ECO mode FORD MONDEO 1993 Service Service Manual

2Using a trolley jack, support the rear lower
arm beneath the coil spring position.
3Unscrew and remove the bolt securing the
rear shock absorber to the knuckle.
4Where applicable, release the ABS wheel
sensor lead from the tie-bar.
5Detach the handbrake cable from the tie-
bar bracket.
6Refer to Chapter 9, and disconnect the
handbrake cable from the rear brake shoes or
rear caliper, as applicable. Pass the cable
through the hole in the tie-bar.
7Unscrew and remove the three bolts
securing the tie-bar to the knuckle (see
illustration).
8Unbolt the tie-bar bracket from the
underbody, and withdraw the assembly from
under the vehicle (see illustrations).
9Mount the tie-bar in a vice, then unscrew
the bolt, and separate the tie-bar from its
bracket.
10It is not possible to renew the rubber bush
in the tie-bar, and if it is excessively worn, the
complete tie-bar must be renewed.
Refitting
11Refitting is a reversal of the removal
procedure, but delay fully tightening the bolt
which secures the arm to the bracket until the
weight of the vehicle is on the rear
suspension. On completion, check the
operation of the handbrake.
Removal
1Chock the front wheels, then jack up the
rear of the vehicle and support on axles
stands. Remove both rear wheels. Make sure
that the vehicle is supported high enough for
the crossmember to be removed.
2Disconnect the handbrake rear cables from
the front primary cable, as described in
Chapter 9.
3Where applicable, remove the ABS wheel
sensors from the rear knuckles, and
disconnect the wiring leads from the clips as
described in Chapter 9.
4Disconnect the flexible brake hoses from
the brackets on both sides of the
crossmember, as described in Chapter 9.
5Working on each side of the vehicle, unbolt
the tie-bar brackets from the underbody.
6Support the rear suspension crossmember
on a trolley jack.
7Unscrew the mounting bolts, and lower the
crossmember to the ground (see
illustrations).
8If necessary, remove the suspension
components from the crossmember as
described in the appropriate Sections of this
Chapter.
Refitting
9Refitting is a reversal of the removal
procedure, noting the following points:
(a) When raising the crossmember, note that
guide pins are provided to ensure correct
alignment (see illustration).
(b) Delay fully tightening the suspension
mounting bolts until the weight of the
vehicle is on the rear suspension.
(c) Tighten all bolts to the specified torque.
(d) Bleed the brake hydraulic system as
described in Chapter 9.
(e) Check, and if necessary adjust, the rear
wheel toe setting as described in Section 36.
Warning: All models are equipped
with an air bag system. Make
sure that the safety
recommendations given in Chapter 12 are
followed, to prevent personal injury.
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.
27 Steering wheel -
removal and refitting
26 Rear suspension
crossmember (Estate
models) - removal and refitting
Suspension and steering systems 10•17
10
26.7A Rear suspension crossmember rear
mounting bolt26.7B Rear suspension crossmember
front mounting bolt26.9 Guide pin (arrowed) for correct
alignment of the rear crossmember
25.7 Bolts (arrowed) securing the rear
suspension tie-bar to the knuckle25.8A Tie-bar bracket front bolt (arrowed)
on the underbody25.8B Tie-bar bracket rear bolt (arrowed)
on the underbody
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2Turn the steering wheel so that the front
wheels are in the straight-ahead position.
3Unscrew the screws, and remove the
steering column upper and lower shrouds.
4From the rear of the steering wheel,
unscrew the air bag module mounting screws.
5Carefully lift the module from the steering
wheel, and disconnect the air bag multi-plug
and horn wiring connections.
Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards as
a precaution against accidental
operation.
6Make sure that the steering lock is not
engaged. Unscrew the retaining bolt from the
centre of the steering wheel (see illustration).
7Remove the steering wheel from the top ofthe column, while feeding the horn and air bag
wiring through the hole in the steering wheel
hub (see illustration).
Refitting
8Make sure that the front wheels are still
facing straight-ahead, then locate the steering
wheel on the top of the steering column.
9Refit the retaining bolt, and tighten it to the
specified torque while holding the steering
wheel (see illustration). Do not tighten the
bolt with the steering lock engaged, as this
may damage the lock.
10Reconnect the horn wiring connections
and air bag multi-plug.
11Locate the air bag module/horn contact
on the steering wheel, then insert the
mounting screws and tighten them.12Refit the steering column upper and lower
shrouds. Insert and tighten the screws.
13Reconnect the battery negative lead.
Warning: All models are equipped
with an air bag system. Make
sure that the safety
recommendations given in
Chapter 12 are followed, to prevent
personal injury.
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.
2Turn the steering wheel so that the front
wheels are in the straight-ahead position.
3Remove the ignition key, then turn the
steering wheel slightly as necessary until the
steering lock engages.
4Unscrew the screws, and remove the
steering column lower and upper shrouds. As
the lower shroud is being removed, it will be
necessary to remove the rubber ring from the
ignition switch/steering lock (see
illustrations).
28 Steering column - removal,
inspection and refitting
10•18 Suspension and steering systems
27.6 Removing the steering wheel
retaining bolt27.7 Feeding the horn and air bag wiring
through the hole in the steering wheel hub27.9 Tightening the steering wheel
retaining bolt
28.4C . . . and remove the lower shroud28.4D Upper shroud retaining screws
(arrowed)
28.4A Unscrew the screws from the lower
shroud . . .28.4B . . . remove the rubber ring . . .
28.4E Removing the upper shroud
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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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models (see illustration). In other countries, it
is available on certain models only. Where
double-locking is fitted, the lock mechanism
is disconnected (when the system is in use)
from the interior door handles, making it
impossible to open any of the doors or the
tailgate/bootlid from inside the vehicle. This
means that, even if a thief should break a side
window, he will not be able to open the door
using the interior handle. Models with the
double-locking system are fitted with a
control module located beneath the facia on
the right-hand side. In the event of a serious
accident, a crash sensor unlocks all doors if
they were previously locked.
Many of the procedures in this Chapter
require the battery to be disconnected. Refer
to Chapter 5, Section 1 first.
The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy, but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts
of the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches, and the lower part of the engine
compartment.
The basic maintenance routine for the
bodywork is washing - preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way, to remove any
accumulated mud, which will retain moisture
and tend to encourage rust. Paradoxically
enough, the best time to clean the underframe
and wheel arches is in wet weather, when the
mud is thoroughly wet and soft. In very wet
weather, the underframe is usually cleaned of
large accumulations automatically, and this is
a good time for inspection.
Periodically, except on vehicles with a wax-
based underbody protective coating, it is a
good idea to have the whole of the
underframe of the vehicle steam-cleaned,
engine compartment included, so that a
thorough inspection can be carried out to see
what minor repairs and renovations are
necessary. Steam-cleaning is available at
many garages, and is necessary for the
removal of the accumulation of oily grime,
which sometimes is allowed to become thick
in certain areas. If steam-cleaning facilities are
not available, there are some excellent grease
solvents available which can be brush-
applied; the dirt can then be simply hosed off.
Note that these methods should not be used
on vehicles with wax-based underbodyprotective coating, or the coating will be
removed. Such vehicles should be inspected
annually, preferably just prior to Winter, when
the underbody should be washed down, and
any damage to the wax coating repaired.
Ideally, a completely fresh coat should be
applied. It would also be worth considering
the use of such wax-based protection for
injection into door panels, sills, box sections,
etc, as an additional safeguard against rust
damage, where such protection is not
provided by the vehicle manufacturer.
After washing paintwork, wipe off with a
chamois leather to give an unspotted clear
finish. A coat of clear protective wax polish
will give added protection against chemical
pollutants in the air. If the paintwork sheenhas dulled or oxidised, use a cleaner/polisher
combination to restore the brilliance of the
shine. This requires a little effort, but such
dulling is usually caused because regular
washing has been neglected. Care needs to
be taken with metallic paintwork, as special
non-abrasive cleaner/polisher is required to
avoid damage to the finish. Always check that
the door and ventilator opening drain holes
and pipes are completely clear, so that water
can be drained out. Brightwork should be
treated in the same way as paintwork.
Windscreens and windows can be kept clear
of the smeary film which often appears, by the
use of proprietary glass cleaner. Never use
any form of wax or other body or chromium
polish on glass.
2 Maintenance -
bodywork and underframe
11•2 Bodywork and fittings
1.5 Central locking component locations
1 Indicator light
2 Buzzer
3 Central locking module4 Infra-red receiver
5 Lock motor
6 Set/reset switch7 Ajar switch
8 Infra-red transmitter
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ease the bezel off the inner door handle (see
illustrations).
3Where applicable, remove the window
operating switch and disconnect the multi-
plug (see illustrations).
Front door
4Carefully prise out the cover, remove the
screws and withdraw the door pull handle
(see illustrations).
5Prise off the plastic cap, remove the screw,
and withdraw the quarter bezel from the front
of the window opening (see illustrations).
Rear door
6Prise off the cap, then remove the screw
and withdraw the door pull handle (see
illustrations).
Front and rear doors
7On models fitted with manual (ie non-
electric) windows, fully shut the window, and
note the position of the regulator handle.
Release the spring clip by inserting a clean
cloth between the handle and the door trim.
Pull the cloth against the open ends of the clip
to release it, at the same time pulling the
handle from the regulator shaft splines.
Withdraw the handle (and where fitted, the
spacer) and recover the clip (see
illustrations).
8Prise the caps from the trim panel retaining
screws, then remove the screws and lift off
the panel. Where a speaker is attached to the
trim panel, disconnect the multi-plug (see
illustrations).
Bodywork and fittings 11•7
11
11.7B Withdrawing the window regulator
handle11.7C Recover the spring clip from the
window regulator handle11.8A Prise out the caps . . .
11.6A Remove the screw . . .11.6B . . . and withdraw the rear door pull
handle11.7A Using a clean cloth to release the
spring clip from the window regulator
handle
11.5A Remove the plastic cap and the
screw . . .
11.5B . . . then withdraw the quarter bezel
11.4A Remove the cover . . .11.4B . . . then remove the screws and
withdraw the door pull handle
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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
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compartment, but on Estate models, it is on
the right-hand side.
Some models are fitted with a headlight
levelling system, which is controlled by a knob
on the facia. On position “0”, the headlights
are in their base position, and on position “5”,
the headlights are in their maximum inclined
angle.
It should be noted that, when portions of
the electrical system are serviced, the cable
should be disconnected from the battery
negative terminal, to prevent electrical shorts
and fires.
Caution: When disconnecting the
battery for work described in the
following Sections, refer to
Chapter 5, Section 1.
Note:Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before starting work. The following tests relate
to testing of the main electrical circuits, and
should not be used to test delicate electronic
circuits (such as engine management systems,
anti-lock braking systems, etc), particularly
where an electronic control module is used.
Also refer to the precautions given in Chapter
5, Section 1.
General
1A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
wiring diagrams are included at the end of this
manual.
2Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a complete understanding
of the components included in the particular
circuit concerned. The possible sources of a
fault can be narrowed down by noting if other
components related to the circuit are
operating properly. If several components or
circuits fail at one time, the problem is likely to
be related to a shared fuse or earth
connection.
3Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay (refer to Section 3 for details of testing
relays). Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked
in order to pinpoint the trouble-spot.
4The basic tools required for electrical fault-
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can alsobe used for certain tests); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
5To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working.
8Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.
Finding an open-circuit
9To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
10Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse. At this point, battery
voltage should be present, unless the lead
from the battery or the fuse itself is faulty
(bearing in mind that some circuits are live
only when the ignition switch is moved to a
particular position).
11Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
the circuit between the relevant connector
and the switch is problem-free.
13Continue to check the remainder of the
circuit in the same fashion.
14When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.
Finding a short-circuit
15To check for a short-circuit, first
disconnect the load(s) from the circuit (loads
are the components which draw current from
a circuit, such as bulbs, motors, heating
elements, etc).
16Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19If no voltage is present during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).
Finding an earth fault
20The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission unit and the vehicle body
- and many systems are wired so that they
only receive a positive feed, the current
returning via the metal of the car body. This
means that the component mounting and the
body form part of that circuit. Loose or
corroded mountings can therefore cause a
range of electrical faults, ranging from total
failure of a circuit, to a puzzling partial failure.
In particular, lights may shine dimly (especially
when another circuit sharing the same earth
point is in operation), motors (eg wiper motors
or the radiator cooling fan motor) may run
slowly, and the operation of one circuit may
have an apparently-unrelated effect on
another. Note that on many vehicles, earth
straps are used between certain components,
such as the engine/transmission and the
body, usually where there is no metal-to-
metal contact between components, due to
flexible rubber mountings, etc.
21To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5, Section 1) and connect one lead
of an ohmmeter to a known good earth point.
Connect the other lead to the wire or earth
connection being tested. The resistance
reading should be zero; if not, check the
connection as follows.
22If an earth connection is thought to be
faulty, dismantle the connection, and clean
both the bodyshell and the wire terminal (or
the component earth connection mating
surface) back to bare metal. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
2 Electrical fault finding -
general information
12•4 Body electrical system
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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
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the specified mileage (or time) since the last
service has been reached.
4To reset the service interval system and
turn off the light, a switch inside the glovebox
must be depressed for a minimum of 4
seconds with the ignition switched on. This
should be carried out by a Ford dealer if the
vehicle is still in the warranty period.
Component renewal
5The following paragraphs describe brief
removal procedures for the auxiliary warning
system components. Disconnect the battery
negative (earth) lead before commencing
work (refer to Chapter 5, Section 1). Refitting
procedures are a reversal of removal.
Display warning bulb
6Remove the control assembly.
7Prise off the cover, and pull out the relevant
bulb and bulbholder.
Low air temperature warning sender
unit
8Remove the front bumper.
9Unclip the sender unit and disconnect the
multi-plug (see illustration).
Engine oil level sensor
10Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
11Place a container beneath the oil level
sensor, to catch any spilt oil.12Unscrew the screws and remove the
cover from the sensor.
13Disconnect the multi-plug.
14Unscrew and remove the sensor, and
remove the seal (see illustration).
Door ajar sensor
15Remove the door lock as described in
Chapter 11, Section 14.
16Unclip the sensor and disconnect the
multi-plug.
Low coolant warning switch
17Refer to Chapter 3, Section 6.
Low washer fluid switch
18Disconnect the multi-plug from the
washer fluid reservoir.
19Drain or syphon out the fluid from the
reservoir.
20Using a screwdriver, lever out the switch
from the reservoir (see illustration).
Service indicator reset switch
21Remove the glove compartment lid as
described in Chapter 11, Section 32.
22Carefully lever out the switch using a
small screwdriver.
23Remove the rear cover and disconnect
the wiring (see illustration).
Control assembly
24Remove the instrument panel surround,
referring to Section 10.25Unscrew the mounting screws,
disconnect the multi-plugs and remove the
assembly.
Bulb failure module
26Remove the lower facia panel from under
the steering wheel.
27Unclip the bulb failure module and
disconnect the multi-plug.
Note: From November 1993, for added
security, a complex Bosch immobiliser system
was fitted to some models. For further details,
refer to your Ford dealer.
1All UK models are fitted with an anti-theft
alarm system, incorporating movement
sensors and an ignition immobiliser. The
system is activated when the vehicle is
locked.
2The system includes a start inhibitor circuit,
which makes it impossible to start the engine
with the system armed.
3The movement sensors consist of two
ultrasonic units, located in the “B” pillars,
incorporating transmitters and receivers (see
illustrations). The receivers check that the
echo frequency matches the original
frequency. If there is any significant
difference, the system triggers the alarm.
20 Anti-theft alarm system- general
information
12•18 Body electrical system
19.9 Low air temperature sender unit
removal
1 Clip 2 Sender unit 3 Multi-plug19.14 Engine oil level sensor removal
1 Cover 2 Multi-plug 3 Sensor 4 Seal19.20 Removing the low washer fluid
switch
19.23 Service indicator switch removal
1 Lever out the switch 2 Cover 3 Wiring20.3A Disconnecting a movement sensor
multi-plug20.3B Removing a movement sensor
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