horn FORD MONDEO 1993 Service Repair Manual

Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
MExamine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible
from inside the vehicle.
MThe front seats themselves must be
securely attached and the backrests must
lock in the upright position.
Doors
MBoth front doors must be able to be opened
and closed from outside and inside, and must
latch securely when closed.
Vehicle identification
MNumber plates must be in good condition,
secure and legible, with letters and numbers
correctly spaced – spacing at (A) should be
twice that at (B).
MThe VIN plate (A) and homologation plate
(B) must be legible.
Electrical equipment
MSwitch on the ignition and check the
operation of the horn.
MCheck the windscreen washers and wipers,
examining the wiper blades; renew damaged
or perished blades. Also check the operation
of the stop-lights.
MCheck the operation of the sidelights and
number plate lights. The lenses and reflectors
must be secure, clean and undamaged.
MCheck the operation and alignment of the
headlights. The headlight reflectors must not
be tarnished and the lenses must be
undamaged.
MSwitch on the ignition and check the
operation of the direction indicators (including
the instrument panel tell-tale) and the hazard
warning lights. Operation of the sidelights and
stop-lights must not affect the indicators - if it
does, the cause is usually a bad earth at the
rear light cluster.
MCheck the operation of the rear foglight(s),
including the warning light on the instrument
panel or in the switch.
Footbrake
MExamine the master cylinder, brake pipes
and servo unit for leaks, loose mountings,
corrosion or other damage.
MThe fluid reservoir must be secure and the
fluid level must be between the upper (A) and
lower (B) markings.MInspect both front brake flexible hoses for
cracks or deterioration of the rubber. Turn the
steering from lock to lock, and ensure that the
hoses do not contact the wheel, tyre, or any
part of the steering or suspension mechanism.
With the brake pedal firmly depressed, check
the hoses for bulges or leaks under pressure.
Steering and suspension
MHave your assistant turn the steering wheel
from side to side slightly, up to the point where
the steering gear just begins to transmit this
movement to the roadwheels. Check for
excessive free play between the steering
wheel and the steering gear, indicating wear or
insecurity of the steering column joints, the
column-to-steering gear coupling, or the
steering gear itself.
MHave your assistant turn the steering wheel
more vigorously in each direction, so that the
roadwheels just begin to turn. As this is done,
examine all the steering joints, linkages,
fittings and attachments. Renew any
component that shows signs of wear or
damage. On vehicles with power steering,
check the security and condition of the
steering pump, drivebelt and hoses.
MCheck that the vehicle is standing level,
and at approximately the correct ride height.
Shock absorbers
MDepress each corner of the vehicle in turn,
then release it. The vehicle should rise and
then settle in its normal position. If the vehicle
continues to rise and fall, the shock absorber
is defective. A shock absorber which has
seized will also cause the vehicle to fail.
2Checks carried out
WITH THE VEHICLE ON THE
GROUND
0•8MOT Test Checks
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Ford Mondeo maintenance schedule
1•3
1
Maintenance schedule
The manufacturer’s recommended maintenance schedule for these
vehicles is as described below - note that the schedule starts from the
vehicle’s date of registration. These are the minimum maintenance
intervals recommended by the factory for Mondeos driven daily, but
subjected only to “normal” use. If you wish to keep your vehicle in
peak condition at all times, you may wish to perform some of these
procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your vehicle,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of
these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit with
the engine idling or drive at low speeds for extended periods (ie, in
heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.
When your vehicle is new, it should be serviced by a Ford dealer
service department to protect the factory warranty. In many cases, the
initial maintenance check is done at no cost to the owner. Note that
this first free service (carried out by the selling dealer 1500 miles or 3
months after delivery), although an important check for a new vehicle,
is not part of the regular maintenance schedule, and is therefore not
mentioned here.
Weekly checks
m mCheck the engine oil level, and top-up if necessary
(Section 3)
m mCheck the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Sections 12 and 22)
m mCheck the windscreen/tailgate washer fluid level, and top-
up if necessary (Section 3)
m mCheck the tyre pressures, including the spare (Section 4)
m mVisually check the tyres for excessive tread wear, or
damage (Section 4)
m mCheck the operation of all (exterior and interior) lights and
the horn, wipers and windscreen/tailgate washer system
(Sections 6 and 8). Renew any blown bulbs (Chapter 12),
and clean the lenses of all exterior lights
Monthly checks
m mCheck the coolant level, and top-up if necessary (Sec-
tion 3)
m mCheck the battery electrolyte level, where applicable
(Section 3)
m mCheck the power steering fluid level, and top-up if
necessary (Section 5)
m mVisually check all reservoirs, hoses and pipes for leakage
(Section 12)
m mCheck the operation of the air conditioning system
(Section 14)
m mCheck the operation of the handbrake (Section 23)
m mCheck the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6)
m mCheck the condition of the wiper blades, renewing them if
worn or no longer effective - note that the manufacturer
recommends renewing the blades as a safety precaution,
irrespective of their apparent condition, at least once a
year (Section 6)
Every 10 000 miles or 12 months,
whichever occurs first
Note:If the vehicle is used regularly for very short (less than
10 miles), stop/go journeys, the oil and filter should be renewed
between services (ie, every 5000 miles/6 months).
m mCheck the electrical system (Section 8)
m mCheck the battery (Section 9)
m mCheck the seat belts (Section 10)
m mCheck the auxiliary drivebelt (Section 11)
m mCheck for fluid leaks and hose condition (Section 12)
m mCheck the condition of all wiring (Section 13)
m mCheck all air conditioning components (Section 14)
m mChange the engine oil and filter (Section 15)
m mCheck the manual transmission oil level (Section 16)
m mCheck the adjustment of the clutch pedal (Section 17)
m mLubricate the automatic transmission linkage (Section 18)
m mCheck the steering, suspension and wheels (Section 19)
m mCheck the driveshaft gaiters and CV joints (Section 20)
m mCheck the exhaust system (Section 21)
m mCheck the underbody, and all fuel/brake lines (Section 22)
m mCheck the brake system (Section 23)
m mCheck and lubricate the doors and bonnet (Section 24)
m mCheck the security of all roadwheel nuts (Section 25)
m mRoad test (Section 26). Check the level of the automatic
transmission fluid with the engine still hot, after the road
test (Section 7)
Every 20 000 miles or 2 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the ventilation system pollen filter (Section 27)
m mRenew the coolant (Sections 2 and 28)
Every 30 000 miles or 3 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the air filter element (Section 29). Note that this
task must be carried out at more frequent intervals if the
vehicle is used in dusty or polluted conditions
m mCheck the Positive Crankcase Ventilation (PCV) system,
and clean the filter (Section 30)
m mRenew the spark plugs (Section 31)
Every 60 000 miles
Carry out all operations listed above, plus the following:
m
mRenew the timing belt (Section 32)
m mRenew the fuel filter (Section 33)
Every 3 years
(regardless of mileage)
m mRenew the brake fluid (Section 34)
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Every 10 000 miles or 12 months
1•11
17.4 Removing the automatic transmission
dipstick from its tube7.6A “MIN” and “MAX” marks on the
dipstick7.6B Adding automatic transmission fluid
through the dipstick tube
Every 10 000 miles
1The level of the automatic transmission fluid
should be carefully maintained. Low fluid level
can lead to slipping or loss of drive, while
overfilling can cause foaming, loss of fluid and
transmission damage.
2The transmission fluid level should only be
checked when the transmission is hot (at its
normal operating temperature). If the vehicle
has just been driven over 10 miles (15 miles in
a cold climate), and the fluid temperature is
160 to 175°F, the transmission is hot.
Caution: If the vehicle has just
been driven for a long time at
high speed or in city traffic in hot
weather, or if it has been pulling
a trailer, an accurate fluid level reading
cannot be obtained. In these
circumstances, allow the fluid to cool
down for about 30 minutes.
3Park the vehicle on level ground, apply the
handbrake, and start the engine. While the
engine is idling, depress the brake pedal and
move the selector lever through all the gear
ranges three times, beginning and ending in
“P”.
4Allow the engine to idle for one minute, then
(with the engine still idling) remove the dipstick
from its tube (see illustration). Note the
condition and colour of the fluid on the dipstick.
5Wipe the fluid from the dipstick with a clean
rag, and re-insert it into the filler tube until the
cap seats.
6Pull the dipstick out again, and note the
fluid level. The level should be between the
“MIN” and “MAX” marks. If the level is on the
“MIN” mark, stop the engine, and add the
specified automatic transmission fluid through
the dipstick tube, using a clean funnel if
necessary (see illustrations). It is important
not to introduce dirt into the transmission
when topping-up.
7Add the fluid a little at a time, and keep
checking the level as previously described
until it is correct.8The need for regular topping-up of the
transmission fluid indicates a leak, which
should be found and rectified without delay.
9The condition of the fluid should also be
checked along with the level. If the fluid at the
end of the dipstick is black or a dark reddish-
brown colour, or if it has a burned smell, the
fluid should be changed. If you are in doubt
about the condition of the fluid, purchase
some new fluid, and compare the two for
colour and smell.
1Check the operation of all external lights
and indicators (front and rear).
2Check for satisfactory operation of the
instrument panel, its illumination and warning
lights, the switches and their function lights.
3Check the horn(s) for satisfactory operation.
4Check all other electrical equipment for
satisfactory operation.
5Check all electrical wiring in the engine
compartment for correct routing, and for any
signs of physical or heat-damage or chafing.
Warning: Certain precautions
must be followed when checking
and servicing the battery.
Hydrogen gas, which is highly
flammable, is always present in the battery
cells, so keep lighted tobacco and all other
open flames and sparks away from the
battery. The electrolyte inside the battery
is actually dilute sulphuric acid, which will
cause injury if splashed on your skin or in
your eyes. It will also ruin clothes and
painted surfaces. When disconnecting the
battery, always detach the negative (earth)
lead first and connect it last!
Note: Before disconnecting the battery, refer
to Section 1 of Chapter 5.
9 Battery check, maintenance
and charging
8 Electrical system check
7 Automatic transmission fluid
level check
9.1 Tools and materials required for
battery maintenance
1Face shield/safety goggles- When
removing corrosion with a brush, the acidic
particles can easily fly up into your eyes
2Baking soda- A solution of baking soda
and water can be used to neutralise corrosion
3Petroleum jelly- A layer of this on the
battery terminals will help prevent corrosion
4Battery terminal/lead cleaner- This wire
brush cleaning tool will remove all traces of
corrosion from the battery terminals and lead
clamps
5Treated felt washers- Placing one of
these on each terminal, directly under the
lead clamps, will help prevent corrosion
6Puller- Sometimes the lead clamps are
very difficult to pull off the terminals, even
after the nut has been completely slackened.
This tool pulls the clamp straight up and off
the terminal without damage
7Battery terminal/lead cleaner- Here is
another cleaning tool which is a slightly
different version of number 4 above, but does
the same thing
8Rubber gloves- Another safety item to
consider when servicing the battery;
remember, that’s acid inside the battery!
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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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Chapter 12 Body electrical system
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 30
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 29
Air bag unit (driver’s side) - removal and refitting . . . . . . . . . . . . . . . 28
Anti-theft alarm system - general information . . . . . . . . . . . . . . . . . . 20
Auxiliary warning system - general information and
component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery - check, maintenance and charging . . . . . . . . See Chapter 1
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . See Chapter 5
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compact disc player - removal and refitting . . . . . . . . . . . . . . . . . . . 25
Cruise control system - general information . . . . . . . . . . . . . . . . . . . 21
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses, relays and timer module - testing and renewal . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight beam alignment - checking and adjustment . . . . . . . . . . 8
Headlight levelling motor - removal and refitting . . . . . . . . . . . . . . . 9Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel components - removal and refitting . . . . . . . . . . . 11
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Radio/cassette player - coding, removal and refitting . . . . . . . . . . . 23
Radio/cassette player power amplifier - removal and refitting . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Speedometer drive cable - removal and refitting . . . . . . . . . . . . . . . 12
Stop-light switch - removal and refitting . . . . . . . . . . . See Chapter 9
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 17
TCS inhibition switch - removal and refitting . . . . . . . . See Chapter 9
Trip computer module - removal and refitting . . . . . . . . . . . . . . . . . 18
Windscreen/tailgate washer system and wiper blade
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Windscreen/tailgate washer system components - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses (auxiliary fusebox in engine compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse No Rating Colour Circuit(s) protected
1 80 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply to main fusebox
2 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fans
3 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Diesel engine glow plugs and/or ABS braking system
4 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system, or ignition and daytime running lights
5 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (left-hand side)
6 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (right-hand side)
7 30 Light green . . . . . . . . . . . . . . . . . . . . . . ABS braking system
8 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air conditioning compressor/heated seats or air conditioning
compressor/daytime running lights
9 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . ECU (petrol), Cold start solenoid (Diesel)
10 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . Ignition switch
11 3 Violet . . . . . . . . . . . . . . . . . . . . . . . . . . ECU memory
12 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Horn and hazard flasher warning system
13 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Oxygen sensor
14 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
15 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (right-hand side)
16 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (left-hand side)
17 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (right-hand side)
18 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (left-hand side)
12•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
12
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Fuses (main fusebox in passenger compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse Rating Colour Circuit(s) protected
19 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Heated door mirrors
20 10 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Front/rear wiper motor (circuit breaker)
21 30 Light green . . . . . . . . . . . . . . . . . . . . . . Front electric windows (only)
21 40 Orange . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear electric windows
22 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . ABS module
23 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Reversing lights
24 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Stop-lights
25 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Central locking system/double-locking/anti-theft alarm
26 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Foglights
27 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter
28 30 Light green . . . . . . . . . . . . . . . . . . . . . . Headlight washer system
29 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated rear window
30 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and auxiliary warning system
31 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel illumination
32 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Radio
33 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (left-hand side)
34 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and digital clock
35 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (right-hand side)
36 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air bag
37 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heater blower
38 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive damping
Relays (auxiliary fusebox in engine compartment)
Relay Colour Circuit(s) protected
R1 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime running lights (left-hand-drive, but not all countries) or dim-
dip lights (UK)
R2 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (high speed)
R3 Blue (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning cut-out
R3 Brown (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning in conjunction with Diesel engine
R4 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen heater time delay
R5 Dark green (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R5 Black (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R6 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter solenoid
R7 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns
R8 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
R9 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlights
R10 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlights
R11 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU power supply (petrol), cold start (Diesel)
Relays (main fusebox in passenger compartment)
Relay Colour Circuit(s) protected
R12 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior, courtesy and footwell lights
R13 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear window
R14 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater blower
R15 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper motor
R16 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition
Auxiliary relays (not in the fuseboxes)
Relay Colour Circuit(s) protected Location
R17 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel glow plug Battery tray
R18 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “One-touch down” Driver’s door
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver’s window relay
R19 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control cut-off Central fuse box bracket the
below instrument panel
R20 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system Bulb module bracket
R21 Orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear screen wiper interval Bulb module bracket
R22 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglights (left-hand-drive only) Interface module bracket
R23 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction indicators Steering column
R24 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (left-hand side) Door lock module bracket
R25 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (right-hand side) Door lock module bracket
R26 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated seats Door lock module bracket
12•2 Body electrical system
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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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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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6Similarly remove the fuel gauge and
temperature gauge by unscrewing the single
screws.
7Remove all the pin contacts.
8Using a small punch, push in the multi-plug
securing pins, and remove the multi-plugs.
9Carefully lift the printed circuit from the
location dowels on the housing, taking care
not to damage it.
Refitting
10Refitting is a reversal of the removal
procedure.
Removal
1Remove the windscreen wiper arms as
described in Section 15.
2With the bonnet closed, release the grille
panel upper edge from just in front of the
windscreen, by prising off the caps and
unscrewing the upper retaining screws.
3Open the bonnet, and support with the
stay.
4Pull off the sealing strip from the cross
panel at the rear of the engine compartment.
5Unscrew the lower screws, and remove the
grille panel halves from in front of thewindscreen, withdrawing first one side and
then the other.
6Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
7Reach in behind the bulkhead. Squeeze the
collar on the upper end of the speedometer
cable, where it is attached to the intermediate
cable from the rear of the speedometer head.
Disconnect the cable, and withdraw it from
the bulkhead inner panel, together with the
rubber grommet (see illustrations).
8Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
9Unscrew the nut and disconnect the
speedometer cable from the vehicle speed
sensor on the transmission, then withdraw the
cable from within the engine compartment.
Use two spanners to loosen the nut - one to
counterhold the sensor, and the other to
unscrew the cable nut (see illustrations).Refitting
10Refitting is a reversal of the removal
procedure.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).2Using a small screwdriver, prise the clock
out of the facia (see illustration). To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the clock, and withdraw the clock (see
illustration).
Refitting
4Refitting is a reversal of the removal
procedure. Reset the clock on completion.
Removal
1Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
2Unscrew the bolts, and release the clips
securing the radiator lower cover to the front
of the vehicle.
3Disconnect the wiring from the horn
terminal.
4Unscrew the mounting bolt, and withdraw
the horn with its mounting bracket from under
the vehicle (see illustration).
Refitting
5Refitting is a reversal of the removal
procedure.
14 Horn - removal and refitting
13 Clock- removal and refitting
12 Speedometer drive cable -
removal and refitting
Body electrical system 12•15
12
12.9B . . . and disconnect the
speedometer cable from the vehicle speed
sensor13.2 Prising the clock out of the facia13.3 Disconnecting the multi-plug from
the rear of the clock
12.7A Squeeze the collar . . .12.7B . . . and disconnect the
speedometer main cable from the
intermediate cable12.9A Unscrew the cable nut . . .
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Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1). If the windscreen
wiper arms are to be removed, close the bonnet.
2With the wiper(s) “parked” (ie in the normal
at-rest position), mark the positions of the
blade(s) on the screen, using a wax crayon or
strips of masking tape.
3Lift up the plastic cap from the bottom of
the wiper arm, and loosen the nut one or two
turns (see illustration).
4Lift the wiper arm, and release it from the
taper on the spindle by moving it to one side.5Completely remove the nut, and withdraw the
wiper arm from the spindle (see illustration).
Refitting
6Refitting is a reversal of the removal
procedure. Make sure that the arm is fitted in
the previously-noted position.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the wiper arms as described in
Section 15.
3With the bonnet closed, release the grillepanel upper edge from just in front of the
windscreen, by prising off the caps and
unscrewing the upper retaining screws (see
illustrations).
4Open the bonnet, and support it with the
stay.
5Pull off the bonnet sealing strip from the
cross panel at the rear of the engine
compartment (see illustration).
6Unscrew the lower screws, and remove the
grille panel halves from in front of the
windscreen, withdrawing one side then the
other side (see illustrations).
7Unscrew the mounting bolts securing the
wiper motor and linkage to the bulkhead. On
right-hand-drive models, the linkage is on the
right-hand side of the bulkhead (see
illustration); on left-hand-drive models, it is
on the left-hand side.
16 Windscreen wiper motor and
linkage - removal and refitting
15 Wiper arms-
removal and refitting
12•16 Body electrical system
14.4 Horn and mounting bracket (arrowed)15.3 Loosening the wiper arm retaining
nut15.5 Removing the wiper arm from the
spindle
16.6A Unscrew the lower screws . . .16.6B . . . and remove the grille panel from
in front of the windscreen16.7 Wiper motor mounting bolt locations
(right-hand-drive)
16.3A Prise off the cap . . .16.3B . . . and remove the upper retaining
screws16.5 Removing the bonnet sealing strip
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