1993 FORD MONDEO sunroof

Chapter 11 Bodywork and fittings
Body side-trim mouldings and adhesive emblems - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . 8
Bonnet lock - removal, refitting and adjustment . . . . . . . . . . . . . . . . 10
Bonnet release cable and lever - removal and refitting . . . . . . . . . . . 9
Boot lid - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Boot lid lock components - removal and refitting . . . . . . . . . . . . . . . 19
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Central locking system components - testing, removal and refitting . 23
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 30
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Door handle and lock components - removal and refitting . . . . . . . . 14
Door inner trim panel - removal and refitting . . . . . . . . . . . . . . . . . . 11
Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . . 12
Door window regulator - removal and refitting . . . . . . . . . . . . . . . . . 13
Exterior mirror and glass - removal and refitting . . . . . . . . . . . . . . . . 16
Facia - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Glovebox - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Interior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 17
Interior trim panels - removal and refitting . . . . . . . . . . . . . . . . . . . . 29
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . 2
Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . 3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhead console - removal and refitting . . . . . . . . . . . . . . . . . . . . . 31
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7
Seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Seats - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sunroof - general information and adjustment . . . . . . . . . . . . . . . . . 26
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tailgate lock components - removal and refitting . . . . . . . . . . . . . . . 22
Tailgate support strut - removal and refitting . . . . . . . . . . . . . . . . . . 21
Wheel arch liner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 34
Windscreen and fixed windows - removal and refitting . . . . . . . . . . 24
Torque wrench settingsNm lbf ft
Bonnet and tailgate hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Boot lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Front seat mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28
Seat belt mounting nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28
Bumper mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
11•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
11
The bodyshell and underframe on all
models is of all-steel welded construction,
incorporating progressive crumple zones at
the front and rear, and a rigid centre safety
cell. The bulkhead behind the engine
compartment incorporates crash grooves
which determine its energy-absorption
characteristics, and special beams to prevent
the intrusion of the front wheels into the
passenger compartment during a serious
accident. All passenger doors incorporate
side impact bars.
All sheet metal surfaces which are prone tocorrosion are galvanized. The painting
process includes a base colour which closely
matches the final topcoat, so that any stone
damage is not noticeable.
Hatchback, Saloon and Estate versions are
available. The front section of the vehicle up to
the “B” pillar is identical on all models.
Automatic seat belts are fitted to all models,
and the front seat belt stalks are mounted on
automatic tensioners (also known as
“grabbers”) (see illustration). In the event of a
serious front impact, a spring mass sensor
releases a coil spring which pulls the stalk
buckle downwards and tensions the seat belt.
It is not possible to reset the tensioner once
fired, and it must therefore be renewed.
In the UK, central locking is standard on all
1 General information
1.4 Automatic seat belt tensioner
1 Coil spring 3 Spring mass sensor
2 Lever system
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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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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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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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Wiring diagrams 12•47
12
Diagram 23: Electric sunroof and (front and rear) electric windows
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REF•19Index
Oil pressure warning light switch - 2A•22
Oil pump - 2A•21
Oil seals - 2A•13, 2A•22, 7A•2, 7B•3, REF•4
Oil separator - 6•19
Open-circuit - 12•4
Overcooling - REF•8
Overhead console - 11•22
Overheating - REF•8
Oxygen sensor - 6•11, 6•12, 6•13
P
Pads - 9•3, 9•8
Pedals - 1•17, 4•5, 8•3, 9•10, 9•11
Piston rings - 2B•19
Pistons - 2B•12, 2B•17, 2B•21, 2B•22
Pitching and/or rolling around corners -
REF•11
Plastic components - 11•4
Plenum chamber - 4•3
Poisonous or irritant substances - 0•5
Pollen filter - 1•20, 3•8
Position sensor - 5•4, 6•10, 6•11, 6•12
Positive Crankcase Ventilation (PCV)
system - 1•23, 6•18, 6•19
Power steering - 1•8, 1•10, 6•11, 6•12,
6•13, 10•20, 10•21, 10•22
Power steering fluid - 1•2
Pressure-control relief valve - 9•13
Pressure-cycling and pressure-regulating
switches - 3•10
Project vehicles - 0•4
Pulse-air - 6•17, 6•18
Purge solenoid valve - 6•14
R
Radiator - 3•4, 3•5
Radiator grille - 11•5
Radio - 12•21, 12•22
Radio aerial - 12•22
Reading light - 12•11
Rear light cluster - 12•9, 12•13
Rear window - 12•8, 12•21
Relays - 12•5
Repair procedures - REF•4
Resonator (engine compartment) - 4•3
Respraying - 11•3
Reversing light switch - 7A•3
Road test - 1•20
Roadwheels - 1•17, 1•18, 1•20
Roll-over valves - 4•8
Routine maintenance and servicing- 1•1et
seq
Rubber gaiters- 1•18, 8•7, 8•9, 10•21
Rust holes in bodywork - 11•3
S
Safety first! - 0•5
Scalding - 0•5
Scratches in bodywork - 11•3
Screw threads and fastenings - REF•4
Seat belts - 0•8, 1•13, 11•19, 11•20Seats - 0•8, 11•18, 12•8
Selector assembly - 7B•2
Selector cable - 7B•2
Selector lever position sensor - 7B•2
Selector panel illumination - 12•11
Service indicator - 12•17, 12•18
Servo unit - 9•12, 9•13
Shock absorbers - 0•8, 0•9, 10•14
Shoes - 9•6
Short-circuit - 12•4
Sidelight - 12•9
Solenoid renewal - 5•8
Spare parts - REF•5
Spark plugs - 1•23
Speakers - 12•22
Speed control - 12•20
Speed sensor - 6•11, 6•12, 6•13
Speedometer - 7A•2, 7A•3, 7B•2, 7B•3,
12•15
Springs - 0•9
Starter motor - 5•7
Starter motor fault - REF•7
Starting system - 5•6
Steering - 0•7, 0•8, 0•9, 1•17, 1•20
Steering angles - 10•22
Steering column - 10•18, 10•20
Steering fault - REF•11
Steering knuckle - 10•5
Steering wheel - 10•17
Stop-light switch - 9•15
Striker - 11•13
Struts - 10•6, 10•7, 10•10, 10•12
Sump - 2A•19
Sun visor - 11•20
Sunroof - 11•18, 12•7
Suspension and steering systems- 0•8,
0•9, 1•17, 1•18, 1•20, 10•1et seq
Suspension and steering systems fault
finding - REF•11
Switches - 2A•22, 3•4, 3•5, 3•10, 4•8-
6•11, 6•12, 6•13, 7A•3, 9•15, 11•17,
12•6, 12•7, 12•8, 12•11, 12•18, 12•20
T
Tailgate - 1•8, 1•10, 11•15, 11•16, 12•17,
12•20, REF•12
Tappets - 2A•14
TCS inhibitor switch - 9•15
TCS throttle actuator - 9•15
Temperature gauge fault - REF•12
Thermostat - 3•3, 3•4
Throttle actuator - 9•15
Throttle housing - 4•9
Throttle potentiometer - 6•11, 6•13
Tie-bar - 10•13, 10•16
Timer module - 12•5
Timing - 5•4, 6•10
Timing belt - 1•26, 2A•10, 2A•13
Tools - REF•1, REF•3, REF•4
Top Dead Centre (TDC) for No 1 piston -
2A•6
Towing - 0•11
Track rod end - 10•22Traction Control System - 9•15, 12•7
Transmission- 1•11, 1•17, 2A•24, 2B•3,
2B•4, 7A•1 et seq, 7B•1 et seq, 12•11
Trim mouldings - 11•17
Trim panels - 11•6, 11•20
Trip computer - 12•17
Tyre wear - REF•11
Tyres - 0•10, 1•8
U
Underbody check - 1•19
Upper suspension arm - 10•16
V
Vacuum hoses - 1•15
Vacuum servo unit - 9•12, 9•13
Valve clearances - 2A•5
Valves - 2B•10, 2B•11
Vehicle identification - 0•8, REF•5
Vehicle pulls to one side - REF•10, REF•11
Vehicle speed sensor - 6•11, 6•12, 6•13
Ventilation system - 1•20, 3•7
Voltage regulator - 5•6
W
Warning lights - 12•11
Warning system - 12•17
Washer jets fault - REF•12
Washer nozzle - 12•21
Washer pump fault - REF•12
Washer reservoir and pump - 12•20
Washer system - 1•8, 1•10, 12•18, 12•20
Water pump - 3•6
Weights - 0•6
Wheel alignment - 10•22
Wheel arch liner - 11•24
Wheel bearings - 0•9
Wheel changing - 0•11
Wheel cylinders - 9•8
Wheel sensors - 9•14
Wheel wobble - REF•11
Wheels - 0•10, 1•17, 1•18, 1•20
Wheels locking - REF•11
Window glass - 11•8
Window regulator - 11•9
Windows - 11•17, 12•7, 12•8, 12•21,
REF•12
Windscreen - 0•7, 1•8, 1•10, 11•17, 12•6,
12•8, 12•16, 12•20, 12•21, REF•12
Wiper arms - 12•16
Wiper blade - 1•10
Wiper blade fault - REF•12
Wiper motor - 12•16, 12•17
Wipers - 12•6
Wiper fault - REF•12
Wiring - 1•15
Wiring diagrams- 12•23et seq
Working facilities - REF•3
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