Haynes Ford Mondeo 1993 Models Owners Workshop Manual 1850109230, 9781850109235

Citation preview

bane!

=

7,

/, .

\

7

||i aWa@\/ :

y

i :

| nn

ea _ 2@

i !

w

=a

~= =

,

o\

Se

ra ————————— a 1 ii a

SPELL, —T

fT MM. a7)

If

“ee }

~~

Ll

so

:

i

4

'

Ui] }/7

THT

7]

( phillip Cox HAYNES © f333

ae

-

-

*

> »

.

fal

i enae

Ford Mondeo Owners

Workshop Manual

Jeremy Churchill and AK Leggucc mm Models covered All Ford Mondeo models with four-cylinder petrol engines, including special/limited editions 1597 cc, 1796 cc, and 1988 cc Does not cover Diesel or V6 engines, or four-wheel-drive models

Haynes Publishing Sparkford Nr Yeovil

Somerset BA22 7JJ England

Tn

EY LIBRARIES

3 0128 01347 0375

Haynes Publications, Inc 861 Lawrence Newbury Park

California 91320 USA

Restoring and Preserving our Motoring Heritage BROMLEY

Few people can have had the luck to realise their dreams to quite

the same extent and in such a remarkable fashion as John Haynes,

f PUBLIC

| LIBRARIES_ | CLASS

am

| 624.2222 FORK 1 ACC

Ol3NTORS

A

“INVOICE DATE

eae

Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair, and to Duckhams Oils, who provided lubrication data. Certain other illustrations are the copyright of the Ford Motor Company, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford and Newbury Park who helped in the production of this manual.

© Haynes Publishing 1993

Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles. A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world. A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum atruly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit. Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia.

From the 1903 Oldsmobile through such classics as an MG Midget to the mighty 'E' Type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill's Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

A book in the Haynes Owners Workshop Manual Series Printed by J.H. Haynes & Co. Ltd., Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 923 0 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design

changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 93-352

Haynes Motor Museum Situated mid-way between London and Museum is located just off the A303 at the Haynes Manual) and is open to the round, except Christmas Day and Boxing

Penzance, the Haynes Motor Sparkford, Somerset (home of public 7 days a week all year Day.

Contents Page Preliminary sections FAGKMOWIBGGOIMGRES preee. 55 S201) DEA Lh kd.civcece coe ee ne Biter Mee eee oa eee aOR eee ee er ee es ee ee AAO CUTE LETS EYTent ACUealatte Pee Re Rta anh dc «ok « vn geese teee COTTE eR eae Hs oe ay Te a OM rca ie gene a neee en, NE lrtrocitetion toutine; EOroMOMCSO yseeer ricco titca cers fatter sec arvcesatieecdansastaeds hose see taety coedin:, ilo ian ete ete tere 5 General imensions :ancawelgintstnc wesc ceases rai ena tee ae lec TR ce eas tt ihe ean, Soest rast POCKIIO GOW IG ANCWSeliChalGinc camer Sssctete romedaecsectccttatevagecttec way Sie tecencdec bets oes itn ARGS ccs ctsae Uh, eRe eee ne Buvingisparerarts and VehicleniGentiticatiomamct ers ec, scence feeeeads< ct ba vcdsctice saz Mcetha cosets sv saPuwads capttceavedee cecil sa.eee as eee SALSA InG eer se ce ce ee er eee SINT IN Bi cal, Bee Heese 2. ui nads BEM swaths, abe amtcevst ractaucha tattered Ate ae ee General repair Drocedtives ree ae. c tema eae es eae ada oe.) ee hes ee RE Fe arctan, ee ee ae ee oe sHODISTANG WOMNKING/TACHITIOS Bese. ncsacters cree erse tents veoteer ome ai oe se Pha Tonos eaeg id syn EN TG Meacde Tasty a= Tore et ee 2 ee ee BOOSIE DALLOMYAUNTO SLAMLIIIG) acc thccccen someerte cla Sicectenctnsce ssec8id uss Lantemcpointonalrss niaitesnectar cee ascS URIs: ooo ren enon ae = a ate RSOMISSION ACTONSsettee eaters vc cee aceTa azn agee tec Ree ad Ueee eM Cae ETRE ae «was c3s ARGC ese AROSUG Nie cm aubcaTlcc NM deseo Caled ROH DoS Te ae ee AUN CAI OSIS ee ee See sea ea eaca ete da save RM aecen Sans na oss d gee anpees SESS RN a sdinaesSone cteey cans -=—=)——__ HA

Gz) I

1SEh—=)— LA/HA (N@/HA)

a z = ZZez

@5

ee

a%e BA/LA HA Na —& —Gs

eee ae)

zZ2z ee

eee

AdbImNxXN

oe

J.) J Le

Se

ay

Py

8+S

2 8

eS

ze

Gg

ae

wayne

0u/Hn_ aun

NG/ LA

eee

€zi)

ae

a

+-

oo

2ss

duind

ee

aS

geo" va

jenuew) Mirra,

3

2 &

xO83SN3

3A/NO

guna

=

a

jusweGHeuew piousjos s}ndjno pue jeny

ay/xE

oulbuy

uolssiwsues} (sjepow +/Z SWUBOUIO OSTY 33S

)—

HANS Mw 3

rin

28. 28

218/18

6

>

>

u

Ses

AdYvITNIXNY

wesbeig :¢

96%

eZ

@) ---

—

zZ—)— nayya 1T)— 34/90 Ore

2A

Ee

2

a

HM

Y24IMS $40 4M TENS BATOA PlouBTOS ab4ng 4e4s!IUOD BATOA TO44U0Q paeads ep! BATOA PIOUBTOS sly SSINg BATOA PlOUaTOS HOI

TET BZ EIT IT

SET FE] EET

+7

saofraful [en4 ZET

apoig ADTaY LO!41U6)

S619 e6u049 90

a

99

uy

MOTIOA SHUM

Pay

«ND

4049 49

vees6-44619

inte i

uge49

Aojay dwng ten4 Aoyay Ajddng weaog TO4pUED 2U044>813 41UN AOL TaN4

ST

ZZ 2]

ZET

AoTPY voipiub, 40g BUiy40ys

QET

40g BUIju0YS

HUN

$ 4043aUU09

€ 4043aUUv09

LoIyIUB} YPLIAS

90/1LA

gu

8/4

3A/8

a

SW3Ll

Gn)

9Z/9/1 SHUHOVIO OSTy 33S

ee

-_—

=.

i

12

ASX O1

+

LE

3/8 nara AE ner 90/98

Tp)—

oI—=)—

eSe—=)— +I —=)— cee=)—

3A/N9 JA/ND 90/78 neve

90/38 2Sp—=)— 2ep—)— Sstp=)— 6e =)— 17

7Se—=)— 9 3A/08 HAE 1S—=)—

H

4484404

12-33 Body electr Ica I system Chapter 12

eed

W

al

|NOMINS

NOILUIEEA HO4 ST3GON HIM

OL

x

c

€/Z SWHYOUIC osu 33S

@) =A eas

ee

+Sp—=)—

fa/8

ee

3A/0E

H

pase

= ca

Be w ae.oo

asx

19s

HA

9

6S

14

0}

0}0

83/818]

fe te6

oO}

Speirs!

fare) (eee

9a

(ee

bey mm

403)

8

v8

4

|

AduIWxn

3

xog]asna

ya

64

|

+ yyasne

48

pop \ ' ' |

BF

Gg

BAlldyGy OL

en

zy ao i 1

' { '

3

'

afi e

a

pi

ee

1

rat

' ‘

a

1'

'

!

' !

,24

’

SOE ES

4 vue

m4

ee

ae

aate

4

eS

8

xa

"lc

Gi)

HA/ND -G

2 ass

HA/NI

-G

--4-

|

y

#

zz9

+515

i

o

ra

ro |

wo

=

a

a

ac

e

BSHNO109 bent SHIM fe

2

c

-—

om

a

=“ =

\ ' ‘3Ss

i

xx

!

als

sh

fat &

ee

o

w

ae

“mo ; \

5

s¢

=> 1

zz

cue

9°

—

Na/Hn S— 3/98 D— 34/90 S— LA/HA (NB/HM)—

Ne/HM >— nena >—

NO/HM — LAH S—

4W/9Z

jUBWaebeueW 4oSsuas s}ndul Ne)

>2

a> z

3/98 S—

> LA/HA S—

g

OT 0

OL

OL

=47 volpiu6) AoTay Bpoig

ZT

uaaog ATddng Avjyay aly SSOW 4osuas 4e4,aW vab HA —— HA

4!U6) vol AoTey

On ther om

ne/Ha

90/78

ae

NO/HA

zi)

AdbITIXN xXOS83SNa

& S

=

=

L_

oe aA

Gu/HA NO/HM HA LA/HR

AIX OL SW3Ll

ines

BF eh

& = =e

Na

LAZHA

u/HA NO/HA

ceed

cZ9

33S OST

ue

HB

aSasE S'S alr

as

Na

HA

HA 24!UA

aaa AOTTOA

U/HA NO/HA

Chapter 12

12-35

Sen

4snoyxy SO9g sunsseig 4osues

OL o1dby

6

>

x

SS

PlouaToS

waysivog

diy astng

BATOA PlOUeTOS 93

PlOUBTOS

ZZ9

+

ZON

TEN 4D 440 Y>4IAS

BINPOW VO!41U6}

4ossauddns

e6ung

s6ntd 4400s pu [109 VO!41U6)

BATDA

404,DBUuU0D €

— C/O

ene

BATDA

BATDA TO44U0Q peads aTp|

BuI4u0yUS 40g 41U6)vol ADyTay

amp) oat —

Gu/NS ng/ng

N@/N9

aA/nQ. ———__ 90/38

Sa

HA/NO

+

4osuag UO!4ISOg/peads 4+04S4U049

Tan4 xUO, $!1un

5

2b1S 7

NS

ag

HAE —G

VT/BK om aeba

i a e =

fu. z39s > Ke

SWALt

BK/YE

21s .

¢e))

Noes

OOM>> ZODuUwW

Ivvow FOMOH

ee

2

w

8Su

fal Al

zl

= EEON

a ee

YD4IMS

oe 619 33s osiy @)

ef

Ze u

Se aSo x8 %

N

~ es

E/ LA

AAD OL

QewetE @m>

MMIT oo>>

Ss.

90/28 cef)—

3A/NO 3A/NO 90/38 na/x8 34/98 HA/38 3A/98 YO/LA

2

(Sjapow uoIssiwisues} 91yeWO Ne) duind jany pue uoNUb! ‘syndjno piousjos - juswWebeueW suIbUy :9 Wesbeig

2/S swwuOUIC

»8/HA

aura nevre

NO/HM

f=—=)— LAVHA

ez )— sik )— +h—)—

90/98

3A/90 3A/2E ayaa nara

SE

ss-)—

Ti=)—

3y/n9 3A/n9 90/28 nara 3/38 Hh/3E 3A/398 re/LA H

A4B440g

He az

aur on

guy

tr

waaog Atddnsg Aojteay

a8

+

z

€

—

90/1LA nay3egu/ND N8/Ne NS/NE ne/7e 3A/90 OW/NS Qu/HA

u

+SIS

€ ON

ADTay feng dwng Tang suoprdafuy 3!1U04458T3 TO4fUOD GuUI440US 41UN 40g }4O,DBUUOD

NO dy ae

90/71A NO/NE 3A/90 naa OY8/NS Ng/Na Qu/NE QU/HA ng/38

NO NO 78

1)— Br f)— esf—)— +1f—)-—

2s—=)— ze )— se-)— 6ef-—)— ssf—)— Bsf—=)— 1Zp—)}— 8 )— |

41UB} VO!

a ———

az9

I

vol 4!Ub;

SyIM

+1/P' OLOuld

rl

NO/NE na/na

Aoyay

SYNO10D

96S

431

kag

pT)

o z

LA

xOgssasna NIQW BK

MOTTOA peyPAS344K abu0u9

301g =n18uaaug

+9TO!A uUmOUg

2bSbZH

uae 46-4467 W

ss

gf

Lid

T ON

Was

apoig

NO Ou Nas La 3A/NO

| | 2 |.

3 ZIalSi & 4 8 WW + T 6

Body electrical system Chapter 12

12-36

3SWOHIUL

821S

OK 3A a Oe ens see -B Ss

BK

o = oO

jw a

— WITH AIR COND.

'

a a ee

===

WITHOUT AIR COND.

BK

------ BK -ak —-

a

AoTey Bpoig

Burvol4ipu09 (ATu9

Yy6Iy Peads Survoijipu03 (Aug 404S!S8y

---------

SUPPRESSOR

esd ==O---4-}--

“I313

TOwLNOD

yuswebeuew Buljooo ‘uey

dil YALNdWOO SsV9z 391ANSS OLISNNOD —C SNWLIO (LSNPGY—C

“9vId 89/61

SYNSS3Yd

plousjos sAjeAPUN pue

HO)

6/HA Gu/4a

OSOUBeIp

NIUW

“suid

OL dOLS

uAOJg nieuaauguaa46-4Y469 S4IUA AMOTTSA

O-- ---------

SUPPRESSOR)

fo

HIGH SPEC

LOW SPEC

ATS

+3TSIA

SHREEGBAGSEY

33S

SWUYOKIC 9/S

BK/WH -BK/WH --

d----}-

C == '

s----F-

BK/WH BK/WH

[N/E

---L-' --- r--

ae Cee=G

SLON3S0 SNIWIA S73G0WHLIA

peu

3LON

UOIssiwsUe.y (sjapow

36u040

C3HSuO SSNI7 NOILUIWLA HO3

kag

XO83SN4

S7/21

32018

$10}.9UU0D D}VEWONe)

a

“ould eu/2z

| 4IMS 446I7 SW31l

36S

& F

Zw 6> Ge

nw

AA/LA

N9/90

ay

au

3°35 4 Hama o ae gaF ee

a

=

62

ts

NOILISNNOD TWNYSLNI 33S NMOHS HOLIMS GHY SLON

6a1S

ee

els

J

GH 404 39b.id eis

GSHOLIAS

ere

HLYYA yUESNE N9/90

@) €t4 NO aol

z

|

au

N9/90

pe

ml

$461 JUsWedWOD sulbus pue xoqano)6 ‘yo10} - Bunyby s01e}U] py}, Wwesbeig

“O

—- 440 an

ieee

YYESNE REE

i

N9/90

6 co> o> cnoo

@)

oa

@z9

Ouvywy

BK BK BK RD

06

€86S —O—— 06/BU

SSS+ZH WL THUAN

Body electrical system Chapter 12

12-44

%

x

XOGSSN4

x

aX

sw

=z

ae

AYBITIXNY

@

fe}

eeIs

% 819 =

SH/1Z “*9bIC Woe OL

+)

S

:

c

S4I4A

+3TOA

SyIA

A> OL SW3LI

TZ BZ 69 BS 72S SS Sg 49 LOIZOUIWNTT] ES 4Y6ITPOeH LDLyAS TELVOg MOPUI_ ZS PSLOB, 4OByY LPHIAS

€/Ze+3

NS/HA

—=)-— 34/8

UOTEUILUN||! 4JOLE}U] 8LUU09 TOU4B4U] 32S) 424SNTD pVEWNA4SL} UPyAS VOI41U6; Asa4409

44617

TeLOg VOI,OUIWNTT] 3I4OWOpNy (VOISSIWSUO4, 40473TSS UOI4204) 48,08 PCT]

BBS) YYAS

Jewwig TO414UOD

ATQWaSSY

2034 HY WHIMS AOPUIA 34433T3 40044 HY UPHAS AOPUI_ 3I4458T3 4JO8Y HT WHIMS AOPUIA 214423T3 4¥044 HT WHS AOPUIA 314458T3 208% HY LOI}OLWIWNTT] BTPLDH 40Og 4044 HY UOlZOUIENTT] STPLOH 400g 403 H] LOILOUIWNTT] STPUDH 400g 4044 H] LOIZOUIWNTT] STPUDH 400g

VOILOUIWNTT! waysds TOU4e4U}

SS 2S se4yndwop $5 dij 9S 40619 4344617 BS Wy SpPIy UPHAS TS ZS ES

vOrpOUIWNTT]) YP AS

12 -45 Body electrical system Chapter 12

12-46

Body electr ical system

Chapter 12

48TO!A 4U044

SHIM SYNO103

dwng

EVVEZ)

WH/BK

een ee

VT/BU

(WH/BK)

HSUM H3dIM YS 6/IbbD oo HLA

INOW tg

— Huu HSUA

ore NE iggeee:

WH/RD

Spee eat

WH YE/BK VT/0G

wuESNE

Hives

WH/GN YE/BK

AU1ay YSHSYA

edimsy pue WesbeIg payeey seysem sjef 9)

ey

Y24IAS VOI 4106)

peLoeH 4BYSOM AvTay+8P +2014

ees

4424408 ABD

weYysoK

ee

OL

4dBY JOON 42d1K $U045 40LOH 4801 UPHIAS 8d1M/USOM BINPOW 4aW!| TO44,UED AOTaY 4106) VO! € 40438UU0) 40g 6uI440U45 @poig ADTaY VO}4106)

SW31!

MOTTRA JBATISS4IUK

“ould svét OL LHOINGUSH

4

= = “NXa =] esom zu

5

xoaasn4 XN Adi

2sIs

»— Na/1A

Ow

Ow

78

LA Nes

1s1S

S+IS

x

x

%%

3A

vee46-44617 kag HA 24!UK 1A veaug

+461TpOa}H

BuI410US GuUI4u0US

e+

Les MOTIaA

AoTay 4eyso4

40g 40g

dung 42yson 44611PO3}q BINPOW TO44U0] asin UPtIAS T2=yA BUI4ea4s U>HAS L4H

Z 4O4,DdaUL0) € 404DdaULv09

Bpoig AoTeY LO!4106)

a ASX

RD

WITH CRUSE CONTROL

BA/LA BA/LA

ou —————————O-——.

-—

-—

na/s0

34/90

——

——

J3dS

J3dS

H9IH

ADT

+/Zvd 9/Z$+9 Vtre2 Z/EovD €/Z>+9

40}461| 48610 pue yoo; ‘usoY ‘“Aoysem WYSpeepH :2) wesbeiq

3L0N

J3dS H9IH J3dS H9IH

WHsTe OL “SvIC SH/TZ

xogasna NIBW

Nels GR

GHT Hod 39¥d STIUL3G NOILOSNNOD WNUALNI

33S NAOHS HILIAS GHY

HIGH SPEC VT/YE

HIGH SPEC OG/GN BK fl hl) VT/YE

-o ou

856

(60g STIOZaQ VOI4IBLLOD

OL

n@/LA

42019 6ur14ds UH AOT®Y

TOU.#34U} 39S) UPLIMS 44617 SW31l

66S

ang 32018 vaoug

12-47 Body electr' ica | system Chapter 12

3A/LA

1

SE

SW31l

sIpi

BTP]

PloUBTOS BAISA

asDas3u) ProUaTOSSpoIg

BesoauDU)

SuIM 271g 30 Pey Gu US LA AS +8TO!A S41UA

e6u049

SYHNO109

WesbeIg :g}

poyeoy Siow pue

a 2S

Payeey

=>

33S

—{0— 1 ©

JB91/4U0jSU99JOS

» So

osw WeYSvIC Zz

Chapter 12

iL

3A/N9

CAG/N9)

40428UU0) J 40429UU0) € TOAZLUeQ4wWIY SINPON P2403_ UBB4ISPUIA YPtIAS P240aH4OaY MOPUI_ UPHAS 4040U484TY payoeH Ueez2spUIA_4UeWweTZ H1 pej0ey LBBISpUIlA+UBWETZ HY P3403 UBBzISPLIA AdT@Y P34034DSY MOPUIA AOT@Y 400g 4011y 49409})) (4U@WeTgZ H1 400g 4O4uW 4®}LOB}) (4U8W8TZ HY PBLOBH4OBY MOPUIA

ASX OL

44a440g BuUly40US 40g BuUIjs0US 40g 90/1LA

+S

9g} ZT Zp 19 739 98 28 BB Gg BE 16 ZG E56

12-48 Body electrical system

=I | g g | && |

AOTIBA

ou

GN/YE

(GN/BK)

48408

96S

SPOW

uly “pueg saossaudwoj 6uiT24Q yrqiag

IY “PLOD VO!}OTNIUIDBY PIOUSTOS BATOA

Se

es

eee ee

3

|g

xogasns

ee

Hides

JOWLNOD

xeSa

JOMO}|q 40}e0Y4 pue HuluOHIPUOd Aly 76}, WesbeIg

es

uuesne

uwuMM

UDLIAS

YPHAS 48K0Tg 484,03H 420g JO}SISSY 4BAOTG 4BLO3} AOTAY BT44044, VEdQ apim “PLOD 4Iy

SBunpousdwa;

“pYED aly

Bunpovsdwa,

Y>4NTD 400g

SPOI 400g

@

VT/BU

LINN

|

| NAOG Z SYNSS3Hd SYNSSSed T BYNSS3Hd TWWHON Z HOIH

4O,OPW

4O}SISSY

OL

2gIs

dn

=

SW31l

S4IUA pey

ABATIS

NO 3/0 3/U 430

Sy yyg

Luis

arg

Pees ees

Onn = 338 430 ——

2°

d 3

OsTd WuHSuIO 81

34/90

ou

omy

ay ————_-@

x8

WesbeIg :z7z

33S

osty WYHOUIC 8T

o!

I iT

O1N}99/F SJOIIIW pue

8

SN

w

5

33s

3

98s

aA

te

c

ae

sowie

—-— 440

Ww

e

ww

S

>

S ¥

a

N

2

eoee@ 5 ye E

att

=>

8

H

914}99/9

96S

aoe

(}U0IJ)

ew

>o

zz

Q a

=e

ZY

as

z> Se

Sx

=z 2z

+8

es

ooo 6&8

&

> uo

9

zo

||

lec

Nag

ay

a

issue)

LHIIY=— —rHY

ee

7an Naog

4

HA

3A

:

ses

SHNOT09

o Me

osty

SWUUOUIC€Z/ST

MOTISA

pay 4BatS 42TO1A 4!UK 2

—————-& 1A/HA —————4A/34

9946-44617 26u0.9

kaag

uaaag

72018 uKoag arta

SHIM

W3ON3SSud dN 8/088+9

Y39N3SSUbd NAOO

33s

x

ASX OL

@)

po §

(a)

DIayDBTAMOPUIM 4O}LOW HH Y>NO| UAOG ADT@Y

te)\——

Bug

Avyay

6uI4404S 40g

$U044

31449873 MOpUIA YP4IMS H1 $0044 3I44>8T3AOpUI_ YDLIAS HY 40044 4009 40.41) H7 400g 40.41) HY 460g 40441, TO44U09 UPHIMS 31442273 MOPUIA 4OLOW H] $U044

4106) vol

W

40}28UU09 €

SW3LI 448440 4106) Lol Y24INS 41U6 Uo xmw

a

aren DWH

8

3

Ss

|

©

cf

T

Wa

Chapter 12

AdvIWNXNY XO83SN4

Ax

12-52 Body electrical system

pay

42.49

42018 5

NIBW

YPPIMSOUDIP

xO83SNa 08

14

[wosshaGROURS +)

Y>4As

&

B4/UA

+8TSIA

SIM

Aoqay UACG YDNE| 3uD

40BY H7 4OLOW MOPUIA 34422

40RY HY 4040W MOPUIA 314438T3

UP4IMS YP4INS Y4IMS Y24IMS

3442913 314429TR 3144523 1443873

4og BuI4,40US

AdTay VO!4106)

AOPUIA AOPUIM MOPUIA AOPUIA

4¥044 HY 4040W MOPULIA 31442913

HY HY HT H7

MSGSESU825SE>

MOTIAA

uMOug

SYNO109

JOOIUNS LVOI4ISOg $OO4UNSAOT@Y FOOIUNS4OLOW — 340

~

‘2

|

Py +5N[ +004UNS

NAO u3ONaSSUd dN W39N3SSUd

YE WH WH

SMOPUIM 914}99/8 (4ee4 PUB }U0.J) pue JOOUUNS J14}99/9 :¢z WesBeIg

.

rr

408Y 40044 4ORY 44044

4484409

LINA

AOOYNNS

——_—_ vt

a6u0u9 AeAIS uUeB849vaes6-44617 ania

3I14438T3 MOPUI_ 4040W H7 4U044

apoig AoTay Vo! 4106) UP>4FIAS LO!41U6;

€ 4043aUU0D

AAD OL SW3LI

WuYdLIC ST

I

5 a cw an

5 n

12-53 Body electr ica Ilsystem Chapter 12

“

zeIs

Ben

8

UAOug

vote

Zane

ae

SYNO103

SunTioy BINPOW

7 u

a

Ba

aa

1a

Ad¥uITNIXNY xOs4asna

oa

40438uU0) €

B6uI4z04S 40g

AOTPY

404338UU09 %

aes

—

@)

naselibetl

Qoxua

coc

axwoa

aie

7 a

@z9

etx

N

”

Yo

aa

v

é

‘ z

z

oO

a

Ou

J

NIWW

cet

9

¥‘an

=

ainyiey

xXO84sns4

wes6beig ‘yz qing

2.71...

SEIS

BA/LA

Burusem weyshs

H

oe )

48

p

—. BA/LA

[2z/39+5]

+5909 —G €8/1LA SS365 — 1A —G 3,708 —~% nays0 esses —-©99 1z799r) S17S900 179989 7179969 ez7earo €z79ah) —-©1,

¥

dOLS LHOIT HOLIAS UIA SSIS “9uId +0/Z1

1A

$$$ 38/4 ei

OL

5

en HOLIAS WIA BETS “OuIG 9f/ZT

>

—— 4

>=.

@)

— +z9

W

WL

319

at i

1a

20T3 6ul4ds a704g TOpag UPJIAS

XO84Sn4

TO4,U0D SINPOW,

GuUI440Y45 40g

UO! 4106}

BuIzea4s TR®YA U>HAS

UP4AS UO!41U6; 4)U6) vol Aopay apoig

esinug

40p3auU0) €

AOT@Y

SW31L1 ASX OL

42a440g

Body electrical system

SYNO1OD

Chapter 12

gu

HA/LA

easing [04jU09

NIWW

3A

“pop

WesbeIG :gz

NOIMLIVHL TOULNOD “SIO Sf/6Z

ausne

MER ai

OL

i

ae

fae! 1

4] oy

> 5 &

"SNUHL

@:

76

“OLN

VT/YE —G

TL

Leeks E1

4 GaSSaud30

au

SS

ee

goSEER TBHYON

du

1 pk&_MonoranmS, (EERRBR BRIHGIGGG A a ee

ES

o!

OGO00004 Le !

pays 2G/HA a Me

aa (eh NG/LA ees 6ee “aa

au a Zu/2Z

“OIC

12/ZT OL LNSWNHLSNI 33vsHSLNI FINGOW

"Sud

S) aata OL dO1S LHOIT HOLIAS af Bir OL STIDIHSA > e V7 “OIG “ould ¥VS a G33dS YOSN3S

ii | “al fs TWNNOW “SNOYL

Hi il | || =I “a

S

% %

2 Yow © 3= ox

3

eZ

osST WeYsbIC

o

coo

Gee Be 33S osy

78

_naowised

3A/48

——C

HT

SA TRA

LNOHS

aNGGa

HT

HY

40193NNO3

—

3ILSONSYIC HA —C HA SAU dbs ——C

1vasseo

Saaees

7asee5| |

GION310S GIONSNOS

5]

INOHS HY

x08 AUTSu

Ye

43H

SATA

U3

Hasxa

ZZ/0SRED|| 9705869

J04jU09 UOI}OB1} YUM Sgy ‘6c Wesbeig

:

Adel —C

Eee

xogasns

¥O.LISNNOD

OL

“9UIG

|

BAlLdbO’

SNidWwO SINGOW

97

:

HOLIAS

14/8Z “OIC TOHLINOD 3SiINKD OL

5

aa

d01S

Seu

Sau

VO!I4D04,

SEY

UO!4304)

LHOIT

TB=UA

Te8uA

TO4ZUOD

TeeuA

[O44U0Q

JOSUaS HY

4OsUes HY

40OSUeS H]

ATQWeSSY [044U0) Sau

WapsXS

OL

SHIM

301g

4044

4JO®y

STZFOUUL

SYNO10D

JO®Y

TOU4BLL]

LoOIysaUL0D SsTio4ag(@60g

UPLIAS

4LVEWNI4SL|4ALSNTBBS)

4106}VOI

4OLOW

$0044 H7 40SUaS T==4K Sau

UPLIAS

apoig AoTay Vo!+4!U6)

—G

Z sop euU0] 40g GuI440US $ 4O4,28UL0Z 40g BuUI4,40US

ST300W ‘

—G 3A7NI —G auws34

—G 34/18

NIBW XOS4SN4 LNOHLIA

one —p

' HSLSWOHSUL

au/Ha

XN

QIONS10S GIONSTOS

SSR25R98R25S5E¥

SW3Ll OL AZ

NO/HA NO/NE 8 HA/

12-59 Body electr ica I system Chapter 12

12-60

Chapter 12

Body electrical system

T2S+ZH

4 DL

hea

@)

V/9S++9 ST/9S++9 TI/9S¢+3 7Z/0Sbb9 ¥Z/0Sb+9 ZI/9Sb+9 2/9Sb+D @8Z/9S++I €/9S++3 21/9S++2

S1/9S++2 S/OS++3

£Z/0Sb+I ¥1/°Sbb2 8I/9S++D

9Z/9S¢+D

SZ/OS++D

ae

TOXLNOD

NOWIbYL NO/48 OL

AUT3u “OID bf/S

“OvIC +0/+ “SHIC ¥O/2 OL ¥OLUIOUH dOls

sandepy Buildwepwa}sAs

38

SAI Lavoe

ONIT003 Nba

a= SNidWYO

33S zrovid

SALA

LA

am =

748 na778 NG/LA Qu/HA

——C

“Suid +1/ZI HOLIMS LHOIT

OL FTDIHSA O34dS YOSN3S “OvIO bf/Z

MM om

Laer

90/78

ee)

NS/HA

“OIC $A/EZ

na738 Na/LA Ou/A8

JILSONSVIC OS! 0O133NNO3 d¥Ou ——C €/HA SAIL SNIdWKO —C JILSONDKIO 3A/N8 HYLS ¥0193NNO9

:

C8@8b/S

=} €Z4

ne/xa N@/LA 8

Ou/78 7a

weibeig og GN BK/RO

LZ] NIbW xOg3SNs n@/7a NG/LA

eis VT/YE

VT/YE

4044 BuIdwogBATOA H]

Y>tIMS

GuUIluaajs UOI4ISOY JOSUaS

wars Spiy

_ =P

Ase440g

AOTIOA

pay ABATIS 491010 244K

a6u049

uae—e49

kaa9

vaes6-44617

SHNO103 Sy

VO!4!U6) AdTSY apoig 6uI,40US 4uog 4opdeuUED € Gul4s404sSINPOY 4og ZsoyDaUU0] aA!,dopy Buidwog Buidwog SATOA H] 40®Yy BUIdwog SATO, HY 403y 40044 Buidwog SATOA HY

xogasna

ce

Avypey vo! 41U6}

Vot4!U6; 424mg

AITIXN

SW3LI

snie 42018 uaoug

3A

YS

7

HA 1A

Ow 90

Ag NO na Na 78

1M

Aaa OL

pUEWN4sU]4B4LsNTQ BBS)

TOUss4,L]

VOI43aUL09 sTIO4aq (260g arlydopy GuIdwog Guivs0M_44617

VT/YE

12 -61

Body electrical system

4UBI9H YPLMS FYB} 4OLOW 4BAdg 40BS 4BAOY 40BS [IZ ZIZ

42408H Y4MS H7 48408} YPHIAS HY

4095 4085

OL AX

Yr41Mg5 VoIyU6)

287 BgZ

SW3LI

4044 HY 49408} 4S8.0g 40a>S 98Z 4U044 H] 48408} 4584730g 408g SEZ

+U044 44044

8s

As0440G

Chapter 12

4¥0.413 +48Z 4085 LOIYSND 48408 HY H7] VOIYSN] 48408} 4¥044 E8Z 4085

GBTYPHAS P8081 4089S AOTSY BIZ 4BACY 4085

4OLOW 4594xI0G

40S 4BACY EIZ 4OSSB10WO 4040 417 4BAOG 4085 4OQWN] SIZ4044 4BACY 4OBS PJOAJOBY/P4ONIOJ 4OLOp 4Y6IB}H 4O4OW IZ 4BACY 40BS 4095 4OBY 44612] 4OLOW ZIZ 4eACY

911}99]0 queunsnipe Puke S,J2AUP poyeoH WesbeIg :,¢ ees S}ees

ei 33S

aSmS

90/1A 90/1A

NOs

BAZLA

STIs

s6eq ule saBuessed pue J9AUG :ze wesbeig

88S

96S

ou

6oquy

se6vessog

Buruds 42013

Hun Goquiy 4eAlag

40g GuIjyu0yUS

Aopay VOI416;

VOI4y.eULED

[OUsa4U] 29S) 4a4sNT] 4LEWN.4sSU

(@60g sTi04eg

44617 Guruso_ Goquiy = g

Bpoig Aopay Vo!4!U6)

€ 4a0p3@uV0

tun

61z wz se Biz BInpoY ezZ Goguiy

416 VO! YD4IMS

SYNO10D

+1 2

T 8 6

SuIM

HSR5598255S4

cox

4484408

ASX OL SW31!

VT/YE VT/06 VT/06

aie

NO/AG au/A8 ausa8

= = =e

ett He

efit’_|

ost

RD BK AD

ae ne ee ee age ap ee ee ee ep ea ie A

Body electrical system Chapter 12

12-62

oI SWUHSIO BZ/21

12-63

Body electrical system

Tousa4y} (e604

ASA OL

YAlsITdWY

vorpiu6; 44617

2€/HA

iT

NE ng ND Ad

SyIM

3113SS¥9/010b"

te WH/GN

OL

: t's

HILIAS NAOHS33S

eee 3A/x8

: :

SLON OHY

WH/GN

0G/BU

“SIC

0

€z9

————__r—

OH1 NOILI3NNOD HOI 39bd “IUNYSNI STIUL3G

98/90 1/2644 o

———-O-——

0G/8U

HA

HIM

“ast f—=)—_—__ +3 +/°€¥ N9/HM 8/Ne S/°6++9 90/38S/°EbbD ¢9is

244A

S¥NO109 CTE

vaosguse49 ang 4a49

NO/38 NO/8

SH/TZ HHL

BS

g BT

=e

AlbubdSS

9/°E+b9 Z/0Ebb9

STIO4eq HUN Bag) @448sso7/oIpoy UPyAS Y>4I/AS LOl428UV0D

Spoway 99 481j/1Swy vaa46-44617 17Z 4U044 26049 ZZZ 487x090 H] P?2y 44024 90 EZZ4014 4exDads H1 4day OY YS HY 42AS +ZZ 4ex0adS HY LA 4P191A SZZ 48x0EdS 40ay AOTTAA 3A

(saytjdwe yy) eyWesseosoipey ‘ee wesbeig

Wala dWY JlvvwvdaS INOHLIM 3113SSuO/010ue

3A/NE LA/HA

Asa440g

SW3LI

Chapter 12

Chapter 12

ZZZ 4ex0edS H] 4U044

BS 34485S07/0IpoyY HUN

6S GD 4e401d

rT

st

Bea

®

|euy(=e.

g

eEaEae a3

@® AL

eyesses/solpey pue GOD J2eAe|dYM)

HSREEIGB2ESEL

|

=

ZZ

Ase4408 I 8 Joueyuj aT +U6ID Y2HMS 33S)

i oF

(42goomaQns

VoIy>aUL0D ST!O4aq (@60g |

33 I

Vojub) SW31LI ASA OL

421j1TOwy 4eyoOMQns 2Z7Z 4espoongng 4ax08dS SZZ S7Z 408y HY Jex0edS 40044 4a7x09dS Hy ZZ 4e7x0edS H1 4038y EZZ

AaHTIwy Spoway 4U044

Urpag

Body electrical system

8 o

as

0G/BU .

we

wesbeig ‘pe

BK/BU 0G/BU

LEIBA NOI 3LON GHYNOILISNNOD HOLIAS NAOHS 33S TWNYSLNI STbL30 39td 303 OH]

Index Note: References throughout this index relate to Chapter and Page numbers, separated by a hyphen.

A About this manual - 0-5 ABS - 9-1 et seq Accumulator/dehydrator (air conditioning system) - 3-11 Acknowledgements - 0-2 Adaptive damping switch - 12-9 Aerial - 12-27

Air bag - 12-27, 12-28 Air conditioning system - 1-21, 3-1 et seg, 6-12 Air filter - 1-1, 1-28 Air mass meter - 6-11, 6-12, 6-13 Alarm/central locking module - 11-21 Alarm system - 12-22 Alternator - 5-5, 5-6 Amplifier (radio/cassette) - 12-26 Anti-lock braking system (ABS) - 9-1 et seq hydraulic unit - 9-16 relay box - 9-17 wheel sensor - 9-16 Anti-roll bar and links - 10-10, 10-16, 10-20 Anti-theft alarm system - 12-22 Antifreeze - 1-3, 1-28 Automatic transmission - 6-12, 7B-1 et seq fault diagnosis - 0-22, 7B-2 fluid level check - 1-15

linkage lubrication - 1-23 oil seals - 7B-4 overhaul - 7B-6 selector assembly - 7B-3 selector cable - 7B-2 selector illumination bulb - 12-13 selector lever position sensor - 7B-3 speedometer drive pinion - 7B-3 Auxiliary drivebelt check - 1-17 Auxiliary warning system - 12-21

Badges - 11-21 Balljoint (front suspension lower arm) - 10-12 Battery - 5-2, 5-3 check/charging - 1-16 electrolyte level - 1-12

flat - 0-17 Beam alignment - 12-16 Big-end bearings - 2B-20, 2B-23

Bleeding braking system - 9-14 power steering system - 10-28

IND

SS

IND-2 Blower motor (ventilation system) - 3-7 Body damage - 11-2, 11-5 Body electrical system - 12-1 et seq Bodywork and fittings - 11-1 et seq Bonnet - 1-25, 11-6

lock - 11-7 release cable/lever - 11-7 Boot lid - 1-25, 11-17 Boot light switch - 12-8 Braking system - 9-1 et seq Anti-lock Braking System (ABS) - 9-1 et seq hydraulic unit - 9-16 relay box - 9-17 wheel sensor - 9-16 bleeding - 9-14 caliper front - 9-4 rear - 9-10 check - 1-25 cross-link shaft (brake pedal-to-servo) - 9-13 disc front - 9-6 rear - 9-11 drum - 9-7 fault diagnosis - 0-23 fluid level - 1-12 renewal - 1-32

handbrake cables/lever - 9-19 hydraulic pipes and hoses - 1-24, 9-14 master cylinder - 9-11 pads front - 9-4 rear - 9-10

pedal - 9-12, 9-13 precautions - 9-4, 9-14 pressure-control relief valve - 9-15, 9-16 road test - 1-26 servo unit - 9-14, 9-15 shoes - 9-7

stop-lights bulb - 12-11

Index

ee

Castor - 10-29 Catalytic converter - 6-21 CD player - 12-27 Central locking system - 11-20 Centre console (front) - 11-25 Charcoal canister - 6-15 Charging system - 5-5, 5-6 Clock - 12-18 illumination bulb - 12-14 Clock spring (air bag) - 12-28 Clutch and driveshafts - 8-1 et seq adjustment - 8-2 cable - 8-3 component renewal - 8-4

fault diagnosis - 0-22 pedal - 8-3 road test - 1-26 Coil spring (rear suspension, Estate) - 10-20 Column (steering) - 10-24, 10-26 Compact disc player - 12-27 Compression test - 2A-7 Compressor (air conditioning system) - 3-11 Computer module (trip computer) - 12-21 Condenser (air conditioning system) - 3-11 Connecting rods - 2B-13, 2B-18 Constant velocity joint rubber boots - 8-9 et seq Contents - 0-3 Control module (air bag) - 12-28 Conversion factors - 0-18 Coolant - 1-5 level - 1-11 low level switch - 3-6 renewal - 1-26 temperature sensor - 6-12 Cooling, heating and air conditioning systems - 3-1 et seq antifreeze - 3-2 check - 1-28 coolant temperature sender - 3-5 expansion tank - 3-6 fan (radiator) - 3-4 fault diagnosis - 0-21 hoses (cooling system) - 3-2

switch - 9-19

wheel cylinder - 9-9 Bulb failure module - 12-22 Bulbs - 12-2, 12-9, 12-21 Bumpers - 11-5 Buying spare parts and vehicle identification numbers - 0-9

radiator - 3-4, 3-6 thermostat - 3-4 water pump - 3-7

Courtesy light switch - 12-9 Crankcase - 2B-15 Crankcase ventilation system - 1-29, 6-20 Crankshaft - 2B-14, 2B-19, 2B-22 oil seals - 2A-26

Cc Cables accelerator - 4-4, 4-5

bonnet release - 11-7 clutch - 8-3 handbrake - 9-19

selector (automatic transmission) - 7B-2 speedometer - 12-17 Calipers (brake) front - 9-4

pulley - 2A-12 speed/position sensor - 5-5, 6-1, 6-11, 6-12 Cross-link shaft (brake pedal-to-servo) - 9-13 Crossmember (rear suspension) - 10-18, 10-23 Cruise control system - 12-23 CV joints check - 1-24

rubber boots - 8-9 et seq Cylinder block/crankcase - 2B-15 Cylinder bores - 2B-17

Cylinder head - 2A-20, 2B-10 to 2B-12 cover - 2A-8

rear - 9-10

Camber - 10-29 Camshafts - 2A-16 drivebelt - 2A-13, 2A-15, 2A-16 drivebelt covers - 2A-12 oil seals - 2A-16 position sensor - 6-11, 6-12, 6-14 Capacities - 1-4 Carpets - 11-2

D Damper (rear suspension) - 10-19 Damping switch - 12-9 Dashboard - 11-27 Dents - 11-4

IND-3

Index Differential side gear oil seals - 7A-3 Dimensions and weights - 0-6

Dipped beam switch - 12-8 Direction indicator bulb - 12-10, 12-11 front - 12-14 rear - 12-15 switch - 12-8

Disable switches (cruise control system) - 12-24 Disc (brake) check - 1-25 front - 9-6 rear - 9-11

Door - 1-25, 11-16 handle (interior) illumination bulb - 12-13 inner trim panel - 11-7 lock, handles and lock barrel - 11-13 mirror - 11-17 switch - 12-8 window glass - 11-10, 11-12 Door-ajar sensor - 12-22

Drivebelt - 1-17, 2A-13, 2A-15, 2A-16 Driveplate - 2A-27

Driveshafts - 8-1 et seq fault diagnosis - 0-23 rubber gaiter check - 1-24 Drum (brake) - 1-25, 9-7

mountings - 2A-28 oil and filter change - 1-21 oil cooler - 2A-25 oil level - 1-11 sensor - 2A-26, 12-21 oil pressure warning light switch - 2A-26 oil pump - 2A-24 oil seals camshaft - 2A-16 crankshaft - 2A-26 overhaul - 2B-1 et seq piston/connecting rod assemblies - 2B-13, 2B-18, 2B-23 piston rings - 2B-21 removal - 2B-3, 2B-4 road test - 1-26

rocker cover - 2A-8 sump - 2A-22 tappets - 2A-16 TDC (locating) - 2A-8 timing belt - 2A-12, 2A-13, 2A-15, 2A-16 valve clearances - 2A-6 valves - 2B-11 Environmental considerations - 0-12 EVAP system - 6-15 Evaporator (air conditioning system) - 3-11 Exhaust gas pressure differential sensor - 6-12, 6-15 Exhaust Gas Recirculation (EGR) system - 6-16 to 6-18 Exhaust manifold - 2A-10 Exhaust system - 1-24, 4-1 et seq

Exterior fittings/exterior trim panels - 11-21 Exterior mirror - 11-17

E Earth fault (finding) - 12-5 Economy/Sport mode switch (automatic transmission) - 12-9 ECU - 6-11, 6-12, 6-13 EGR system - 6-16 to 6-18 Electric seat switch - 12-9 Electric window switch - 12-8 Electrical equipment (road test) - 1-26 Electrical system body - 12-1 et seq check - 1-16 engine - 5-1 et seq fault diagnosis - 0-24, 12-4 Emissions control systems - 6-1 et seq Engine (in-car repair) - 2A-1 et seq Engine (removal and overhaul) - 2B-1 et seq big-end bearings - 2B-20, 2B-23 block - 2B-15 bores - 2B-17 camshafts - 2A-16 drivebelt - 2A-12, 2A-13, 2A-15, 2A-16 oil seals - 2A-16 codes - 2A-1 compartment - 1-7

light bulb - 12-12 compression test - 2A-7 connecting rods - 2B-13, 2B-18 crankcase - 2B-15 crankshaft - 2B-14, 2B-19, 2B-22 oil seals - 2A-26 pulley - 2A-12 cylinder head - 2A-8, 2A-20, 2B-10 to 2B-12 exhaust manifold - 2A-10 fault diagnosis - 0-20 flywheel - 2A-27 hydraulic tappets - 2A-16 inlet manifold - 2A-9 lubrication system - 2A-3

main and big-end bearings - 2B-20, 2B-22 management system - 6-1 et seq

Facia - 11-27 Fanbelt - 1-17 Fault code read-out (engine management system) - 6-7 Fault diagnosis - 0-19 et seq automatic transmission - 7B-2

braking system - 0-23 clutch - 0-22 cooling system - 0-21 driveshafts - 0-23 electrical system - 0-24, 12-4 engine - 0-20 fuel and exhaust systems - 0-21, 4-10 gearbox/transmission - 0-22 steering - 0-23 suspension - 0-23 Firing order - 1-2 Flat battery - 0-17 Fluids - 1-3 leaks - 1-19 level checks - 1-11 Flywheel/driveplate - 2A-27 Foglights - 12-15 bulb - 12-11 switch - 12-7 Front grille - 11-6 Front sidelight bulb - 12-10 Fuel and exhaust systems - 4-1 et seq, 6-11 accelerator cable/pedal - 4-4, 4-5, 4-6 air cleaner assembly - 4-3, 4-4 air filter - 1-1, 1-28 CO (mixture) adjustment - 4-10 cut-off switch - 4-9 depressurising - 4-2 exhaust system - 4-13 fault diagnosis - 0-21, 4-10

©

IND-4 a fuel filter - 1-1, 1-31 fuel gauge - 4-7, 12-17 fuel pressure check - 4-6 fuel pressure regulator - 4-12 fuel pump - 4-6, 4-7 fuel rail and injectors - 4-11 hoses - 1-20, 1-24, 4-3 idle speed and mixture adjustment - 4-10 idle speed control valve - 4-12 idle-increase solenoid valve - 4-13 injection system - 4-10 injector(s) - 4-11 mixture adjustment - 4-10 plenum chamber - 4-4 resonator (engine compartment) - 4-4 roll-over valves - 4-9 tank - 4-7, 4-9 throttle housing - 4-11 Fuses - 12-1, 12-5

G Gear lever - 7A-2 Gear ratios - 7A-1 Gearbox - see Manual or Automatic transmission Gearchange linkage - 7A-2

Gearchange selector shaft oil seal - 7A-3 Glass - 11-10, 11-21 Glovebox - 11-27 light bulb - 12-13

H Handbrake cables - 9-19 lever - 9-19 -on switch - 12-9 Hazard flashers switch - 12-8

warning light bulb - 12-13 Headlight - 12-14 beam alignment - 12-16 bulb - 12-9, 12-10 dipped beam switch - 12-8 levelling motor - 12-16 Heated rear window switch - 12-9 Heated seat switch - 12-9 Heated windscreen switch - 12-9

Index

Idle speed - 6-10 Ignition system - 5-1 et seq, 6-11 coil - 5-4 module - 5-4 switch/lock - 12-7 timing - 5-1, 5-5, 6-10 Indicators bulb - 12-10, 12-11 front - 12-14 rear - 12-15 switch - 12-8

Inlet manifold - 2A-9 Instruments illumination bulb - 12-13, 12-16 illumination rheostat - 12-8 panel - 12-16 road test - 1-26 Intake air temperature sensor - 6-12, 6-14 Interior light bulbs - 12-12 light switch - 12-9 Interior mirror - 11-17 Interior trim - 11-24 Introduction to the Ford Mondeo - 0-5

J Jacking, towing and wheel changing - 0-7, 0-11 Jump starting - 0-17

L Levelling motor (headlight) - 12-16 Light switch - 12-7 Locks bonnet - 11-7 boot lid - 11-17 door - 11-13

ignition/steering - 12-7 tailgate - 11-19 Low air temperature sender unit - 12-21 Lower arm

front suspension - 10-11, 10-12 rear suspension - 10-17, 10-21 Lubricants and fluids - 1-3 Lubrication system - 2A-3 Luggage compartment light switch - 12-8

Heater/ventilation components - 3-1 et seq, 3-7, 3-9 control illumination bulb - 12-14 fan switch illumination bulb - 12-13 Horn - 12-18 switch - 12-8, 12-27 Hoses (general check) - 1-19, 1-20 brake - 1-24, 9-14, 9-15 fuel - 1-24 vacuum - 1-20 HT leads - 1-30 Hub assembly front - 10-6 rear - 10-12, 10-13, 10-19 Hydraulic systems bleeding brakes - 9-14

power steering - 10-28 Hydraulic tappets - 2A-16 Hydraulic unit (ABS) - 9-16

M Main and big-end bearings - 2B-20, 2B-22 Maintenance - see Routine maintenance Manual transmission - 7A-1 et seq differential side gear oil seals - 7A-3 fault diagnosis - 0-22 gear lever - 7A-2 gear ratios - 7A-1 gearchange linkage - 7A-2 oil level check - 1-22 oil seals manual transmission - 7A-3 overhaul - 7A-7 reversing light switch - 7A-3 speedometer drive pinion - 7A-2 Master cylinder (brake) - 9-11 Matrix (heater) - 3-8

Index Mirror switch - 12-8 Mirrors - 11-17 MOT test checks - 0-26 Mountings (engine/transmission) - 2A-28

N Number plate light - 12-15

bulb - 12-12

O Oil Oil Oil Oil Oil Oil Oil

change - 1-21 cooler - 2A-25 filter - 1-1, 1-21 level sensor - 2A-26, 12-21 pressure warning light switch - 2A-26 pump - 2A-24 seals - 0-12 automatic transmission - 7B-4 camshaft - 2A-16 crankshaft - 2A-26 manual transmission - 7A-3

Oil separator (PCV system) - 6-20 Oils - 1-3 Open-circuit (finding) - 12-4 Overhaul automatic transmission - 7B-6 engine - 2B-1 et seq manual transmission - 7A-7 Overhead console - 11-26 Oxygen sensor - 6-12, 6-15

P Pads (brake) front - 9-4 rear - 9-10 Paintwork damage - 11-3

Parts - 0-9 PCV system - 1-29, 6-20 Pedals accelerator - 4-6

brake - 9-12, 9-13 clutch - 8-3 Piston/connecting rod assemblies - 2B-13, 2B-18, 2B-23 Piston rings - 2B-21 Plastic components - 11-5 Plug leads - 1-30 Plug renewal - 1-2, 1-29

Pollen filter - 1-26 Positive Crankcase Ventilation system - 6-20 Power steering - a/so see Steering fluid level - 1-14 gear - 10-26 to 10-28 pressure switch - 6-12, 6-14 pump - 10-29 system bleeding - 10-28 Pressure-control relief valve (braking system) - 9-15, 9-16 Pressure switches (air conditioning system) - 3-12 Pulse-air system - 6-18, 6-19 Punctures - 0-7

R Radiator grille - 11-6 Radio aerial - 12-27

IND-5

Radio/cassette player - 12-26 Reading light bulb - 12-13 Rear light cluster - 12-15 Rear view mirror - 11-17 Regulator (door window) - 11-12 Relays - 12-2, 12-5 relay box (ABS) - 9-17 Release bearing (clutch) - 8-5 Repair procedures - 0-12 Respraying - 11-4 Reversing lights bulb - 12-11 switch - 7A-3 Rings (piston) - 2B-21 Road test - 1-26 Roadwheel check - 1-24 Rocker cover - 2A-8 Roll bars - 10-10, 10-16, 10-20 Routine maintenance and servicing - 1-1 et seq procedures - 1-11 et seq schedule - 1-5 Rubbing strips - 11-21

S Safety first! - 0-10 air conditioning system - 3-10 alternator/charging system - 5-5 braking system - 9-4, 9-14

engine electrical system - 5-2 fuel and exhaust systems - 4-2 ignition system - 5-3 starting system - 5-7 Scratches - 11-3 Seat belts - 1-17, 11-22 Seat switch - 12-9 Seats - 11-21 Selector (automatic transmission)

assembly - 7B-3 cable - 7B-2 illumination bulb - 12-13 lever position sensor - 7B-3

Selector shaft oil seal (manual transmission) - 7A-3 Sender units coolant temperature - 3-5 engine oil level - 12-21 fuel gauge - 4-7 low air temperature - 12-21 oil level - 2A-26 Sensors (engine management system) - 6-11, 6-12 Service interval reminder - 12-21, 12-22 Servicing - see Routine maintenance Servo unit (braking system) - 9-14, 9-15 Shock absorber (rear suspension) - 10-19

Shoes (brake) - 9-7 Short-circuit (finding) - 12-4 Side protection mouldings - 11-21 Side repeater bulb - 12-10 Sidelight bulb - 12-10 Solenoid (starter motor) - 5-7 to 5-10 Spare parts - 0-9 Spark plug leads - 1-30 Spark plugs - 1-2, 1-29 Speakers - 12-27 Special tools - 0-12, 0-15 Speed control switch/actuator (cruise control system) - 12-24 Speedometer - 12-17 cable - 12-17 drive pinion (automatic transmission) - 7B-3 drive pinion (manual transmission) - 7A-2

IND-6 Spring (rear suspension, Estate) - 10-20 Starter motor - 5-7 to 5-10 Starter solenoid - 5-7 to 5-10 Starting system - 5-7 Steering - 10-1 et seq angles/alignment - 10-29

check - 1-23 column - 10-24, 10-26 fault diagnosis - 0-23 gear - 10-26 to 10-28 knuckle and hub assembly - 10-6 lock - 12-7 pump - 10-29 road test - 1-26 wheel - 10-23 Stop-lights

bulb = 12-11 switch - 9-19 Strut front suspension - 10-7, 10-9 rear suspension - 10-13, 10-16 Sump - 2A-22

Sunroof - 11-21 switch - 12-9 Support strut (tailgate) - 11-19 Suspension - 10-1 et seq anti-roll bars - 10-10, 10-16, 10-20 arm (rear) - 10-17, 10-21, 10-22 balljoint - 10-12 check - 1-23, 1-24 crossmember (rear) - 10-18, 10-23 fault diagnosis - 0-23 lower arm (front) - 10-11, 10-12 road test - 1-26 shock absorber (rear) - 10-19 spring (rear, Estate) - 10-20 strut (front) - 10-7, 10-9, 10-13, 10-16 tie-bar (rear) - 10-18, 10-22 Switches - 12-7 to 12-9, 12-21, 12-22, 12-24 oil pressure warning light - 2A-26 reversing light - 7A-3 stop-light - 9-19 traction control system - 9-17, 12-9

T Tachometer - 12-17 Tailgate - 1-25, 11-18 glass - 11-21 lock - 11-19 support strut - 11-19 washer - 12-25 wiper motor - 12-20 Tappets - 2A-16 TCS - see Traction control system TDC (locating) - 2A-8 Temperature gauge - 12-17 sender unit - 3-5 Throttle potentiometer - 6-12, 6-14

Tie-bar (rear suspension) - 10-18, 10-22 Tie-rod end - 10-29 Timer module - 12-5 Timing belt - 2A-12, 2A-13, 2A-15, 2A-16 Toe setting - 10-2, 10-29 Tools and working facilities - 0-13

Top Dead Centre (locating) - 2A-8 Towing - 0-8

Index

Er

Track rod end - 10-29 Tracking - 10-2, 10-29 Traction control system - 9-1 et seq switches - 9-17, 12-9 throttle actuator - 9-17 Transmission - 7A-1, 7B-1 et seq Trim panels door - 11-7 interior - 11-24 Trip computer module - 12-21 Tyre pressures - 1-2 Tyres - 1-13

U Underbody - 11-2 check - 1-24

views - 1-8 to 1-10 Underbonnet light bulb - 12-12 Upholstery and carpets - 11-2 Upper arm (rear suspension, Estate) - 10-22

V Vacuum hoses - 1-20 Vacuum servo unit (braking system) - 9-14, 9-15 Valve clearances - 2A-6 Valves - 2B-11 Vehicle identification numbers - 0-9 Vehicle speed sensor - 6-12, 6-14 Ventilation system - 3-1 et seq pollen filter - 1-26 Voltage regulator - 5-5, 5-6

W Warning light bulbs - 12-13, 12-16 Washer fluid level - 1-12 switch - 12-22 Washers - 12-25 Weights - 0-6 Wheel (steering) - 10-23 Wheel alignment and steering angles - 10-2, 10-29 Wheel arch liner - 11-28 Wheel changing - 0-7 Wheel cylinder (brake) - 9-9 Wheel sensor (ABS) - 9-16 Wheels - 1-24, 1-26 Window glass - 11-10 Window regulator - 11-12 Window switch - 12-8 Windscreen and rear window/tailgate glass - 11-21 Windscreen washers - 12-25 Windscreen wiper motor - 12-19 Wiper arms - 12-19 Wiper blades - 1-2 Wiper motor tailgate - 12-20 windscreen - 12-19 Wiper switch - 12-7 Wipers and washers check - 1-14 Wiring check (engine compartment) - 1-20 Wiring diagrams - 12-29 et seq Working facilities - 0-16

iy

P) iy

ml

)

ISBN 1 85010 923 0

CIN Ra sen pI Seay