1993 FORD MONDEO set clock

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
procarmanuals.com

located above the front direction indicator
(see illustration).
11Withdraw the front direction indicator light
unit.
12Rotate the bulbholder anti-clockwise, and
withdraw it from the light unit. Alternatively,
the wiring plug can be disconnected from the
bulbholder, leaving the bulb in position (see
illustration). Remove the light unit.
Foglight (front)
13Unscrew the cross-head screws securing
the front foglight unit to the valance, and
withdraw the light unit from the valance.
14Prise open the plastic clips, and remove
the rear cover from the light unit.
15Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
Remove the foglight unit.
Rear light cluster
16With the tailgate or bootlid open, unhook
the parcel net (where fitted) from the rear of
the luggage compartment.
17On Saloon and Hatchback models,
remove the screws, release the clips, and
remove the trim panel from the rear cross
panel. On Estate models, it is sufficient to
open the flap.
18Remove the screws, and press the rear
light trim cover from the guides (where
applicable).
19Disconnect the wiring multi-plug.
20Unscrew the four mounting nuts, and
withdraw the light unit from the outside of the
vehicle (see illustrations).
Rear number plate light assembly
21Remove both number plate lights as
described in Section 5.
22With the tailgate or bootlid open, remove
the screws and withdraw the inner trim panel.
23Unscrew the nuts, and remove the outer
cover and number plate base from the
tailgate.
24Disconnect the multi-plug and remove the
light assembly.
Refitting
25Refitting of all the external light units is a
reversal of the removal procedure, noting the
following points:(a) When refitting the rubber seal on the
headlight unit, note that it has a tapered
seat.
(b) If one or both headlights have been
disturbed, have the beam alignment
checked as described in the next Section.
(c) When refitting the rear light cluster, check
the condition of the sealer on the body
panel, and if necessary renew it.
1Accurate adjustment of the headlight beam
is only possible using optical beam-setting
equipment. This work should therefore be
carried out by a Ford dealer, or other service
station with the necessary facilities.
2Temporary adjustment can be made after
renewal of a headlight bulb or unit, or as an
emergency measure if the alignment is
incorrect following accident damage. Turn the
adjustment screws on the top of the headlamp
unit to make the adjustment (see illustration).
3Before making any adjustments to the
settings, it is important that the tyre pressures
are correct, and that the vehicle is standing on
level ground. Bounce the front of the vehicle a
few times to settle the suspension. Ideally,
somebody of average size should sit in the
driver’s seat during the adjustment, and the
vehicle should have a full tank of fuel. Where a
vehicle is fitted with an electrical beam
levelling system, set the switch to the “O”
position before making any adjustments.4Whenever temporary adjustments are
made, the settings must be checked and if
necessary reset by a Ford dealer or other
qualified person as soon as possible.
Removal
1Remove the headlight unit as described in
Section 7, then remove the cover.
2Disconnect the wiring multi-plug from the
motor.
3Rotate the motor upwards approximately
60°, then pull it forwards slightly.
4Disconnect the adjustment spindle by
pressing the ball coupling to one side, away
from the socket on the reflector.
5Withdraw the motor from the headlight unit.
Refitting
6Refitting is a reversal of the removal
procedure, but make sure that the motor is
turned down until it engages the stop.
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
10 Instrument panel -
removal and refitting
9 Headlight levelling motor -
removal and refitting
8 Headlight beam alignment-
checking and adjustment
Body electrical system 12•13
12
7.20B Removing the rear light cluster unit
8.2 Headlight beam setting adjustment
screws
1 Vertical alignment screw
2 Horizontal alignment screw
7.10 Loosen the front direction indicator
retaining screw7.12 Disconnecting the wiring plug from
the indicator bulbholder7.20A Rear light cluster mounting nuts
(arrowed)
procarmanuals.com

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 . . .
procarmanuals.com

switches mounted in the engine compartment
with a control cable connected to the throttle
valve actuator, driver-operated switches,
brake and clutch pedal switches, an indicator
light, and a road speed sensor.
4The driver-operated switches are mounted
on the steering wheel, and allow the driver to
control the various functions.
5The vehicle speed sensor uses the
speedometer cable drive pinion to generate
pulses which are fed to the speed control unit.
6The stop-light switch, brake pedal switch
and (when applicable) clutch pedal switch are
used to disable the cruise control system. The
stop-light switch is activated when the brake
pedal is applied gently, and the brake pedal
switch is activated when the brake pedal is
applied forcibly.
7An indicator light on the instrument panel is
illuminated when the system is in operation.
8The following paragraphs describe brief
removal procedures for the cruise control
system components. The battery negative
(earth) lead should be disconnected before
commencing work (refer to Chapter 5, Sec-
tion 1). Refitting is a reversal of removal.
Speed control switch
9Remove the steering column upper and
lower shrouds, with reference to Chapter 10.
10Remove the air bag module as described
in Section 29.11Disconnect the multi-plugs, then unscrew
the screws and remove the switch.
Disable switches
12Remove the lower facia panel from under
the steering column.
13Disconnect the multi-plugs from the
clutch switch, brake pedal switch and stop-
light switch.
14To remove the clutch and brake pedal
switches, twist them anti-clockwise. To
remove the stop-light switch, twist it
clockwise (see illustration).
15Refitting is the reverse of removal. To
ensure correct operation of the brake pedal
switches, reset the switch by fully extending
its plunger (see illustration).Depress the
pedal until the distance between it and the
mounting bracket is as shown in Chapter 9,
illustration 25.6. Hold the pedal in this
position, clip the switch securely into position
and gently raise the pedal to the at-rest
position. This will automatically set the
position of the switch.
Speed control actuator
16Remove the air cleaner as described in
Chapter 4.
17Disconnect the actuator cable from the
throttle linkage on the throttle housing, by
releasing the inner cable end fitting from the
segment and unclipping the outer cable from
the bracket.
18Unscrew the actuator mounting bolt, thenslide the actuator out of the mounting pin
holes.
19Disconnect the multi-plug and remove the
assembly.
20Depress the actuating cable cap locking
arm, and remove the cap by turning it anti-
clockwise (see illustration).
21Gently raise the cable retaining lug by a
maximum of 0.5 mm, and push the cable end
out of the slot in the pulley.
22When refitting, make sure that the cable
end locks into the slot in the pulley.
23To locate the cable cap onto the actuator
pulley, keep the cable taut and in the pulley
groove, and pull the throttle linkage end of the
cable to draw the cable cap onto the pulley.
24To refit the cable cap, keep the cable taut
and the pulley still, then refit the cable cap
tabs into the actuator slots; turn the cap
clockwise until the locking arm locates on the
locking stop. Note:Incorrect assembly of the
cable onto the pulley may result in a high idle
speed. Check that the throttle lever is in its
idle position after refitting the actuator.
Removal
Washer reservoir and pump
1Unscrew the bolts, and release the clips to
remove the radiator lower cover.
2Unscrew the mounting bolts, and pull the
reservoir forwards slightly (see illustration).
For better access, it may be necessary to
remove the front bumper.
3Disconnect the multi-plugs for the
windscreen washer pump and fluid level
sensor (see illustration).
4Disconnect the hoses from the windscreen
washer pump and (where applicable) from the
headlamp washer pump. Anticipate some loss
of fluid by placing a container beneath the
reservoir.
5Withdraw the reservoir from the vehicle.
6Pull the level sensor, the windscreen
washer pump, and (where applicable) the
22 Windscreen/tailgate washer
system components -
removal and refitting
12•20 Body electrical system
21.14 Removal of the speed control
disable switches
1 Clutch switch 3 Stop-light switch
2 Brake pedal switch21.15 Resetting the brake pedal and stop-
light switches21.20 Removing the actuator cable
locking arm
22.2 Washer reservoir mounting bolts
(arrowed)22.3 Disconnecting the washer pump and
level sensor multi-plugs
procarmanuals.com

1A compact disc (CD) player is available as
an optional extra on most models. On some
models, an autochanger version is available,
which can hold a number of discs at a time.
Removal
2The battery negative (earth) lead should be
disconnected before commencing work.
CD player, or autochanger control
unit
3The procedure is identical to that for the
radio/cassette player described in Section 23.
CD player autochanger
4The CD player autochanger unit is mounted
on the right-hand side of the luggage
compartment. The wiring loom passes up the
“C” pillar, across to the left-hand side “A”
pillar, then to the centre console area.
5Remove the trim cover from the
autochanger unit.
6Unscrew the mounting screws, and remove
the autochanger unit from its mounting
bracket.
7Disconnect the multi-plug and remove the
unit from inside the vehicle.
Refitting
8Refitting is a reversal of the removal
procedure.
Removal
1Remove the door trim panel as described in
Chapter 11.
2Unscrew the cross-head screws, and
withdraw the speaker from the door inner
panel.
3Disconnect the wiring and remove the
speaker.
Refitting
4Refitting is a reversal of the removal
procedure.
Removal
1Prise out the trim cover from the headlining
immediately below the base of the aerial.
2Unscrew the cross-head screw from the
base of the aerial, and remove the aerial mast.
Refitting
3Refitting is a reversal of the removal
procedure.
Warning: Handle the air bag unit
with extreme care, as a
precaution against personal
injury, and always hold it with the
cover facing away from the body. If in
doubt concerning any proposed work
involving the air bag unit or its control
circuitry, consult a Ford dealer or other
qualified specialist.
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.
2Rotate the steering wheel so that one of the
mounting bolt holes is visible above the
steering column upper shroud.
3Unscrew and remove the first mounting
bolt, then turn the steering wheel as
necessary and remove the remaining
mounting bolts (see illustration).
4Carefully withdraw the air bag unit from the
steering wheel far enough to disconnect the
wiring multi-plug, then remove it from inside
the vehicle (see illustration). Warning: Stand the unit with the
cover uppermost, and do not
expose it to heat sources in
excess of 100ºC.
Warning: Do not attempt to open
or repair the air bag unit, or apply
any electrical current to it. Do not
use any air bag unit which is visibly
damaged or which has been tampered
with.
Refitting
5Refitting is a reversal of the removal
procedure.
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.
2Remove the facia panel as described in
Chapter 11.
3Disconnect the multi-plug from the module,
by pressing the locking tab upwards and
swivelling the retaining strap.
4Unscrew the mounting bolts and remove
the module from the vehicle.
Refitting
5Refitting is a reversal of the removal
procedure.
Removal
1Remove the air bag unit as described in
Section 28.
2Disconnect the horn switch multi-plug.
3If fitted, disconnect the multi-plugs for the
cruise control.
4Remove the steering wheel and shrouds.
5Using a small screwdriver, release the
retaining tabs, then remove the clock spring
from the steering column.
Refitting
6Refitting is a reversal of the removal
procedure, but make sure that the steering
wheel is centralised. The clock spring must be
fitted in its central position, with the special
alignment marks aligned and the TOP mark
uppermost. To check for this position, turn the
clock spring housing anti-clockwise until it is
tight, then turn in the opposite direction by
two-and-three-quarter turns.
30 Air bag clock spring-
removal and refitting
29 Air bag control module -
removal and refitting
28 Air bag unit (driver’s side) -
removal and refitting
27 Radio aerial -
removal and refitting
26 Speakers -
removal and refitting
25 Compact disc player -
removal and refitting
12•22 Body electrical system
28.3 Unscrewing an air bag mounting bolt28.4 Disconnecting the air bag wiring
multi-plug (arrowed)
procarmanuals.com

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
procarmanuals.com