1993 FORD MONDEO Service Repair Manual

Exhaust system
MStart the engine. With your assistant
holding a rag over the tailpipe, check the
entire system for leaks. Repair or renew
leaking sections.
Jack up the front and rear of the vehicle,
and securely support it on axle stands.
Position the stands clear of the suspension
assemblies. Ensure that the wheels are
clear of the ground and that the steering
can be turned from lock to lock.
Steering mechanism
MHave your assistant turn the steering from
lock to lock. Check that the steering turns
smoothly, and that no part of the steering
mechanism, including a wheel or tyre, fouls
any brake hose or pipe or any part of the body
structure.
MExamine the steering rack rubber gaiters
for damage or insecurity of the retaining clips.
If power steering is fitted, check for signs of
damage or leakage of the fluid hoses, pipes or
connections. Also check for excessive
stiffness or binding of the steering, a missing
split pin or locking device, or severe corrosion
of the body structure within 30 cm of any
steering component attachment point.
Front and rear suspension and
wheel bearings
MStarting at the front right-hand side, grasp
the roadwheel at the 3 o’clock and 9 o’clock
positions and shake it vigorously. Check for
free play or insecurity at the wheel bearings,
suspension balljoints, or suspension mount-
ings, pivots and attachments.
MNow grasp the wheel at the 12 o’clock and
6 o’clock positions and repeat the previous
inspection. Spin the wheel, and check for
roughness or tightness of the front wheel
bearing.
MIf excess free play is suspected at a
component pivot point, this can be confirmed
by using a large screwdriver or similar tool and
levering between the mounting and the
component attachment. This will confirm
whether the wear is in the pivot bush, its
retaining bolt, or in the mounting itself (the bolt
holes can often become elongated).
MCarry out all the above checks at the other
front wheel, and then at both rear wheels.
Springs and shock absorbers
MExamine the suspension struts (when
applicable) for serious fluid leakage, corrosion,
or damage to the casing. Also check the
security of the mounting points.
MIf coil springs are fitted, check that the
spring ends locate in their seats, and that the
spring is not corroded, cracked or broken.
MIf leaf springs are fitted, check that all
leaves are intact, that the axle is securely
attached to each spring, and that there is no
deterioration of the spring eye mountings,
bushes, and shackles.MThe same general checks apply to vehicles
fitted with other suspension types, such as
torsion bars, hydraulic displacer units, etc.
Ensure that all mountings and attachments are
secure, that there are no signs of excessive
wear, corrosion or damage, and (on hydraulic
types) that there are no fluid leaks or damaged
pipes.
MInspect the shock absorbers for signs of
serious fluid leakage. Check for wear of the
mounting bushes or attachments, or damage
to the body of the unit.
Driveshafts
(fwd vehicles only)
MRotate each front wheel in turn and inspect
the constant velocity joint gaiters for splits or
damage. Also check that each driveshaft is
straight and undamaged.
Braking system
MIf possible without dismantling, check
brake pad wear and disc condition. Ensure
that the friction lining material has not worn
excessively, (A) and that the discs are not
fractured, pitted, scored or badly worn (B).
MExamine all the rigid brake pipes
underneath the vehicle, and the flexible
hose(s) at the rear. Look for corrosion, chafing
or insecurity of the pipes, and for signs of
bulging under pressure, chafing, splits or
deterioration of the flexible hoses.
MLook for signs of fluid leaks at the brake
calipers or on the brake backplates. Repair or
renew leaking components.
MSlowly spin each wheel, while your
assistant depresses and releases the
footbrake. Ensure that each brake is operating
and does not bind when the pedal is released.
3Checks carried out
WITH THE VEHICLE RAISED
AND THE WHEELS FREE TO
TURN
0•9MOT Test Checks
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0•10
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test
can be carried out later to check that the
vehicle pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-
bearing areas. (These include chassis box
sections, side sills, cross-members, pillars,
and all suspension, steering, braking system
and seat belt mountings and anchorages.)
Any corrosion which has seriously reduced
the thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allow
the engine speed to return to idle, and watchfor smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time or writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000
rpm; if the HC level is then 1200 ppm or less,
this counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM
MOT Test Checks
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0•11Roadside Repairs
To change a wheel, remove the spare
wheel and jack, apply the handbrake, and
chock the wheel diagonally opposite the
one to be changed. On manual transmission
models, select first or reverse gear; on
automatic transmission models, place the
selector lever in “P”. Make sure that the
vehicle is located on firm level ground. Use
the flat end of the wheelbrace carefully to
remove the trim covering the wheel nuts,
then slightly loosen the wheel nuts with the
brace (see illustrations). Locate the jack
head in the jacking point nearest to the
wheel to be changed, ensuring that the
channel in the jack head fits over the body
flange (see illustrations)and turn its
handle to raise the jack. When the wheel is
clear of the ground, remove the nuts and lift
off the wheel. Fit the spare wheel, and
moderately tighten the nuts. Lower the
vehicle, then tighten the nuts fully and refit
the trim. With the spare wheel in position,
remove the chock, and stow the jack and
tools.
When jacking up the vehicle to carry out
repair or maintenance tasks, position the jack
as follows.
If the front of the vehicle is to be raised,
either place the jack head under the sump,
with a block of wood to prevent damage, or
place a jacking beam across the two front
points “B” shown in the accompanying
illustration, and lift the vehicle evenly.
To raise the rear of the vehicle, place a
jacking beam across the two rear points “B”
shown in the accompanying illustration, and
lift the vehicle evenly.
To raise the side of the vehicle, place the
jack head under the appropriate point
indicated in the accompanying illustration - if
a trolley jack or similar is used on the points
“A” provided for the vehicle’s jack, make up a
wooden spacer with a groove cut in it to
accept the underbody flange, so that there isno risk of the jack slipping or buckling the
flange. Never work under, around or near a
raised vehicle unless it is adequately
supported in at least two places with axle
stands or suitable sturdy blocks.
The vehicle may be towed, for breakdown
recovery purposes only, using the towing eyes
positioned at the front and rear of the vehicle
(see illustrations). These eyes are intended
for towing loads only, and must not be used
for lifting the vehicle, either directly or
indirectly.If the vehicle is equipped with automatic
transmission, the following precautions must
be observed if the vehicle is to be towed,
particularly if any kind of transmission fault is
suspected. Preferably, a front-end-suspended
tow should be used (ie with the front wheels
off the ground). If this is not possible, place
the selector lever in “N” and tow the vehicle -
forwards only, never backwards - for a
distance of no more than 30 miles (50 km),
and at speeds no greater than 30 mph
(50 km/h).
Jacking, towing and wheel changing
Front towing eyeRear towing eye
Use flat end of wheelbrace to remove trim
covering roadwheel nutsSlacken roadwheel nuts in diagonal
sequence
With jack base on firm ground, locate jack
head in jacking point - indentations
(arrowed) in sill identify jacking points
Jacking and supporting
points
A Jacking points (for
vehicle jack in roadside
use) - support points (for
axle stands in
servicing/overhaul work)
B Jacking points (for
trolley jack or workshop
hoist in
servicing/overhaul work)
- additional support
points
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0•12
When jump-starting a car using a
booster battery, observe the following
precautions:
A)Before connecting the booster
battery, make sure that the ignition is
switched off.
B)Ensure that all electrical equipment
(lights, heater, wipers, etc) is
switched off.C)Make sure that the booster battery is
the same voltage as the discharged
one in the vehicle.
D)If the battery is being jump-started
from the battery in another vehicle,
the two vehcles MUST NOT TOUCH
each other.
E)Make sure that the transmission is in
neutral (or PARK, in the case of
automatic transmission).
Jump starting will get you out
of trouble, but you must correct
whatever made the battery go
flat in the first place. There are
three possibilities:
1The battery has been drained by
repeated attempts to start, or by
leaving the lights on.
2The charging system is not working
properly (alternator drivebelt slack
or broken, alternator wiring fault or
alternator itself faulty).
3The battery itself is at fault
(electrolyte low, or battery worn out).
Connect one end of the red jump lead to
the positive (+) terminal of the flat
batteryConnect the other end of the red lead to
the positive (+) terminal of the booster
battery.Connect one end of the black jump lead
to the negative (-) terminal of the
booster battery
Connect the other end of the black
jump lead to a bolt or bracket on the
engine block, well away from the
battery, on the vehicle to be started.
123
4
Make sure that the jump leads will not
come into contact with the fan, drive-
belts or other moving parts of the
engine.5
Start the engine using the booster
battery, then with the engine running at
idle speed, disconnect the jump leads in
the reverse order of connection.6
Roadside Repairs
Booster battery (jump) starting
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0•13Roadside Repairs
Puddles on the garage floor or drive, or
obvious wetness under the bonnet or
underneath the car, suggest a leak that needs
investigating. It can sometimes be difficult to
decide where the leak is coming from,
especially if the engine bay is very dirty
already. Leaking oil or fluid can also be blown
rearwards by the passage of air under the car,
giving a false impression of where the
problem lies.Warning: Most automotive oils
and fluids are poisonous. Wash
them off skin, and change out of
contaminated clothing, without
delay.
Identifying leaks
The smell of a fluid leaking
from the car may provide a
clue to what’s leaking. Some
fluids are distictively coloured.
It may help to clean the car carefully
and to park it over some clean paper
overnight as an aid to locating the
source of the leak.
Remember that some leaks may only
occur while the engine is running.
Sump oil
Gearbox oil
Brake fluid Power steering fluid Oil from filter
Antifreeze
Engine oil may leak from the drain plug......or from the base of the oil filter.
Leaking antifreeze often leaves a crystalline
deposit like this.Gearbox oil can leak from the seals at the
inboard ends of the driveshafts.
A leak occurring at a wheel is almost
certainly brake fluid.Power steering fluid may leak from the pipe
connectors on the steering rack.
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0•14Conversion Factors
Length (distance)
Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in)
Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft)
Miles x 1.609 = Kilometres (km) x 0.621 = Miles
Volume (capacity)
Cubic inches (cu in; in3) x 16.387 = Cubic centimetres (cc; cm3) x 0.061 = Cubic inches (cu in; in3)
Imperial pints (Imp pt) x 0.568 = Litres (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Litres (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Litres (l) x 1.057 = US quarts (US qt)
Imperial gallons (Imp gal) x 4.546 = Litres (l) x 0.22 = Imperial gallons (Imp gal)
Imperial gallons (Imp gal) x 1.201 = US gallons (US gal) x 0.833 = Imperial gallons (Imp gal)
US gallons (US gal) x 3.785 = Litres (l) x 0.264 = US gallons (US gal)
Mass (weight)
Ounces (oz) x 28.35 = Grams (g) x 0.035 = Ounces (oz)
Pounds (lb) x 0.454 = Kilograms (kg) x 2.205 = Pounds (lb)
Force
Ounces-force (ozf; oz) x 0.278 = Newtons (N) x 3.6 = Ounces-force (ozf; oz)
Pounds-force (lbf; lb) x 4.448 = Newtons (N) x 0.225 = Pounds-force (lbf; lb)
Newtons (N) x 0.1 = Kilograms-force (kgf; kg) x 9.81 = Newtons (N)
Pressure
Pounds-force per square inch x 0.070 = Kilograms-force per square x 14.223 = Pounds-force per square inch
(psi; lbf/in2; lb/in2) centimetre (kgf/cm2; kg/cm2) (psi; lbf/in2; lb/in2)
Pounds-force per square inch x 0.068 = Atmospheres (atm) x 14.696 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inch x 0.069 = Bars x 14.5 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inch x 6.895 = Kilopascals (kPa) x 0.145 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Kilopascals (kPa) x 0.01 = Kilograms-force per square x 98.1 = Kilopascals (kPa)
centimetre (kgf/cm
2; kg/cm2)
Millibar (mbar) x 100 = Pascals (Pa) x 0.01 = Millibar (mbar)
Millibar (mbar) x 0.0145 = Pounds-force per square inch x 68.947 = Millibar (mbar)
(psi; lbf/in
2; lb/in2)
Millibar (mbar) x 0.75 = Millimetres of mercury (mmHg) x 1.333 = Millibar (mbar)
Millibar (mbar) x 0.401 = Inches of water (inH
2O) x 2.491 = Millibar (mbar)
Millimetres of mercury (mmHg) x 0.535 = Inches of water (inH
2O) x 1.868 = Millimetres of mercury (mmHg)
Inches of water (inH
2O) x 0.036 = Pounds-force per square inch x 27.68 = Inches of water (inH2O)
(psi; lbf/in2; lb/in2)
Torque (moment of force)
Pounds-force inches x 1.152 = Kilograms-force centimetre x 0.868 = Pounds-force inches
(lbf in; lb in) (kgf cm; kg cm) (lbf in; lb in)
Pounds-force inches x 0.113 = Newton metres (Nm) x 8.85 = Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force inches x 0.083 = Pounds-force feet (lbf ft; lb ft) x 12 = Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force feet (lbf ft; lb ft) x 0.138 = Kilograms-force metres x 7.233 = Pounds-force feet (lbf ft; lb ft)
(kgf m; kg m)
Pounds-force feet (lbf ft; lb ft) x 1.356 = Newton metres (Nm) x 0.738 = Pounds-force feet (lbf ft; lb ft)
Newton metres (Nm) x 0.102 = Kilograms-force metres x 9.804 = Newton metres (Nm)
(kgf m; kg m)
Power
Horsepower (hp) x 745.7 = Watts (W) x 0.0013 = Horsepower (hp)
Velocity (speed)
Miles per hour (miles/hr; mph) x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph)
Fuel consumption*
Miles per gallon (mpg) x 0.354 = Kilometres per litre (km/l) x 2.825 = Miles per gallon (mpg)
Temperature
Degrees Fahrenheit = (°C x 1.8) + 32 Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56
* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 282
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Chapter 1 Routine maintenance and servicing
Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 7
Automatic transmission linkage lubrication . . . . . . . . . . . . . . . . . . . 18
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery check, maintenance and charging . . . . . . . . . . . . . . . . . . . . 9
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 28
Door and bonnet check and lubrication . . . . . . . . . . . . . . . . . . . . . . 24
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 20
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Idle speed and mixture check and adjustment . . . . . . See Chapter 4Ignition timing check . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 16
Positive Crankcase Ventilation (PCV) system check
and filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power steering fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . See end of Chapter
Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 19
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tyre and tyre pressure checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 22
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 12
Ventilation system pollen filter renewal . . . . . . . . . . . . . . . . . . . . . . . 27
Windscreen/tailgate washer system and wiper blade check . . . . . . 6
1•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty Contents
1
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1•2Lubricants, Fluids & Capacities
Lubricants and fluids
Component or system Lubricant type/specification
EngineMultigrade engine oil to specification API SG/CD or better, viscosity range 5W/50 to 10W/30
Manual transmissionGear oil to Ford specification ESD-M2C-186-A
Automatic transmissionTransmission fluid to Ford specification ESP-M2C-166-H
Power steeringTransmission fluid to Ford specification ESP-M2C-166-H
Cooling systemSoft water, and antifreeze (ethylene glycol-based, suitable for use in mixed-metal cooling systems) to
Ford specification ESD-M97B-49-A
Braking systemHydraulic fluid to Ford specification ESD-M6C-57-A, Super DOT 4 or equivalent
Driveshaft jointsLong-life grease to Ford specification SQM-1C 9004-A
Capacities
Engine oil:
At oil and filter change . . . . . . . . . . . . . . . . . . . . . . . 4.25 litres
Dry - at engine overhaul . . . . . . . . . . . . . . . . . . . . . . 4.50 litres
Difference between dipstick minimum and
maximum level notches . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.0 litre
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 litresCooling system:
Manual transmission models . . . . . . . . . . . . . . . . . . 6.6 litres
Automatic transmission models . . . . . . . . . . . . . . . 7.1 litres
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 litres
Automatic transmission:
Total, including fluid cooler . . . . . . . . . . . . . . . . . . . 7.2 litres
Drain and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 litres
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