Ford Mondeo (petrol engines). Manual - part 46

11.3B  . . . and disconnect the multi-plug

uniform gap all round. Adjust the rear height
of the bonnet by repositioning it on the
hinges. Adjust the front height by
repositioning the lock (see Section 10) and
turning the rubber buffers on the engine
compartment front cross panel up or down to
support the bonnet (see illustration).

Removal

1 With the bonnet open, disconnect the
battery negative (earth) lead (Chapter 5,
Section 1).
2 Working inside the vehicle, remove the trim
from the “B” pillar, and pull off the door

weatherstrips from the bottom of the door
apertures.
3 Remove the clips and screws, and
withdraw the lower side trim, to give access to
the bonnet release lever (see illustration).
4 Release the outer cable from the lever
bracket.
5 Unscrew and remove the lever mounting
screws, and turn the lever clockwise through
a quarter-turn to disconnect it from the cable.
6 Remove the radiator grille (Section 7). Also
remove the backing panel from the engine
compartment front crossmember.
7 Release the inner and outer cables from the
lock.
8 Withdraw the cable from the engine
compartment, feeding it through the front
crossmember, and removing the grommet
from the bulkhead.

Refitting

9 Refitting is a reversal of the removal
procedure.

Removal

1 Remove the radiator grille (Section 7).
2 Release the inner and outer cables from the
bonnet lock.
3 Mark the position of the lock on the
crossmember, then unscrew the mounting
nuts and withdraw the lock.

Refitting and adjustment

4 Refitting is a reversal of the removal
procedure, starting by positioning the lock as
noted before removal.
5 If the front of the bonnet is not level with the
front wings, the lock may be moved up or
down within the mounting holes. After making
an adjustment, raise or lower the rubber
buffers to support the bonnet correctly.

Removal

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Carefully prise out the plastic cover with a
small screwdriver. Remove the screw, and

11 Door inner trim panel -

removal and refitting

10 Bonnet lock - removal,

refitting and adjustment

9 Bonnet release cable and

lever - removal and refitting

11•6 Bodywork and fittings

8.8  Removing the bonnet

8.9  Buffer for adjustment of the bonnet

front height

9.3  Bonnet release lever

11.2B  . . . remove the screw . . .

11.2A  Prise out the plastic cover . . .

11.2C  . . . and withdraw the bezel from the

inner door handle

11.3A  Remove the window operating

switch . . .

ease the bezel off the inner door handle (see
illustrations).
3 Where applicable, remove the window
operating switch and disconnect the multi-
plug (see illustrations).

Front door

4 Carefully prise out the cover, remove the
screws and withdraw the door pull handle
(see illustrations).
5 Prise off the plastic cap, remove the screw,
and withdraw the quarter bezel from the front
of the window opening (see illustrations).

Rear door

6 Prise off the cap, then remove the screw
and withdraw the door pull handle (see
illustrations).

Front and rear doors

7 On models fitted with manual (ie non-
electric) windows, fully shut the window, and
note the position of the regulator handle.
Release the spring clip by inserting a clean
cloth between the handle and the door trim.
Pull the cloth against the open ends of the clip
to release it, at the same time pulling the
handle from the regulator shaft splines.
Withdraw the handle (and where fitted, the
spacer) and recover the clip (see
illustrations).
8 Prise the caps from the trim panel retaining
screws, then remove the screws and lift off
the panel. Where a speaker is attached to the
trim panel, disconnect the multi-plug (see
illustrations).

Bodywork and fittings  11•7

11

11.7B  Withdrawing the window regulator

handle

11.7C  Recover the spring clip from the

window regulator handle

11.8A  Prise out the caps . . .

11.6A  Remove the screw . . .

11.6B  . . . and withdraw the rear door pull

handle

11.7A  Using a clean cloth to release the

spring clip from the window regulator

handle

11.5A  Remove the plastic cap and the

screw . . .

11.5B  . . . then withdraw the quarter bezel

11.4A  Remove the cover . . .

11.4B  . . . then remove the screws and

withdraw the door pull handle

9 If necessary, the foam insulation may be
removed from the door. First remove the
speaker as described in Chapter 12.
10 On models with manual windows, remove
the foam spacer from the regulator spindle
(see illustration).
11 On the rear door, unscrew the screws and
remove the door pull bracket (see
illustration).
12 Carefully cut the adhesive with a knife,
and remove the foam insulation (see
illustration).

Refitting

13 Refitting is a reversal of the removal
procedure.

Removal

Front (manual/non-electric)

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Remove the door inner trim panel (Sec-
tion 11).
3 Remove the door exterior mirror (Sec-
tion 16).
4 Temporarily refit the regulator handle on its
splines.
5 Lower the window until the glass support
bracket is visible through the holes in the door
inner panel. Remove the regulator handle.

12 Door window glass - 

removal and refitting

11•8 Bodywork and fittings

11.8B  . . . remove the inner-facing 

screws . . .

11.8C  . . . and the side screws . . .

11.8D  . . . then lift off the trim panel

11.10  Removing the foam spacer

11.11  Removing the door pull bracket

from a rear door

11.12  Removing the foam insulation

11.8E  Door trim panel components

1  Door
2  Foam seal
3  Trim panel
4  Top mounting
5  Centre mounting

6 Carefully prise off the weatherstrip from the
outside of the door.
7 Support the glass, then unscrew the bolts
from the support bracket.
8 Lift the glass from the door while tilting it at
the rear, and withdraw it from the outside.

Front (electric)

9 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
10 Remove the door inner trim panel (Sec-
tion 11).
11 Remove the door exterior mirror (Section 16).
12 Temporarily reconnect the battery and the
window operating switch. Lower the window
until the support bracket and bolts are visible
through the holes in the door inner panel (see
illustration). Disconnect the battery lead and
the operating switch again.
13 Carefully prise off the weatherstrip from
the outside of the door (see illustration).
14 Support the glass, then unscrew the bolts
from the support bracket.
15 Lift the glass from the door while tilting it
at the rear, and withdraw it from the outside
(see illustration).

Rear (manual/non-electric)

16 Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
17 Remove the door inner trim panel (Sec-
tion 11).
18 Temporarily refit the regulator handle on
its splines.

19 Lower the window until the glass support
bracket and bolts are visible through the holes
in the door inner panel. Remove the regulator
handle.
20 Support the glass, then unscrew the bolts
from the support bracket.
21 Unscrew the screws, and remove the air
vent grilles from the rear of the rear door (see
illustrations).
22 Carefully prise off the weatherstrip from
the outside of the door.
23 Have an assistant raise the glass from the
outside, and hold it near its shut position.
24 Loosen (but do not remove) the three
regulator mounting bolts, then slide the top
bolts to the right, and push them out. Slide the
bottom bolt upwards, and push it out. Lower
the regulator assembly inside the door.
25 Working inside the door, lower the glass
until it is below the regulator position, and
move the glass to the outer side of its
channels.
26 With the help of an assistant, lift the glass
out of the door, and withdraw it from the
outside (see illustration).

Rear (electric)

27 The procedure is as just described for
manual windows, making allowances for the
difference in the regulator mechanism.

Refitting

All doors

28 Refitting is a reversal of the removal

procedure, making sure that the glass is
correctly located in the support bracket.

Removal

1 Remove the window glass (Section 12).
2 Loosen (but do not remove) the regulator
and manual winder/electric motor mounting
bolts (see illustrations).
3 Twist the winder or motor (as applicable) in
the bolt slots, and push it inwards.
4 Slide the top bolts to the right, and push
them out. Slide the bottom bolt upwards, and
push it out.

13 Door window regulator -

removal and refitting

Bodywork and fittings  11•9

11

12.21B  . . . and remove the air vent grilles

from the rear door

12.26  Lifting the glass from the rear door

13.2A  Window regulator upper mounting

bolts (front door)

12.12  Window support bracket bolts

(arrowed) viewed through the holes in the

door inner panel

12.13  Removing the weatherstrip from the

outside of the door

12.15  Lifting the glass from the front door

12.21A  Unscrew the screws . . .