Ford Mondeo (petrol engines). Manual - part 65

12•58

Wiring diagrams

Diagram 34: Radio/cassette and CD player (with subwoofer)

Introduction

A selection of good tools is a fundamental

requirement for anyone contemplating the
maintenance and repair of a motor vehicle.
For the owner who does not possess any,
their purchase will prove a considerable
expense, offsetting some of the savings made
by doing-it-yourself. However, provided that
the tools purchased meet the relevant national
safety standards and are of good quality, they
will last for many years and prove an
extremely worthwhile investment.

To help the average owner to decide which

tools are needed to carry out the various tasks
detailed in this manual, we have compiled
three lists of tools under the following
headings: Maintenance and minor repair,
Repair and overhaul, and Special. Newcomers
to practical mechanics should start off with
the Maintenance and minor repair tool kit, and
confine themselves to the simpler jobs around
the vehicle. Then, as confidence and
experience grow, more difficult tasks can be
undertaken, with extra tools being purchased
as, and when, they are needed. In this way, a
Maintenance and minor repair tool kit can be
built up into a Repair and overhaul tool kit over
a considerable period of time, without any
major cash outlays. The experienced do-it-
yourselfer will have a tool kit good enough for
most repair and overhaul procedures, and will
add tools from the Special category when it is
felt that the expense is justified by the amount
of use to which these tools will be put.

Maintenance and minor repair 
tool kit

The tools given in this list should be

considered as a minimum requirement if
routine maintenance, servicing and minor
repair operations are to be undertaken. We
recommend the purchase of combination
spanners (ring one end, open-ended the
other); although more expensive than open-
ended ones, they do give the advantages of
both types of spanner.
M Combination spanners:

Metric - 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 
19, 21, 22, 24 & 26 mm

M Adjustable spanner - 35 mm jaw (approx)

M Transmission drain plug key (Allen type)

M Set of feeler gauges

M Spark plug spanner (with rubber insert)

M Spark plug gap adjustment tool

M Brake adjuster spanner (where applicable)

M Brake bleed nipple spanner

M Screwdrivers:

Flat blade - approx 100 mm long x  6 mm dia
Cross blade - approx 100 mm long x 
6 mm dia

M Combination pliers

M Hacksaw (junior)

M Tyre pump

M Tyre pressure gauge

M Oil can

M Oil filter removal tool

M Fine emery cloth

M Wire brush (small)

M Funnel (medium size)

Repair and overhaul tool kit

These tools are virtually essential for

anyone undertaking any major repairs to a
motor vehicle, and are additional to those
given in the Maintenance and minor repair list.
Included in this list is a comprehensive set of
sockets. Although these are expensive, they
will be found invaluable as they are so
versatile - particularly if various drives are
included in the set. We recommend the half-
inch square-drive type, as this can be used
with most proprietary torque wrenches. If you
cannot afford a socket set, even bought
piecemeal, then inexpensive tubular box
spanners are a useful alternative.

The tools in this list will occasionally need to

be supplemented by tools from the Special
list:
M Sockets (or box spanners) to cover range in

previous list 

M Reversible ratchet drive (for use with

sockets) (see illustration)

M Extension piece, 250 mm (for use with

sockets)

M Universal joint (for use with sockets)

M Torque wrench (for use with sockets)

M Self-locking grips

M Ball pein hammer

M Soft-faced mallet (plastic/aluminium or

rubber)

M Screwdrivers:

Flat blade - long & sturdy, short (chubby), 
and narrow (electrician’s) types
Cross blade - Long & sturdy, and short

(chubby) types

M Pliers:

Long-nosed
Side cutters (electrician’s)
Circlip (internal and external)

M Cold chisel - 25 mm

M Scriber

M Scraper

M Centre-punch

M Pin punch

M Hacksaw

M Brake hose clamp

M Brake bleeding kit

M Selection of twist drills

M Steel rule/straight-edge

M Allen keys (inc. splined/Torx type) (see

illustrations)

M Selection of files

M Wire brush

M Axle stands

M Jack (strong trolley or hydraulic type)

M Light with extension lead

Special tools

The tools in this list are those which are not

used regularly, are expensive to buy, or which
need to be used in accordance with their
manufacturers’ manuals. Unless relatively
difficult mechanical jobs are undertaken
frequently, it will not be economic to buy
many of these tools. Where this is the case,
you could consider clubbing together with
friends (or joining a motorists’ club) to make a
joint purchase, or borrowing the tools against
a deposit from a local garage or tool hire
specialist. It is worth noting that many of the
larger DIY superstores now carry a large range
of special tools for hire at modest rates.

The following list contains only those tools

and instruments freely available to the public,
and not those special tools produced by the
vehicle manufacturer specifically for its dealer
network. You will find occasional references
to these manufacturers’ special tools in the
text of this manual. Generally, an alternative
method of doing the job without the vehicle
manufacturers’ special tool is given. However,
sometimes there is no alternative to using
them. Where this is the case and the relevant
tool cannot be bought or borrowed, you will
have to entrust the work to a franchised
garage.
M Valve spring compressor (see illustration)

M Valve grinding tool

M Piston ring compressor (see illustration)

M Piston ring removal/installation tool (see 

illustration)

M Cylinder bore hone (see illustration)

M Balljoint separator

M Coil spring compressors (where applicable)

M Two/three-legged hub and bearing puller 

(see illustration)

REF•1

Sockets and reversible ratchet drive

Spline bit set

Tools and Working Facilities

REF•2

Spline key set

Valve spring compressor

Piston ring compressor

Compression testing gauge

Clutch plate alignment set

Brake shoe steady spring cup removal tool

Piston ring removal/installation tool

Cylinder bore hone

Three-legged hub and bearing puller

Micrometer set

Vernier calipers

Dial test indicator and magnetic stand

Tools and Working Facilities

REF•3

M Impact screwdriver

M Micrometer and/or vernier calipers (see 

illustrations)

M Dial gauge (see illustration)

M Universal electrical multi-meter

M Cylinder compression gauge 

(see illustration)

M Clutch plate alignment set (see illustration)

M Brake shoe steady spring cup removal tool 

(see illustration)

M Bush and bearing removal/installation set 

(see illustration)

M Stud extractors (see illustration)

M Tap and die set (see illustration)

M Lifting tackle

M Trolley jack

Buying tools

For practically all tools, a tool factor is the

best source, since he will have a very
comprehensive range compared with the
average garage or accessory shop. Having
said that, accessory shops often offer
excellent quality tools at discount prices, so it
pays to shop around.

Remember, you don’t have to buy the most

expensive items on the shelf, but it is always
advisable to steer clear of the very cheap
tools. There are plenty of good tools around at

reasonable prices, but always aim to purchase
items which meet the relevant national safety
standards. If in doubt, ask the proprietor or
manager of the shop for advice before making
a purchase.

Care and maintenance of tools

Having purchased a reasonable tool kit, it is

necessary to keep the tools in a clean and
serviceable condition. After use, always wipe
off any dirt, grease and metal particles using a
clean, dry cloth, before putting the tools away.
Never leave them lying around after they have
been used. A simple tool rack on the garage
or workshop wall for items such as
screwdrivers and pliers is a good idea. Store
all normal spanners and sockets in a metal
box. Any measuring instruments, gauges,
meters, etc, must be carefully stored where
they cannot be damaged or become rusty.

Take a little care when tools are used.

Hammer heads inevitably become marked,
and screwdrivers lose the keen edge on their
blades from time to time. A little timely
attention with emery cloth or a file will soon
restore items like this to a good serviceable
finish.

Working facilities

Not to be forgotten when discussing tools is

the workshop itself. If anything more than
routine maintenance is to be carried out, some
form of suitable working area becomes
essential.

It is appreciated that many an owner-

mechanic is forced by circumstances to
remove an engine or similar item without the
benefit of a garage or workshop. Having done
this, any repairs should always be done under
the cover of a roof.

Wherever possible, any dismantling should

be done on a clean, flat workbench or table at
a suitable working height.

Any workbench needs a vice; one with a

jaw opening of 100 mm is suitable for most
jobs. As mentioned previously, some clean
dry storage space is also required for tools, as
well as for any lubricants, cleaning fluids,
touch-up paints and so on, which become
necessary.

Another item which may be required, and

which has a much more general usage, is an
electric drill with a chuck capacity of at least 8
mm. This, together with a good range of twist
drills, is virtually essential for fitting
accessories.

Last, but not least, always keep a supply of

old newspapers and clean, lint-free rags
available, and try to keep any working area as
clean as possible.

Bush and bearing removal/installation set

Stud extractor set

Tap and die set

Tools and Working Facilities