FORD MONDEO 1993 Service Repair Manual

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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headlamp washer pump, from the reservoir
(see illustration).
7Remove the rubber seals.
Washer nozzle (windscreen)
8With the bonnet supported in its open
position, carefully disconnect the washer tube
from the bottom of the nozzle.
9Using a screwdriver and working from
under the bonnet, carefully prise out the
nozzle. Where necessary, disconnect the
wiring for the nozzle heater.
Washer nozzle (rear window)
10With the tailgate open, carefully pull off
the inner trim panel from the top of the
tailgate.
11Pull the washer tube from the bottom of
the nozzle (see illustration).
12Carefully prise the nozzle out of the
tailgate glass, then prise out the rubber
grommet (see illustrations). Where
necessary, disconnect the wiring for the
nozzle heater.
Refitting
13Refitting is a reversal of the removal
procedure. In the case of the washer nozzles,
press them in until they are fully engaged. The
rear window washer nozzle must rest against
the rubber seal.
Note:Special tools are required to remove the
radio.
Coding
1If a Ford “Keycode” unit is fitted, and the
unit and/or the battery is disconnected, the
unit will not function again on reconnection
until the correct security code is entered.
Details of this procedure are given in the
“Ford Audio Systems Operating Guide”
supplied with the vehicle when new, with the
code itself being given in a “Radio Passport”
and/or a “Keycode Label” at the same time.
2For obvious security reasons, the re-coding
procedure is not given in this manual - if youdo not have the code or details of the correct
procedure, but can supply proof of ownership
and a legitimate reason for wanting this
information, the vehicle’s selling dealer may
be able to help.
3Note that these units will allow only ten
attempts at entering the code - any further
attempts will render the unit permanently
inoperative until it has been reprogrammed by
Ford themselves. At first, three consecutive
attempts are allowed; if all three are incorrect,
a 30-minute delay is required before another
attempt can be made. Each of any
subsequent attempts (up to the maximum of
ten) can be made only after a similar delay.
Removal
4Disconnect the battery negative (earth)
lead.
5Where fitted, prise the cover/surround from
the front of the radio/cassette player. Note
that the cover is not fitted to all models.
6In order to release the radio retaining clips,
two U-shaped rods must be inserted into the
special holes on each side of the radio (see
illustration). If possible, it is preferable to
obtain purpose-made rods from an audio
specialist, as these have cut-outs which snap
firmly into the clips so that the radio can be
pulled out. Pull the unit squarely from its
aperture, or it may jam. If the unit proves
difficult to withdraw, remove the cassette tray
(or where applicable, the CD player) frombeneath the unit, then reach through the
aperture and ease it out from behind.
7With the radio partly withdrawn, disconnect
the feed, earth, aerial and speaker leads.
Where applicable, also detach and remove
the plastic support bracket from the rear of
the unit.
Refitting
6Refitting is a reversal of removal. With the
leads reconnected to the rear of the unit,
press it into position until the retaining clips
are felt to engage. Reactivate the unit by
entering the correct code in accordance with
the maker’s instructions.
Removal
1Disconnect the battery negative (earth)
lead. See Chapter 5, Section 1.
2Unscrew the screws and remove the lower
facia panel.
3The radio/cassette player power amplifier is
located beneath the facia.
4Unscrew the cross-head screws, dis-
connect the wiring and remove the amplifier.
Refitting
5Refitting is a reversal of the removal
procedure.
24 Radio/cassette player
power amplifier -
removal and refitting
23 Radio/cassette player -
coding, removal and refitting
Body electrical system 12•21
12
22.12B . . . and prise out the rubber
grommet23.6 Using the special U-shaped rods to
remove the radio
22.6 Pulling the windscreen washer pump
from the reservoir22.11 Pull the washer tube from the
bottom of the nozzle22.12A Remove the nozzle from the
tailgate glass . . .
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1A compact disc (CD) player is available as
an optional extra on most models. On some
models, an autochanger version is available,
which can hold a number of discs at a time.
Removal
2The battery negative (earth) lead should be
disconnected before commencing work.
CD player, or autochanger control
unit
3The procedure is identical to that for the
radio/cassette player described in Section 23.
CD player autochanger
4The CD player autochanger unit is mounted
on the right-hand side of the luggage
compartment. The wiring loom passes up the
“C” pillar, across to the left-hand side “A”
pillar, then to the centre console area.
5Remove the trim cover from the
autochanger unit.
6Unscrew the mounting screws, and remove
the autochanger unit from its mounting
bracket.
7Disconnect the multi-plug and remove the
unit from inside the vehicle.
Refitting
8Refitting is a reversal of the removal
procedure.
Removal
1Remove the door trim panel as described in
Chapter 11.
2Unscrew the cross-head screws, and
withdraw the speaker from the door inner
panel.
3Disconnect the wiring and remove the
speaker.
Refitting
4Refitting is a reversal of the removal
procedure.
Removal
1Prise out the trim cover from the headlining
immediately below the base of the aerial.
2Unscrew the cross-head screw from the
base of the aerial, and remove the aerial mast.
Refitting
3Refitting is a reversal of the removal
procedure.
Warning: Handle the air bag unit
with extreme care, as a
precaution against personal
injury, and always hold it with the
cover facing away from the body. If in
doubt concerning any proposed work
involving the air bag unit or its control
circuitry, consult a Ford dealer or other
qualified specialist.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
Warning: Before proceeding, wait
a minimum of 15 minutes, as a
precaution against accidental
firing of the air bag unit. This
period ensures that any stored energy in
the back-up capacitor is dissipated.
2Rotate the steering wheel so that one of the
mounting bolt holes is visible above the
steering column upper shroud.
3Unscrew and remove the first mounting
bolt, then turn the steering wheel as
necessary and remove the remaining
mounting bolts (see illustration).
4Carefully withdraw the air bag unit from the
steering wheel far enough to disconnect the
wiring multi-plug, then remove it from inside
the vehicle (see illustration). Warning: Stand the unit with the
cover uppermost, and do not
expose it to heat sources in
excess of 100ºC.
Warning: Do not attempt to open
or repair the air bag unit, or apply
any electrical current to it. Do not
use any air bag unit which is visibly
damaged or which has been tampered
with.
Refitting
5Refitting is a reversal of the removal
procedure.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
Warning: Before proceeding, wait
a minimum of 15 minutes, as a
precaution against accidental
firing of the air bag unit. This
period ensures that any stored energy in
the back-up capacitor is dissipated.
2Remove the facia panel as described in
Chapter 11.
3Disconnect the multi-plug from the module,
by pressing the locking tab upwards and
swivelling the retaining strap.
4Unscrew the mounting bolts and remove
the module from the vehicle.
Refitting
5Refitting is a reversal of the removal
procedure.
Removal
1Remove the air bag unit as described in
Section 28.
2Disconnect the horn switch multi-plug.
3If fitted, disconnect the multi-plugs for the
cruise control.
4Remove the steering wheel and shrouds.
5Using a small screwdriver, release the
retaining tabs, then remove the clock spring
from the steering column.
Refitting
6Refitting is a reversal of the removal
procedure, but make sure that the steering
wheel is centralised. The clock spring must be
fitted in its central position, with the special
alignment marks aligned and the TOP mark
uppermost. To check for this position, turn the
clock spring housing anti-clockwise until it is
tight, then turn in the opposite direction by
two-and-three-quarter turns.
30 Air bag clock spring-
removal and refitting
29 Air bag control module -
removal and refitting
28 Air bag unit (driver’s side) -
removal and refitting
27 Radio aerial -
removal and refitting
26 Speakers -
removal and refitting
25 Compact disc player -
removal and refitting
12•22 Body electrical system
28.3 Unscrewing an air bag mounting bolt28.4 Disconnecting the air bag wiring
multi-plug (arrowed)
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Wiring diagrams 12•23
12
Notes, internal connection details and key to symbols
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12•24 Wiring diagrams
Internal connection details continued
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Wiring diagrams 12•25
12
Diagram 1: Starting, charging, warning lights and gauges
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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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