1993 FORD MONDEO cooling

back again, as an assistant depresses the
accelerator pedal. If the valve shows any sign
of stiffness, sticking or otherwise-inhibited
movement (and the accelerator cable is
known from the previous check to be in good
condition), spray the throttle linkage with
penetrating lubricant, allow time for it to work,
and repeat the check; if no improvement is
obtained, the complete throttle housing must
be renewed (Chapter 4).
15Unclip the air cleaner cover, and check
that the air filter element and the crankcase
ventilation system filter are not clogged or
soaked. (A clogged air filter will obstruct the
intake air flow, causing a noticeable effect on
engine performance; a clogged crankcase
ventilation system filter will inhibit crankcase
“breathing”). Renew or clean the filter(s) as
appropriate; refer to the relevant Sections of
Chapter 1 for further information, if required.
Before refitting the air cleaner cover, check
that the air intake (located under the front left-
hand wing, opening behind the direction
indicator/headlight assembly) is clear. It
should be possible to blow through the intake,
or to probe it (carefully) as far as the rear of
the direction indicator light.
16Start the engine and allow it to idle.
Note:Working in the engine compartment
while the engine is running requires great care
if the risk of personal injury is to be avoided;
among the dangers are burns from contact
with hot components, or contact with moving
components such as the radiator cooling fan
or the auxiliary drivebelt. Refer to “Safety
first!” at the front of this manual before
starting, and ensure that your hands, and long
hair or loose clothing, are kept well clear of hot
or moving components at all times.
17Working from the air intake junction at the
inner wing panel, via the air cleaner assembly
and air mass meter, to the resonator, plenum
chamber, throttle housing and inlet manifold
(and including the various vacuum hoses and
pipes connected to these), check for air leaks.
Usually, these will be revealed by sucking or
hissing noises, but minor leaks may be traced
by spraying a solution of soapy water on to
the suspect joint; if a leak exists, it will be
shown by the change in engine note and the
accompanying air bubbles (or sucking-in of
the liquid, depending on the pressure
difference at that point). If a leak is found at
any point, tighten the fastening clamp and/or
renew the faulty components, as applicable.
18Similarly, work from the cylinder head, via
the manifold (and not forgetting the related
EGR and pulse-air system components) to the
tailpipe, to check that the exhaust system is
free from leaks. The simplest way of doing
this, if the vehicle can be raised and
supported safely and with complete security
while the check is made, is to temporarily
block the tailpipe while listening for the sound
of escaping exhaust gases; any leak should
be evident. If a leak is found at any point,
tighten the fastening clamp bolts and/or nuts,
renew the gasket, and/or renew the faultysection of the system, as necessary, to seal
the leak.
19It is possible to make a further check of
the electrical connections by wiggling each
electrical connector of the system in turn as
the engine is idling; a faulty connector will be
immediately evident from the engine’s
response as contact is broken and remade. A
faulty connector should be renewed to ensure
the future reliability of the system; note that
this may mean the renewal of that entire
section of the loom - see your local Ford
dealer for details.
20Switch off the engine. If the fault is not yet
identified, the next step is to check the
ignition voltages, using an engine analyser
with an oscilloscope - without such
equipment, the only tests possible are to
remove and check each spark plug in turn, to
check the spark plug (HT) lead connections
and resistances, and to check the
connections and resistances of the ignition
coil. Refer to the relevant Sections of
Chapters 1 and 5.
21The final step in these preliminary checks
would be to use an exhaust gas analyser to
measure the CO level at the exhaust tailpipe.This check cannot be made without special
test equipment - see your local Ford dealer for
details.
Fault code read-out
22As noted in the general comments at the
beginning of this Section, the preliminary
checks outlined above should eliminate the
majority of faults from the engine
management system. If the fault is not yet
identified, the next step is to connect a fault
code reader to the ECU, so that its self-
diagnosis facility can be used to identify the
faulty part of the system; further tests can
then be made to identify the exact cause of
the fault.
23In their basic form, fault code readers are
simply hand-held electronic devices, which
take data stored within an ECU’s memory and
display it when required as two- or three-digit
fault codes. The more sophisticated versions
now available can also control sensors and
actuators, to provide more effective testing;
some can store information, so that a road
test can be carried out, and any faults
encountered during the test can be displayed
afterwards.
6•6 Emissions control systems
3.26 Location and terminal identification of engine management system self-test,
diagnosis and service connectors
1 Power steering fluid reservoir
2 Diagnosis connector - for Ford diagnostic equipment FDS 2000
3 Self-test connector - for fault code read-out - pin 17 is output terminal, pin 48 is input
terminal, pin 40/60 is earth
4 Service connector - for octane adjustment
5 Plug-in bridge - to suit 95 RON fuel
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Code Meaning Action327 EGR system exhaust gas pressure
differential sensor or solenoid valve Check components (Section 6 of this Chapter)
328 EGR system solenoid valve Check component (Section 6 of this Chapter)
332 EGR valve not opening Check component (Section 6 of this Chapter)
334 EGR system solenoid valve Check component (Section 6 of this Chapter)335 EGR system exhaust gas pressure
differential sensor Check component (Section 6 of this Chapter)
336 Exhaust gas pressure too high Check system (Section 6 of this Chapter)337 EGR system exhaust gas pressure
differential sensor or solenoid valve Check components (Section 6 of this Chapter)
338, 339 Coolant temperature sensor Carry out system test (see below)
341 Service connector earthed Unplug connector and repeat test - reconnect on completion
411 Engine speed too low during test Check for air leaks, then repeat test
412 Engine speed too high during test Check for air leaks, then repeat test
413 to 416 Idle speed control valve Check component (Chapter 4, Section 16)
452 Vehicle speed sensor Check component (Section 4 of this Chapter)
511, 512 ECU memory Check whether battery was disconnected, then check fuse 11 - if fault still
exists, renew ECU (Section 6 of this Chapter)
513 ECU reference voltage Carry out system test (see below)
519, 521 Power steering pressure switch not Check component is fitted and connected, then repeat test - if fault still
operated during test exists, carry out system test (see below)
522, 523 Selector lever position sensor Check component (Chapter 7, Part B)
536 Brake on/off switch not activated
during test Repeat test
538 Operator error during test Repeat test
539 Air conditioning switched on during test Switch off and repeat test
542, 543 Fuel pump circuit Carry out system test (see below)
551 Idle speed control valve circuit Carry out system test (see below)
552 Pulse-air system circuit Carry out system test (see below)
556 Fuel pump circuit Check fuel pump relay - if fault still exists, carry out system test (see below)
558 EGR system solenoid valve circuit Carry out system test (see below)
563 Radiator (high-speed) electric
cooling fan relay and/or circuit Carry out system test (see below)564 Radiator electric cooling fan relay
and/or circuit Carry out system test (see below)
565 Charcoal canister-purge solenoid valve Check component (Section 5 of this Chapter)573 Radiator electric cooling fan relay
and/or circuit Carry out system test (see below)
574 Radiator (high-speed) electric
cooling fan relay and/or circuit Carry out system test (see below)575 Fuel pump and/or fuel cut-off
switch circuits Carry out system test (see below)
576, 577 Accelerator pedal not depressed fully during
test procedure - automatic transmission
kickdown not activated Repeat test
621 Automatic transmission shift solenoid 1 circuit Refer to Chapter 7, Part B
622 Automatic transmission shift solenoid 2 circuit Refer to Chapter 7, Part B
624 Automatic transmission electronic
pressure control solenoid Refer to Chapter 7, Part B
625 Automatic transmission electronic
pressure control solenoid circuit Refer to Chapter 7, Part B
629 Automatic transmission torque
converter clutch solenoid Refer to Chapter 7, Part B
634 Selector lever position sensor circuit Check component (Chapter 7, Part B)
635, 637 Automatic transmission fluid temperature sensor Refer to Chapter 7, Part B
639 Automatic transmission speed sensor Refer to Chapter 7, Part B
645 Automatic transmission 1st speed Refer to Chapter 7, Part B
646 Automatic transmission 2nd speed Refer to Chapter 7, Part B
647 Automatic transmission 3rd speed Refer to Chapter 7, Part B
648 Automatic transmission 4th speed Refer to Chapter 7, Part B
653 Automatic transmission overdrive
cancel button and “Economy/Sport”
mode switch not operated during test Repeat test
998 Warning code Check fault(s) indicated by subsequent code(s)
Emissions control systems 6•9
6
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Ignition timing and base idle
speed check
Note:The following procedure is a check only,
essentially of the ECU. Both the ignition timing
and the base idle speed are controlled by the
ECU. The ignition timing is not adjustable at
all; the base idle speed is set in production,
and should not be altered.
38If the fault code read-out (with any checks
resulting from it) has not eliminated the fault,
the next step is to check the ECU’s control of
the ignition timing and the base idle speed.
This task requires the use of a Ford STAR
tester (a proprietary fault code reader can be
used only if it is capable of inducing the ECU
to enter its “Service Adjustment Programme”),
coupled with an accurate tachometer and a
good-quality timing light. Without this
equipment, the task is not possible; the
vehicle must be taken to a Ford dealer for
attention.
39To make the check, apply the handbrake,
switch off the air conditioning (where fitted)
and any other electrical loads (lights, heated
rear window, etc), then select neutral (manual
transmission) or the “P” position (automatic
transmission). Start the engine, and warm it
up to normal operating temperature. The
radiator electric cooling fan must be running
continuously while the check is made; this
should be activated by the ECU, when
prompted by the tester. Switch off the engine,
and connect the test equipment as directed
by the manufacturer - refer to paragraph 26
above for details of STAR tester connection.
40Raise and support the front of the vehicle
securely, and remove the auxiliary drivebelt
cover (see Chapter 1). Emphasise the two
pairs of notches in the inner and outer rims of
the crankshaft pulley, using white paint. Note
that an ignition timing reference mark is not
provided on the pulley - in the normal
direction of crankshaft rotation (clockwise,
seen from the right-hand side of the vehicle)
the first pair of notches are irrelevant to the
vehicles covered in this manual, while the
second pair indicate Top Dead Centre (TDC)
when aligned with the rear edge of the raised
mark on the sump; when checking the ignition
timing, therefore, the (rear edge of the) sumpmark should appear just before the TDC
notches (see Part A of Chapter 2, Section 4,
for further information if required).
41Start the engine and allow it to idle. Work
through the engine-running test procedure
until the ECU enters its “Service Adjustment
Programme” - see paragraph 35 above.
42Use the timing light to check that the
timing marks appear approximately as
outlined above at idle speed. Do not spend
too much time on this check; if the timing
appears to be incorrect, the system may have
a fault, and a full system test must be carried
out (see below) to establish its cause.
43Using the tachometer, check that the
base idle speed is as given in the
Specifications Section of Chapter 4.
44If the recorded speed differs significantly
from the specified value, check for air leaks,
as described in the preliminary checks
(paragraphs 15 to 18 above), or any other
faults which might cause the discrepancy.
45The base idle speed is set in production
by means of an air bypass screw (located in
the front right-hand corner of the throttle
housing) which controls the amount of air that
is allowed to pass through a bypass passage,
past the throttle valve when it is fully closed in
the idle position; the screw is then sealed with
a white tamperproof plug (see illustration). In
service, the idle speed is controlled by the
ECU, which has the ability to compensate for
engine wear, build-up of dirt in the throttle
housing, and other factors which might
require changes in idle speed. The air bypass
screw setting should not, therefore, be
altered. If any alterations are made, a blue
tamperproof plug must be fitted, and the
engine should be allowed to idle for at least
five minutes on completion, so that the ECU
can re-learn its idle values.
46When both checks have been made and
the “Service Adjustment Programme” is
completed, follow the tester instructions to
return to the fault code read-out, and
establish whether the fault has been cured or
not.
Basic check of ignition system
47If the checks so far have not eliminated
the fault, the next step is to carry out a basic
check of the ignition system components,
using an engine analyser with an oscilloscope
- without such equipment, the only tests
possible are to remove and check each spark
plug in turn, to check the spark plug (HT) lead
connections and resistances, and to check
the connections and resistances of the
ignition coil. Refer to the relevant Sections of
Chapters 1 and 5.
Basic check of fuel system
48If the checks so far have not eliminated
the fault, the next step is to carry out a basic
check of the fuel system components.
49Assuming that the preliminary checks
have established that the fuel pump is
operating correctly, that the fuel filter isunlikely to be blocked, and also that there are
no leaks in the system, the next step is to
check the fuel pressure (see Chapter 4). If this
is correct, check the injectors (see Chapter 4)
and the Positive Crankcase Ventilation system
(see Chapter 1).
System test
50The final element of the Ford testing
procedure is to carry out a system test, using
a break-out box - this is a device that is
connected between the ECU and its electrical
connector, so that the individual circuits
indicated by the fault code read-out can be
tested while connected to the system, if
necessary with the engine running. In the case
of many of the system’s components, this
enables their output voltages to be measured
- a more accurate means of testing.
51In addition to the break-out box and the
adaptors required to connect it, several items
of specialist equipment are needed to
complete these tests. This puts them quite
beyond the scope of many smaller dealers, let
alone the DIY owner; the vehicle should be
taken to a Ford dealer for attention.
Note:This Section is concerned principally
with the sensors which give the ECU the
information it needs to control the various
engine management sub-systems - for further
details of those systems and their other
components, refer to the relevant Chapter of
this manual.
General
ECU (Electronic Control Unit)
1This component is the heart of the entire
engine management system, controlling the
fuel injection, ignition and emissions control
systems. It also controls sub-systems such as
the radiator cooling fan, air conditioning and
automatic transmission, where appropriate.
Refer to Section 2 of this Chapter for an
illustration of how it works.
Air mass meter
2This uses a “hot-wire” system, sending the
ECU a constantly-varying (analogue) voltage
signal corresponding to the mass of air
passing into the engine. Since air mass varies
with temperature (cold air being denser than
warm), measuring air mass provides the ECU
with a very accurate means of determining the
correct amount of fuel required to achieve the
ideal air/fuel mixture ratio.
Crankshaft speed/position sensor
3This is an inductive pulse generator bolted
(in a separate bracket) to the cylinder
block/crankcase, to scan the ridges between
36 holes machined in the inboard (right-hand)
face of the flywheel/driveplate. As each ridge
4 Information sensors -
general information, testing,
removal and refitting
6•10 Emissions control systems
3.45 Throttle housing air bypass screw is
sealed on production with a white
tamperproof plug (arrowed)
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components are worn or damaged, the
assembly must be renewed.
18Refitting is the reverse of the removal
procedure.
Pulse-air piping
Note:This component, and those around it,
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.
19Disconnect the battery negative (earth)
lead - see Section 1 of Chapter 5.
20Remove the air mass meter and resonator
- refer to Chapter 4.
21Unbolt the exhaust manifold heat shield;
unclip the coolant hose to allow the upper
part to be withdrawn. Apply penetrating oil to
the EGR pipe sleeve nut, and to the pulse-air
system sleeve nuts.
22Remove the EGR pipe (see Section 6).
23Remove the screws securing the filter
housing to the piping - see illustration 7.16.
Unscrew the four sleeve nuts securing the
pipes into the exhaust manifold, and remove
the piping as an assembly, taking care not to
distort it (see illustration).
24Carefully clean the piping, particularly its
threads and those of the manifold, removing
all traces of corrosion, which might prevent
them seating properly, causing air leaks when
the engine is restarted.
25On refitting, insert the piping carefully into
the cylinder head ports, taking care not to
bend or distort it. Apply anti-seize compound
to the threads, and tighten the retaining sleeve
nuts while holding each pipe firmly in its port;
if a suitable spanner is available, tighten the
sleeve nuts to the specified torque wrench
setting.
26The remainder of the refitting procedure is
the reverse of removal.
Pulse-air filter housing and piping
assembly
Note:These components, and those around
them, 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.
27Disconnect the battery negative (earth)
lead - see Chapter 5, Section 1. Unbolt theresonator support bracket from the engine
compartment front crossmember. Slacken the
two clamp screws securing the resonator to
the air mass meter and plenum chamber
hoses, then swing the resonator up clear of
the thermostat housing (see Chapter 4).
28Drain the cooling system (see Chapter 1)
and disconnect the coolant hose and the
coolant pipe/hose from the thermostat
housing.
29Unbolt the exhaust manifold heat shield.
Apply penetrating oil to the EGR pipe sleeve
nut, and to the pulse-air system sleeve nuts.
30Remove the EGR pipe (see Section 6).
31Unscrew the filter housing mounting bolt.
Unscrew the four sleeve nuts securing the
pipes into the exhaust manifold and remove
the assembly, taking care not to distort it (see
illustration).
32Clean the piping, particularly its threads
and those of the manifold, removing all tracesof corrosion, which might prevent them
seating properly, causing air leaks when the
engine is restarted.
33On refitting, insert the piping carefully into
the cylinder head ports, taking care not to
bend or distort it. Apply anti-seize compound
to the threads, and tighten the retaining sleeve
nuts while holding each pipe firmly in its port;
if a suitable spanner is available, tighten the
sleeve nuts to the specified torque wrench
setting.
34The remainder of the refitting procedure is
the reverse of removal. Refill the cooling
system (see Chapter 1). Run the engine,
check for exhaust leaks, and check the
coolant level when it is fully warmed-up.
General information
1The crankcase ventilation system main
components are the oil separator mounted on
the front (radiator) side of the cylinder
block/crankcase, and the Positive Crankcase
Ventilation (PCV) valve set in a rubber
grommet in the separator’s left-hand upper
end. The associated pipework consists of a
crankcase breather pipe and two flexible
hoses connecting the PCV valve to a union on
the left-hand end of the inlet manifold, and a
crankcase breather hose connecting the
cylinder head cover to the air cleaner
assembly (see illustration). A small foam filter
in the air cleaner prevents dirt from being
drawn directly into the engine.
8 Positive Crankcase Ventilation
(PCV) system -
general information
6•18 Emissions control systems
7.23 Removing pulse-air piping - take care
not to bend or distort it7.31 Remove mounting bolt (arrowed) to
remove complete pulse-air assembly -
again, take care not to bend or distort
piping
8.1 Positive Crankcase Ventilation system
1 Oil separator
2 Gasket
3 Positive Crankcase Ventilation (PCV) valve4 Cylinder block/crankcase opening
5 Crankcase breather pipe and flexible hoses
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2The function of these components is to
reduce the emission of unburned
hydrocarbons from the crankcase, and to
minimise the formation of oil sludge. By
ensuring that a depression is created in the
crankcase under most operating conditions,
particularly at idle, and by positively inducing
fresh air into the system, the oil vapours and
“blow-by” gases collected in the crankcase
are drawn from the crankcase, through the oil
separator, into the inlet tract, to be burned by
the engine during normal combustion.
Checking
3Checking procedures for the system
components are included in Chapter 1.
Component renewal
Cylinder head-to-air cleaner hose
4See Chapter 1.
Positive Crankcase Ventilation (PCV)
valve
5The valve is plugged into the oil separator.
Depending on the tools available, access to
the valve may be possible once the pulse-air
assembly has been removed (see Section 7).
If this is not feasible, proceed as outlined in
paragraph 6 below.
Oil separator
6Remove the exhaust manifold (see Chap-
ter 2, Part A). The Positive Crankcase
Ventilation (PCV) valve can now be unplugged
and flushed, or renewed, as required, as
described in Chapter 1.
7Unbolt the oil separator from the cylinder
block/crankcase, and withdraw it; remove and
discard the gasket.
8Flush out or renew the oil separator, as
required (see Chapter 1).
9On reassembly, fit a new gasket, and
tighten the fasteners to the torque wrench
settings given in the Specifications Section of
Chapter 2, Part B.
10The remainder of the refitting procedure is
the reverse of removal. Refill the cooling
system (see Chapter 1). Run the engine,
check for exhaust leaks, and check the
coolant level when it is fully warmed-up.
General information
1The exhaust gases of any petrol engine
(however efficient or well-tuned) consist
largely (approximately 99 %) of nitrogen (N
2),
carbon dioxide (CO
2), oxygen (O2), other inert
gases and water vapour (H
2O). The remaining
1 % is made up of the noxious materials
which are currently seen (CO
2apart) as the
major polluters of the environment: carbon
monoxide (CO), unburned hydrocarbons (HC),oxides of nitrogen (NO
x) and some solid
matter, including a small lead content.
2Left to themselves, most of these pollutants
are thought eventually to break down naturally
(CO and NO
x, for example, break down in the
upper atmosphere to release CO
2) having first
caused ground-level environmental problems.
The massive increase world-wide in the use of
motor vehicles, and the current popular
concern for the environment has caused the
introduction in most countries of legislation, in
varying degrees of severity, to combat the
problem.
3The device most commonly used to clean
up vehicle exhausts is the catalytic converter.
It is fitted into the vehicle’s exhaust system,
and uses precious metals (platinum and
palladium or rhodium) as catalysts to speed
up the reaction between the pollutants and
the oxygen in the vehicle’s exhaust gases, CO
and HC being oxidised to form H
2O and CO2and (in the three-way type of catalytic
converter) NO
xbeing reduced to N2. Note:
The catalytic converter is not a filter in the
physical sense; its function is to promote a
chemical reaction, but it is not itself affected
by that reaction.
4The converter consists of an element (or
“substrate”) of ceramic honeycomb, coated
with a combination of precious metals in such
a way as to produce a vast surface area over
which the exhaust gases must flow; the whole
being mounted in a stainless-steel box. A
simple “oxidation” (or “two-way”) catalytic
converter can deal with CO and HC only,
while a “reduction” (or “three-way”) catalytic
converter can deal with CO, HC and NO
x.
Three-way catalytic converters are further
sub-divided into “open-loop” (or
“uncontrolled”) converters which can remove
50 to 70 % of pollutants and “closed-loop”
(also known as “controlled” or “regulated”)
converters which can remove over 90 % of
pollutants.
5The catalytic converter fitted to the Mondeo
models covered in this manual is of the three-
way closed-loop type.
6The catalytic converter is a reliable and
simple device, which needs no maintenance
in itself, but there are some facts of which an
owner should be aware if the converter is to
function properly for its full service life.
(a) DO NOT use leaded petrol in a vehicle
equipped with a catalytic converter - the
lead will coat the precious metals,
reducing their converting efficiency, and
will eventually destroy the converter; it will
also affect the operation of the oxygen
sensor, requiring its renewal if lead-
fouled. Opinions vary as to how much
leaded fuel is necessary to affect the
converter’s performance, and whether it
can recover even if only unleaded petrol is
used afterwards; the best course of action
is, therefore, to assume the worst, and to
ensure that NO leaded petrol is used at
any time.
(b) Always keep the ignition and fuel systemswell-maintained in accordance with the
manufacturer’s schedule (Chapter 1) -
particularly, ensure that the air filter
element, the fuel filter and the spark plugs
are renewed at the correct intervals. If the
intake air/fuel mixture is allowed to
become too rich due to neglect, the
unburned surplus will enter and burn in
the catalytic converter, overheating the
element and eventually destroying the
converter.
(c) If the engine develops a misfire, do not
drive the vehicle at all (or at least as little
as possible) until the fault is cured - the
misfire will allow unburned fuel to enter
the converter, which will result in its
overheating, as noted above. For the
same reason, do not persist if the engine
refuses to start - either trace the problem
and cure it yourself, or have the vehicle
checked immediately by a qualified
mechanic.
(d) Avoid allowing the vehicle to run out of
petrol.
(e) DO NOT push- or tow-start the vehicle
unless no other alternative exists,
especially if the engine and exhaust are at
normal operating temperature. Starting
the engine in this way may soak the
catalytic converter in unburned fuel,
causing it to overheat when the engine
does start - see (b) above.
(f) DO NOT switch off the ignition at high
engine speeds, in particular, do not “blip”
the throttle immediately before switching
off. If the ignition is switched off at
anything above idle speed, unburned fuel
will enter the (very hot) catalytic converter,
with the possible risk of its igniting on the
element and damaging the converter.
(g) Avoid repeated successive cold starts
followed by short journeys. If the
converter is never allowed to reach its
proper working temperature, it will gather
unburned fuel, allowing some to pass into
the atmosphere and the rest to soak in
the element, causing it to overheat when
a long journey is made - see (b) above.
(h) DO NOT use fuel or engine oil additives -
these may contain substances harmful to
the catalytic converter. Similarly, DO NOT
use silicone-based sealants on any part of
the engine or fuel system, and do not use
exhaust sealants on any part of the
exhaust system upstream of the catalytic
converter. Even if the sealant itself does
not contain additives harmful to the
converter, pieces of it may break off and
foul the element, causing local
overheating.
(i) DO NOT continue to use the vehicle if the
engine burns oil to the extent of leaving a
visible trail of blue smoke. Unburned
carbon deposits will clog the converter
passages and reduce its efficiency; in
severe cases, the element will overheat.
(j) Remember that the catalytic converter
operates at very high temperatures -
9 Catalytic converter -
general information, checking
and component renewal
Emissions control systems 6•19
6
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10•4 Suspension and steering systems
pressed-steel lower side arms. A tie-bar on
each side supports the rear suspension
knuckles. The coil springs are separate from
the shock absorbers (see illustration).
A rear anti-roll bar is fitted to all models. On
SI models, the front and rear shock absorbers
are gas-filled; on other models, they are filled
with fluid. Self-levelling rear shock absorbers
are fitted as standard to Ghia Estate models.
A variable-ratio type rack-and-pinion
steering gear is fitted, together with a
conventional column and telescopic coupling,
incorporating two universal joints. Power-
assisted steering is fitted to all models. A
power steering system fluid cooler is fitted, in
front of the cooling system radiator on the
crossmember (see illustration). On models
with adaptive damping, a steering position
sensor with sensor disc is located above the
upper universal joint.
On models with adaptive damping, it is
possible to select a hard or soft setting for the
front and rear shock absorbers. The system iscomputer-controlled; a switch is provided
near the handbrake lever for selection of
“Sport” or “Normal” mode. With this system, a
solenoid valve is fitted to each suspension
strut. When the valve is open, the hydraulic oil
inside the shock absorber is routed through a
bypass channel, making the action “softer”.
When the solenoid valve is closed, the shock
absorber action becomes “harder”. The
system takes into consideration the
roadspeed of the vehicle; at high speeds, the
shock absorbers are automatically set to
“hard”. The adaptive damping computer
module is located in the luggage
compartment, behind the rear seat, and
incorporates a self-test function. Adaptive
damping is not available on Estate models
(see illustrations).
When working on the suspension or
steering, you may come across nuts or bolts
which seem impossible to loosen. These nuts
and bolts on the underside of the vehicle are
continually subjected to water, road grime,mud, etc, and can become rusted or seized,
making them extremely difficult to remove. In
order to unscrew these stubborn nuts and
bolts without damaging them (or other
components), use lots of penetrating oil, and
allow it to soak in for a while. Using a wire
brush to clean exposed threads will also ease
removal of the nut or bolt, and will help to
prevent damage to the threads. Sometimes, a
sharp blow with a hammer and punch will
break the bond between a nut and bolt, but
care must be taken to prevent the punch from
slipping off and ruining the threads. Heating
the nut or bolt and surrounding area with a
blow lamp sometimes helps too, but this is
not recommended, because of the obvious
dangers associated with fire. Extension bars
or pipes will increase leverage, but never use
one on a ratchet, as the internal mechanism
could be damaged. Actually tighteningthe nut
or bolt first may help to break it loose. Nuts or
bolts which have required drastic measures to
remove them should always be renewed.
1.5 The power steering system fluid cooler
is located in front of the radiator
1.6A Adaptive damping switch located
near the handbrake lever1.6B Adaptive damping computer module
located in the luggage compartment
1.3 Rear suspension components on
Estate models
1 Tie-bar bracket
2 Short front lower arm
3 Long front upper arm
4 Shock absorber
5 Crossmember
6 Anti-roll bar
7 Coil spring
8 Rear lower arm
9 Stub axle (part of hub and bearing
assembly)
10 Knuckle
11 Brake caliper (disc brake models)
12 Hub nut
13 Brake drum
14 Splash guard (disc brake models)
15 Brake disc
16 Hub and bearing assembly
17 Backplate (drum brake models)
18 ABS wheel sensor
19 Tie-bar
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Chapter 12 Body electrical system
Air bag clock spring - removal and refitting . . . . . . . . . . . . . . . . . . . 30
Air bag control module - removal and refitting . . . . . . . . . . . . . . . . . 29
Air bag unit (driver’s side) - removal and refitting . . . . . . . . . . . . . . . 28
Anti-theft alarm system - general information . . . . . . . . . . . . . . . . . . 20
Auxiliary warning system - general information and
component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery - check, maintenance and charging . . . . . . . . See Chapter 1
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . See Chapter 5
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bulbs (interior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compact disc player - removal and refitting . . . . . . . . . . . . . . . . . . . 25
Cruise control system - general information . . . . . . . . . . . . . . . . . . . 21
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Exterior light units - removal and refitting . . . . . . . . . . . . . . . . . . . . . 7
Fuses, relays and timer module - testing and renewal . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight beam alignment - checking and adjustment . . . . . . . . . . 8
Headlight levelling motor - removal and refitting . . . . . . . . . . . . . . . 9Horn - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel components - removal and refitting . . . . . . . . . . . 11
Radio aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Radio/cassette player - coding, removal and refitting . . . . . . . . . . . 23
Radio/cassette player power amplifier - removal and refitting . . . . . 24
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Speedometer drive cable - removal and refitting . . . . . . . . . . . . . . . 12
Stop-light switch - removal and refitting . . . . . . . . . . . See Chapter 9
Switches - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tailgate wiper motor assembly - removal and refitting . . . . . . . . . . . 17
TCS inhibition switch - removal and refitting . . . . . . . . See Chapter 9
Trip computer module - removal and refitting . . . . . . . . . . . . . . . . . 18
Windscreen/tailgate washer system and wiper blade
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Windscreen/tailgate washer system components - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Windscreen wiper motor and linkage - removal and refitting . . . . . . 16
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses (auxiliary fusebox in engine compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse No Rating Colour Circuit(s) protected
1 80 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply to main fusebox
2 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fans
3 60 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Diesel engine glow plugs and/or ABS braking system
4 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system, or ignition and daytime running lights
5 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (left-hand side)
6 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated windscreen (right-hand side)
7 30 Light green . . . . . . . . . . . . . . . . . . . . . . ABS braking system
8 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air conditioning compressor/heated seats or air conditioning
compressor/daytime running lights
9 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . ECU (petrol), Cold start solenoid (Diesel)
10 20 Light blue . . . . . . . . . . . . . . . . . . . . . . . Ignition switch
11 3 Violet . . . . . . . . . . . . . . . . . . . . . . . . . . ECU memory
12 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Horn and hazard flasher warning system
13 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Oxygen sensor
14 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
15 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (right-hand side)
16 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlight (left-hand side)
17 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (right-hand side)
18 10 Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlight (left-hand side)
12•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
Specifications Contents
12
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Fuses (main fusebox in passenger compartment)
Note:Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.
Fuse Rating Colour Circuit(s) protected
19 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Heated door mirrors
20 10 Black . . . . . . . . . . . . . . . . . . . . . . . . . . Front/rear wiper motor (circuit breaker)
21 30 Light green . . . . . . . . . . . . . . . . . . . . . . Front electric windows (only)
21 40 Orange . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear electric windows
22 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . ABS module
23 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Reversing lights
24 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Stop-lights
25 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Central locking system/double-locking/anti-theft alarm
26 20 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . Foglights
27 15 Light blue . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter
28 30 Light green . . . . . . . . . . . . . . . . . . . . . . Headlight washer system
29 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heated rear window
30 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and auxiliary warning system
31 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel illumination
32 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Radio
33 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (left-hand side)
34 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Interior lighting and digital clock
35 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear sidelights (right-hand side)
36 30 Light green . . . . . . . . . . . . . . . . . . . . . . Air bag
37 30 Light green . . . . . . . . . . . . . . . . . . . . . . Heater blower
38 7.5 Brown . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive damping
Relays (auxiliary fusebox in engine compartment)
Relay Colour Circuit(s) protected
R1 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime running lights (left-hand-drive, but not all countries) or dim-
dip lights (UK)
R2 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (high speed)
R3 Blue (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning cut-out
R3 Brown (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning in conjunction with Diesel engine
R4 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen heater time delay
R5 Dark green (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R5 Black (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator electric cooling fan (low speed)
R6 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter solenoid
R7 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns
R8 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump
R9 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam headlights
R10 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam headlights
R11 Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU power supply (petrol), cold start (Diesel)
Relays (main fusebox in passenger compartment)
Relay Colour Circuit(s) protected
R12 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior, courtesy and footwell lights
R13 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear window
R14 Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater blower
R15 Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper motor
R16 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition
Auxiliary relays (not in the fuseboxes)
Relay Colour Circuit(s) protected Location
R17 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel glow plug Battery tray
R18 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “One-touch down” Driver’s door
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver’s window relay
R19 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control cut-off Central fuse box bracket the
below instrument panel
R20 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system Bulb module bracket
R21 Orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear screen wiper interval Bulb module bracket
R22 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglights (left-hand-drive only) Interface module bracket
R23 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction indicators Steering column
R24 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (left-hand side) Door lock module bracket
R25 White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (right-hand side) Door lock module bracket
R26 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated seats Door lock module bracket
12•2 Body electrical system
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