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
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