1993 FORD MONDEO Service Repair Manual

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
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14Release the door-ajar sensor from the clip
near the lock (see illustration).
15Using a Torx key, unscrew the lock
mounting screws, and withdraw the lock for
access to the cables (see illustration).
16Disconnect both the inner and outer
cables from the lock bracket (see
illustration).
17Prise open the plastic clip, and remove
the central locking control rod.
18Withdraw the lock assembly.
Lock (Estate)
19Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
20Open the tailgate. Undo the screws and
remove the inner trim.
21Using a Torx key, unscrew the lock
mounting screws, and carefully withdraw the
lock (see illustration).
22Release the door-ajar sensor from the clip
near the lock.
23Disconnect the barrel operating rod, and
remove the lock.
24If necessary, the lock striker assembly
may be removed by disconnecting the release
cable and unscrewing the mounting bolts (see
illustration).
Refitting
Lock barrel and lock - all models
25Refitting is a reversal of the removal
procedure.
Testing
1The central locking module incorporates a
service-test mode, which is activated by
operating one of the lock position switches 8
times within 10 seconds. A buzzer will sound,
to indicate that the service-test mode is
operating, and to indicate that no faults have
been found in the system. If a fault has been
found, the system should be checked by a
Ford dealer or electrical specialist. The central
locking module also incorporates the alarm
system module.
Removal
Central locking/alarm module
2To remove the module, first remove the
lower right-hand facia panel (right-hand-drive
models) or the glovebox (left-hand-drive
models).
3Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
4Unscrew the mounting bolts, and remove
the module from the bracket beneath the
facia.
5Disconnect the wiring multi-plug, and
withdraw the module from inside the vehicle.6Note that a different module is used for
models without an anti-theft alarm.
Central locking set/reset switch
7This procedure is covered in Section 14,
under front door handle removal.
Central locking door-ajar switch
8This procedure is covered in Section 14,
under front door lock motor removal.
Refitting
Central locking/alarm module
9Refitting is a reversal of the removal
procedure.
Central locking set/reset switch
10Refitting is a reversal of the removal
procedure.
Central locking door-ajar switch
11Refitting is a reversal of the removal
procedure.
1The windscreen and rear window on all
models are bonded in place with special
mastic, as are the rear side windows on
Estate models. Special tools are required to
cut free the old units and fit replacements;
special cleaning solutions and primer are also
required. It is therefore recommended that
this work is entrusted to a Ford dealer or
windscreen replacement specialist.
2Note that the windscreen contributes
towards the structural strength of the vehicle
as a whole, so it is important that it is fitted
correctly.
Removal
1Insert a length of strong cord (fishing line is
ideal) behind the moulding or emblem
concerned. With a sawing action, break the
25 Body side-trim mouldings
and adhesive emblems -
removal and refitting
24 Windscreen and fixed
windows - removal and refitting
23 Central locking system
components-
testing, removal and refitting
Bodywork and fittings 11•17
11
22.21 Tailgate lock - Estate models22.24 Lock striker assembly - Estate
models
22.14 Removing the door-ajar sensor from
the lock22.15 Removing a lock mounting screw22.16 Disconnecting the cables from the
lock
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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
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Warning: Be careful when
handling the seat belt tensioning
device (“grabber”). It contains a
powerful spring, which could
cause injury if released in an uncontrolled
fashion. Once fired, the grabber cannot be
reset, and must be renewed. Note also
that seat belts and associated
components which have been subject to
impact loads must be renewed.
Removal
Front seat belt
1Remove the trim from the “B” pillar and the
scuttle.
2Unscrew the mounting bolts and remove
the seat belt reel unit (see illustration).
3Unscrew the bolt securing the seat belt
guide to the “B” pillar, then unscrew the nut
securing the seat belt shackle (see
illustrations).
4Detach the stalk cable, then undo the
mounting nut, and remove the stalk and
grabber assembly from the front seat (see
illustrations).
Warning: There is a potential risk
of the grabber firing during
removal, so it should be handled
carefully. As an extra precaution,a spacer may be fitted on the cable before
removal. Hold the adjustment lever in the
“adjust” position while inserting the
spacer.
5Remove the recline adjustment knob and
trim from the outer side of the front seat, then
unscrew the bolt and remove the seat belt
end from the seat (see illustrations).
Rear side seat belt
6Unscrew the screws and remove the trim
from the “C” pillar. It will be necessary to
detach the rear seat release cable, and
remove the plastic cover from the rear seat
lock (see illustrations).
7Fold the rear seat cushions forward.
Unscrew the mounting bolts from the seat belt
shackle and reel (see illustrations).
28 Seat belts -
removal and refitting
Bodywork and fittings 11•19
11
28.5B . . . unscrew the trim retaining
screws . . .28.5C . . . and unscrew the seat belt end
retaining bolt28.6A Detach the rear seat release cable
28.4A Front seat belt stalk cable
28.4B Front seat stalk mounting nut28.5A Remove the recline adjustment
knob . . .
28.2 Front seat belt reel unit lower
mounting bolt28.3A Front seat belt guide and mounting
bolt28.3B Front seat belt shackle and
mounting nut
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8Unscrew the mounting bolt securing the
seat belt stalk, and withdraw the stalk. Also
unscrew the mounting bolt from the lower
anchorage, where applicable (see
illustration).
Rear centre seat belt
9Unscrew the mounting bolts securing the
seat belt and stalks to the floor. Note that the
stalks are handed, and are marked Left or
Right.
Refitting
10Refitting is a reversal of the removal
procedure. Tighten the mounting nuts and
bolts to the specified torque.
Removal
Sun visor
1Disconnect the wiring for the vanity mirror
light, where fitted.
2Unscrew the mounting screws and remove
the visor.
3Prise up the cover, unscrew the inner
bracket mounting screws, and remove the
bracket.
Passenger grab handle
4Prise up the covers, then unscrew the
mounting screws and remove the grab
handle.
“A” pillar trim
5Pull away the door weatherstrip in the area
of the trim.
6Release the alarm and aerial wiring from the
upper and middle clips.
7Carefully press the trim away from the
upper and middle clips, and pull the trim
upwards. Recover the lower sealing strip.
8Remove the upper and middle clips from
the pillar.
“B” pillar and cowl side trim
9Pull away the door weatherstrip in the area
of the trim.
10Undo the screws, release the fasteners
and remove the lower trim (see illustrations).
11Carefully separate the lower trim from the
upper trim, using a screwdriver if necessary
(see illustration).
12Unscrew the seat belt mounting bolt from
under the front seat, remove the remaining
trim from the “B” pillar, and feed the belt
through the trim.
“C” pillar trim (Saloon and Hatchback)
13Pull away the door weatherstrip in the
area of the trim.
14Fold the rear seat cushion forwards.
15Pull up the rear seat bolster, and release
29 Interior trim panels-
removal and refitting
11•20 Bodywork and fittings
28.6B Removing the plastic cover from the
rear seat lock28.7A Rear seat belt shackle mounting
bolt28.7B Rear seat belt reel mounting bolt
29.10B Releasing the fasteners from the
cowl side trim29.11 Separating the “B” pillar lower and
upper trim
28.8 Rear seat belt lower anchorage29.10A Removing a middle screw from the
lower trim
29.15A Pull up the rear seat bolster . . .
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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 . . .
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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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Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2Remove the windscreen wiper arms
(Chapter 12), then remove the cowl from just
in front of the windscreen. The cowl is in two
sections, with retaining screws located along
its front edge. With the cowl removed,
disconnect the speedometer cable by pulling
it from the intermediate inner cable extension.
3Remove the centre console (Section 30),
then unscrew the screws and remove the
heater side covers (see illustrations).
4Remove the steering column (Chapter 10).
5Remove the instrument panel (Chapter 12).
6Where fitted, unscrew the screws and
remove the automatic warning system
display.
7Remove the radio and (if fitted) the CD
player (Chapter 12).
8Remove the heater control panel (Chap-
ter 3).
9Using a screwdriver, carefully prise out the
headlight switch panel, and disconnect the
wiring multi-plugs.
10Remove the glovebox (Section 32).
11Remove the small piece of carpet from
under the passenger side of the facia.
12Remove the side trim panels from the “A”and “B” pillars on each side of the vehicle
(Section 29). The upper panels on the “B”
pillars can be left in position.
13At the base of the right-hand “A” pillar,
disconnect the wiring multi-plugs, earth leads
and aerial, noting their fitted positions.
14Identify the position of the wiring multi-
plugs on the fusebox, then disconnect them.
15Disconnect the wiring from the footwell
lights, where fitted.
16Prise out the speedometer cable rubber
grommet at the bulkhead near the pedal
bracket, then release the cable from the clips.
17Remove the screws and withdraw the
glovebox side trim, for access to the side
facia mounting screw.
18Open the front doors. Prise off the trim
covers, then pull away the door weatherstrip
by the side mounting bolt positions on each
side (see illustrations).
19Unscrew the facia side mounting bolts.
20Unscrew the facia centre mounting bolts
(see illustrations).
21Withdraw the facia from the bulkhead, far
enough to be able to reach in behind it.
22Disconnect the remaining multi-plugs and
connections, noting their locations on the
various components for correct refitting. It will
also be necessary to release some wiring
loom holders, clips and plastic ties, and the
fresh air vent hoses (see illustration).
23Withdraw the facia from one side of the
vehicle.
33 Facia - removal and refitting
Bodywork and fittings 11•23
11
33.20B Facia mounting bolt next to the
glovebox33.20C Facia centre mounting bolt next to
the heater panel33.20D Facia mounting bolt near the
heater
33.3A Unscrew the screws . . .33.3B . . . and remove the heater side
covers33.18A Prise off the covers . . .
33.18B . . . and pull away the weatherstrip
to reveal the facia mounting bolts
33.20A Facia mounting bolt positions (left-
hand-drive shown, right-hand-drive
similar)
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