down the rear edge of the
headlining for access to the nuts. Take care
not to damage the headlining.
3Remove the parcel shelf left-hand support
bracket as follows. Fold the rear seat
forwards, and disconnect the left-hand seat
pull cable from the bracket and clips.
Unscrew the screws and remove the bracket.
4Pull up the rear seat side bolster, then
carefully remove the side trim from the left-
hand side of the luggage area. On low-series
models, the bolster is retained with a screw.5Separate the tailgate wiring loom multi-
plugs, located on the left-hand side of the
luggage compartment, on top of the wheel
arch.
6Unclip and remove the upper trim panel
from the inside of the tailgate. Also remove
the rear shelf cord plastic post (see
illustrations).
7Prise out the rubber grommet from the top
of the tailgate aperture, and pull the wiring
loom out through the hole in the body (see
illustration).
8Disconnect the rear window washer tube
from the jet.
9Prise out the rubber grommet from the
right-hand side of the tailgate aperture, and
pull out the washer tube.
10Have an assistant support the tailgate in
its open position.
11Using a small screwdriver, prise off the
clips securing the struts to the tailgate. Pull
the sockets from the ball-studs, and move the
struts downwards.
12If the headlining has been pulled back,
unscrew and remove the hinge nuts from the
roof panel. Otherwise, unscrew the bolts
securing the tailgate to the hinges (see
illustration).
13Withdraw the tailgate from the body
aperture, taking care not to damage the
paintwork.
Estate
14Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
15The tailgate may be unbolted from the
hinges and the hinges left in position, or the
hinges may be detached from the rear roof
panel by unscrewing the mounting nuts. In the
latter case, carefully pull down the rear edge
of the headlining for access to the nuts. Take
care not to damage the headlining.
16Unscrew the retaining screws, then unclip
the “D” pillar trim panels from both sides (see
illustration).
17Unclip and remove the upper trim panel
from inside the tailgate.
18Carefully remove the side trim from the
left-hand side of the luggage area, and
separate the tailgate wiring loom multi-plugs
in the rear light cluster housing.
20 Tailgate -
removal and refitting
19 Boot lid lock components-
removal and refitting
Bodywork and fittings 11•15
11
20.12 Unscrewing the bolts securing the
tailgate to the hinges20.16 “D” pillar trim panel retaining
screws (arrowed) - Estate models
20.6A Unclipping the upper trim panel
from the tailgate20.6B Shelf cord post removal20.7 Removing the wiring loom rubber
grommet
procarmanuals.com

19Attach a strong fine cord to the end of the
wiring loom, to act as an aid to guiding the
wiring through the tailgate when it is refitted.
20Prise the rubber grommet from the top
left-hand side of the tailgate aperture, and pull
out the wiring loom. Untie the cord, leaving it
in position in the “D” pillar.
21Disconnect the rear window washer tube
from the jet. Pull out the rubber grommet, and
remove the tube.
22Have an assistant support the tailgate in
its open position.
23Using a small screwdriver, prise off the
clip securing the struts to the tailgate. Pull the
sockets from the ball-studs, and move the
struts downwards.
24Unscrew and remove the hinge nuts from
the roof panel, or the hinge bolts from thehinge, as desired (see illustration). Withdraw
the tailgate from the body aperture, taking
care not to damage the paintwork.
Refitting
Hatchback and Estate
25Refitting is a reversal of the removal
procedure, but check that the tailgate is
located centrally in the body aperture, and
that the striker enters the lock centrally. If
necessary, loosen the mounting nuts and re-
position the tailgate as required.
Removal
1Support the tailgate in its open position.
2Prise off the upper spring clip securing the
strut to the tailgate, then pull the socket from
the ball-stud (see illustration).
3Similarly prise off the bottom clip (see
illustration), and pull the socket from the ball-
stud. Withdraw the strut.
Refitting
4Refitting is a reversal of the removal
procedure, but make sure that the piston end
of the strut is fitted on the body (ie
downwards).
Removal
Lock barrel (Hatchback)
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2With the tailgate open, pull up the
weatherstrip for access to the lock. Remove
the screws and clips, and remove the trim
panel from the rear of the luggage
compartment.
3Unhook the parcel net, then remove the
screws and clips, and remove the rear
crossmember trim.
4Remove the screws, and prise out the rear
light trim cover from the guides.
5Release the door-ajar sensor from the clip
near the lock.
6Slide the outer cable from the lock bracket.
Raise the inner cable until it is aligned with the
slot in the barrel lever, and disconnect it (see
illustration).
7Pull out the lock barrel locating spring clip.
8Detach the cable mounting bracket from
the barrel, and remove the barrel and cylinder
(see illustrations).
Lock barrel (Estate)
9Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
10Unclip and remove the tailgate trim panel.
Undo the three screws and remove the lock
shield, then unclip the door-ajar sensor.
11Working through the aperture in the
tailgate inner panel, pull out the lock barrel
locating spring clip. Unhook the operating rod
and withdraw the lock barrel.
Lock (Hatchback)
12Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
13With the tailgate open, pull up the
weatherstrip for access to the lock. Remove
the screws and clips, and remove the trim
panel from the rear of the luggage
compartment.
22 Tailgate lock components -
removal and refitting
21 Tailgate support strut-
removal and refitting
11•16 Bodywork and fittings
20.24 Tailgate hinge and bolts - Estate
models21.2 Prising the spring clip from the upper
end of the strut
21.3 Prising the spring clip from the lower
end of the strut
22.6 Tailgate lock barrel and bracket22.8A Removing the lock barrel . . .22.8B . . . and cylinder
procarmanuals.com

14Release the door-ajar sensor from the clip
near the lock (see illustration).
15Using a Torx key, unscrew the lock
mounting screws, and withdraw the lock for
access to the cables (see illustration).
16Disconnect both the inner and outer
cables from the lock bracket (see
illustration).
17Prise open the plastic clip, and remove
the central locking control rod.
18Withdraw the lock assembly.
Lock (Estate)
19Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
20Open the tailgate. Undo the screws and
remove the inner trim.
21Using a Torx key, unscrew the lock
mounting screws, and carefully withdraw the
lock (see illustration).
22Release the door-ajar sensor from the clip
near the lock.
23Disconnect the barrel operating rod, and
remove the lock.
24If necessary, the lock striker assembly
may be removed by disconnecting the release
cable and unscrewing the mounting bolts (see
illustration).
Refitting
Lock barrel and lock - all models
25Refitting is a reversal of the removal
procedure.
Testing
1The central locking module incorporates a
service-test mode, which is activated by
operating one of the lock position switches 8
times within 10 seconds. A buzzer will sound,
to indicate that the service-test mode is
operating, and to indicate that no faults have
been found in the system. If a fault has been
found, the system should be checked by a
Ford dealer or electrical specialist. The central
locking module also incorporates the alarm
system module.
Removal
Central locking/alarm module
2To remove the module, first remove the
lower right-hand facia panel (right-hand-drive
models) or the glovebox (left-hand-drive
models).
3Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
4Unscrew the mounting bolts, and remove
the module from the bracket beneath the
facia.
5Disconnect the wiring multi-plug, and
withdraw the module from inside the vehicle.6Note that a different module is used for
models without an anti-theft alarm.
Central locking set/reset switch
7This procedure is covered in Section 14,
under front door handle removal.
Central locking door-ajar switch
8This procedure is covered in Section 14,
under front door lock motor removal.
Refitting
Central locking/alarm module
9Refitting is a reversal of the removal
procedure.
Central locking set/reset switch
10Refitting is a reversal of the removal
procedure.
Central locking door-ajar switch
11Refitting is a reversal of the removal
procedure.
1The windscreen and rear window on all
models are bonded in place with special
mastic, as are the rear side windows on
Estate models. Special tools are required to
cut free the old units and fit replacements;
special cleaning solutions and primer are also
required. It is therefore recommended that
this work is entrusted to a Ford dealer or
windscreen replacement specialist.
2Note that the windscreen contributes
towards the structural strength of the vehicle
as a whole, so it is important that it is fitted
correctly.
Removal
1Insert a length of strong cord (fishing line is
ideal) behind the moulding or emblem
concerned. With a sawing action, break the
25 Body side-trim mouldings
and adhesive emblems -
removal and refitting
24 Windscreen and fixed
windows - removal and refitting
23 Central locking system
components-
testing, removal and refitting
Bodywork and fittings 11•17
11
22.21 Tailgate lock - Estate models22.24 Lock striker assembly - Estate
models
22.14 Removing the door-ajar sensor from
the lock22.15 Removing a lock mounting screw22.16 Disconnecting the cables from the
lock
procarmanuals.com

Chapter 12 Body electrical system
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 30
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 29
Air bag unit (driver’s side) - removal and refitting . . . . . . . . . . . . . . . 28
Anti-theft alarm system - general information . . . . . . . . . . . . . . . . . . 20
Auxiliary warning system - general information and
component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery - check, maintenance and charging . . . . . . . . See Chapter 1
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . See Chapter 5
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compact disc player - removal and refitting . . . . . . . . . . . . . . . . . . . 25
Cruise control system - general information . . . . . . . . . . . . . . . . . . . 21
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses, relays and timer module - testing and renewal . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight beam alignment - checking and adjustment . . . . . . . . . . 8
Headlight levelling motor - removal and refitting . . . . . . . . . . . . . . . 9Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel components - removal and refitting . . . . . . . . . . . 11
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Radio/cassette player - coding, removal and refitting . . . . . . . . . . . 23
Radio/cassette player power amplifier - removal and refitting . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Speedometer drive cable - removal and refitting . . . . . . . . . . . . . . . 12
Stop-light switch - removal and refitting . . . . . . . . . . . See Chapter 9
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 17
TCS inhibition switch - removal and refitting . . . . . . . . See Chapter 9
Trip computer module - removal and refitting . . . . . . . . . . . . . . . . . 18
Windscreen/tailgate washer system and wiper blade
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Windscreen/tailgate washer system components - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses (auxiliary fusebox in engine compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse No Rating Colour Circuit(s) protected
1 80 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply to main fusebox
2 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fans
3 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Diesel engine glow plugs and/or ABS braking system
4 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system, or ignition and daytime running lights
5 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (left-hand side)
6 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (right-hand side)
7 30 Light green . . . . . . . . . . . . . . . . . . . . . . ABS braking system
8 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air conditioning compressor/heated seats or air conditioning
compressor/daytime running lights
9 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . ECU (petrol), Cold start solenoid (Diesel)
10 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . Ignition switch
11 3 Violet . . . . . . . . . . . . . . . . . . . . . . . . . . ECU memory
12 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Horn and hazard flasher warning system
13 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Oxygen sensor
14 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
15 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (right-hand side)
16 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (left-hand side)
17 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (right-hand side)
18 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (left-hand side)
12•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
12
procarmanuals.com

Main light, auxiliary foglight and rear
foglight combination switch
Note:From July 1994 a rvised main light
switch was introduced; this was fitted as
standard in production. If the revised switch is
to be fitted to a pre-July 1994 model, an
adapter lead will also be required to prevent
electrical damage ocurring. Refer to your Ford
dealer for further information
9Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
10Carefully prise the switch panel from the
facia, using a screwdriver against a cloth pad
to prevent damage to the facia (see
illustration).
11Disconnect the multi-plugs and withdraw
the switch panel (see illustration).
12Unscrew the four mounting screws, and
remove the switch from the panel.
13Pull off the switch control knob, and
remove the blanking plug and retainer.
14Depress the plastic tabs, and remove the
front cover and switch.
Instrument light rheostat
15Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
16Carefully prise the light switch panel from
the facia, using a screwdriver against a cloth
pad to prevent damage to the facia.
17Disconnect the multi-plugs from the rear
of the switch, then remove the screws and
withdraw the instrument light rheostat from
the panel.
Door mirror control switch
18Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
19Carefully prise the switch from the facia,
using a screwdriver against a cloth pad to
prevent damage to the facia.
20Disconnect the multi-plug and withdraw
the switch.
Direction indicator, dipped beam and
hazard flasher multi-function switch
21Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
22Remove the rubber gaiters and locking
rings, then remove the screws and take off the
steering column upper shroud.23Depress the retaining lug and withdraw
the switch assembly, then disconnect the
multi-plug (see illustration).
24With the switch assembly removed, pull
out the direction indicator relay if required.
Horn switch (steering wheel without
air bag)
Note:When an air bag is fitted, the horn
switch is removed with the air bag unit. Refer
to Section 28.
25Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
26Carefully pull off the padded centre of the
steering wheel which incorporates the horn
switch.
27Disconnect the wiring and remove the
switch assembly.
Luggage compartment switch
28Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
29With the tailgate/bootlid open, pull the
weatherstrip from the centre of the rear cross
panel.
30Carefully prise out the trim fasteners from
the bottom corners of the rear trim, then
unscrew the retaining screws and remove the
trim panel.
31Disconnect the wiring multi-plug, and pull
out the switch.
Electrically-operated window switch
(single)
32Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
33Carefully prise out the switch from the
door inner trim panel, using a cloth pad to
prevent damage to the trim.
34Disconnect the multi-plug and remove the
switch.
Electrically-operated window switch
(multiple) and isolator
35Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
36Prise the blanking cap from inside the
inner door handle cavity, and remove the
screw.
37Hold the inner door handle in its open
position, then remove the bezel and withdraw
it over the handle.38Depress the retaining lug and remove the
switch assembly, then disconnect the multi-
plug.
Electrically-operated sunroof switch
and traction control switch
39Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
40Carefully prise out the switch with a
screwdriver, using a cloth pad to prevent
damage to the trim.
41Disconnect the multi-plug and remove the
switch.
Handbrake-on warning switch
42Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
43Remove the centre console as described
in Chapter 11.
44Disconnect the multi-plug, then remove
the screw and withdraw the switch from the
handbrake lever mounting bracket (see
illustration).
“Economy/Sport” mode switch
(automatic transmission models)
45Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
46Select Neutral, then prise out the selector
indicator panel, using a cloth pad to prevent
damage to the surrounding trim.
47Push the switch out of the panel, and
disconnect the multi-plug.
Body electrical system 12•7
12
4.44 Disconnecting the multi-plug from
the handbrake lever
4.10 Prising out the light switch4.11 Disconnecting the multi-plugs from
the light switch and rheostat4.23 Removing the direction indicator,
dipped beam and hazard flasher multi-
function switch. Direction indicator relay
(flasher unit) is attached
procarmanuals.com

6Pull out the bulb and disconnect the wiring
lead (see illustration).
7Fit the new bulb using a reversal of the
removal procedure, making sure that the
bulbholder is correctly located in the headlight
unit. Have the headlight beam alignment
checked as described later in this Chapter.
Front sidelight
8Working under the bonnet, depress the
plastic clips and remove the cover from the
rear of the headlight unit.
9Pull the bulbholder from the rear of the
headlight unit (see illustration).
10Pull the wedge-type bulb from the
bulbholder (see illustration).
11Fit the new bulb using a reversal of the
removal procedure.
Front direction indicator
12Open the bonnet. Loosen (but do not
remove) the screw located above the front
direction indicator (see illustration 7.10).
13Withdraw the front direction indicator light
unit.
14Rotate the bulbholder anti-clockwise, and
withdraw it from the light unit.
15Twist the bulb anti-clockwise, and remove
it from the bulbholder (see illustration).
16Fit the new bulb using a reversal of the
removal procedure, but before refitting the
light unit, first insert the holding spring in its
bore.
Side repeaters
17The side repeater light is held in position
by spring pressure.
18Depending on how the light unit was
previously fitted, press it either forwards or
rearwards, and remove it from the front wing
(see illustration).
19Turn the bulbholder anti-clockwise, and
disconnect it from the housing (see
illustration).
20Pull the wedge-type bulb from the holder
(see illustration).
21Fit the new bulb using a reversal of the
removal procedure.
Front foglight
22Unscrew the cross-head screws securingthe front foglight unit to the valance, and
withdraw the light unit.
23Prise open the plastic clips and remove
the rear cover from the light unit.
24Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
25Fit the new bulb using a reversal of the
removal procedure.
Rear light cluster
26With the tailgate or bootlid open, flip open
the trim cover to reveal the bulbholder in the
rear corner of the luggage compartment. On
Estate models, pull back the weatherstrip and
unclip the trim cover (see illustrations).
27Press the two plastic locking tabs
together, and withdraw the complete rear light
cluster (see illustrations).
Body electrical system 12•9
12
5.19 Removing the bulbholder from the
side repeater lens/bulbholder5.20 Removing the wedge-type bulb from
the side repeater bulbholder5.26A Pull back the weatherstrip . . .
5.15 Removing the front direction
indicator bulb5.18 Removing the side repeater from the
front wing
5.6 Removing the headlight (main beam)
bulb from the bulbholder5.9 Removing the front sidelight bulb-
holder from the rear of the headlight unit5.10 Pulling the wedge-type bulb from the
bulbholder
procarmanuals.com

located above the front direction indicator
(see illustration).
11Withdraw the front direction indicator light
unit.
12Rotate the bulbholder anti-clockwise, and
withdraw it from the light unit. Alternatively,
the wiring plug can be disconnected from the
bulbholder, leaving the bulb in position (see
illustration). Remove the light unit.
Foglight (front)
13Unscrew the cross-head screws securing
the front foglight unit to the valance, and
withdraw the light unit from the valance.
14Prise open the plastic clips, and remove
the rear cover from the light unit.
15Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
Remove the foglight unit.
Rear light cluster
16With the tailgate or bootlid open, unhook
the parcel net (where fitted) from the rear of
the luggage compartment.
17On Saloon and Hatchback models,
remove the screws, release the clips, and
remove the trim panel from the rear cross
panel. On Estate models, it is sufficient to
open the flap.
18Remove the screws, and press the rear
light trim cover from the guides (where
applicable).
19Disconnect the wiring multi-plug.
20Unscrew the four mounting nuts, and
withdraw the light unit from the outside of the
vehicle (see illustrations).
Rear number plate light assembly
21Remove both number plate lights as
described in Section 5.
22With the tailgate or bootlid open, remove
the screws and withdraw the inner trim panel.
23Unscrew the nuts, and remove the outer
cover and number plate base from the
tailgate.
24Disconnect the multi-plug and remove the
light assembly.
Refitting
25Refitting of all the external light units is a
reversal of the removal procedure, noting the
following points:(a) When refitting the rubber seal on the
headlight unit, note that it has a tapered
seat.
(b) If one or both headlights have been
disturbed, have the beam alignment
checked as described in the next Section.
(c) When refitting the rear light cluster, check
the condition of the sealer on the body
panel, and if necessary renew it.
1Accurate adjustment of the headlight beam
is only possible using optical beam-setting
equipment. This work should therefore be
carried out by a Ford dealer, or other service
station with the necessary facilities.
2Temporary adjustment can be made after
renewal of a headlight bulb or unit, or as an
emergency measure if the alignment is
incorrect following accident damage. Turn the
adjustment screws on the top of the headlamp
unit to make the adjustment (see illustration).
3Before making any adjustments to the
settings, it is important that the tyre pressures
are correct, and that the vehicle is standing on
level ground. Bounce the front of the vehicle a
few times to settle the suspension. Ideally,
somebody of average size should sit in the
driver’s seat during the adjustment, and the
vehicle should have a full tank of fuel. Where a
vehicle is fitted with an electrical beam
levelling system, set the switch to the “O”
position before making any adjustments.4Whenever temporary adjustments are
made, the settings must be checked and if
necessary reset by a Ford dealer or other
qualified person as soon as possible.
Removal
1Remove the headlight unit as described in
Section 7, then remove the cover.
2Disconnect the wiring multi-plug from the
motor.
3Rotate the motor upwards approximately
60°, then pull it forwards slightly.
4Disconnect the adjustment spindle by
pressing the ball coupling to one side, away
from the socket on the reflector.
5Withdraw the motor from the headlight unit.
Refitting
6Refitting is a reversal of the removal
procedure, but make sure that the motor is
turned down until it engages the stop.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
10 Instrument panel -
removal and refitting
9 Headlight levelling motor -
removal and refitting
8 Headlight beam alignment-
checking and adjustment
Body electrical system 12•13
12
7.20B Removing the rear light cluster unit
8.2 Headlight beam setting adjustment
screws
1 Vertical alignment screw
2 Horizontal alignment screw
7.10 Loosen the front direction indicator
retaining screw7.12 Disconnecting the wiring plug from
the indicator bulbholder7.20A Rear light cluster mounting nuts
(arrowed)
procarmanuals.com

8Disconnect the wiper motor multi-plug.
9Withdraw the wiper motor, complete with
the linkage, from the bulkhead (see
illustration).
10Mark the position of the motor arm on the
mounting plate, then unscrew the centre nut
(see illustration).
11Unscrew the motor mounting bolts, and
separate the motor from the linkage assembly.
Refitting
12Refitting is a reversal of the removal
procedure. There are two tightening torques
for the motor mounting bolts - the lower one
for bolts that are being re-inserted into an old
motor, and the higher ones for bolts that are
being inserted into a new motor. Make sure
that the wiper motor is in its “parked” position
before fitting the motor arm, and check that
the wiper linkage is in line with the motor arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the tailgate wiper arm as
described in Section 15.
3Remove the tailgate inner trim panel by
unscrewing the retaining screws.
4Release the multi-plug from the clip, then
disconnect it (see illustration).5Disconnect the wiper motor earth lead.
6Unscrew the mounting bolts, and remove
the wiper motor from inside the tailgate (see
illustrations).
7Unbolt and remove the mounting plate. If
necessary, remove the mounting rubbers for
renewal (see illustrations).
Refitting
8Refitting is a reversal of the removal
procedure. Make sure that the wiper motor is
in its “parked” position before fitting the wiper
arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Using a small screwdriver, prise the trip
computer module out of the facia. To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the trip computer module, and withdraw the
unit.
4If necessary, the bulb can be removed by
twisting it anti-clockwise.
Refitting
5Refitting is a reversal of the removal
procedure.1Some models are fitted with an auxiliary
warning system, which monitors brake lights,
sidelights, dipped beam and tail lights,
external temperature, and door/tailgate/
bootlid opening. An engine oil level warning
light on the instrument panel is also part of the
system.
2The auxiliary warning system module and
graphic warning display are combined into
one unit.
Service interval reminder
3The system also includes a service interval
reminder warning light, which is illuminated if
19 Auxiliary warning system -
general information and
component renewal
18 Trip computer module-
removal and refitting
17 Tailgate wiper motor
assembly - removal and refitting
Body electrical system 12•17
12
17.6B . . . and remove the tailgate wiper
motor assembly (Hatchback shown -
Estate similar)17.7A Tailgate wiper motor assembly and
mounting plate17.7B A mounting rubber removed from
the mounting plate
17.6A Unscrew the mounting bolts . . .
16.9 Removing the wiper motor and
linkage16.10 Wiper motor arm and mounting
plate located on the motor17.4 Disconnecting the tailgate wiper
motor multi-plug
procarmanuals.com

4The system module is located on a bracket
beneath the right-hand side of the facia. The
set and reset switches are located in a
housing by the lock barrel holder in the doors,
tailgate or bootlid.
5To allow temporary opening of the tailgate
or bootlid, an inhibit switch is fitted to the lock
barrel. This suppresses the alarm system until
the tailgate or bootlid is closed again.
6Where remote central locking is fitted, an
infra-red receiver is located on the exterior
door handle (see illustration). Note that
excessive heat can destroy this receiver;
therefore, it should be covered with aluminium
tape if (for instance) a paint-drying heat
process is to be used.
7The alarm system is fitted with its own horn.
On Hatchback and Saloon models, it is
located on the left-hand side of the luggage
compartment; on Estate models, it is located
on the right-hand side of the luggage
compartment (see illustration).
8The alarm system incorporates a self-test
function, which can be activated by operating
the bonnet switch or one of the lock position
switches eight times within 10 seconds.
During the check, the horn or buzzer issues
acoustic signals which should occur every
time a door, bonnet or tailgate is opened. If
the doors are double-locked, the signal will
occur when something is moved within the
passenger compartment. A more
comprehensive test can be made using the
Ford FDS 2000 diagnostic tester.
9The door lock switches associated with the
alarm system are located behind the door trim
panels (see illustration).
1Cruise control is available as an option on
some models.
2The cruise control system components are
shown in the accompanying illustration (see
illustration). The system is active at road
speeds between 25 mph and 125 mph.
3The system comprises an electronic speed
control unit with integral actuator and
21 Cruise control system -
general information
Body electrical system 12•19
12
21.2 Cruise control component location on left-hand drive models
1 Speed control unit
2 Vehicle speed sensor (VSS)
3 Throttle valve actuator
4 Interrupt relay (vehicles with traction control
system only)5 Stop-light switch, brake and clutch pedal-
operated disable switches
6 Driver’s controls (buttons on steering wheel)
20.6 Infra-red receiver location on the
door handle
1 Receiver 2 Infra-red eye on the door handle20.7 Alarm system horn location on
Hatchback and Saloon models20.10 Alarm system door lock switch
removal
1 Clips (arrowed) 2 Multi-plug
procarmanuals.com

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
procarmanuals.com