Ford Mondeo (petrol engines). Manual - part 55

the specified mileage (or time) since the last
service has been reached.
4 To reset the service interval system and
turn off the light, a switch inside the glovebox
must be depressed for a minimum of 4
seconds with the ignition switched on. This
should be carried out by a Ford dealer if the
vehicle is still in the warranty period.

Component renewal

5 The following paragraphs describe brief
removal procedures for the auxiliary warning
system components. Disconnect the battery
negative (earth) lead before commencing
work (refer to Chapter 5, Section 1). Refitting
procedures are a reversal of removal.

Display warning bulb

6 Remove the control assembly.
7 Prise off the cover, and pull out the relevant
bulb and bulbholder.

Low air temperature warning sender
unit

8 Remove the front bumper.
9 Unclip the sender unit and disconnect the
multi-plug (see illustration).

Engine oil level sensor

10 Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
11 Place a container beneath the oil level
sensor, to catch any spilt oil.

12 Unscrew the screws and remove the
cover from the sensor.
13 Disconnect the multi-plug.
14 Unscrew and remove the sensor, and
remove the seal (see illustration).

Door ajar sensor

15 Remove the door lock as described in
Chapter 11, Section 14.
16 Unclip the sensor and disconnect the
multi-plug.

Low coolant warning switch

17 Refer to Chapter 3, Section 6.

Low washer fluid switch

18 Disconnect the multi-plug from the
washer fluid reservoir.
19 Drain or syphon out the fluid from the
reservoir.
20 Using a screwdriver, lever out the switch
from the reservoir (see illustration).

Service indicator reset switch

21 Remove the glove compartment lid as
described in Chapter 11, Section 32.
22 Carefully lever out the switch using a
small screwdriver.
23 Remove the rear cover and disconnect
the wiring (see illustration).

Control assembly

24 Remove the instrument panel surround,
referring to Section 10.

25 Unscrew the mounting screws,
disconnect the multi-plugs and remove the
assembly.

Bulb failure module

26 Remove the lower facia panel from under
the steering wheel.
27 Unclip the bulb failure module and
disconnect the multi-plug.

Note:  From November 1993, for added
security, a complex Bosch immobiliser system
was fitted to some models. For further details,
refer to your Ford dealer.
1 All UK models are fitted with an anti-theft
alarm system, incorporating movement
sensors and an ignition immobiliser. The
system is activated when the vehicle is
locked.
2 The system includes a start inhibitor circuit,
which makes it impossible to start the engine
with the system armed.
3 The movement sensors consist of two
ultrasonic units, located in the “B” pillars,
incorporating transmitters and receivers (see
illustrations). The receivers check that the
echo frequency matches the original
frequency. If there is any significant
difference, the system triggers the alarm.

20 Anti-theft alarm system - general

information

12•18 Body electrical system

19.9  Low air temperature sender unit

removal

1  Clip     2  Sender unit     3  Multi-plug

19.14  Engine oil level sensor removal

1  Cover    2  Multi-plug    3  Sensor    4  Seal

19.20  Removing the low washer fluid

switch

19.23  Service indicator switch removal

1  Lever out the switch    2  Cover    3  Wiring

20.3A  Disconnecting a movement sensor

multi-plug

20.3B  Removing a movement sensor

4 The system module is located on a bracket
beneath the right-hand side of the facia. The
set and reset switches are located in a
housing by the lock barrel holder in the doors,
tailgate or bootlid.
5 To allow temporary opening of the tailgate
or bootlid, an inhibit switch is fitted to the lock
barrel. This suppresses the alarm system until
the tailgate or bootlid is closed again.
6 Where remote central locking is fitted, an
infra-red receiver is located on the exterior
door handle (see illustration). Note that
excessive heat can destroy this receiver;
therefore, it should be covered with aluminium
tape if (for instance) a paint-drying heat
process is to be used.
7 The alarm system is fitted with its own horn.
On Hatchback and Saloon models, it is
located on the left-hand side of the luggage
compartment; on Estate models, it is located
on the right-hand side of the luggage
compartment 

(see illustration).

8 The alarm system incorporates a self-test
function, which can be activated by operating
the bonnet switch or one of the lock position
switches eight times within 10 seconds.
During the check, the horn or buzzer issues
acoustic signals which should occur every
time a door, bonnet or tailgate is opened. If
the doors are double-locked, the signal will
occur when something is moved within the
passenger compartment. A more
comprehensive test can be made using the
Ford FDS 2000 diagnostic tester.
9 The door lock switches associated with the
alarm system are located behind the door trim
panels (see illustration).

1 Cruise control is available as an option on
some models.
2 The cruise control system components are
shown in the accompanying illustration (see
illustration). The system is active at road
speeds between 25 mph and 125 mph.
3 The system comprises an electronic speed
control unit with integral actuator and

21 Cruise control system -

general information

Body electrical system  12•19

12

21.2  Cruise control component location on left-hand drive models

1  Speed control unit
2  Vehicle speed sensor (VSS)
3  Throttle valve actuator
4  Interrupt relay (vehicles with traction control 

system only)

5  Stop-light switch, brake and clutch pedal-

operated disable switches

6  Driver’s controls (buttons on steering wheel)

20.6  Infra-red receiver location on the

door handle

1  Receiver   2  Infra-red eye on the door handle

20.7  Alarm system horn location on

Hatchback and Saloon models

20.10  Alarm system door lock switch

removal

1  Clips (arrowed)     2  Multi-plug

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.
4 The driver-operated switches are mounted
on the steering wheel, and allow the driver to
control the various functions.
5 The vehicle speed sensor uses the
speedometer cable drive pinion to generate
pulses which are fed to the speed control unit.
6 The 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.
7 An indicator light on the instrument panel is
illuminated when the system is in operation.
8 The 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

9 Remove the steering column upper and
lower shrouds, with reference to Chapter 10.
10 Remove the air bag module as described
in Section 29.

11 Disconnect the multi-plugs, then unscrew
the screws and remove the switch.

Disable switches

12 Remove the lower facia panel from under
the steering column.
13 Disconnect the multi-plugs from the
clutch switch, brake pedal switch and stop-
light switch.
14 To remove the clutch and brake pedal
switches, twist them anti-clockwise. To
remove the stop-light switch, twist it
clockwise 

(see illustration).

15 Refitting 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

16 Remove the air cleaner as described in
Chapter 4.
17 Disconnect 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.
18 Unscrew the actuator mounting bolt, then

slide the actuator out of the mounting pin
holes.
19 Disconnect the multi-plug and remove the
assembly.
20 Depress the actuating cable cap locking
arm, and remove the cap by turning it anti-
clockwise (see illustration).
21 Gently raise the cable retaining lug by a
maximum of 0.5 mm, and push the cable end
out of the slot in the pulley.
22 When refitting, make sure that the cable
end locks into the slot in the pulley.
23 To 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.
24 To 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

1 Unscrew the bolts, and release the clips to
remove the radiator lower cover.
2 Unscrew the mounting bolts, and pull the
reservoir forwards slightly (see illustration).
For better access, it may be necessary to
remove the front bumper.
3 Disconnect the multi-plugs for the
windscreen washer pump and fluid level
sensor (see illustration).
4 Disconnect 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.
5 Withdraw the reservoir from the vehicle.
6 Pull 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 switch

21.15  Resetting the brake pedal and stop-

light switches

21.20  Removing the actuator cable

locking arm

22.2  Washer reservoir mounting bolts

(arrowed)

22.3  Disconnecting the washer pump and

level sensor multi-plugs

headlamp washer pump, from the reservoir
(see illustration).
7 Remove the rubber seals.

Washer nozzle (windscreen)

8 With the bonnet supported in its open
position, carefully disconnect the washer tube
from the bottom of the nozzle.
9 Using a screwdriver and working from
under the bonnet, carefully prise out the
nozzle. Where necessary, disconnect the
wiring for the nozzle heater.

Washer nozzle (rear window)

10 With the tailgate open, carefully pull off
the inner trim panel from the top of the
tailgate.
11 Pull the washer tube from the bottom of
the nozzle (see illustration).
12 Carefully prise the nozzle out of the
tailgate glass, then prise out the rubber
grommet 

(see illustrations). Where

necessary, disconnect the wiring for the
nozzle heater.

Refitting

13 Refitting is a reversal of the removal
procedure. In the case of the washer nozzles,
press them in until they are fully engaged. The
rear window washer nozzle must rest against
the rubber seal.

Note: Special tools are required to remove the
radio.

Coding

1 If a Ford “Keycode” unit is fitted, and the
unit and/or the battery is disconnected, the
unit will not function again on reconnection
until the correct security code is entered.
Details of this procedure are given in the
“Ford Audio Systems Operating Guide”
supplied with the vehicle when new, with the
code itself being given in a “Radio Passport”
and/or a “Keycode Label” at the same time.
2 For obvious security reasons, the re-coding
procedure is not given in this manual - if you

do not have the code or details of the correct
procedure, but can supply proof of ownership
and a legitimate reason for wanting this
information, the vehicle’s selling dealer may
be able to help.
3 Note that these units will allow only ten
attempts at entering the code - any further
attempts will render the unit permanently
inoperative until it has been reprogrammed by
Ford themselves. At first, three consecutive
attempts are allowed; if all three are incorrect,
a 30-minute delay is required before another
attempt can be made. Each of any
subsequent attempts (up to the maximum of
ten) can be made only after a similar delay.

Removal

4 Disconnect the battery negative (earth)
lead.
5 Where fitted, prise the cover/surround from
the front of the radio/cassette player. Note
that the cover is not fitted to all models.
6 In order to release the radio retaining clips,
two U-shaped rods must be inserted into the
special holes on each side of the radio (see
illustration). If possible, it is preferable to
obtain purpose-made rods from an audio
specialist, as these have cut-outs which snap
firmly into the clips so that the radio can be
pulled out. Pull the unit squarely from its
aperture, or it may jam. If the unit proves
difficult to withdraw, remove the cassette tray
(or where applicable, the CD player) from

beneath the unit, then reach through the
aperture and ease it out from behind.
7 With the radio partly withdrawn, disconnect
the feed, earth, aerial and speaker leads.
Where applicable, also detach and remove
the plastic support bracket from the rear of
the unit.

Refitting

6 Refitting is a reversal of removal. With the
leads reconnected to the rear of the unit,
press it into position until the retaining clips
are felt to engage. Reactivate the unit by
entering the correct code in accordance with
the maker’s manuals.

Removal

1 Disconnect the battery negative (earth)
lead. See Chapter 5, Section 1.
2 Unscrew the screws and remove the lower
facia panel.
3 The radio/cassette player power amplifier is
located beneath the facia.
4 Unscrew the cross-head screws, dis-
connect the wiring and remove the amplifier.

Refitting

5 Refitting is a reversal of the removal
procedure.

24 Radio/cassette player 

power amplifier - 
removal and refitting

23 Radio/cassette player -

coding, removal and refitting

Body electrical system  12•21

12

22.12B  . . . and prise out the rubber

grommet

23.6  Using the special U-shaped rods to

remove the radio

22.6  Pulling the windscreen washer pump

from the reservoir

22.11  Pull the washer tube from the

bottom of the nozzle

22.12A  Remove the nozzle from the

tailgate glass . . .