1993 FORD MONDEO battery

30Detach the mounting plate from the lock.
31Release the door-ajar sensor from the clip
(see illustration).
32Prise the plastic shield from the locating
post (see illustration).
33Slide the outer cable from the lock
bracket (see illustration), then turn the inner
cable through a quarter-turn to remove it from
the bell crank.
34Unscrew the mounting screws and
remove the lock motor (see illustration).
Lock motor - rear door
35Remove the exterior handle as described
earlier in this Section.
36Unscrew and remove the three lock
mounting screws.
37Release the sensor wiring loom from the
clip on the door.
38Disconnect the wiring multi-plug from the
door lock.
39Disconnect the interior handle illumination
light.
40Remove the screws, and remove the
interior handle.
41Remove the lock assembly.
42Release the door-ajar sensor from the
clip.
43Prise the plastic shield from the locating
post.
44Slide the outer cable from the lock
bracket, then turn the inner cable through a
quarter-turn to remove it from the bell crank.
45Unscrew the mounting screws andremove the lock motor.
Striker
46Using a pencil, mark the position of the
striker.
47Undo the mounting screws using a Torx
key, and remove the striker.
Check strap
48Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
49Using a Torx key, unscrew and remove
the check strap mounting screw(s). On the
front door, there are two screws; on the rear
door, there is only one.
50Prise the rubber grommet from the door
aperture, then unscrew the mounting nuts and
withdraw the check strap from the door.
Refitting
Handles (exterior and interior)
51Refitting is a reversal of the removal
procedure.
Lock barrel
52Check that the retaining clip is fitted
correctly.
53Align the grooves on the barrel with the
grooves on the body and operating lever, then
carefully push the barrel into the handle until it
engages the clip.
54The remaining refitting procedure is a
reversal of removal.
Lock motor
55Refitting is a reversal of the removal
procedure.
Striker
56Refitting is a reversal of the removal
procedure, but check that the door lock
passes over the striker centrally. If necessary,
re-position the striker before fully tightening
the mounting screws.
Check strap
59Refitting is a reversal of the removal
procedure.
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2Using a Torx key, unscrew and remove the
check strap mounting screw(s). On the front
door, there are two screws; on the rear door,
there is only one (see illustrations).
3Disconnect the wiring connector(s) by
twisting them anti-clockwise. On the front
door, there are two connectors; on the rear
door, there is only one (see illustration).
4Extract the small circlips from the top of the
upper and lower hinge pins (see illustration).
5Have an assistant support the weight of the
15 Door - removal and refitting
Bodywork and fittings 11•13
11
15.2B Front door check strap removed15.3 Disconnecting a door wiring
connector15.4 Extract the small circlips . . .
14.33 Slide the outer cable from the lock
bracket14.34 Removing a lock motor15.2A Front door check strap mounting
screw removal
procarmanuals.com

door, then drive the hinge pins down through
the hinges using a small drift (see
illustrations).
6Carefully withdraw the door from the
hinges.
Refitting
7Refitting is a reversal of the removal
procedure, but check that the door lock
passes over the striker centrally. If necessary,
re-position the striker.
Removal
1Where electric mirrors are fitted, disconnect
the battery negative (earth) lead (Chapter 5,
Section 1).
2Prise off the cap, unscrew the screw, and
remove the quarter bezel from the front of the
window opening.
3On manual mirrors, detach the adjustment
lever.
4On electric mirrors, disconnect the wiring
multi-plug (see illustration).
5On both types of mirror, use a Torx key to
unscrew the mirror mounting screws, then
withdraw the mirror from the outside of the
door (see illustrations). Recover the gasket.
Refitting
6Refitting is a reversal of the removal
procedure.
Removal
1Using a length of strong thin cord or fishing
line, break the adhesive bond between the
base of the mirror and the glass. Have an
assistant support and remove the mirror as it
is released.
2If the original mirror is to be refitted,
thoroughly clean its base with methylated
spirit and a lint-free cloth. Allow a period of
one minute for the spirit to evaporate. Clean
the windscreen black patch in a similar
manner.
Refitting
3During the installation of the mirror, it is
important that the mirror base, windscreen
black patch and the adhesive patch are not
touched or contaminated in any way,
otherwise poor adhesion will result.
4Prior to fitting the mirror, the vehicle should
have been at an ambient temperature of at
least 20ºC.
5With the contact surfaces thoroughly
cleaned, remove the protective tape from one
side of the adhesive patch, and press it firmly
into contact with the mirror base.
6If fitting the mirror to a new windscreen, the
protective tape must also be removed from
the windscreen black patch.
7Using a hairdryer or a hot air gun, warm themirror base and the adhesive patch for about
30 seconds to a temperature of 50 to 70ºC.
Peel back the protective tape from the other
side of the adhesive patch on the mirror base.
Align the mirror base and the windscreen
patch, and press the mirror firmly into
position. Hold the base of the mirror firmly
against the windscreen for a minimum period
of two minutes, to ensure full adhesion.
8Wait at least thirty minutes before adjusting
the mirror position.
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1), and open the boot lid.
2Where applicable, pull off the trim covering,
and release the wiring on the hinge arm.
3Where fitted, remove the trim from inside
the boot lid.
4Disconnect the wiring at the connectors
visible through the boot lid inner skin aperture.
5Attach a length of strong cord to the end of
the wires in the aperture, to act as an aid to
guiding the wiring through the lid when it is
refitted.
6Release the cable guide rubber grommet,
and withdraw the wiring loom through it. Untie
the cord, and leave it in the boot lid.
7Mark the position of the hinge arms with a
pencil.
8Place rags beneath each corner of the boot
lid, to prevent damage to the paintwork.
9With the help of an assistant, unscrew the
mounting bolts and lift the boot lid from the
car.
Refitting
10Refitting is a reversal of the removal
procedure. Check that the boot lid is correctly
aligned with the surrounding bodywork, with
an equal clearance around its edge.
Adjustment is made by loosening the hinge
bolts, and moving the boot lid within the
elongated mounting holes. Check that the
lock enters the striker centrally when the boot
lid is closed.
18 Boot lid - removal and refitting
17 Interior mirror -
removal and refitting
16 Exterior mirror and glass-
removal and refitting
11•14 Bodywork and fittings
15.5A . . . then drive out the hinge pins . . .15.5B . . . and remove them16.4 Disconnecting the wiring multi-plug
from an electric exterior mirror
16.5A Unscrew the screws . . .16.5B . . . and withdraw the mirror
procarmanuals.com

Removal
Lock barrel
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2With the boot lid open, remove the luggage
space trim from the right-hand rear corner.
3Remove the screws, and prise out the rear
light trim cover from the guides.
4Release the door-ajar sensor from the clip
near the lock.
5Slide the outer cable from the lock bracket.
Raise the inner cable until it is aligned with the
slot in the barrel lever, and disconnect it.
6Pull out the lock locating spring clip.
7Detach the cable mounting bracket from
the barrel, and remove the barrel.
Lock
8Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
9With the boot lid open, prise out the clips
and remove the trim from inside the boot lid.
10Release the door-ajar sensor from the clip
near the lock.
11Using a Torx key, unscrew the lock
mounting screws, and withdraw the lock for
access to the cables.
12Disconnect both the inner and outer
cables from the lock bracket.13Prise open the plastic lip, and remove the
central locking control rod.
14Withdraw the lock assembly.
Refitting
Lock barrel and lock
15Refitting is a reversal of the removal
procedure.
Removal
Hatchback
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1). Open the tailgate.
2The tailgate may be unbolted from the
hinges and the hinges left in position, or the
hinges may be detached from the roof panel
by unscrewing the mounting nuts. In the latter
case, carefully pull down the rear edge of the
headlining for access to the nuts. Take care
not to damage the headlining.
3Remove the parcel shelf left-hand support
bracket as follows. Fold the rear seat
forwards, and disconnect the left-hand seat
pull cable from the bracket and clips.
Unscrew the screws and remove the bracket.
4Pull up the rear seat side bolster, then
carefully remove the side trim from the left-
hand side of the luggage area. On low-series
models, the bolster is retained with a screw.5Separate the tailgate wiring loom multi-
plugs, located on the left-hand side of the
luggage compartment, on top of the wheel
arch.
6Unclip and remove the upper trim panel
from the inside of the tailgate. Also remove
the rear shelf cord plastic post (see
illustrations).
7Prise out the rubber grommet from the top
of the tailgate aperture, and pull the wiring
loom out through the hole in the body (see
illustration).
8Disconnect the rear window washer tube
from the jet.
9Prise out the rubber grommet from the
right-hand side of the tailgate aperture, and
pull out the washer tube.
10Have an assistant support the tailgate in
its open position.
11Using a small screwdriver, prise off the
clips securing the struts to the tailgate. Pull
the sockets from the ball-studs, and move the
struts downwards.
12If the headlining has been pulled back,
unscrew and remove the hinge nuts from the
roof panel. Otherwise, unscrew the bolts
securing the tailgate to the hinges (see
illustration).
13Withdraw the tailgate from the body
aperture, taking care not to damage the
paintwork.
Estate
14Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
15The tailgate may be unbolted from the
hinges and the hinges left in position, or the
hinges may be detached from the rear roof
panel by unscrewing the mounting nuts. In the
latter case, carefully pull down the rear edge
of the headlining for access to the nuts. Take
care not to damage the headlining.
16Unscrew the retaining screws, then unclip
the “D” pillar trim panels from both sides (see
illustration).
17Unclip and remove the upper trim panel
from inside the tailgate.
18Carefully remove the side trim from the
left-hand side of the luggage area, and
separate the tailgate wiring loom multi-plugs
in the rear light cluster housing.
20 Tailgate -
removal and refitting
19 Boot lid lock components-
removal and refitting
Bodywork and fittings 11•15
11
20.12 Unscrewing the bolts securing the
tailgate to the hinges20.16 “D” pillar trim panel retaining
screws (arrowed) - Estate models
20.6A Unclipping the upper trim panel
from the tailgate20.6B Shelf cord post removal20.7 Removing the wiring loom rubber
grommet
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19Attach a strong fine cord to the end of the
wiring loom, to act as an aid to guiding the
wiring through the tailgate when it is refitted.
20Prise the rubber grommet from the top
left-hand side of the tailgate aperture, and pull
out the wiring loom. Untie the cord, leaving it
in position in the “D” pillar.
21Disconnect the rear window washer tube
from the jet. Pull out the rubber grommet, and
remove the tube.
22Have an assistant support the tailgate in
its open position.
23Using a small screwdriver, prise off the
clip securing the struts to the tailgate. Pull the
sockets from the ball-studs, and move the
struts downwards.
24Unscrew and remove the hinge nuts from
the roof panel, or the hinge bolts from thehinge, as desired (see illustration). Withdraw
the tailgate from the body aperture, taking
care not to damage the paintwork.
Refitting
Hatchback and Estate
25Refitting is a reversal of the removal
procedure, but check that the tailgate is
located centrally in the body aperture, and
that the striker enters the lock centrally. If
necessary, loosen the mounting nuts and re-
position the tailgate as required.
Removal
1Support the tailgate in its open position.
2Prise off the upper spring clip securing the
strut to the tailgate, then pull the socket from
the ball-stud (see illustration).
3Similarly prise off the bottom clip (see
illustration), and pull the socket from the ball-
stud. Withdraw the strut.
Refitting
4Refitting is a reversal of the removal
procedure, but make sure that the piston end
of the strut is fitted on the body (ie
downwards).
Removal
Lock barrel (Hatchback)
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2With the tailgate open, pull up the
weatherstrip for access to the lock. Remove
the screws and clips, and remove the trim
panel from the rear of the luggage
compartment.
3Unhook the parcel net, then remove the
screws and clips, and remove the rear
crossmember trim.
4Remove the screws, and prise out the rear
light trim cover from the guides.
5Release the door-ajar sensor from the clip
near the lock.
6Slide the outer cable from the lock bracket.
Raise the inner cable until it is aligned with the
slot in the barrel lever, and disconnect it (see
illustration).
7Pull out the lock barrel locating spring clip.
8Detach the cable mounting bracket from
the barrel, and remove the barrel and cylinder
(see illustrations).
Lock barrel (Estate)
9Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
10Unclip and remove the tailgate trim panel.
Undo the three screws and remove the lock
shield, then unclip the door-ajar sensor.
11Working through the aperture in the
tailgate inner panel, pull out the lock barrel
locating spring clip. Unhook the operating rod
and withdraw the lock barrel.
Lock (Hatchback)
12Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
13With the tailgate open, pull up the
weatherstrip for access to the lock. Remove
the screws and clips, and remove the trim
panel from the rear of the luggage
compartment.
22 Tailgate lock components -
removal and refitting
21 Tailgate support strut-
removal and refitting
11•16 Bodywork and fittings
20.24 Tailgate hinge and bolts - Estate
models21.2 Prising the spring clip from the upper
end of the strut
21.3 Prising the spring clip from the lower
end of the strut
22.6 Tailgate lock barrel and bracket22.8A Removing the lock barrel . . .22.8B . . . and cylinder
procarmanuals.com

14Release the door-ajar sensor from the clip
near the lock (see illustration).
15Using a Torx key, unscrew the lock
mounting screws, and withdraw the lock for
access to the cables (see illustration).
16Disconnect both the inner and outer
cables from the lock bracket (see
illustration).
17Prise open the plastic clip, and remove
the central locking control rod.
18Withdraw the lock assembly.
Lock (Estate)
19Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
20Open the tailgate. Undo the screws and
remove the inner trim.
21Using a Torx key, unscrew the lock
mounting screws, and carefully withdraw the
lock (see illustration).
22Release the door-ajar sensor from the clip
near the lock.
23Disconnect the barrel operating rod, and
remove the lock.
24If necessary, the lock striker assembly
may be removed by disconnecting the release
cable and unscrewing the mounting bolts (see
illustration).
Refitting
Lock barrel and lock - all models
25Refitting is a reversal of the removal
procedure.
Testing
1The central locking module incorporates a
service-test mode, which is activated by
operating one of the lock position switches 8
times within 10 seconds. A buzzer will sound,
to indicate that the service-test mode is
operating, and to indicate that no faults have
been found in the system. If a fault has been
found, the system should be checked by a
Ford dealer or electrical specialist. The central
locking module also incorporates the alarm
system module.
Removal
Central locking/alarm module
2To remove the module, first remove the
lower right-hand facia panel (right-hand-drive
models) or the glovebox (left-hand-drive
models).
3Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
4Unscrew the mounting bolts, and remove
the module from the bracket beneath the
facia.
5Disconnect the wiring multi-plug, and
withdraw the module from inside the vehicle.6Note that a different module is used for
models without an anti-theft alarm.
Central locking set/reset switch
7This procedure is covered in Section 14,
under front door handle removal.
Central locking door-ajar switch
8This procedure is covered in Section 14,
under front door lock motor removal.
Refitting
Central locking/alarm module
9Refitting is a reversal of the removal
procedure.
Central locking set/reset switch
10Refitting is a reversal of the removal
procedure.
Central locking door-ajar switch
11Refitting is a reversal of the removal
procedure.
1The windscreen and rear window on all
models are bonded in place with special
mastic, as are the rear side windows on
Estate models. Special tools are required to
cut free the old units and fit replacements;
special cleaning solutions and primer are also
required. It is therefore recommended that
this work is entrusted to a Ford dealer or
windscreen replacement specialist.
2Note that the windscreen contributes
towards the structural strength of the vehicle
as a whole, so it is important that it is fitted
correctly.
Removal
1Insert a length of strong cord (fishing line is
ideal) behind the moulding or emblem
concerned. With a sawing action, break the
25 Body side-trim mouldings
and adhesive emblems -
removal and refitting
24 Windscreen and fixed
windows - removal and refitting
23 Central locking system
components-
testing, removal and refitting
Bodywork and fittings 11•17
11
22.21 Tailgate lock - Estate models22.24 Lock striker assembly - Estate
models
22.14 Removing the door-ajar sensor from
the lock22.15 Removing a lock mounting screw22.16 Disconnecting the cables from the
lock
procarmanuals.com

adhesive bond between the moulding or
emblem and the panel (see illustration).
2Thoroughly clean all traces of adhesive
from the panel using
methylated spirit, and allow the location to
dry.
Refitting
3Peel back the protective paper from the
rear face of the new moulding or emblem.
Carefully fit it into position on the panel
concerned, but take care not to touch the
adhesive. When in position, apply hand
pressure to the moulding/emblem for a short
period, to ensure maximum adhesion to the
panel.1The sunroof should operate freely, without
sticking or binding, as it is opened and
closed. When in the closed position, check
that the panel is flush with the surrounding
roof panel.
2If adjustment is required, open the sun
blind, but leave the glass panel shut. Unscrew
and remove the three lower frame-to-glass
panel retaining screws. Slide the lower frame
back into the roof.
3Loosen the central and front securing
screws. Adjust the glass roof panel so that it is
flush at its front edge with the roof panel, then
retighten the securing screws.
4Pull the lower frame forwards, and insert
and tighten its retaining screws to complete.
Removal
Front seat
1Release the seat belt, and slide the seat
fully forwards.
2Using a Torx key, undo the screws and
remove the rear mounting trims, then unscrew
the rear mounting bolts (see illustrations).
3Slide the seat fully rearwards.
4Where electric seats are fitted, disconnectthe battery negative (earth) lead (Chapter 5,
Section 1). Disconnect the seat wiring multi-
plugs (see illustration).
5Unscrew the front mounting bolts, and
remove the seat from the vehicle (see
illustration).
Rear seat cushion
6Fold the rear seat cushion forwards. (Note
that, on some models, the seat cushion is
held in place by screws which must be
removed first.) Using a Torx key, unscrew and
remove the mounting bolts from the hinges on
each side (see illustration).
7Withdraw the seat cushion from the vehicle.
Rear seat backrest
8Fold the rear seat cushion and both
backrests forwards.
9Unclip the backrest rear trims, where fitted,
and raise them.
10Using a Torx key, unscrew the mounting
bolts (see illustration).
11Withdraw the backrest from inside the
vehicle.
Rear seat side bolster
12Fold the rear seat backrest forwards.
13On low-series models, remove the screw
and pull the bolster forwards to disengage the
clips. On high-series models, simply pull the
bolster upwards to disengage the clips.
Refitting
14Refitting is a reversal of the removal
procedure, but tighten the mounting bolts to
the specified torque.
27 Seats - removal and refitting
26 Sunroof - general
information and adjustment
11•18 Bodywork and fittings
25.1 Using a length of cord to remove the
emblem from the radiator grille27.2A Unscrew the Torx-headed
screws . . .27.2B . . . and remove the mounting trims
for access to the front seat rear mounting
bolts
27.5 Front seat front mounting bolt
27.4 Disconnecting an electric seat multi-
plug
27.6 Rear seat cushion hinge bolt27.10 Rear seat backrest mounting bolts
procarmanuals.com

the upper hook. Note that, on low-series
models, the bolster is retained with a screw
(see illustrations).
16Undo the screw, release the clips, and
detach the upper trim.
17Remove the rear seat belt lower mounting
bolt, then remove the trim, and pass the seat
belt through it.
“C” pillar trim (Estate)
18Prise off the caps, unscrew the screws,
and remove the upper trim from the “C” pillar
(see illustration).
19Unscrew the mounting bolt securing the
rear seat belt upper shackle to the “C” pillar.
20Unclip and remove the trim.
“D” pillar trim (Estate)
21Remove the three mounting screws, then
unclip the trim from the “D” pillar.
Lower facia panel
22Remove the steering column top and
bottom shrouds.
23Unscrew the mounting screws from the
upper corners and above the coin tray
position, and withdraw the lower facia panel
from the facia (see illustrations).
Refitting
24Refitting is a reversal of the removal
procedure. Where seat belt fastenings have
been disturbed, make sure that they are
tightened to the specified torque.
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2Pull the ashtray from the facia.
3Pull off the gear lever (or selector lever)
knob (see illustration).
4Using a screwdriver, carefully prise out the
gear lever gaiter/switch panel or selector lever
panel, as applicable. When necessary,
disconnect the wiring multi-plugs (see
illustration).
5Remove the adaptive damping switch,
when fitted (Chapter 12).
30 Centre console-
removal and refitting
Bodywork and fittings 11•21
11
30.4 Prising out the gear lever gaiter30.6A Prise off the plastic caps . . .30.6B . . . and unscrew the mounting
screws at the front top . . .
29.23B . . . and above the coin tray
position . . .
29.23C . . . and withdraw the lower facia
panel30.3 Gear lever knob removal
29.15B . . . and release the upper hook29.18 Screw locations (arrowed) for the
“C” pillar upper trim - Estate models29.23A Unscrew the mounting screws
from the upper corners . . .
procarmanuals.com

6Prise off the plastic caps, then unscrew the
centre console mounting screws. These are
located on each side, on the front top, and
inside the cassette storage box. The screws
with the washers go on the side of the
console; the front screws are smaller than the
others, and black in colour (see illustrations).
7Fully apply the handbrake lever. Withdraw
the centre console, at the same time passing
the gaiter over the handbrake lever (see
illustrations).
8Disconnect the cigar lighter wiring (see
illustration).
Refitting
9Refitting is a reversal of the removal
procedure.
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2When applicable, remove the sunroof
switch (Chapter 12).
3When applicable, remove the sunroof
handle, after undoing the securing screw (see
illustration).
3Push the console towards the windscreen,
to disengage it from the clips.
Refitting
4Refitting is a reversal of the removal
procedure.
Removal
1Open the glovebox. Using a screwdriver,
carefully press in one side of the glovebox
near the hinge, to release it from the plastic
clip (see illustration).
2Withdraw the glovebox and, where
necessary, disconnect the wiring multi-plug
for the light.
3If necessary, the lock may be removed by
unscrewing the mounting screws and removing
the lock plate and spring (see illustration).
4To remove the lock barrel, depress the
spring tabs.
Refitting
5Locate the barrel in the lock plate, making
sure that the clips are fully engaged.
6Hold the latch pins together, and engage
the right-hand pin of the lock plate.
7Refit the spring, and engage the left-hand
pin of the lock plate.
8Refit the lock plate, and tighten the screws.
9Reconnect the wiring multi-plug and refit
the glovebox, making sure that it is fully
inserted in the plastic clips.
32 Glovebox -
removal and refitting
31 Overhead console -
removal and refitting
11•22 Bodywork and fittings
30.6C . . . at the sides . . .30.6D . . . and inside the cassette storage
box30.7A Withdrawing the front of the
console from the facia
31.3 Removing the sunroof handle
securing screw32.1 Glovebox removal
30.8 Disconnecting the cigar lighter wiring
30.7B Passing the gaiter over the
handbrake lever
32.3 Glovebox lock mounting screws
(arrowed)
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