Ford Mondeo (petrol engines). Manual - part 53

28 Depress and twist the appropriate bulb to
remove it from the bulbholder (see
illustrations).
29 Fit the new bulb using a reversal of the
removal procedure. Make sure that the rear
light cluster is fully inserted.

Number plate light

30 Remove the cross-head screws from the
number plate light, and remove the light unit
(see illustration).
31 Release the festoon-type bulb from the
contact springs (see illustration).
32 Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.

12•10 Body electrical system

5.26B  . . . and unclip the trim cover

5.27A  Pressing the two plastic locking

tabs together (Estate)

5.30  Remove the cross-head screws . . .

5.31  . . . for access to the festoon-type

bulb

5.27B  Removing the rear light cluster

(Estate)

5.28A  Removing a bulb from the rear light

cluster bulbholder

5.27C  Removing the rear light cluster

(Saloon)

5.28B  Bulb positions in the rear light cluster

Engine compartment light

1 With the bonnet open, pull the wedge-type
bulb from the bulbholder.
2 Fit the new bulb using a reversal of the
removal procedure.

Interior lights

3 Switch off the interior light by locating the
switch in its middle position.
4 Using a small screwdriver, carefully prise
out the light or bulb cover, as applicable (see
illustration).
5 Lift up the reflector, then release the
festoon-type bulb from the contact springs
(see illustration).
6 Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.

Reading light

7 With the reading light switched off, prise
out the light using a small screwdriver.
8 Hinge back the contact plate, and release
the festoon-type bulb from the contact
springs.

9 Fit the new bulb using a reversal of the
removal procedure. Make sure that the
tension of the contact springs is sufficient to
hold the bulb firmly.

Instrument panel illumination and
warning lights

10 Remove the instrument panel as
described in Section 10.
11 Twist the bulbholder anti-clockwise to
remove it (see illustration).
12 Fit the new bulbholder using a reversal of
the removal procedure.

Foglight warning indicator

13 Using a screwdriver, prise out the
indicator from the facia, and disconnect the
multi-plug.
14 Twist the bulbholder anti-clockwise with
the screwdriver, and remove it (see
illustration).
15 Fit the new bulb using a reversal of the
removal procedure.

Hazard warning light

16 Pull the cover directly up from the switch,
then remove the bulb (see illustrations).
17 Fit the new bulb using a reversal of the
removal procedure.

Glovebox light

18 Open the glovebox, then pull out the
wedge-type bulb from the light located under
the upper edge.

Heater fan switch illumination

19 Pull off the switch knob, then depress and
twist the bulb to remove it.

Automatic transmission selector
panel illumination

20 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
21 Remove the ashtray.
22 Select Neutral, then prise out the panel
from the centre console.
23 Disconnect the multi-plug from the
overdrive control switch.
24 Disconnect the bulbholder and pull out
the wedge-type bulb.
25 Fit the new bulb using a reversal of the
removal procedure.

Interior door handle illumination

26 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
27 Remove the door interior trim panel as
described in Chapter 11.
28 Using a knife, cut free the foam
watershield for access to the rear of the
interior door handle.
29 Pull out the bulbholder and remove the
bulb.

Clock illumination

30 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
31 Remove the clock as described in Sec-
tion 13.

6 Bulbs (interior lights) - renewal

Body electrical system  12•11

12

6.14  Removing the bulb from the foglight

warning indicator

6.16A  Pull off the hazard warning light

cover . . .

6.16B  . . . and remove the bulb

6.4  Prise out the interior light with a

screwdriver

6.5  Lifting the reflector from the interior

light

6.11  Removing a bulb from the rear of the

instrument panel

32 Twist the bulbholder anti-clockwise using
a screwdriver, then remove the bulbholder
from the rear of the clock (see illustrations).

Heater control illumination

33 Remove the heater control panel (Chapter
3), then twist the bulbholder anti-clockwise
and remove the bulb from the rear of the
panel.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).

Headlight unit

2 With the bonnet supported in its open
position, loosen (but do not remove) the screw
located above the front direction indicator.
3 Withdraw the front direction indicator unit
forwards, and disconnect the wiring multi-
plug. Place the unit to one side.
4 Disconnect the wiring multi-plug for the
headlight unit (see illustration).
5 Remove the radiator grille as described in
Chapter 11.
6 Remove the front bumper as described in
Chapter 11.
7 The headlights fitted from new are a single
unit, joined by a plastic back-piece running
across the front of the vehicle. However, if it is
required to renew a headlight unit on one side

only, the back-piece must first be removed
complete, then cut in half on the bench.
8 Unscrew the mounting bolts from each side
of the headlight unit, and withdraw the unit
from the front of the vehicle (see
illustrations). Use a hacksaw to cut through
the centre of the headlight unit (ie between the
two headlights), and obtain a connecting kit
from a Ford dealer to attach the new unit.
9 If necessary, the lens may be removed
separately by releasing the clips (see
illustrations). To remove the diffuser, release
the clips, then remove the rubber seal.

Front direction indicator

10 With the bonnet supported in its open
position, loosen (but do not remove) the screw

7 Exterior light units - 

removal and refitting

12•12 Body electrical system

6.32A  Twist the bulbholder 

anti-clockwise . . .

6.32B  . . . and remove it from the rear of

the clock

7.4  Disconnecting the headlight unit

wiring multi-plug

7.8D  Using a hacksaw to cut through the

middle of the headlight back-piece, in

order to fit a new unit

7.9A  Release the clips . . .

7.9B  . . . and remove the headlight lens

7.8A  Unscrew the outer mounting 

screws . . .

7.8B  . . . and inner mounting screws . . .

7.8C  . . . and withdraw the headlight unit

assembly

located above the front direction indicator
(see illustration).
11 Withdraw the front direction indicator light
unit.
12 Rotate 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)

13 Unscrew the cross-head screws securing
the front foglight unit to the valance, and
withdraw the light unit from the valance.
14 Prise open the plastic clips, and remove
the rear cover from the light unit.
15 Release the spring clips and withdraw the
bulb, then pull off the wiring connector.
Remove the foglight unit.

Rear light cluster

16 With the tailgate or bootlid open, unhook
the parcel net (where fitted) from the rear of
the luggage compartment.
17 On 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.
18 Remove the screws, and press the rear
light trim cover from the guides (where
applicable).
19 Disconnect the wiring multi-plug.
20 Unscrew the four mounting nuts, and
withdraw the light unit from the outside of the
vehicle (see illustrations).

Rear number plate light assembly

21 Remove both number plate lights as
described in Section 5.
22 With the tailgate or bootlid open, remove
the screws and withdraw the inner trim panel.
23 Unscrew the nuts, and remove the outer
cover and number plate base from the
tailgate.
24 Disconnect the multi-plug and remove the
light assembly.

Refitting

25 Refitting 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.

1 Accurate 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.
2 Temporary 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).
3 Before 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.

4 Whenever 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

1 Remove the headlight unit as described in
Section 7, then remove the cover.
2 Disconnect the wiring multi-plug from the
motor.
3 Rotate the motor upwards approximately
60

∞

, then pull it forwards slightly.

4 Disconnect the adjustment spindle by
pressing the ball coupling to one side, away
from the socket on the reflector.
5 Withdraw the motor from the headlight unit.

Refitting

6 Refitting is a reversal of the removal
procedure, but make sure that the motor is
turned down until it engages the stop.

Removal

1 Disconnect 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 screw

7.12  Disconnecting the wiring plug from

the indicator bulbholder

7.20A  Rear light cluster mounting nuts

(arrowed)