fog light bulb FORD MONDEO 1993 Service Repair Manual

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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Heated windscreen switch and heated
rear window switch
48Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
49Carefully prise out the switch, using a
cloth pad to prevent damage to the trim (see
illustration).
50Disconnect the multi-plug and remove the
switch (see illustration).
Electrically-operated seat switch and
heated seat switch
51Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
52Carefully prise out the switch, using a
cloth pad to prevent damage to the trim.
53Disconnect the multi-plug and remove the
switch.
Adaptive damping switch
54Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
55Carefully prise out the switch, using a
cloth pad to prevent damage to the trim.
56Disconnect the multi-plug and remove the
switch.
Courtesy light door switch
57Open the door, then unscrew the cross-
head screw and carefully pull the switch from
the pillar (see illustrations). Take care not to
force the wire from the switch terminal,
otherwise it will be difficult to retrieve it from
the pillar.
58Disconnect the wire, and tie it in a loose
knot to prevent it dropping back into the
pillar.
Refitting
59Refitting of all switches is a reversal of the
removal procedure.
Note:Ensure that all exterior lights are
switched off before disconnecting the wiring
connectors from any exterior light bulbs. Do
not touch the glass of halogen-type bulbs
(headlights, front foglights) with the fingers; if
the glass is accidentally touched, clean it with
methylated spirit.
Headlight (dipped beam)
1Working under the bonnet, depress the
plastic clips and remove the cover from the
rear of the headlight unit (see illustration).
2Release the spring clip and withdraw the
bulb, then disconnect the wiring lead (see
illustrations).
3Fit the new bulb using a reversal of the
removal procedure. Have the headlight beam
alignment checked as described later in this
Chapter.
Headlight (main beam)
4Working under the bonnet, depress the
plastic clips and remove the cover from the
rear of the headlight unit.
5Turn the bulbholder anti-clockwise, and
remove it from the rear of the headlight unit
(see illustration).
5 Bulbs (exterior lights) -
renewal
12•8 Body electrical system
4.49 Prising out the heated rear window
switch4.50 Disconnecting the multi-plug from
the heated rear window switch4.57A Unscrew the cross-head screw . . .
5.2A Release the spring clip . . .5.2B . . . and withdraw the headlight bulb
4.57B . . . and pull out the courtesy light
switch5.1 Removing the cover from the rear of
the headlight
5.5 Removing the headlight (main beam)
bulbholder
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6Pull out the bulb and disconnect the wiring
lead (see illustration).
7Fit the new bulb using a reversal of the
removal procedure, making sure that the
bulbholder is correctly located in the headlight
unit. Have the headlight beam alignment
checked as described later in this Chapter.
Front sidelight
8Working under the bonnet, depress the
plastic clips and remove the cover from the
rear of the headlight unit.
9Pull the bulbholder from the rear of the
headlight unit (see illustration).
10Pull the wedge-type bulb from the
bulbholder (see illustration).
11Fit the new bulb using a reversal of the
removal procedure.
Front direction indicator
12Open the bonnet. Loosen (but do not
remove) the screw located above the front
direction indicator (see illustration 7.10).
13Withdraw the front direction indicator light
unit.
14Rotate the bulbholder anti-clockwise, and
withdraw it from the light unit.
15Twist the bulb anti-clockwise, and remove
it from the bulbholder (see illustration).
16Fit the new bulb using a reversal of the
removal procedure, but before refitting the
light unit, first insert the holding spring in its
bore.
Side repeaters
17The side repeater light is held in position
by spring pressure.
18Depending on how the light unit was
previously fitted, press it either forwards or
rearwards, and remove it from the front wing
(see illustration).
19Turn the bulbholder anti-clockwise, and
disconnect it from the housing (see
illustration).
20Pull the wedge-type bulb from the holder
(see illustration).
21Fit the new bulb using a reversal of the
removal procedure.
Front foglight
22Unscrew the cross-head screws securingthe front foglight unit to the valance, and
withdraw the light unit.
23Prise open the plastic clips and remove
the rear cover from the light unit.
24Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
25Fit the new bulb using a reversal of the
removal procedure.
Rear light cluster
26With the tailgate or bootlid open, flip open
the trim cover to reveal the bulbholder in the
rear corner of the luggage compartment. On
Estate models, pull back the weatherstrip and
unclip the trim cover (see illustrations).
27Press the two plastic locking tabs
together, and withdraw the complete rear light
cluster (see illustrations).
Body electrical system 12•9
12
5.19 Removing the bulbholder from the
side repeater lens/bulbholder5.20 Removing the wedge-type bulb from
the side repeater bulbholder5.26A Pull back the weatherstrip . . .
5.15 Removing the front direction
indicator bulb5.18 Removing the side repeater from the
front wing
5.6 Removing the headlight (main beam)
bulb from the bulbholder5.9 Removing the front sidelight bulb-
holder from the rear of the headlight unit5.10 Pulling the wedge-type bulb from the
bulbholder
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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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located above the front direction indicator
(see illustration).
11Withdraw the front direction indicator light
unit.
12Rotate the bulbholder anti-clockwise, and
withdraw it from the light unit. Alternatively,
the wiring plug can be disconnected from the
bulbholder, leaving the bulb in position (see
illustration). Remove the light unit.
Foglight (front)
13Unscrew the cross-head screws securing
the front foglight unit to the valance, and
withdraw the light unit from the valance.
14Prise open the plastic clips, and remove
the rear cover from the light unit.
15Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
Remove the foglight unit.
Rear light cluster
16With the tailgate or bootlid open, unhook
the parcel net (where fitted) from the rear of
the luggage compartment.
17On Saloon and Hatchback models,
remove the screws, release the clips, and
remove the trim panel from the rear cross
panel. On Estate models, it is sufficient to
open the flap.
18Remove the screws, and press the rear
light trim cover from the guides (where
applicable).
19Disconnect the wiring multi-plug.
20Unscrew the four mounting nuts, and
withdraw the light unit from the outside of the
vehicle (see illustrations).
Rear number plate light assembly
21Remove both number plate lights as
described in Section 5.
22With the tailgate or bootlid open, remove
the screws and withdraw the inner trim panel.
23Unscrew the nuts, and remove the outer
cover and number plate base from the
tailgate.
24Disconnect the multi-plug and remove the
light assembly.
Refitting
25Refitting of all the external light units is a
reversal of the removal procedure, noting the
following points:(a) When refitting the rubber seal on the
headlight unit, note that it has a tapered
seat.
(b) If one or both headlights have been
disturbed, have the beam alignment
checked as described in the next Section.
(c) When refitting the rear light cluster, check
the condition of the sealer on the body
panel, and if necessary renew it.
1Accurate adjustment of the headlight beam
is only possible using optical beam-setting
equipment. This work should therefore be
carried out by a Ford dealer, or other service
station with the necessary facilities.
2Temporary adjustment can be made after
renewal of a headlight bulb or unit, or as an
emergency measure if the alignment is
incorrect following accident damage. Turn the
adjustment screws on the top of the headlamp
unit to make the adjustment (see illustration).
3Before making any adjustments to the
settings, it is important that the tyre pressures
are correct, and that the vehicle is standing on
level ground. Bounce the front of the vehicle a
few times to settle the suspension. Ideally,
somebody of average size should sit in the
driver’s seat during the adjustment, and the
vehicle should have a full tank of fuel. Where a
vehicle is fitted with an electrical beam
levelling system, set the switch to the “O”
position before making any adjustments.4Whenever temporary adjustments are
made, the settings must be checked and if
necessary reset by a Ford dealer or other
qualified person as soon as possible.
Removal
1Remove the headlight unit as described in
Section 7, then remove the cover.
2Disconnect the wiring multi-plug from the
motor.
3Rotate the motor upwards approximately
60°, then pull it forwards slightly.
4Disconnect the adjustment spindle by
pressing the ball coupling to one side, away
from the socket on the reflector.
5Withdraw the motor from the headlight unit.
Refitting
6Refitting is a reversal of the removal
procedure, but make sure that the motor is
turned down until it engages the stop.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
10 Instrument panel -
removal and refitting
9 Headlight levelling motor -
removal and refitting
8 Headlight beam alignment-
checking and adjustment
Body electrical system 12•13
12
7.20B Removing the rear light cluster unit
8.2 Headlight beam setting adjustment
screws
1 Vertical alignment screw
2 Horizontal alignment screw
7.10 Loosen the front direction indicator
retaining screw7.12 Disconnecting the wiring plug from
the indicator bulbholder7.20A Rear light cluster mounting nuts
(arrowed)
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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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