1993 FORD MONDEO auxiliary battery

remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer
such as Holts Damp Start, or a water-
dispersant lubricant such as Holts Wet Start.
Note:It is important to note that the ignition
switch and the appropriate electrical circuit
must always be switched off before any of the
fuses (or relays) are removed and renewed. In
the event of the fuse/relay unit having to be
removed, the battery earth lead must be
disconnected. When reconnecting the battery,
reference should be made to Chapter 5.
1Fuses are designed to break a circuit when
a predetermined current is reached, in order
to protect components and wiring which
could be damaged by excessive current flow.
Any excessive current flow will be due to a
fault in the circuit, usually a short-circuit (see
Section 2). The main fusebox, which also
carries some relays, is located inside the
vehicle below the facia panel on the
passenger’s side, and is accessed by a lever
behind the glovebox (see illustration).
2A central timer module is located on the
bottom of the main fusebox. This module
contains the time control elements for the
heated rear window, interior lights and
intermittent wiper operation. The module also
activates a warning buzzer/chime when the
vehicle is left with the lights switched on, or if
a vehicle fitted with automatic transmission is
not parked in position “P”.
3The auxiliary fusebox is located on the front
left-hand side of the engine compartment,
and is accessed by unclipping and removing
the cover. The auxiliary fusebox also contains
some relays (see illustration). Each circuit is
identified by numbers on the main fusebox
and on the inside of the auxiliary fusebox
cover. Reference to the fuse chart in the
Specifications at the start of this Chapter will
indicate the circuits protected by each fuse.
Plastic tweezers are attached to the main
fusebox and to the inside face of the auxiliary
fuse and block cover, to remove and fit the
fuses and relays.
4To remove a fuse, use the tweezers
provided to pull it out of the holder. Slide the
fuse sideways from the tweezers. The wire
within the fuse is clearly visible, and it will be
broken if the fuse is blown (see illustration).
5Always renew a fuse with one of an
identical rating. Never substitute a fuse of a
higher rating, or make temporary repairs using
wire or metal foil; more serious damage, or
even fire, could result. The fuse rating is
stamped on top of the fuse. Never renew a
fuse more than once without tracing the
source of the trouble.
6Spare fuses of various current ratings areprovided in the cover of the auxiliary fusebox.
Note that if the vehicle is to be laid up for a
long period, fuse 34 in the main fusebox
should be removed, to prevent the ancillary
electrical components from discharging the
battery.
7Relays are electrically-operated switches,
which are used in certain circuits. The various
relays can be removed from their respective
locations by carefully pulling them from the
sockets. Each relay in the fuseboxes has a
plastic bar on its upper surface to enable the
use of the tweezers. The locations and
3 Fuses, relays and timer
module- testing and renewal
Body electrical system 12•5
12
3.4 The fuses can be checked visually to
determine if they are blown
3.1 Main fusebox layout
1 Fuse/relay removal tweezers 2 Diode 3 Multi-plug connections
3.3 Auxiliary fusebox layout
1 Fuses 1 to 3 3 Relays R2, R5 and R6 5 Relay sockets for relays R1 and R4
2 Fuses 4 to 8, 11 to 14 4 Relays R7 to R11 6 Diode
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Main light, auxiliary foglight and rear
foglight combination switch
Note:From July 1994 a rvised main light
switch was introduced; this was fitted as
standard in production. If the revised switch is
to be fitted to a pre-July 1994 model, an
adapter lead will also be required to prevent
electrical damage ocurring. Refer to your Ford
dealer for further information
9Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
10Carefully prise the switch panel from the
facia, using a screwdriver against a cloth pad
to prevent damage to the facia (see
illustration).
11Disconnect the multi-plugs and withdraw
the switch panel (see illustration).
12Unscrew the four mounting screws, and
remove the switch from the panel.
13Pull off the switch control knob, and
remove the blanking plug and retainer.
14Depress the plastic tabs, and remove the
front cover and switch.
Instrument light rheostat
15Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
16Carefully prise the light switch panel from
the facia, using a screwdriver against a cloth
pad to prevent damage to the facia.
17Disconnect the multi-plugs from the rear
of the switch, then remove the screws and
withdraw the instrument light rheostat from
the panel.
Door mirror control switch
18Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
19Carefully prise the switch from the facia,
using a screwdriver against a cloth pad to
prevent damage to the facia.
20Disconnect the multi-plug and withdraw
the switch.
Direction indicator, dipped beam and
hazard flasher multi-function switch
21Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
22Remove the rubber gaiters and locking
rings, then remove the screws and take off the
steering column upper shroud.23Depress the retaining lug and withdraw
the switch assembly, then disconnect the
multi-plug (see illustration).
24With the switch assembly removed, pull
out the direction indicator relay if required.
Horn switch (steering wheel without
air bag)
Note:When an air bag is fitted, the horn
switch is removed with the air bag unit. Refer
to Section 28.
25Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
26Carefully pull off the padded centre of the
steering wheel which incorporates the horn
switch.
27Disconnect the wiring and remove the
switch assembly.
Luggage compartment switch
28Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
29With the tailgate/bootlid open, pull the
weatherstrip from the centre of the rear cross
panel.
30Carefully prise out the trim fasteners from
the bottom corners of the rear trim, then
unscrew the retaining screws and remove the
trim panel.
31Disconnect the wiring multi-plug, and pull
out the switch.
Electrically-operated window switch
(single)
32Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
33Carefully prise out the switch from the
door inner trim panel, using a cloth pad to
prevent damage to the trim.
34Disconnect the multi-plug and remove the
switch.
Electrically-operated window switch
(multiple) and isolator
35Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
36Prise the blanking cap from inside the
inner door handle cavity, and remove the
screw.
37Hold the inner door handle in its open
position, then remove the bezel and withdraw
it over the handle.38Depress the retaining lug and remove the
switch assembly, then disconnect the multi-
plug.
Electrically-operated sunroof switch
and traction control switch
39Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
40Carefully prise out the switch with a
screwdriver, using a cloth pad to prevent
damage to the trim.
41Disconnect the multi-plug and remove the
switch.
Handbrake-on warning switch
42Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
43Remove the centre console as described
in Chapter 11.
44Disconnect the multi-plug, then remove
the screw and withdraw the switch from the
handbrake lever mounting bracket (see
illustration).
“Economy/Sport” mode switch
(automatic transmission models)
45Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
46Select Neutral, then prise out the selector
indicator panel, using a cloth pad to prevent
damage to the surrounding trim.
47Push the switch out of the panel, and
disconnect the multi-plug.
Body electrical system 12•7
12
4.44 Disconnecting the multi-plug from
the handbrake lever
4.10 Prising out the light switch4.11 Disconnecting the multi-plugs from
the light switch and rheostat4.23 Removing the direction indicator,
dipped beam and hazard flasher multi-
function switch. Direction indicator relay
(flasher unit) is attached
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8Disconnect the wiper motor multi-plug.
9Withdraw the wiper motor, complete with
the linkage, from the bulkhead (see
illustration).
10Mark the position of the motor arm on the
mounting plate, then unscrew the centre nut
(see illustration).
11Unscrew the motor mounting bolts, and
separate the motor from the linkage assembly.
Refitting
12Refitting is a reversal of the removal
procedure. There are two tightening torques
for the motor mounting bolts - the lower one
for bolts that are being re-inserted into an old
motor, and the higher ones for bolts that are
being inserted into a new motor. Make sure
that the wiper motor is in its “parked” position
before fitting the motor arm, and check that
the wiper linkage is in line with the motor arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Remove the tailgate wiper arm as
described in Section 15.
3Remove the tailgate inner trim panel by
unscrewing the retaining screws.
4Release the multi-plug from the clip, then
disconnect it (see illustration).5Disconnect the wiper motor earth lead.
6Unscrew the mounting bolts, and remove
the wiper motor from inside the tailgate (see
illustrations).
7Unbolt and remove the mounting plate. If
necessary, remove the mounting rubbers for
renewal (see illustrations).
Refitting
8Refitting is a reversal of the removal
procedure. Make sure that the wiper motor is
in its “parked” position before fitting the wiper
arm.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2Using a small screwdriver, prise the trip
computer module out of the facia. To prevent
damage to the facia, place a cloth pad
beneath the screwdriver.
3Disconnect the multi-plug from the rear of
the trip computer module, and withdraw the
unit.
4If necessary, the bulb can be removed by
twisting it anti-clockwise.
Refitting
5Refitting is a reversal of the removal
procedure.1Some models are fitted with an auxiliary
warning system, which monitors brake lights,
sidelights, dipped beam and tail lights,
external temperature, and door/tailgate/
bootlid opening. An engine oil level warning
light on the instrument panel is also part of the
system.
2The auxiliary warning system module and
graphic warning display are combined into
one unit.
Service interval reminder
3The system also includes a service interval
reminder warning light, which is illuminated if
19 Auxiliary warning system -
general information and
component renewal
18 Trip computer module-
removal and refitting
17 Tailgate wiper motor
assembly - removal and refitting
Body electrical system 12•17
12
17.6B . . . and remove the tailgate wiper
motor assembly (Hatchback shown -
Estate similar)17.7A Tailgate wiper motor assembly and
mounting plate17.7B A mounting rubber removed from
the mounting plate
17.6A Unscrew the mounting bolts . . .
16.9 Removing the wiper motor and
linkage16.10 Wiper motor arm and mounting
plate located on the motor17.4 Disconnecting the tailgate wiper
motor multi-plug
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the specified mileage (or time) since the last
service has been reached.
4To reset the service interval system and
turn off the light, a switch inside the glovebox
must be depressed for a minimum of 4
seconds with the ignition switched on. This
should be carried out by a Ford dealer if the
vehicle is still in the warranty period.
Component renewal
5The following paragraphs describe brief
removal procedures for the auxiliary warning
system components. Disconnect the battery
negative (earth) lead before commencing
work (refer to Chapter 5, Section 1). Refitting
procedures are a reversal of removal.
Display warning bulb
6Remove the control assembly.
7Prise off the cover, and pull out the relevant
bulb and bulbholder.
Low air temperature warning sender
unit
8Remove the front bumper.
9Unclip the sender unit and disconnect the
multi-plug (see illustration).
Engine oil level sensor
10Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
11Place a container beneath the oil level
sensor, to catch any spilt oil.12Unscrew the screws and remove the
cover from the sensor.
13Disconnect the multi-plug.
14Unscrew and remove the sensor, and
remove the seal (see illustration).
Door ajar sensor
15Remove the door lock as described in
Chapter 11, Section 14.
16Unclip the sensor and disconnect the
multi-plug.
Low coolant warning switch
17Refer to Chapter 3, Section 6.
Low washer fluid switch
18Disconnect the multi-plug from the
washer fluid reservoir.
19Drain or syphon out the fluid from the
reservoir.
20Using a screwdriver, lever out the switch
from the reservoir (see illustration).
Service indicator reset switch
21Remove the glove compartment lid as
described in Chapter 11, Section 32.
22Carefully lever out the switch using a
small screwdriver.
23Remove the rear cover and disconnect
the wiring (see illustration).
Control assembly
24Remove the instrument panel surround,
referring to Section 10.25Unscrew the mounting screws,
disconnect the multi-plugs and remove the
assembly.
Bulb failure module
26Remove the lower facia panel from under
the steering wheel.
27Unclip the bulb failure module and
disconnect the multi-plug.
Note: From November 1993, for added
security, a complex Bosch immobiliser system
was fitted to some models. For further details,
refer to your Ford dealer.
1All UK models are fitted with an anti-theft
alarm system, incorporating movement
sensors and an ignition immobiliser. The
system is activated when the vehicle is
locked.
2The system includes a start inhibitor circuit,
which makes it impossible to start the engine
with the system armed.
3The movement sensors consist of two
ultrasonic units, located in the “B” pillars,
incorporating transmitters and receivers (see
illustrations). The receivers check that the
echo frequency matches the original
frequency. If there is any significant
difference, the system triggers the alarm.
20 Anti-theft alarm system- general
information
12•18 Body electrical system
19.9 Low air temperature sender unit
removal
1 Clip 2 Sender unit 3 Multi-plug19.14 Engine oil level sensor removal
1 Cover 2 Multi-plug 3 Sensor 4 Seal19.20 Removing the low washer fluid
switch
19.23 Service indicator switch removal
1 Lever out the switch 2 Cover 3 Wiring20.3A Disconnecting a movement sensor
multi-plug20.3B Removing a movement sensor
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REF•12
Battery will not hold a charge more than a few days
m mBattery defective internally (Chapter 5).
m mBattery electrolyte level low (Chapter 1).
m mBattery terminal connections loose or corroded (Chapter 5).
m mAuxiliary drivebelt worn or incorrectly-adjusted (Chapter 1).
m mAlternator not charging at correct output (Chapter 5).
m mAlternator or voltage regulator faulty (Chapter 5).
m mShort-circuit causing continual battery drain (Chapters 5 and 12).
Ignition (no-charge) warning light remains
illuminated with engine running
m mAuxiliary drivebelt broken, worn, or incorrectly-adjusted (Chapter 1).
m mAlternator brushes worn, sticking, or dirty (Chapter 5).
m mAlternator brush springs weak or broken (Chapter 5).
m mInternal fault in alternator or voltage regulator (Chapter 5).
m mBroken, disconnected, or loose wiring in charging circuit (Chapter 5).
Ignition (no-charge) warning light fails to come on
m
mWarning light bulb blown (Chapter 12).
m mBroken, disconnected, or loose wiring in warning light circuit
(Chapters 5 and 12).
m mAlternator faulty (Chapter 5).
Lights inoperative
m
mBulb blown (Chapter 12).
m mCorrosion of bulb or bulbholder contacts (Chapter 12).
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken, loose, or disconnected wiring (Chapter 12).
m mFaulty switch (Chapter 12).
Instrument readings inaccurate or erratic
Instrument readings increase with engine speed
m
mFaulty voltage regulator (Chapter 12).
Fuel or temperature gauges give no reading
m
mFaulty gauge sender unit (Chapters 3 or 4).
m mWiring open-circuit (Chapter 12).
m mFaulty gauge (Chapter 12).
Fuel or temperature gauges give continuous maximum reading
m mFaulty gauge sender unit (Chapters 3 or 4).
m mWiring short-circuit (Chapter 12).
m mFaulty gauge (Chapter 12).
Horn inoperative, or unsatisfactory in operation
Horn fails to operate
m
mBlown fuse (Chapter 12).
m mCable or cable connections loose, broken or disconnected (Chapter 12).
m mFaulty horn (Chapter 12).
Horn emits intermittent or unsatisfactory sound
m
mCable connections loose (Chapter 12).
m mHorn mountings loose (Chapter 12).
m mFaulty horn (Chapter 12).
Horn operates all the time
m
mHorn push either earthed or stuck down (Chapter 12).
m mHorn cable to horn push earthed (Chapter 12).
Windscreen/tailgate wipers inoperative or
unsatisfactory in operation
Wipers fail to operate, or operate very slowly
m mWiper blades stuck to screen, or linkage seized or binding (Chapter 12).
m mBlown fuse (Chapter 12).
m mCable or cable connections loose, broken or disconnected (Chapter 12).
m mFaulty relay (Chapter 12).
m mFaulty wiper motor (Chapter 12).
Wiper blades sweep over too large or too small an area of
the glass
m mWiper arms incorrectly-positioned on spindles (Chapter 1).
m mExcessive wear of wiper linkage (Chapter 1).
m mWiper motor or linkage mountings loose or insecure (Chapter 12).
Wiper blades fail to clean the glass effectively
m
mWiper blade rubbers worn or perished (Chapter 1).
m mWiper arm tension springs broken, or arm pivots seized (Chapter 1).
m mInsufficient windscreen washer additive to adequately remove road
film (Chapter 1).
Windscreen/tailgate washers inoperative, or
unsatisfactory in operation
One or more washer jets inoperative
m mBlocked washer jet (Chapter 1).
m mDisconnected, kinked or restricted fluid hose (Chapter 1).
m mInsufficient fluid in washer reservoir (Chapter 1).
Washer pump fails to operate
m
mBroken or disconnected wiring or connections (Chapter 12).
m mBlown fuse (Chapter 12).
m mFaulty washer switch (Chapter 12).
m mFaulty washer pump (Chapter 12).
Washer pump runs for some time before fluid is emitted
from jets
m mFaulty one-way valve in fluid supply hose (Chapter 12).
Electric windows inoperative, or unsatisfactory in
operation
Window glass will only move in one direction
m mFaulty switch (Chapter 12).
Window glass slow to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m mRegulator seized or damaged, or in need of lubrication (Chapter 11).
m mDoor internal components or trim fouling regulator (Chapter 11).
m mFaulty motor (Chapter 12).
Window glass fails to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken or disconnected wiring or connections (Chapter 12).
m mFaulty motor (Chapter 12).
Central locking system inoperative, or
unsatisfactory in operation
Complete system failure
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken or disconnected wiring or connections (Chapter 12).
Latch locks but will not unlock, or unlocks but will not lock
m
mFaulty master switch (Chapter 11).
m mBroken or disconnected latch operating rods or levers (Chapter 11).
m mFaulty relay (Chapter 12).
One lock motor fails to operate
m
mBroken or disconnected wiring or connections (Chapter 12).
m mFaulty lock motor (Chapter 11).
m mBroken, binding or disconnected latch operating rods or levers
(Chapter 11).
m mFault in door latch (Chapter 11).
Fault Finding
10 Electrical system
Note:For problems associated with the starting system, refer to the faults listed under “Engine”earlier in this Section.
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REF•17Index
A
A pillar trim - 11•20
ABS - 9•14
Accelerator cable - 4•4
Accelerator pedal - 4•5
Accumulator - 3•9
Acknowledgements - 0•4
Adaptive damping switch - 12•8
Aerial - 12•22
Air bag - 0•5, 1•22, 12•22
Air cleaner - 4•3, 6•19
Air conditioning - 1•15, 3•2, 3•8, 3•9, 6•11
Air distribution control - 3•8
Air induction system - 4•9
Air intake components - 4•3
Air mass meter - 4•3, 6•10, 6•11, 6•12
Air temperature warning sender unit -
12•18
Alarm - 11•17, 12•18
Alternator - 5•5, 5•6
Amplifier - 12•21
Anti-lock Braking System - 9•14
Anti-roll bar - 10•8, 10•12, 10•15
Anti-theft alarm system - 12•18
Antifreeze - 1•2, 1•22, 3•2
Asbestos - 0•5
ATF - 1•2
Automatic transmission- 1•11, 1•17,
2A•24, 2B•3, 2B•4, 6•11, 7B•1et seq,
12•11
Automatic transmission fault finding -
REF•10
Automatic transmission fluid - 1•2
Auxiliary drivebelt - 1•13
Auxiliary warning system - 12•17
B
B pillar trim - 11•20
Backfire - REF•8
Backrest - 11•18
Battery - 0•5, 1•8, 1•11, 5•2, 5•3
Battery fault - REF•12
Big-end bearings - 2B•18, 2B•21
Bleeding brakes - 9•12
Bleeding power steering - 10•21
Blower/air conditioning control - 3•8Body corrosion - 0•10
Body electrical system- 12•1et seq
Bodywork and fittings- 11•1et seq
Bonnet - 1•20, 11•5, 11•6
Booster battery (jump) starting - 0•12
Boot - 11•14, 11•15
Brake check - 1•19
Brake fluid - 1•2, 1•8, 1•26
Brake line check - 1•19
Braking system- 0•7, 0•8, 0•9, 1•20, 9•1et
seq
Braking system fault finding - REF•10
Brush renewal - 5•8
Bulb failure module - 12•18
Bulbs - 12•8, 12•11, 12•18
Bumpers - 11•4, 11•5
Burning - 0•5
C
C pillar trim - 11•20, 11•21
Cables - 4•4, 7B•2, 8•2, 9•16, 11•6, 12•15
Calipers - 9•4, 9•9
Camshaft - 2A•13, 2A•14, 6•11, 6•12
Cassette player - 12•21
Catalytic converter - 6•19
CD player - 12•22
Central locking system - 11•17
Central locking system fault - REF•12
Centre console - 11•21
Charcoal canister - 6•14
Charging - 1•12, 5•5
Check strap - 11•13
Clock - 12•11, 12•15
Clutch and driveshafts- 1•17, 1•20, 8•1et
seq
Clutch fault finding - REF•9
CO emissions (mixture) - 0•10
Coil spring - 10•15
Compact disc player - 12•22
Compression test - 2A•5
Compressor - 3•9
Condenser - 3•9
Connecting rods - 2B•12, 2B•17, 2B•21,
2B•22
Console - 11•21, 11•22
Contents - 0•2
Conversion factors - 0•14Coolant - 1•2, 1•6, 1•7, 1•21
Coolant leakage - REF•9
Coolant low level switch - 3•5
Coolant temperature gauge sender - 3•4
Coolant temperature sensor - 3•5, 6•11,
6•13
Coolant warning switch - 12•18
Cooling, heating, and air conditioning
systems- 1•22, 3•1et seq
Cooling, heating, and air conditioning
systems fault finding - REF•8
Corrosion - REF•9
Courtesy light - 12•8
Crankcase - 2B•13
Crankshaft - 2A•9, 2A•13, 2A•22, 2B•13,
2B•18, 2B•20, 5•4, 6•10, 6•11, 6•12
Crossmember - 10•13, 10•17
Cruise control system - 12•19
Crushing - 0•5
Cushion - 11•18
CV joints - 1•18, 8•7, 8•9
Cylinder block - 2B•13
Cylinder head - 2A•6, 2A•17, 2B•9, 2B•10,
2B•11, 6•19
D
D pillar trim - 11•21
Damping switch - 12•8
Dehydrator - 3•9
Dents in bodywork - 11•3
Depressurisation - 4•2
Diagnosis system - 6•4
Differential - 7A•2, 7B•3
Dimensions - 0•6
Dipped beam switch - 12•7
Direction indicators - 12•7, 12•9, 12•12
Discs - 1•19, 9•5, 9•10
Display warning bulb - 12•18
Doors - 0•8, 1•20, 11•6, 11•7, 11•8, 11•9,
11•10, 11•11, 11•13, 12•7, 12•8, 12•11,
12•18
Drivebelts - 1•13
Driveplate - 2A•24
Driveshafts - 0•9, 1•18, 8•5, 8•6, 8•7, 8•9,
8•10
Driveshafts fault finding - REF•10
Drivetrain - 1•20
Drums - 1•19, 9•6 Note: References throughout this index relate to Chapter•page number
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