1993 FORD MONDEO differential

EGR valve, and check the valve and the
inlet manifold for blockage. Clean or
renew parts as necessary, and recheck.
EGR system
6Any further checking of the system requires
special tools and test equipment. Take the
vehicle to a dealer service department for
checking.
Component renewal
Note:These components will be very hot
when the engine is running. Always allow the
engine to cool down fully before starting work,
to prevent the possibility of burns.
EGR valve
7Disconnect the battery negative (earth) lead
- see Section 1 of Chapter 5.
8Remove the air mass meter and resonator -
refer to Chapter 4.
9Detach the vacuum hose, unscrew the
sleeve nut securing the EGR pipe to the valve,
remove the two valve mounting bolts, and
withdraw the valve from the inlet manifold
(see illustrations). Ensure that the end of the
pipe is not damaged or distorted as the valve
is withdrawn, and note the valve’s gasket; this
must be renewed whenever the valve is
disturbed.
10Note that the metal pipe from the valve to
the manifold itself should not be disturbed - it
is not available separately from the manifold.However, check whenever the manifold is
removed that the pipe’s end fitting is securely
fastened (see illustration).
11Check the valve for sticking and heavy
carbon deposits. If such is found, clean the
valve or renew it.
12Refitting is the reverse of the removal
procedure. Apply a smear of anti-seize
compound to the sleeve nut threads, fit a new
gasket, and tighten the valve bolts to the
specified torque wrench setting.
EGR pipe
13Disconnect the battery negative (earth)
lead - see Section 1 of Chapter 5.
14Remove the air mass meter and resonator
- refer to Chapter 4.
15Unbolt the exhaust manifold heat shield
and remove both parts, or move them aside
as required to reach the end of the EGR pipe.
Unscrew the sleeve nut securing the pipe to
the exhaust manifold (see illustration).
16Undo the two screws securing the pipe to
the ignition coil bracket, then disconnect the
two vacuum hoses - note that these are of
different sizes, to ensure that they cannot be
mixed up on reconnection. Unscrew the
sleeve nut securing the EGR pipe to the valve
(see illustration). Withdraw the pipe.
17Check the condition of both hoses, and
renew them if necessary (see Chapter 1). Note
that if the exhaust gases have been backfiring
excessively - eg, due to a blocked exhaust
system - both hoses must be renewed, andtheir connections on the pipe must be cleaned
thoroughly.
18Refitting is the reverse of the removal
procedure; ensure that the hoses are securely
connected to the correct unions. Apply a
smear of anti-seize compound to the sleeve
nut threads, tighten the nuts securely, and
tighten the two screws to their specified
torque wrench setting.
EGR exhaust gas pressure differential
sensor
19Refer to Section 4 of this Chapter.
EGR solenoid valve
Note:This component can be identified by its
larger top and its two fastening screws. Do not
confuse it with the adjacent pulse-air solenoid
valve, especially when reconnecting vacuum
hoses.
20Disconnect the battery negative (earth)
lead - see Section 1 of Chapter 5.
21Remove the air mass meter and resonator
- refer to Chapter 4. If better access is
required, remove the plenum chamber also
(see illustration).
22Releasing its wire clip, unplug the
electrical connector from the valve. Remove
the two retaining screws, and withdraw the
valve from the bulkhead mounting bracket,
then label and disconnect the two vacuum
hoses.
23Refitting is the reverse of the removal
procedure; ensure that the hoses are correctly
reconnected.
6•16 Emissions control systems
6.9A Disconnecting vacuum hose from
Exhaust Gas Recirculation (EGR) valve . . .6.9B . . . unscrew EGR pipe sleeve nut and
remove bolts (arrowed) to release valve
from inlet manifold6.10 Check end fitting of EGR pipe into
inlet manifold whenever manifold is
removed, but do not disturb
6.15 Unbolt exhaust manifold heat shield,
and unscrew sleeve nut (arrowed) securing
EGR pipe to exhaust manifold . . .6.16 . . . undo screws “A” and sleeve
nut “B”, then disconnect hoses “C” - note
different sizes - to release EGR pipe6.21 EGR solenoid valve “A” and EGR
exhaust gas pressure differential sensor
“B”, located on bulkhead mounting bracket
procarmanuals.com

REF•9
Excessive fuel consumption
m mUnsympathetic driving style, or adverse conditions.
m mAir filter element dirty or clogged (Chapter 1).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mIgnition timing incorrect (Chapters 5 and 6).
m mTyres under-inflated (Chapter 1).
Fuel leakage and/or fuel odour
m
mDamaged or corroded fuel tank, pipes or connections (Chapter 1).
m mCharcoal canister and/or connecting pipes leaking (Chapter 6).
Excessive noise or fumes from exhaust system
m
mLeaking exhaust system or manifold joints (Chapters 1, 2 Part A,
and 4).
m mLeaking, corroded or damaged silencers or pipe (Chapter 1).
m mBroken mountings, causing body or suspension contact (Chap-
ters 1 and 4).
Fault Finding
3 Fuel and exhaust system
Noisy in neutral with engine running
m mInput shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7, Part A).*
m mClutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 8).
Noisy in one particular gear
m mWorn, damaged or chipped gear teeth (Chapter 7, Part A).*
Difficulty engaging gears
m
mClutch fault (Chapter 8).
m mWorn or damaged gear linkage (Chapter 7, Part A).
m mIncorrectly-adjusted gear linkage (Chapter 7, Part A).
m mWorn synchroniser assemblies (Chapter 7, Part A).*
Vibration
m
mLack of oil (Chapter 1).
m mWorn bearings (Chapter 7, Part A).*
Jumps out of gear
m
mWorn or damaged gear linkage (Chapter 7, Part A).
m mIncorrectly-adjusted gear linkage (Chapter 7, Part A).
m mWorn synchroniser assemblies (Chapter 7, Part A).*
m mWorn selector forks (Chapter 7, Part A).*
Lubricant leaks
m
mLeaking differential side gear oil seal (Chapter 7, Part A).
m mLeaking housing joint (Chapter 7, Part A).*
m mLeaking input shaft oil seal (Chapter 7, Part A).*
m mLeaking selector shaft oil seal (Chapter 7, Part A).
m mLeaking speedometer drive pinion O-ring (Chapter 7, Part A).
* Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.
4 Clutch
5 Manual transmission
Pedal travels to floor - no pressure or very little
resistance
m mBroken clutch cable (Chapter 8).
m mIncorrect clutch adjustment (Chapter 8).
m mBroken clutch release bearing or fork (Chapter 8).
m mBroken diaphragm spring in clutch pressure plate (Chapter 8).
Clutch fails to disengage (unable to select gears)
m
mIncorrect clutch adjustment (Chapter 8).
m mClutch disc sticking on transmission input shaft splines (Chapter 8).
m mClutch disc sticking to flywheel or pressure plate (Chapter 8).
m mFaulty pressure plate assembly (Chapter 8).
m mClutch release mechanism worn or incorrectly assembled (Chapter 8).
Clutch slips (engine speed increases with no
increase in vehicle speed)
m mIncorrect clutch adjustment (Chapter 8).
m mClutch disc linings excessively worn (Chapter 8).m mClutch disc linings contaminated with oil or grease (Chapter 8).
m mFaulty pressure plate or weak diaphragm spring (Chapter 8).
Judder as clutch is engaged
m
mClutch disc linings contaminated with oil or grease (Chapter 8).
m mClutch disc linings excessively worn (Chapter 8).
m mClutch cable sticking or frayed (Chapter 8).
m mFaulty or distorted pressure plate or diaphragm spring (Chapter 8).
m mWorn or loose engine/transmission mountings (Chapter 2, Part A).
m mClutch disc hub or transmission input shaft splines worn (Chap-
ter 8).
Noise when depressing or releasing clutch pedal
m mWorn clutch release bearing (Chapter 8).
m mWorn or dry clutch pedal bushes (Chapter 8).
m mFaulty pressure plate assembly (Chapter 8).
m mPressure plate diaphragm spring broken (Chapter 8).
m mBroken clutch disc cushioning springs (Chapter 8).
Internal coolant leakage
m
mLeaking cylinder head gasket (Chapter 2, Part A).
m mCracked cylinder head or cylinder bore (Chapter 2, Part B).
Corrosion
m
mInfrequent draining and flushing (Chapter 1).
m mIncorrect antifreeze mixture, or inappropriate antifreeze type
(Chapter 1).
procarmanuals.com

6 Automatic transmission
REF•10Fault Finding
Note:Due to the complexity of the automatic transmission and its
electronic control system, it is difficult for the home mechanic to
properly diagnose and service this unit. For problems other than the
following, the vehicle should be taken to a dealer service department
or automatic transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.
m mTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
(a) Housing joints (Chapters 1 and 7, Part B).
(b) Dipstick tube (Chapters 1 and 7, Part B).
(c) Transmission-to-fluid cooler pipes/unions (Chapters 3 and 7,
Part B).
(d) Speedometer drive pinion O-ring (Chapter 7, Part B).
(e) Differential side gear oil seals (Chapter 7, Part B).
Transmission fluid brown, or has burned smell
m mTransmission fluid level low, or fluid in need of renewal (Chapter 1).
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
m mLow transmission fluid level (Chapter 1).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
General gear selection problems
m
mChapter 7, Part B, deals with checking and adjusting the selector
cable on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:
(a) Engine starting in gears other than Park or Neutral.
(b) Indicator on gear selector lever pointing to a gear other than the
one actually being used.
(c) Vehicle moves when in Park or Neutral.
(d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7, Part B for the selector cable adjustment
procedure.
Engine will not start in any gear, or starts in gears
other than Park or Neutral
m mIncorrect selector lever position sensor adjustment (Chapter 7,
Part B).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.
7 Driveshafts
Clicking or knocking noise on turns (at slow speed
on full-lock)
m mLack of constant velocity joint lubricant (Chapter 8).
m mWorn outer constant velocity joint (Chapter 8).
Vibration when accelerating or decelerating
m
mWorn inner constant velocity joint (Chapter 8).
m mBent or distorted driveshaft (Chapter 8).
8 Braking system
Note:Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose
connections, any faults occurring on the Anti-lock Braking System (ABS) should be referred to a Ford dealer for diagnosis - the same applies to the
components of the Traction Control System (TCS).
Vehicle pulls to one side under braking
m mWorn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).
m mSeized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).
m mA mixture of brake pad/shoe lining materials fitted between sides
(Chapter 1).
m mBrake caliper mounting bolts loose (Chapter 9).
m mRear brake backplate mounting bolts loose (Chapter 9).
m mWorn or damaged steering or suspension components (Chap-
ter 10).
Noise (grinding or high-pitched squeal) when brakes
applied
m mBrake pad or shoe friction lining material worn down to metal
backing (Chapter 1).
m mExcessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).
m mForeign object (stone chipping, etc) trapped between brake disc
and splash shield (Chapter 1).
Excessive brake pedal travel
m mInoperative rear brake self-adjust mechanism (Chapter 9).
m mFaulty master cylinder (Chapter 9).
m mAir in hydraulic system (Chapter 9).
procarmanuals.com

REF•13Glossary of Technical Terms
A
ABS (Anti-lock brake system)A system,
usually electronically controlled, that senses
incipient wheel lockup during braking and
relieves hydraulic pressure at wheels that are
about to skid.
Air bag An inflatable bag hidden in the
steering wheel (driver’s side) or the dash or
glovebox (passenger side). In a head-on
collision, the bags inflate, preventing the
driver and front passenger from being thrown
forward into the steering wheel or windscreen.
Air cleanerA metal or plastic housing,
containing a filter element, which removes
dust and dirt from the air being drawn into the
engine.
Air filter elementThe actual filter in an air
cleaner system, usually manufactured from
pleated paper and requiring renewal at regular
intervals.
Allen keyA hexagonal wrench which fits into
a recessed hexagonal hole.
Alligator clipA long-nosed spring-loaded
metal clip with meshing teeth. Used to make
temporary electrical connections.
AlternatorA component in the electrical
system which converts mechanical energy
from a drivebelt into electrical energy to
charge the battery and to operate the starting
system, ignition system and electrical
accessories.
Ampere (amp)A unit of measurement for the
flow of electric current. One amp is the
amount of current produced by one volt
acting through a resistance of one ohm.
Anaerobic sealerA substance used to
prevent bolts and screws from loosening.
Anaerobic means that it does not require
oxygen for activation. The Loctite brand is
widely used.
AntifreezeA substance (usually ethylene
glycol) mixed with water, and added to a
vehicle’s cooling system, to prevent freezing
of the coolant in winter. Antifreeze also
contains chemicals to inhibit corrosion and
the formation of rust and other deposits that
would tend to clog the radiator and coolant
passages and reduce cooling efficiency.
Anti-seize compoundA coating that
reduces the risk of seizing on fasteners that
are subjected to high temperatures, such as
exhaust manifold bolts and nuts.
AsbestosA natural fibrous mineral with great
heat resistance, commonly used in the
composition of brake friction materials.Asbestos is a health hazard and the dust
created by brake systems should never be
inhaled or ingested.
AxleA shaft on which a wheel revolves, or
which revolves with a wheel. Also, a solid
beam that connects the two wheels at one
end of the vehicle. An axle which also
transmits power to the wheels is known as a
live axle.
AxleshaftA single rotating shaft, on either
side of the differential, which delivers power
from the final drive assembly to the drive
wheels. Also called a driveshaft or a halfshaft.
BBall bearingAn anti-friction bearing
consisting of a hardened inner and outer race
with hardened steel balls between two races.
BearingThe curved surface on a shaft or in a
bore, or the part assembled into either, that
permits relative motion between them with
minimum wear and friction.
Big-end bearingThe bearing in the end of
the connecting rod that’s attached to the
crankshaft.
Bleed nippleA valve on a brake wheel
cylinder, caliper or other hydraulic component
that is opened to purge the hydraulic system
of air. Also called a bleed screw.
Brake bleedingProcedure for removing air
from lines of a hydraulic brake system.
Brake discThe component of a disc brake
that rotates with the wheels.Brake drumThe component of a drum brake
that rotates with the wheels.
Brake liningsThe friction material which
contacts the brake disc or drum to retard the
vehicle’s speed. The linings are bonded or
riveted to the brake pads or shoes.
Brake padsThe replaceable friction pads
that pinch the brake disc when the brakes are
applied. Brake pads consist of a friction
material bonded or riveted to a rigid backing
plate.
Brake shoeThe crescent-shaped carrier to
which the brake linings are mounted and
which forces the lining against the rotating
drum during braking.
Braking systemsFor more information on
braking systems, consult the Haynes
Automotive Brake Manual.
Breaker barA long socket wrench handle
providing greater leverage.
BulkheadThe insulated partition between
the engine and the passenger compartment.
CCaliperThe non-rotating part of a disc-brake
assembly that straddles the disc and carries
the brake pads. The caliper also contains the
hydraulic components that cause the pads to
pinch the disc when the brakes are applied. A
caliper is also a measuring tool that can be set
to measure inside or outside dimensions of an
object.
CamshaftA rotating shaft on which a series
of cam lobes operate the valve mechanisms.
The camshaft may be driven by gears, by
sprockets and chain or by sprockets and a
belt.
CanisterA container in an evaporative
emission control system; contains activated
charcoal granules to trap vapours from the
fuel system.
CarburettorA device which mixes fuel with
air in the proper proportions to provide a
desired power output from a spark ignition
internal combustion engine.
CastellatedResembling the parapets along
the top of a castle wall. For example, a
castellated balljoint stud nut.
CastorIn wheel alignment, the backward or
forward tilt of the steering axis. Castor is
positive when the steering axis is inclined
rearward at the top.
Canister
Brake bleeding
Bearing
Air filter
procarmanuals.com

REF•15Glossary of Technical Terms
GGapThe distance the spark must travel in
jumping from the centre electrode to the side
electrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV)A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
LocknutA nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
LockwasherA form of washer designed to
prevent an attaching nut from working loose.
MMacPherson strutA type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
creates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location.
MultimeterAn electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOxOxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhmThe unit of electrical resistance. One
volt applied to a resistance of one ohm will
produce a current of one amp.
OhmmeterAn instrument for measuring
electrical resistance.
O-ringA type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action.
Overhead cam (ohc) engineAn engine with
the camshaft(s) located on top of the cylinder
head(s).Overhead valve (ohv) engineAn engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensorA device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screwA type of screw head having a
cross instead of a slot for a corresponding
type of screwdriver.
PlastigageA thin strip of plastic thread,
available in different sizes, used for measuring
clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts are
assembled and dismantled; the width of the
crushed strip indicates the clearance between
journal and bearing.
Propeller shaftThe long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential
on front-engined rear wheel drive vehicles.
Proportioning valveA hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steeringA steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
rods to the steering arms at the wheels.
RadiatorA liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
RefrigerantAny substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful to
the ozone in the upper atmosphere.
Rocker armA lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
Adjusting spark plug gap
Plastigage
Gasket
procarmanuals.com

REF•17Index
A
A pillar trim - 11•20
ABS - 9•14
Accelerator cable - 4•4
Accelerator pedal - 4•5
Accumulator - 3•9
Acknowledgements - 0•4
Adaptive damping switch - 12•8
Aerial - 12•22
Air bag - 0•5, 1•22, 12•22
Air cleaner - 4•3, 6•19
Air conditioning - 1•15, 3•2, 3•8, 3•9, 6•11
Air distribution control - 3•8
Air induction system - 4•9
Air intake components - 4•3
Air mass meter - 4•3, 6•10, 6•11, 6•12
Air temperature warning sender unit -
12•18
Alarm - 11•17, 12•18
Alternator - 5•5, 5•6
Amplifier - 12•21
Anti-lock Braking System - 9•14
Anti-roll bar - 10•8, 10•12, 10•15
Anti-theft alarm system - 12•18
Antifreeze - 1•2, 1•22, 3•2
Asbestos - 0•5
ATF - 1•2
Automatic transmission- 1•11, 1•17,
2A•24, 2B•3, 2B•4, 6•11, 7B•1et seq,
12•11
Automatic transmission fault finding -
REF•10
Automatic transmission fluid - 1•2
Auxiliary drivebelt - 1•13
Auxiliary warning system - 12•17
B
B pillar trim - 11•20
Backfire - REF•8
Backrest - 11•18
Battery - 0•5, 1•8, 1•11, 5•2, 5•3
Battery fault - REF•12
Big-end bearings - 2B•18, 2B•21
Bleeding brakes - 9•12
Bleeding power steering - 10•21
Blower/air conditioning control - 3•8Body corrosion - 0•10
Body electrical system- 12•1et seq
Bodywork and fittings- 11•1et seq
Bonnet - 1•20, 11•5, 11•6
Booster battery (jump) starting - 0•12
Boot - 11•14, 11•15
Brake check - 1•19
Brake fluid - 1•2, 1•8, 1•26
Brake line check - 1•19
Braking system- 0•7, 0•8, 0•9, 1•20, 9•1et
seq
Braking system fault finding - REF•10
Brush renewal - 5•8
Bulb failure module - 12•18
Bulbs - 12•8, 12•11, 12•18
Bumpers - 11•4, 11•5
Burning - 0•5
C
C pillar trim - 11•20, 11•21
Cables - 4•4, 7B•2, 8•2, 9•16, 11•6, 12•15
Calipers - 9•4, 9•9
Camshaft - 2A•13, 2A•14, 6•11, 6•12
Cassette player - 12•21
Catalytic converter - 6•19
CD player - 12•22
Central locking system - 11•17
Central locking system fault - REF•12
Centre console - 11•21
Charcoal canister - 6•14
Charging - 1•12, 5•5
Check strap - 11•13
Clock - 12•11, 12•15
Clutch and driveshafts- 1•17, 1•20, 8•1et
seq
Clutch fault finding - REF•9
CO emissions (mixture) - 0•10
Coil spring - 10•15
Compact disc player - 12•22
Compression test - 2A•5
Compressor - 3•9
Condenser - 3•9
Connecting rods - 2B•12, 2B•17, 2B•21,
2B•22
Console - 11•21, 11•22
Contents - 0•2
Conversion factors - 0•14Coolant - 1•2, 1•6, 1•7, 1•21
Coolant leakage - REF•9
Coolant low level switch - 3•5
Coolant temperature gauge sender - 3•4
Coolant temperature sensor - 3•5, 6•11,
6•13
Coolant warning switch - 12•18
Cooling, heating, and air conditioning
systems- 1•22, 3•1et seq
Cooling, heating, and air conditioning
systems fault finding - REF•8
Corrosion - REF•9
Courtesy light - 12•8
Crankcase - 2B•13
Crankshaft - 2A•9, 2A•13, 2A•22, 2B•13,
2B•18, 2B•20, 5•4, 6•10, 6•11, 6•12
Crossmember - 10•13, 10•17
Cruise control system - 12•19
Crushing - 0•5
Cushion - 11•18
CV joints - 1•18, 8•7, 8•9
Cylinder block - 2B•13
Cylinder head - 2A•6, 2A•17, 2B•9, 2B•10,
2B•11, 6•19
D
D pillar trim - 11•21
Damping switch - 12•8
Dehydrator - 3•9
Dents in bodywork - 11•3
Depressurisation - 4•2
Diagnosis system - 6•4
Differential - 7A•2, 7B•3
Dimensions - 0•6
Dipped beam switch - 12•7
Direction indicators - 12•7, 12•9, 12•12
Discs - 1•19, 9•5, 9•10
Display warning bulb - 12•18
Doors - 0•8, 1•20, 11•6, 11•7, 11•8, 11•9,
11•10, 11•11, 11•13, 12•7, 12•8, 12•11,
12•18
Drivebelts - 1•13
Driveplate - 2A•24
Driveshafts - 0•9, 1•18, 8•5, 8•6, 8•7, 8•9,
8•10
Driveshafts fault finding - REF•10
Drivetrain - 1•20
Drums - 1•19, 9•6 Note: References throughout this index relate to Chapter•page number
procarmanuals.com

REF•18Index
E
Earth fault - 12•4
Economy/Sport mode switch - 12•7
ECU (Electronic Control Unit) - 6•10, 6•11,
6•12
EGR exhaust gas pressure differential
sensor - 6•16
EGR system - 6•15, 6•16
Electric shock - 0•5
Electric windows fault - REF•12
Electrical system - 0•8, 1•11, 1•20
Electrical system fault - REF•12
Electrically-operated windows - 12•7
Electrolyte - 1•8
Electronic control system - 4•9, 6•2
Emblems - 11•17
Emission checks - 0•10
Emissions control systems - 6•1
Engine compartment light - 12•11
Engine electrical systems- 5•1et seq
Engine fault finding - REF•7, REF•8, REF•10
Engine management system - 4•8, 4•9
Engine oil - 1•2, 1•6, 1•16
Engine oil level sensor - 12•18
Engine removal and general engine
overhaul procedures- 2B•1et seq
Environmental considerations - REF•4
Evaporative emissions control (EVAP)
system - 6•14
Evaporator - 3•9
Exhaust gas pressure differential sensor -
6•11, 6•12, 6•13
Exhaust Gas Recirculation (EGR) system -
6•15, 6•16
Exhaust manifold - 2A•8
Exhaust system - 0•9, 0•10, 1•18, 4•12,
REF•9
Expansion tank - 3•5, 3•6
FFacia - 11•21, 11•23
Fan(s) - 3•4, 12•11
Fault code read-out - 6•6
Fault finding- REF•6et seq
Fault finding - automatic transmission -
7B•1
Fault finding - electrical system - 12•4
Filling - 11•3
Fire - 0•5
Fluid level checks - 1•6
Flywheel - 2A•24
Foglight - 12•7, 12•9, 12•13
Foglight warning indicator - 12•11
Fuel and exhaust systems- 0•10, 4•1et
seq
Fuel and exhaust system fault finding -
REF•9
Fuel consumption high - REF•9
Fuel cut-off switch - 4•8
Fuel filter - 1•26
Fuel gauge - 4•6
Fuel gauge fault - REF•12
Fuel hoses - 1•15
Fuel injection system - 4•8, 4•9
Fuel injectors - 4•10
Fuel lines - 1•19, 4•2
Fuel odour - REF•9Fuel pressure check - 4•5
Fuel pressure regulator - 4•11
Fuel pump - 4•5, 4•6
Fuel rail - 4•10
Fuel system - 4•2
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fumes from exhaust system - REF•9
Fuses - 12•5
G
Gaiters - 1•18, 8•7, 8•9, 10•21
Gashes in bodywork - 11•3
Gaskets - REF•4
Gear lever - 7A•2
Gear selection problems - REF•9, REF•10
Gearbox oil - 1•2
Gearchange linkage - 7A•2
Gearchange selector shaft - 7A•3
Glossary of technical terms - REF•13
Glovebox - 11•22
Glovebox light - 12•11
Grab handle - 11•20
H
Handbrake - 0•7, 9•16, 12•7
Handles - 11•10, 11•11, 11•12, 11•13,
12•11
Hazard flashers - 12•7, 12•11
HC emissions - 0•10
Headlight - 1•8, 12•7, 12•8, 12•12, 12•13
Heated rear window - 12•8
Heated seat - 12•8
Heated windscreen - 12•8
Heater - 3•2, 3•7, 3•8, 12•11, 12•12
Horn - 12•7, 12•15
Horn fault - REF•12
Hoses - 1•14, 3•2, 9•11
HT leads - 1•24
Hub and bearings - 10•5, 10•9, 10•14
Hydraulic fluid - 1•2
Hydraulic pipes and hoses - 9•11
Hydraulic system - 9•12
Hydraulic tappets - 2A•14
Hydrofluoric acid - 0•5
I
Idle speed - 4•9, 4•11, 6•10
Idle-increase solenoid valve - 4•12
Ignition coil - 5•3
Ignition module - 5•4
Ignition switch - 12•6
Ignition system - 5•3
Ignition timing - 5•4, 6•10
In-car engine repair procedures- 2A•1et
seq
Indicators - 12•7, 12•9, 12•12
Information sensors - 6•10
Inlet manifold - 2A•7
Instrument panel - 12•7, 12•11, 12•14
Instruments - 1•20
Instruments fault - REF•12
Intake air temperature sensor - 6•11, 6•13
Introduction to the Ford Mondeo - 0•4
J
Jacking - 0•11
Joint mating faces - REF•4
Jump starting - 0•12
K
Knuckle - 10•5, 10•10, 10•14
L
Leaks - 0•13, 1•14, REF•9
Light units - 12•12
Lights - 12•7, 12•11
Lights inoperative - REF•12
Locknuts, locktabs and washers - REF•4
Locks - 11•6, 11•10, 11•12, 11•13, 11•15,
11•16, 11•17, 12•6, REF•12
Low air temperature warning sender unit -
12•18
Low coolant warning switch - 12•18
Low washer fluid switch - 12•18
Lower suspension arm - 10•8, 10•9, 10•13,
10•16
Lubrication system - 2A•4
Luggage compartment switch - 12•7
M
Main bearings - 2B•18, 2B•20
Maintenance- Also see Routine
maintenance
Maintenance - bodywork and underframe -
11•2
Maintenance - upholstery and carpets -
11•3
Manifolds - 2A•7, 2A•8
Manual transmission- 1•17, 2A•24, 2B•3,
2B•4, 7A•1et seq
Manual transmission fault finding - REF•9
Manual transmission oil - 1•2
Master cylinder - 9•10
Mirrors - 0•7, 11•14, 12•7
Misfire - REF•7, REF•8
Mixture - 0•10, 4•9
MOT test checks- 0•7et seq
Mountings - 2A•24, 7A•7, 7B•5
N
Number plate light - 12•10, 12•13
O
Oil (transmission) - 1•2
Oil (engine) - 1•2, 1•6, 1•16
Oil cooler - 2A•22
Oil level sensor - 2A•22, 12•18
Oil pressure warning light illuminated -
REF•8
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