Ford Mondeo (petrol engines). Manual - part 47

5 On electric windows, disconnect the wiring
multi-plug from the motor (see illustration).
6 Withdraw the window regulator mechanism
from inside the door, through the hole in the
inner panel (see illustrations).

Refitting

7 Refitting is a reversal of the removal
procedure.

Removal

Front door exterior handle

1 Remove the door inner trim panel (Sec-
tion 11).
2 Use a knife to cut through the adhesive
strip, so that the foam insulator can be peeled
back locally for access to the lock. Do not
peel back the foam insulator without first
cutting through the adhesive strip, otherwise
the insulator will be damaged. To ensure a
good seal when the insulator is pressed back,
do not touch the adhesive strip.
3 Unscrew and remove the two bolts for the
exterior handle outer bezel, and remove the
bezel (see illustrations).

14 Door handle and lock

components - 
removal and refitting

11•10 Bodywork and fittings

13.2B  Electric window motor mounting

bolts (front door)

13.2C  Window regulator mounting bolts -

arrowed (rear door)

13.2D  Manual winder mounting bolts (rear

door)

13.5  Disconnecting the wiring multi-plug

from an electrically-operated window

13.6A  Removing the window regulator

mechanism from the front door

13.6B  Front door window regulator

removed from the vehicle

13.6C  Removing the window regulator

mechanism from the rear door

13.6D  Rear door window regulator

removed from the vehicle

14.3A  Remove the two bolts (arrowed) . . .

14.3B  . . . followed by the exterior handle

bezel

4 Unscrew and remove the lock mounting
bolts on the inner rear edge of the door, and
remove the plate. Also remove the additional
support screw (see illustrations).
5 Unclip and disconnect the wiring multi-
plugs for the central locking and alarm
systems (see illustration).
6 Disconnect the wiring multi-plug from the
door lock.
7 Disconnect the inner handle illumination
light. Undo the screws and remove the inner
handle. Disconnect the operating cable from
the inner handle, as described later in this
Section (see illustrations).
8 Manipulate the lock and handle assembly
as necessary, and disconnect the wiring
multi-plugs for the alarm sensor and central
locking. Withdraw the complete assembly
from inside the door (see illustrations).
9 To disconnect the handle assembly from
the lock bracket, slide the rubber posts
inwards, and push out the assembly (see
illustration).
10 To remove the handle itself, twist the door
handle through a quarter-turn, and pull out the
connecting rods (see illustration).
11 Remove the alarm sensor and the central
locking “Set-reset” sensor (see illustration).

Rear door exterior handle

12 Remove the door inner trim panel (Sec-
tion 11).
13 Use a knife to cut through the adhesive

Bodywork and fittings  11•11

11

14.8B  Front door lock and exterior handle

assembly removed from the vehicle

14.9  Disconnecting the handle assembly

from the lock bracket

14.10  Pulling out the handle connecting

rods

14.4A  Unscrew the lock mounting 

bolts . . .

14.4B  . . . and remove the plate

14.4C  Removing the additional support

screw

14.5  Disconnecting the central locking

and alarm system wiring multi-plugs

14.7A  Removing the inner handle

14.7B  Disconnecting the operating cable

from the inner handle

14.8A  Removing the lock and exterior

handle assembly from inside the door

strip, so that the foam insulator can be peeled
back for access to the lock. Do not peel back
the foam insulator without first cutting through
the adhesive strip. To ensure a good seal
when the insulator is pressed back, do not
touch the adhesive strip.
14 Prise out the plug from the rear edge of
the door, then unscrew the handle mounting
nuts (see illustrations).
15 Prise up the clip, and disconnect the
operating rod from the lock (see illustration).
16 Withdraw the handle from the outside of
the door (see illustration).

Interior handle

17 Remove the door inner trim panel (Sec-
tion 11).
18 Use a knife to cut through the adhesive
strip, so that the foam insulator can be peeled

back for access to the lock. Do not peel back
the foam insulator without first cutting through
the adhesive strip. To ensure a good seal
when the insulator is pressed back, do not
touch the adhesive strip.
19 Disconnect the interior handle illumination
light.
20 Undo the screws and remove the interior
handle.
21 To remove the cable, first pull back the
plastic outer cable end and blanking piece.
Apply light inward pressure to the control
lever, with the lever in the locked position,
until the inner cable is aligned with the release
slot in the bottom of the cable holder.
22 Push down on the cable ferrule, and
disconnect the inner cable. Remove the
handle assembly.

Lock barrel

23 Remove the exterior handle as described
earlier in this Section.
24 Prise out the barrel retaining tab from the
handle body, using a small screwdriver (see
illustration).
25 Insert the key, turn it so that it engages
the barrel, then pull out the barrel (see
illustration).

Lock motor - front door

26 Remove the exterior handle as described
earlier in this Section.
27 Extract the clip, and pull out the operating
rod.
28 Remove the operating rod from the plastic
bush, by turning it through a quarter-turn.
29 Release the sensor wiring loom from the
clip.

11•12 Bodywork and fittings

14.11  Removing the central locking “Set-

reset” sensor

14.14A  Prise out the plug . . .

14.14B  . . . and unscrew the handle

mounting nuts

14.25  . . . and pull out the lock barrel

14.31  Unclipping the door-ajar sensor

14.32  Removing the plastic shield from the

locating post

14.15  Disconnect the operating rod from

the lock

14.16  Removing the rear door exterior

handle

14.24  Prise out the barrel retaining tab . . .

30 Detach the mounting plate from the lock.
31 Release the door-ajar sensor from the clip
(see illustration).
32 Prise the plastic shield from the locating
post (see illustration).
33 Slide the outer cable from the lock
bracket (see illustration), then turn the inner
cable through a quarter-turn to remove it from
the bell crank.
34 Unscrew the mounting screws and
remove the lock motor (see illustration).

Lock motor - rear door

35 Remove the exterior handle as described
earlier in this Section.
36 Unscrew and remove the three lock
mounting screws.
37 Release the sensor wiring loom from the
clip on the door.
38 Disconnect the wiring multi-plug from the
door lock.
39 Disconnect the interior handle illumination
light.
40 Remove the screws, and remove the
interior handle.
41 Remove the lock assembly.
42 Release the door-ajar sensor from the
clip.
43 Prise the plastic shield from the locating
post.
44 Slide the outer cable from the lock
bracket, then turn the inner cable through a
quarter-turn to remove it from the bell crank.
45 Unscrew the mounting screws and

remove the lock motor.

Striker

46 Using a pencil, mark the position of the
striker.
47 Undo the mounting screws using a Torx
key, and remove the striker.

Check strap

48 Disconnect the battery negative (earth)
lead (Chapter 5, Section 1).
49 Using a Torx key, unscrew and remove
the check strap mounting screw(s). On the
front door, there are two screws; on the rear
door, there is only one.
50 Prise the rubber grommet from the door
aperture, then unscrew the mounting nuts and
withdraw the check strap from the door.

Refitting

Handles (exterior and interior)

51 Refitting is a reversal of the removal
procedure.

Lock barrel

52 Check that the retaining clip is fitted
correctly.
53 Align the grooves on the barrel with the
grooves on the body and operating lever, then
carefully push the barrel into the handle until it
engages the clip.
54 The remaining refitting procedure is a
reversal of removal.

Lock motor

55 Refitting is a reversal of the removal
procedure.

Striker

56 Refitting is a reversal of the removal
procedure, but check that the door lock
passes over the striker centrally. If necessary,
re-position the striker before fully tightening
the mounting screws.

Check strap

59 Refitting is a reversal of the removal
procedure.

Removal

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Using a Torx key, unscrew and remove the
check strap mounting screw(s). On the front
door, there are two screws; on the rear door,
there is only one (see illustrations).
3 Disconnect the wiring connector(s) by
twisting them anti-clockwise. On the front
door, there are two connectors; on the rear
door, there is only one (see illustration).
4 Extract the small circlips from the top of the
upper and lower hinge pins (see illustration).
5 Have an assistant support the weight of the

15 Door - removal and refitting

Bodywork and fittings  11•13

11

15.2B  Front door check strap removed

15.3  Disconnecting a door wiring

connector

15.4  Extract the small circlips . . .

14.33  Slide the outer cable from the lock

bracket

14.34  Removing a lock motor

15.2A  Front door check strap mounting

screw removal