change FORD MONDEO 1993 Service Owner's Guide

hence the heat shields on the vehicle
underbody - and the casing will become
hot enough to ignite combustible
materials which brush against it. DO NOT,
therefore, park the vehicle in dry
undergrowth, over long grass or piles of
dead leaves.
(k) Remember that the catalytic converter is
FRAGILE. Do not strike it with tools
during servicing work, and take great care
when working on the exhaust system (see
Chapter 4). Ensure that the converter is
well clear of any jacks or other lifting gear
used to raise the vehicle. Do not drive the
vehicle over rough ground, road humps,
etc, in such a way as to “ground” the
exhaust system.
(l) In some cases, particularly when the
vehicle is new and/or is used for
stop/start driving, a sulphurous smell (like
that of rotten eggs) may be noticed fromthe exhaust. This is common to many
catalytic converter-equipped vehicles,
and seems to be due to the small amount
of sulphur found in some petrols reacting
with hydrogen in the exhaust, to produce
hydrogen sulphide (H
2S) gas; while this
gas is toxic, it is not produced in sufficient
amounts to be a problem. Once the
vehicle has covered a few thousand miles,
the problem should disappear - in the
meanwhile, a change of driving style, or of
the brand of petrol used, may effect a
solution.
(m) The catalytic converter on a well-
maintained and well-driven vehicle should
last for between 50 000 and 100 000
miles. From this point on, careful checks
should be made at regular intervals to
ensure that the converter is still operating
efficiently. If the converter is no longer
effective, it must be renewed.
Checking
7Checking the operation of a catalytic
converter requires expensive and
sophisticated diagnostic equipment, starting
with a high-quality exhaust gas analyser. If the
level of CO in the exhaust gases is too high, a
full check of the engine management system
must be carried out (see Section 3 of this
Chapter) to eliminate all other possibilities
before the converter is suspected of being
faulty.
8The vehicle should be taken to a Ford
dealer for this work to be carried out using the
correct diagnostic equipment; do not waste
time trying to test the system without such
facilities.
Component renewal
9The catalytic converter is part of the
exhaust system front downpipe - see Chap-
ter 4 for details of removal and refitting.
6•20 Emissions control systems
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15Locate the steering column shaft on the
flexible coupling, swivel the clamp plate
round, then insert the bolt and tighten to the
specified torque.
16Refit the driver’s side lower trim panel.
17Refit the steering column upper and lower
shrouds.
18Reconnect the battery negative lead.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Turn the steering wheel so that the front
wheels are in the straight-ahead position.
Remove the ignition key, then turn the
steering wheel slightly as necessary until the
steering lock engages.
3Unscrew the clamp plate bolt securing the
steering column shaft to the flexible coupling.
Swivel the clamp plate around, and disengage
it from the flexible coupling stub.
4Carefully prise the rubber boot from the
bulkhead, and withdraw it into the passenger
compartment. Take care not to damage the
sealing lip of the boot.
5Using an Allen key, unscrew the clamp bolt
securing the flexible coupling to the pinion
shaft on the steering gear, and withdraw the
coupling from inside the vehicle.
Refitting
6Refitting is a reversal of the removal
procedure, but tighten the clamp bolts to the
specified torque. Make sure that the rubber
boot engages correctly in the bulkhead and
on the flexible coupling.
Removal
1Remove the steering column flexible
coupling as described in Section 29.
2Apply the handbrake, then jack up the frontof the vehicle and support it on axle stands.
Remove both front wheels.
3Working beneath the vehicle, unbolt the
rear engine mounting from the transmission
and underbody.
4Extract the split pins from the track rod end
balljoint nuts, then unscrew the nuts, and
detach the rods from the arms on the steering
knuckles using a conventional balljoint
removal tool. Take care not to damage the
balljoint seals.
5Position a suitable container beneath the
steering gear, then unscrew the union nuts
securing the power steering fluid supply,
return, and cooler lines to the steering gear.
Identify the lines for position, then unbolt the
clamps, disconnect the lines, and allow the
fluid to drain into the container. Cover the
apertures in the steering gear and also the
ends of the fluid pipes, to prevent the ingress
of dust and dirt into the hydraulic circuit.
6Unscrew and remove the steering gear
mounting bolts. The bolts are located on top
of the steering gear, and are difficult to reach.
Ideally, the special U-shaped Ford spanner
should be used, but it is just possible to reach
them with a normal spanner (see illustration).
7Withdraw the steering gear through the
wheel arch.
Refitting
8If the steering gear is being replaced with a
new one, the new unit will be supplied
together with union nuts already fitted. The
new nuts must only be used with new feed
and return lines - otherwise, they must be
removed and discarded. If the original lines
and union nuts are being used, the Teflon
rings on the union nuts must be renewed. To
do this, the rings must be expanded
individually onto a fitting adaptor (see
illustration), then located in the grooves of
the union nuts.
9Locate the steering gear on the subframe,
and insert the two mounting bolts. Tighten the
bolts to the specified torque (see illustration).
Note that, if the special Ford tool is being
used, the bottom of the tool must be turned
anti-clockwise in order to tighten the
mounting bolts.10Remove the covers from the apertures on
the steering gear, then reconnect the fluid
lines and tighten the union nuts to the
specified torque. Refit the clamps and tighten
the bolts.
11Refit the track rod end balljoints to the
steering knuckles, and tighten the nuts to the
specified torque. Check that the split pin
holes are aligned; if necessary, turn the nuts
to the nearest alignment, making sure that the
torque wrench setting is still within the
specified range. Insert new split pins, and
bend them back to secure.
12Refit the rear engine mounting to the
transmission and underbody, and tighten the
bolts to the specified torque.
13Refit the front wheels, and lower the
vehicle to the ground.
14Refit the steering column flexible coupling
with reference to Section 29.
15Bleed the power steering hydraulic
system as described in Section 33.
16Have the front wheel alignment checked,
and if necessary adjusted, at the earliest
opportunity (refer to Section 36).Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Working inside the vehicle, unscrew the
clamp plate bolt securing the steering column
shaft to the flexible coupling. Swivel the clamp
plate around, and disengage it from the
flexible coupling stub.
3Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands.
Remove both wheels.
4On manual transmission models,
disconnect the gearchange linkage and
support rods from the transmission, as
described in Chapter 7, Part A.
5Remove the exhaust downpipe complete,
as described in Chapter 4.
6Remove the cover from under the radiator
by unscrewing the screws and releasing the
clips.
31 Power steering gear
(left-hand-drive models with
ABS) - removal and refitting
30 Power steering gear (all except
left-hand-drive models with
ABS) - removal and refitting
29 Steering column flexible
coupling - removal and refitting
10•20 Suspension and steering systems
30.6 U-shaped Ford spanner for
unscrewing the steering gear mounting
bolts
30.8 Using an adaptor to fit the Teflon
rings to the union nuts
1 Adaptor 2 Teflon ring 3 Union nut
4 Groove location for the Teflon ring
30.9 Tightening the steering gear
mounting bolts using the U-shaped
spanner (arrowed)
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7Support the radiator in its raised position,
by inserting split pins through the small holes
in the radiator mounting extensions which
protrude through the upper mountings (see
illustration).
8Unbolt and remove the radiator lower
mounting brackets.
9Where applicable, unscrew the bolts
securing the air conditioning accumulator to
the subframe.
10Working beneath the vehicle, unbolt the
engine rear mounting from the transmission
and underbody.
11Unscrew the front engine mounting-to-
cylinder block bolts, and also the through-
bolt.
12Extract the split pins from the track rod
end balljoint nuts, then unscrew the nuts, and
detach the rods from the arms on the steering
knuckles using a conventional balljoint
removal tool. Take care not to damage the
balljoint seals.
13Working on each side in turn, unscrew the
mounting nuts, and remove the anti-roll bar
links from the front suspension struts. Note
that, on models fitted with ABS, the ABS
sensor wiring support brackets are located
beneath the nuts.
14Working on each side in turn, note which
way round the front suspension lower arm
balljoint clamp bolt is fitted, then unscrew and
remove it from the knuckle assembly. Lever
the balljoint down from the knuckle - if it is
tight, prise the joint open carefully using a
large flat-bladed tool. Take care not to
damage the balljoint seal during the
separation procedure.
15Support the weight of the front subframe
assembly on two trolley jacks (or two scissor
jacks).
16Unscrew and remove the subframe
mounting bolts, then lower the subframe
sufficiently to gain access to the power
steering fluid pipes on top of the steering
gear. Note that the front subframe mountingbolts are gold in colour - the rear ones are
silver.
17Position a suitable container beneath the
steering gear, then unscrew the union nuts
securing the power steering fluid supply,
return, and cooler lines to the steering gear.
Identify the lines for position, then unbolt the
clamps, disconnect the lines, and allow the
fluid to drain into the container. Cover the
apertures in the steering gear and also the
ends of the fluid pipes, to prevent the ingress
of dust and dirt into the hydraulic circuit.
18Lower the subframe, together with the
power steering gear, to the ground.
19Unscrew the mounting bolts and remove
the power steering gear from the subframe.
20Using a suitable Allen key, unscrew the
clamp bolt securing the flexible coupling to
the pinion shaft on the steering gear, and
withdraw the coupling.
21Refer to Section 30, paragraph 8 for
details of renewing the Teflon rings.Refitting
22Refit the flexible coupling to the pinion
shaft on the steering gear, then insert and
tighten the clamp bolt using an Allen key.
23Locate the power steering gear on the
subframe, then insert the mounting bolts and
tighten to the specified torque.
24Raise the subframe until it is possible to
refit the fluid lines. Tighten the union nuts and
clamps.
25Raise the subframe, making sure that the
alignment holes are in line with the holes in
the underbody. At the same time, make sure
that the flexible coupling locates correctly on
the steering column. Ford technicians use a
special tool to ensure that the subframe is
correctly aligned - refer to Chapter 2 for more
details of the alignment procedure. With the
subframe aligned, insert and tighten the
mounting bolts to the specified torque. Note
that the front mounting bolts are gold in
colour - the rear bolts are silver.
26Working on each side in turn, refit the
front suspension lower arm balljoint to the
knuckle assembly, and insert the clamp bolt
with its head facing forwards. Refit the nut
and tighten to the specified torque.
27Working on each side in turn, refit the
anti-roll bar links and tighten the mounting
nuts to the specified torque. On models fitted
with ABS, don’t forget to locate the wheel
sensor wiring support brackets beneath the
nuts.
28Refit the track rod end balljoints to the
steering knuckles, and tighten the nuts to the
specified torque. Check if the split pin holes
are aligned, and if necessary turn the nuts to
the nearest alignment, making sure that the
torque wrench setting is still within the
specified range. Insert new split pins, and
bend them back to secure.
29Refit and tighten the engine front
mounting bolts.
30Refit the engine rear mounting and tighten
the bolts.31Where applicable, insert and tighten the
air conditioning accumulator bolts.
32Refit the radiator lower mounting brackets
and tighten the bolts.
33Remove the split pins supporting the
radiator in its raised position.
34Refit the cover under the radiator.
35Refit the exhaust downpipe as described
in Chapter 4.
36On manual transmission models,
reconnect the gearchange linkage and
support rods.
37Refit the front wheels, and lower the
vehicle to the ground.
38Working inside the vehicle, reconnect the
steering column clamp plate, then insert the
bolt and tighten to the specified torque.
39Reconnect the battery negative lead.
40Bleed the power steering hydraulic
system as described in Section 33.
41Have the front wheel alignment checked,
and if necessary adjusted, at the earliest
opportunity (refer to Section 36).
1Remove the track rod end and its locknut
from the track rod, as described in Section 35.
Make sure that a note is made of the exact
position of the track rod end on the track rod,
in order to retain the front wheel alignment
setting on refitting.
2Release the outer retaining clip and inner
plastic clamp band, and disconnect the gaiter
from the steering gear housing.
3Disconnect the breather from the gaiter,
then slide the gaiter off the track rod.
4Scrape off all grease from the old gaiter,
and apply to the track rod inner joint. Wipe
clean the seating areas on the steering gear
housing and track rod.
5Slide the new gaiter onto the track rod and
steering gear housing, and reconnect the
breather.
6Fit a new inner plastic clamp band and
outer retaining clip.
7Refit the track rod end as described in
Section 35.
8Have the front wheel alignment checked,
and if necessary adjusted, at the earliest
opportunity (refer to Section 36).
1Following any operation in which the power
steering fluid lines have been disconnected,
the power steering system must be bled, to
remove any trapped air.
2With the front wheels in the straight-ahead
position, check the power steering fluid level
in the reservoir and, if low, add fresh fluid until
it reaches the “MAX” or “MAX COLD” mark.
Pour the fluid slowly, to prevent air bubbles
forming, and use only the specified fluid (refer
to Chapter 1 Specifications).
33 Power steering hydraulic
system - bleeding
32 Power steering gear rubber
gaiters - renewal
Suspension and steering systems 10•21
10
31.7 Method of supporting the radiator in
its raised position
1 Radiator upper mounting extension
2 Small hole
3 Pin or split pin inserted through hole
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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
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Fuses (main fusebox in passenger 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 Rating Colour Circuit(s) protected
19 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Heated door mirrors
20 10 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Front/rear wiper motor (circuit breaker)
21 30 Light green . . . . . . . . . . . . . . . . . . . . . . Front electric windows (only)
21 40 Orange . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear electric windows
22 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . ABS module
23 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Reversing lights
24 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Stop-lights
25 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Central locking system/double-locking/anti-theft alarm
26 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Foglights
27 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter
28 30 Light green . . . . . . . . . . . . . . . . . . . . . . Headlight washer system
29 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated rear window
30 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and auxiliary warning system
31 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel illumination
32 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Radio
33 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (left-hand side)
34 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and digital clock
35 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (right-hand side)
36 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air bag
37 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heater blower
38 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive damping
Relays (auxiliary fusebox in engine compartment)
Relay Colour Circuit(s) protected
R1 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime running lights (left-hand-drive, but not all countries) or dim-
dip lights (UK)
R2 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (high speed)
R3 Blue (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning cut-out
R3 Brown (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning in conjunction with Diesel engine
R4 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen heater time delay
R5 Dark green (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R5 Black (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R6 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter solenoid
R7 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns
R8 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
R9 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlights
R10 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlights
R11 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU power supply (petrol), cold start (Diesel)
Relays (main fusebox in passenger compartment)
Relay Colour Circuit(s) protected
R12 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior, courtesy and footwell lights
R13 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear window
R14 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater blower
R15 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper motor
R16 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition
Auxiliary relays (not in the fuseboxes)
Relay Colour Circuit(s) protected Location
R17 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel glow plug Battery tray
R18 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “One-touch down” Driver’s door
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver’s window relay
R19 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control cut-off Central fuse box bracket the
below instrument panel
R20 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system Bulb module bracket
R21 Orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear screen wiper interval Bulb module bracket
R22 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglights (left-hand-drive only) Interface module bracket
R23 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction indicators Steering column
R24 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (left-hand side) Door lock module bracket
R25 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (right-hand side) Door lock module bracket
R26 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated seats Door lock module bracket
12•2 Body electrical system
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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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Buying spare parts
Spare parts are available from many
sources; for example, Ford garages, other
garages and accessory shops, and motor
factors. Our advice regarding spare part
sources is as follows.
Officially-appointed Ford garages- This is
the best source for parts which are peculiar to
your vehicle, and which are not generally
available (eg complete cylinder heads, internal
transmission components, badges, interior
trim etc). It is also the only place at which you
should buy parts if the vehicle is still under
warranty. To be sure of obtaining the correct
parts, it will be necessary to give the storeman
the full Vehicle Identification Number, and if
possible, to take the old parts along for
positive identification. Many parts are
available under a factory exchange scheme -
any parts returned should always be clean. It
obviously makes good sense to go straight to
the specialists on your vehicle for this type of
part, as they are best equipped to supply you.
Other garages and accessory shops- These
are often very good places to buy materials
and components needed for the maintenance
of your vehicle (eg oil filters, spark plugs,
bulbs, drivebelts, oils and greases, touch-up
paint, filler paste, etc). They also sell general
accessories, usually have convenient opening
hours, charge lower prices, and can often be
found not far from home.
Motor factors- Good factors will stock all
the more important components which wear
out comparatively quickly (eg exhaust
systems, brake pads, seals and hydraulic
parts, clutch components, bearing shells,
pistons, valves etc). Motor factors will often
provide new or reconditioned components on
a part-exchange basis - this can save a
considerable amount of money.
Vehicle identification numbers
Modifications are a continuing and
unpublicised process in vehicle manufacture,
quite apart from major model changes. Spare
parts manuals and lists are compiled upon a
numerical basis, the appropriate identification
number or code being essential to correct
identification of the component concerned.
When ordering spare parts, always give asmuch information as possible. Quote the
vehicle model, year of manufacture, Vehicle
Identification Number and engine numbers, as
appropriate.
The vehicle identification plateis located on
the engine compartment front crossmember
(see illustration). In addition to many other
details, it carries the Vehicle Identification
Number, maximum vehicle weight
information, and codes for interior trim and
body colours.
The Vehicle Identification Numberis given
on the vehicle identification plate. It is also
stamped on the engine compartment
bulkhead, behind the air intake plenum
chamber, and into the body, so that it can be
seen through the bottom left-hand corner of
the windscreen (see illustrations).The engine number, consisting of two
letters and five digits, with the three-letter
engine code nearby, is stamped into a flat-
machined surface on the cylinder
block/crankcase’s forward-facing flange,
between the pulse-air filter housing and the
transmission. To read the number without
removing the engine compartment air intake
resonator - see Chapter 4 - it is easiest to
raise and support the front of the vehicle on
axle stands, so that the number can be seen
from underneath (see illustration). If the
number cannot be seen in this location,
possible alternative sites are on a lower flange
on the cylinder block’s forward face,
immediately above the sump mating surface,
or on the left-hand end of the cylinder head,
between the oil filler cap and ignition coil.
REF•5
Vehicle identification plate on engine
compartment front crossmember
Vehicle identification number in body,
visible through bottom left-hand corner of
windscreen
Vehicle identification number on engine
compartment bulkhead
Engine number (arrowed) on front of
cylinder block/crankcase - seen from
beneath vehicle
Spare Parts/Vehicle Identification
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6 Automatic transmission
REF•10Fault Finding
Note:Due to the complexity of the automatic transmission and its
electronic control system, it is difficult for the home mechanic to
properly diagnose and service this unit. For problems other than the
following, the vehicle should be taken to a dealer service department
or automatic transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.
m mTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
(a) Housing joints (Chapters 1 and 7, Part B).
(b) Dipstick tube (Chapters 1 and 7, Part B).
(c) Transmission-to-fluid cooler pipes/unions (Chapters 3 and 7,
Part B).
(d) Speedometer drive pinion O-ring (Chapter 7, Part B).
(e) Differential side gear oil seals (Chapter 7, Part B).
Transmission fluid brown, or has burned smell
m mTransmission fluid level low, or fluid in need of renewal (Chapter 1).
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
m mLow transmission fluid level (Chapter 1).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
General gear selection problems
m
mChapter 7, Part B, deals with checking and adjusting the selector
cable on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:
(a) Engine starting in gears other than Park or Neutral.
(b) Indicator on gear selector lever pointing to a gear other than the
one actually being used.
(c) Vehicle moves when in Park or Neutral.
(d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7, Part B for the selector cable adjustment
procedure.
Engine will not start in any gear, or starts in gears
other than Park or Neutral
m mIncorrect selector lever position sensor adjustment (Chapter 7,
Part B).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.
7 Driveshafts
Clicking or knocking noise on turns (at slow speed
on full-lock)
m mLack of constant velocity joint lubricant (Chapter 8).
m mWorn outer constant velocity joint (Chapter 8).
Vibration when accelerating or decelerating
m
mWorn inner constant velocity joint (Chapter 8).
m mBent or distorted driveshaft (Chapter 8).
8 Braking system
Note:Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose
connections, any faults occurring on the Anti-lock Braking System (ABS) should be referred to a Ford dealer for diagnosis - the same applies to the
components of the Traction Control System (TCS).
Vehicle pulls to one side under braking
m mWorn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).
m mSeized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).
m mA mixture of brake pad/shoe lining materials fitted between sides
(Chapter 1).
m mBrake caliper mounting bolts loose (Chapter 9).
m mRear brake backplate mounting bolts loose (Chapter 9).
m mWorn or damaged steering or suspension components (Chap-
ter 10).
Noise (grinding or high-pitched squeal) when brakes
applied
m mBrake pad or shoe friction lining material worn down to metal
backing (Chapter 1).
m mExcessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).
m mForeign object (stone chipping, etc) trapped between brake disc
and splash shield (Chapter 1).
Excessive brake pedal travel
m mInoperative rear brake self-adjust mechanism (Chapter 9).
m mFaulty master cylinder (Chapter 9).
m mAir in hydraulic system (Chapter 9).
procarmanuals.com

REF•18Index
E
Earth fault - 12•4
Economy/Sport mode switch - 12•7
ECU (Electronic Control Unit) - 6•10, 6•11,
6•12
EGR exhaust gas pressure differential
sensor - 6•16
EGR system - 6•15, 6•16
Electric shock - 0•5
Electric windows fault - REF•12
Electrical system - 0•8, 1•11, 1•20
Electrical system fault - REF•12
Electrically-operated windows - 12•7
Electrolyte - 1•8
Electronic control system - 4•9, 6•2
Emblems - 11•17
Emission checks - 0•10
Emissions control systems - 6•1
Engine compartment light - 12•11
Engine electrical systems- 5•1et seq
Engine fault finding - REF•7, REF•8, REF•10
Engine management system - 4•8, 4•9
Engine oil - 1•2, 1•6, 1•16
Engine oil level sensor - 12•18
Engine removal and general engine
overhaul procedures- 2B•1et seq
Environmental considerations - REF•4
Evaporative emissions control (EVAP)
system - 6•14
Evaporator - 3•9
Exhaust gas pressure differential sensor -
6•11, 6•12, 6•13
Exhaust Gas Recirculation (EGR) system -
6•15, 6•16
Exhaust manifold - 2A•8
Exhaust system - 0•9, 0•10, 1•18, 4•12,
REF•9
Expansion tank - 3•5, 3•6
FFacia - 11•21, 11•23
Fan(s) - 3•4, 12•11
Fault code read-out - 6•6
Fault finding- REF•6et seq
Fault finding - automatic transmission -
7B•1
Fault finding - electrical system - 12•4
Filling - 11•3
Fire - 0•5
Fluid level checks - 1•6
Flywheel - 2A•24
Foglight - 12•7, 12•9, 12•13
Foglight warning indicator - 12•11
Fuel and exhaust systems- 0•10, 4•1et
seq
Fuel and exhaust system fault finding -
REF•9
Fuel consumption high - REF•9
Fuel cut-off switch - 4•8
Fuel filter - 1•26
Fuel gauge - 4•6
Fuel gauge fault - REF•12
Fuel hoses - 1•15
Fuel injection system - 4•8, 4•9
Fuel injectors - 4•10
Fuel lines - 1•19, 4•2
Fuel odour - REF•9Fuel pressure check - 4•5
Fuel pressure regulator - 4•11
Fuel pump - 4•5, 4•6
Fuel rail - 4•10
Fuel system - 4•2
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fumes from exhaust system - REF•9
Fuses - 12•5
G
Gaiters - 1•18, 8•7, 8•9, 10•21
Gashes in bodywork - 11•3
Gaskets - REF•4
Gear lever - 7A•2
Gear selection problems - REF•9, REF•10
Gearbox oil - 1•2
Gearchange linkage - 7A•2
Gearchange selector shaft - 7A•3
Glossary of technical terms - REF•13
Glovebox - 11•22
Glovebox light - 12•11
Grab handle - 11•20
H
Handbrake - 0•7, 9•16, 12•7
Handles - 11•10, 11•11, 11•12, 11•13,
12•11
Hazard flashers - 12•7, 12•11
HC emissions - 0•10
Headlight - 1•8, 12•7, 12•8, 12•12, 12•13
Heated rear window - 12•8
Heated seat - 12•8
Heated windscreen - 12•8
Heater - 3•2, 3•7, 3•8, 12•11, 12•12
Horn - 12•7, 12•15
Horn fault - REF•12
Hoses - 1•14, 3•2, 9•11
HT leads - 1•24
Hub and bearings - 10•5, 10•9, 10•14
Hydraulic fluid - 1•2
Hydraulic pipes and hoses - 9•11
Hydraulic system - 9•12
Hydraulic tappets - 2A•14
Hydrofluoric acid - 0•5
I
Idle speed - 4•9, 4•11, 6•10
Idle-increase solenoid valve - 4•12
Ignition coil - 5•3
Ignition module - 5•4
Ignition switch - 12•6
Ignition system - 5•3
Ignition timing - 5•4, 6•10
In-car engine repair procedures- 2A•1et
seq
Indicators - 12•7, 12•9, 12•12
Information sensors - 6•10
Inlet manifold - 2A•7
Instrument panel - 12•7, 12•11, 12•14
Instruments - 1•20
Instruments fault - REF•12
Intake air temperature sensor - 6•11, 6•13
Introduction to the Ford Mondeo - 0•4
J
Jacking - 0•11
Joint mating faces - REF•4
Jump starting - 0•12
K
Knuckle - 10•5, 10•10, 10•14
L
Leaks - 0•13, 1•14, REF•9
Light units - 12•12
Lights - 12•7, 12•11
Lights inoperative - REF•12
Locknuts, locktabs and washers - REF•4
Locks - 11•6, 11•10, 11•12, 11•13, 11•15,
11•16, 11•17, 12•6, REF•12
Low air temperature warning sender unit -
12•18
Low coolant warning switch - 12•18
Low washer fluid switch - 12•18
Lower suspension arm - 10•8, 10•9, 10•13,
10•16
Lubrication system - 2A•4
Luggage compartment switch - 12•7
M
Main bearings - 2B•18, 2B•20
Maintenance- Also see Routine
maintenance
Maintenance - bodywork and underframe -
11•2
Maintenance - upholstery and carpets -
11•3
Manifolds - 2A•7, 2A•8
Manual transmission- 1•17, 2A•24, 2B•3,
2B•4, 7A•1et seq
Manual transmission fault finding - REF•9
Manual transmission oil - 1•2
Master cylinder - 9•10
Mirrors - 0•7, 11•14, 12•7
Misfire - REF•7, REF•8
Mixture - 0•10, 4•9
MOT test checks- 0•7et seq
Mountings - 2A•24, 7A•7, 7B•5
N
Number plate light - 12•10, 12•13
O
Oil (transmission) - 1•2
Oil (engine) - 1•2, 1•6, 1•16
Oil cooler - 2A•22
Oil level sensor - 2A•22, 12•18
Oil pressure warning light illuminated -
REF•8
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