All about Ford Mondeo

Exterior light units - removal and refitting
Body electrical system / Exterior light units - removal and refitting


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 multiplug.

Place the unit to one side.

4 Disconnect the wiring multi-plug for the headlight unit (see illustration).

7.4 Disconnecting the headlight unit wiring multi-plug
7.4 Disconnecting the headlight unit wiring multi-plug

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.

7.8A Unscrew the outer mounting screws . . .
7.8A Unscrew the outer mounting screws . . .

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

7.8C . . . and withdraw the headlight unit assembly
7.8C . . . and withdraw the headlight unit assembly

7.8D Using a hacksaw to cut through the middle of the headlight back-piece,
7.8D Using a hacksaw to cut through the middle of the headlight back-piece, in order to fit a 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.

7.9A Release the clips . . .
7.9A Release the clips . . .

7.9B . . . and remove the headlight lens
7.9B . . . and remove the headlight lens

Front direction indicator 10 With the bonnet supported in its open position, loosen (but do not remove) the screw located above the front direction indicator (see illustration).

7.10 Loosen the front direction indicator retaining screw
7.10 Loosen the front direction indicator retaining screw

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.

7.12 Disconnecting the wiring plug from the indicator bulbholder
7.12 Disconnecting the wiring plug from the indicator bulbholder

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).

7.20A Rear light cluster mounting nuts (arrowed)
7.20A Rear light cluster mounting nuts (arrowed)

7.20B Removing the rear light cluster unit
7.20B Removing the rear light cluster unit

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.


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