warning FORD MONDEO 1993 Service Manual PDF

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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BulbsWattage Type
Headlight main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Headlight dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Foglights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Halogen
Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Direction indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Side repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Stop-lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Reversing lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bayonet
Rear fog/tail lights (Saloon and Estate) . . . . . . . . . . . . . . . . . . . . . . . . . . 21/4 Bayonet
Rear tail light (Saloon and Hatchback) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bayonet
Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Festoon
Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wedge
Interior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Festoon
Reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wedge
Torque wrench settingsNm lbf ft
Windscreen wiper motor bolts:
Into old motor (see text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Into new motor (see text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Body electrical system 12•3
12
Warning: Before carrying out any
work on the electrical system,
read through the precautions
given in “Safety first!” at the beginning of
this manual.The electrical system is of 12-volt negative
earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid battery which is charged by the
alternator.
This Chapter covers repair and service
procedures for the various electrical
components not associated with the engine.
Information on the battery, ignition system,alternator, and starter motor can be found in
Chapter 5.
All models are fitted with a driver’s air bag,
which is designed to prevent serious chest
and head injuries to the driver during an
accident. A similar bag for the front seat
passenger is also available (see illustration).
The sensor and electronic unit for the air bag
is located next to the steering column inside
the vehicle, and contains a back-up capacitor,
crash sensor, decelerometer, safety sensor,
integrated circuit and microprocessor (see
illustration). The air bag is inflated by a gas
generator, which forces the bag out of the
module cover in the centre of the steering
wheel. A “clock spring” ensures that a good
electrical connection is maintained with the air
bag at all times - as the steering wheel is
turned in each direction, the spring winds and
unwinds.
All UK models are fitted with an alarm
system incorporating a movement sensor and
ignition immobiliser. On Saloon and
Hatchback models, the alarm system horn is
located on the left-hand side of the luggage
1 General information
1.3A Air bag system components
1 Air bag module (driver’s)
2 Clock spring3 Diagnostic and sensor unit
4 Air bag indicator light5 Air bag module
(passenger’s)
1.3B Air bag sensor and electronic unit
1 Crash sensor
2 Safety sensor
3 Voltage back-up
4 Application Specific Integrated Circuit
5 Microprocessor
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remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer
such as Holts Damp Start, or a water-
dispersant lubricant such as Holts Wet Start.
Note:It is important to note that the ignition
switch and the appropriate electrical circuit
must always be switched off before any of the
fuses (or relays) are removed and renewed. In
the event of the fuse/relay unit having to be
removed, the battery earth lead must be
disconnected. When reconnecting the battery,
reference should be made to Chapter 5.
1Fuses are designed to break a circuit when
a predetermined current is reached, in order
to protect components and wiring which
could be damaged by excessive current flow.
Any excessive current flow will be due to a
fault in the circuit, usually a short-circuit (see
Section 2). The main fusebox, which also
carries some relays, is located inside the
vehicle below the facia panel on the
passenger’s side, and is accessed by a lever
behind the glovebox (see illustration).
2A central timer module is located on the
bottom of the main fusebox. This module
contains the time control elements for the
heated rear window, interior lights and
intermittent wiper operation. The module also
activates a warning buzzer/chime when the
vehicle is left with the lights switched on, or if
a vehicle fitted with automatic transmission is
not parked in position “P”.
3The auxiliary fusebox is located on the front
left-hand side of the engine compartment,
and is accessed by unclipping and removing
the cover. The auxiliary fusebox also contains
some relays (see illustration). Each circuit is
identified by numbers on the main fusebox
and on the inside of the auxiliary fusebox
cover. Reference to the fuse chart in the
Specifications at the start of this Chapter will
indicate the circuits protected by each fuse.
Plastic tweezers are attached to the main
fusebox and to the inside face of the auxiliary
fuse and block cover, to remove and fit the
fuses and relays.
4To remove a fuse, use the tweezers
provided to pull it out of the holder. Slide the
fuse sideways from the tweezers. The wire
within the fuse is clearly visible, and it will be
broken if the fuse is blown (see illustration).
5Always renew a fuse with one of an
identical rating. Never substitute a fuse of a
higher rating, or make temporary repairs using
wire or metal foil; more serious damage, or
even fire, could result. The fuse rating is
stamped on top of the fuse. Never renew a
fuse more than once without tracing the
source of the trouble.
6Spare fuses of various current ratings areprovided in the cover of the auxiliary fusebox.
Note that if the vehicle is to be laid up for a
long period, fuse 34 in the main fusebox
should be removed, to prevent the ancillary
electrical components from discharging the
battery.
7Relays are electrically-operated switches,
which are used in certain circuits. The various
relays can be removed from their respective
locations by carefully pulling them from the
sockets. Each relay in the fuseboxes has a
plastic bar on its upper surface to enable the
use of the tweezers. The locations and
3 Fuses, relays and timer
module- testing and renewal
Body electrical system 12•5
12
3.4 The fuses can be checked visually to
determine if they are blown
3.1 Main fusebox layout
1 Fuse/relay removal tweezers 2 Diode 3 Multi-plug connections
3.3 Auxiliary fusebox layout
1 Fuses 1 to 3 3 Relays R2, R5 and R6 5 Relay sockets for relays R1 and R4
2 Fuses 4 to 8, 11 to 14 4 Relays R7 to R11 6 Diode
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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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Engine compartment light
1With the bonnet open, pull the wedge-type
bulb from the bulbholder.
2Fit the new bulb using a reversal of the
removal procedure.
Interior lights
3Switch off the interior light by locating the
switch in its middle position.
4Using a small screwdriver, carefully prise
out the light or bulb cover, as applicable (see
illustration).
5Lift up the reflector, then release the
festoon-type bulb from the contact springs
(see illustration).
6Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.
Reading light
7With the reading light switched off, prise
out the light using a small screwdriver.
8Hinge back the contact plate, and release
the festoon-type bulb from the contact
springs.9Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.
Instrument panel illumination and
warning lights
10Remove the instrument panel as
described in Section 10.
11Twist the bulbholder anti-clockwise to
remove it (see illustration).
12Fit the new bulbholder using a reversal of
the removal procedure.
Foglight warning indicator
13Using a screwdriver, prise out the
indicator from the facia, and disconnect the
multi-plug.
14Twist the bulbholder anti-clockwise with
the screwdriver, and remove it (see
illustration).
15Fit the new bulb using a reversal of the
removal procedure.
Hazard warning light
16Pull the cover directly up from the switch,
then remove the bulb (see illustrations).
17Fit the new bulb using a reversal of the
removal procedure.
Glovebox light
18Open the glovebox, then pull out the
wedge-type bulb from the light located under
the upper edge.
Heater fan switch illumination
19Pull off the switch knob, then depress and
twist the bulb to remove it.
Automatic transmission selector
panel illumination
20Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
21Remove the ashtray.
22Select Neutral, then prise out the panel
from the centre console.
23Disconnect the multi-plug from the
overdrive control switch.
24Disconnect the bulbholder and pull out
the wedge-type bulb.
25Fit the new bulb using a reversal of the
removal procedure.
Interior door handle illumination
26Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
27Remove the door interior trim panel as
described in Chapter 11.
28Using a knife, cut free the foam
watershield for access to the rear of the
interior door handle.
29Pull out the bulbholder and remove the
bulb.
Clock illumination
30Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
31Remove the clock as described in Sec-
tion 13.
6 Bulbs (interior lights) - renewal
Body electrical system 12•11
12
6.14 Removing the bulb from the foglight
warning indicator6.16A Pull off the hazard warning light
cover . . .6.16B . . . and remove the bulb
6.4 Prise out the interior light with a
screwdriver6.5 Lifting the reflector from the interior
light6.11 Removing a bulb from the rear of the
instrument panel
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2Where fitted, remove the clock as
described in Section 13.
3Where fitted, remove the trip computer
module as described in Section 18.
4Remove the heated rear window switch as
described in Section 4.
5Where fitted, remove the heated
windscreen switch.
6Where fitted, remove the display assembly
warning indicator for the foglights (see
illustration).
7Remove any blanking covers from the
unused switch positions (see illustration).
8Prise out the blanking covers, then unscrew
the retaining screws and remove the
instrument panel surround (see illustrations).
9Unscrew the mounting screws, andwithdraw the instrument panel a little way
from the facia (see illustration).
10Disconnect the two multi-plugs from the
rear of the instrument panel (see illustration).
11Withdraw the instrument panel from the
facia, at the same time releasing the
speedometer intermediate cable.
Refitting
12Refitting is a reversal of the removal
procedure.
Removal
1Remove the warning light and illumination
bulbs by twisting them anti-clockwise (see
illustration).
2Carefully prise off the glass and bezel from
the front of the instrument panel, noting the
positions of the retaining lugs (see
illustration).
3Note the positions of the five diffusers, then
remove them from the instrument panel.
4To remove the speedometer head, unscrew
the three mounting screws and withdraw the
head from the housing.
5To remove the tachometer, unscrew the
single screw and withdraw it from the
housing.
11 Instrument panel
components-
removal and refitting
12•14 Body electrical system
10.6 Removing the foglight warning
indicator10.7 Removing a switch blanking cover10.8A With the blanking covers removed,
unscrew the concealed screws . . .
10.10 Disconnecting the multi-plugs from
the rear of the instrument panel11.1 Rear view of the instrument panel,
showing bulbholders11.2 Bezel retaining lug on the instrument
panel
10.8C . . . and lift out the instrument panel
surround10.9 Three of the instrument panel
mounting screws (arrowed)
10.8B . . . and the remaining screws . . .
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8Disconnect the wiper motor multi-plug.
9Withdraw the wiper motor, complete with
the linkage, from the bulkhead (see
illustration).
10Mark the position of the motor arm on the
mounting plate, then unscrew the centre nut
(see illustration).
11Unscrew the motor mounting bolts, and
separate the motor from the linkage assembly.
Refitting
12Refitting is a reversal of the removal
procedure. There are two tightening torques
for the motor mounting bolts - the lower one
for bolts that are being re-inserted into an old
motor, and the higher ones for bolts that are
being inserted into a new motor. Make sure
that the wiper motor is in its “parked” position
before fitting the motor arm, and check that
the wiper linkage is in line with the motor arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the tailgate wiper arm as
described in Section 15.
3Remove the tailgate inner trim panel by
unscrewing the retaining screws.
4Release the multi-plug from the clip, then
disconnect it (see illustration).5Disconnect the wiper motor earth lead.
6Unscrew the mounting bolts, and remove
the wiper motor from inside the tailgate (see
illustrations).
7Unbolt and remove the mounting plate. If
necessary, remove the mounting rubbers for
renewal (see illustrations).
Refitting
8Refitting is a reversal of the removal
procedure. Make sure that the wiper motor is
in its “parked” position before fitting the wiper
arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Using a small screwdriver, prise the trip
computer module out of the facia. To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the trip computer module, and withdraw the
unit.
4If necessary, the bulb can be removed by
twisting it anti-clockwise.
Refitting
5Refitting is a reversal of the removal
procedure.1Some models are fitted with an auxiliary
warning system, which monitors brake lights,
sidelights, dipped beam and tail lights,
external temperature, and door/tailgate/
bootlid opening. An engine oil level warning
light on the instrument panel is also part of the
system.
2The auxiliary warning system module and
graphic warning display are combined into
one unit.
Service interval reminder
3The system also includes a service interval
reminder warning light, which is illuminated if
19 Auxiliary warning system -
general information and
component renewal
18 Trip computer module-
removal and refitting
17 Tailgate wiper motor
assembly - removal and refitting
Body electrical system 12•17
12
17.6B . . . and remove the tailgate wiper
motor assembly (Hatchback shown -
Estate similar)17.7A Tailgate wiper motor assembly and
mounting plate17.7B A mounting rubber removed from
the mounting plate
17.6A Unscrew the mounting bolts . . .
16.9 Removing the wiper motor and
linkage16.10 Wiper motor arm and mounting
plate located on the motor17.4 Disconnecting the tailgate wiper
motor multi-plug
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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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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•25
12
Diagram 1: Starting, charging, warning lights and gauges
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