1993 FORD MONDEO wipers

Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
MExamine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible
from inside the vehicle.
MThe front seats themselves must be
securely attached and the backrests must
lock in the upright position.
Doors
MBoth front doors must be able to be opened
and closed from outside and inside, and must
latch securely when closed.
Vehicle identification
MNumber plates must be in good condition,
secure and legible, with letters and numbers
correctly spaced – spacing at (A) should be
twice that at (B).
MThe VIN plate (A) and homologation plate
(B) must be legible.
Electrical equipment
MSwitch on the ignition and check the
operation of the horn.
MCheck the windscreen washers and wipers,
examining the wiper blades; renew damaged
or perished blades. Also check the operation
of the stop-lights.
MCheck the operation of the sidelights and
number plate lights. The lenses and reflectors
must be secure, clean and undamaged.
MCheck the operation and alignment of the
headlights. The headlight reflectors must not
be tarnished and the lenses must be
undamaged.
MSwitch on the ignition and check the
operation of the direction indicators (including
the instrument panel tell-tale) and the hazard
warning lights. Operation of the sidelights and
stop-lights must not affect the indicators - if it
does, the cause is usually a bad earth at the
rear light cluster.
MCheck the operation of the rear foglight(s),
including the warning light on the instrument
panel or in the switch.
Footbrake
MExamine the master cylinder, brake pipes
and servo unit for leaks, loose mountings,
corrosion or other damage.
MThe fluid reservoir must be secure and the
fluid level must be between the upper (A) and
lower (B) markings.MInspect both front brake flexible hoses for
cracks or deterioration of the rubber. Turn the
steering from lock to lock, and ensure that the
hoses do not contact the wheel, tyre, or any
part of the steering or suspension mechanism.
With the brake pedal firmly depressed, check
the hoses for bulges or leaks under pressure.
Steering and suspension
MHave your assistant turn the steering wheel
from side to side slightly, up to the point where
the steering gear just begins to transmit this
movement to the roadwheels. Check for
excessive free play between the steering
wheel and the steering gear, indicating wear or
insecurity of the steering column joints, the
column-to-steering gear coupling, or the
steering gear itself.
MHave your assistant turn the steering wheel
more vigorously in each direction, so that the
roadwheels just begin to turn. As this is done,
examine all the steering joints, linkages,
fittings and attachments. Renew any
component that shows signs of wear or
damage. On vehicles with power steering,
check the security and condition of the
steering pump, drivebelt and hoses.
MCheck that the vehicle is standing level,
and at approximately the correct ride height.
Shock absorbers
MDepress each corner of the vehicle in turn,
then release it. The vehicle should rise and
then settle in its normal position. If the vehicle
continues to rise and fall, the shock absorber
is defective. A shock absorber which has
seized will also cause the vehicle to fail.
2Checks carried out
WITH THE VEHICLE ON THE
GROUND
0•8MOT Test Checks
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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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Ford Mondeo maintenance schedule
1•3
1
Maintenance schedule
The manufacturer’s recommended maintenance schedule for these
vehicles is as described below - note that the schedule starts from the
vehicle’s date of registration. These are the minimum maintenance
intervals recommended by the factory for Mondeos driven daily, but
subjected only to “normal” use. If you wish to keep your vehicle in
peak condition at all times, you may wish to perform some of these
procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your vehicle,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of
these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit with
the engine idling or drive at low speeds for extended periods (ie, in
heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.
When your vehicle is new, it should be serviced by a Ford dealer
service department to protect the factory warranty. In many cases, the
initial maintenance check is done at no cost to the owner. Note that
this first free service (carried out by the selling dealer 1500 miles or 3
months after delivery), although an important check for a new vehicle,
is not part of the regular maintenance schedule, and is therefore not
mentioned here.
Weekly checks
m mCheck the engine oil level, and top-up if necessary
(Section 3)
m mCheck the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Sections 12 and 22)
m mCheck the windscreen/tailgate washer fluid level, and top-
up if necessary (Section 3)
m mCheck the tyre pressures, including the spare (Section 4)
m mVisually check the tyres for excessive tread wear, or
damage (Section 4)
m mCheck the operation of all (exterior and interior) lights and
the horn, wipers and windscreen/tailgate washer system
(Sections 6 and 8). Renew any blown bulbs (Chapter 12),
and clean the lenses of all exterior lights
Monthly checks
m mCheck the coolant level, and top-up if necessary (Sec-
tion 3)
m mCheck the battery electrolyte level, where applicable
(Section 3)
m mCheck the power steering fluid level, and top-up if
necessary (Section 5)
m mVisually check all reservoirs, hoses and pipes for leakage
(Section 12)
m mCheck the operation of the air conditioning system
(Section 14)
m mCheck the operation of the handbrake (Section 23)
m mCheck the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6)
m mCheck the condition of the wiper blades, renewing them if
worn or no longer effective - note that the manufacturer
recommends renewing the blades as a safety precaution,
irrespective of their apparent condition, at least once a
year (Section 6)
Every 10 000 miles or 12 months,
whichever occurs first
Note:If the vehicle is used regularly for very short (less than
10 miles), stop/go journeys, the oil and filter should be renewed
between services (ie, every 5000 miles/6 months).
m mCheck the electrical system (Section 8)
m mCheck the battery (Section 9)
m mCheck the seat belts (Section 10)
m mCheck the auxiliary drivebelt (Section 11)
m mCheck for fluid leaks and hose condition (Section 12)
m mCheck the condition of all wiring (Section 13)
m mCheck all air conditioning components (Section 14)
m mChange the engine oil and filter (Section 15)
m mCheck the manual transmission oil level (Section 16)
m mCheck the adjustment of the clutch pedal (Section 17)
m mLubricate the automatic transmission linkage (Section 18)
m mCheck the steering, suspension and wheels (Section 19)
m mCheck the driveshaft gaiters and CV joints (Section 20)
m mCheck the exhaust system (Section 21)
m mCheck the underbody, and all fuel/brake lines (Section 22)
m mCheck the brake system (Section 23)
m mCheck and lubricate the doors and bonnet (Section 24)
m mCheck the security of all roadwheel nuts (Section 25)
m mRoad test (Section 26). Check the level of the automatic
transmission fluid with the engine still hot, after the road
test (Section 7)
Every 20 000 miles or 2 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the ventilation system pollen filter (Section 27)
m mRenew the coolant (Sections 2 and 28)
Every 30 000 miles or 3 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the air filter element (Section 29). Note that this
task must be carried out at more frequent intervals if the
vehicle is used in dusty or polluted conditions
m mCheck the Positive Crankcase Ventilation (PCV) system,
and clean the filter (Section 30)
m mRenew the spark plugs (Section 31)
Every 60 000 miles
Carry out all operations listed above, plus the following:
m
mRenew the timing belt (Section 32)
m mRenew the fuel filter (Section 33)
Every 3 years
(regardless of mileage)
m mRenew the brake fluid (Section 34)
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REF•6Fault Finding
Engine 1
m mEngine backfires
m mEngine difficult to start when cold
m mEngine difficult to start when hot
m mEngine fails to rotate when attempting to start
m mEngine hesitates on acceleration
m mEngine idles erratically
m mEngine lacks power
m mEngine misfires at idle speed
m mEngine misfires throughout the driving speed range
m mEngine noises
m mEngine rotates but will not start
m mEngine runs-on after switching off
m mEngine stalls
m mEngine starts but stops immediately
m mOil pressure warning light illuminated with engine running
m mStarter motor noisy or excessively-rough in engagement
Cooling system 2
m
mCorrosion
m mExternal coolant leakage
m mInternal coolant leakage
m mOvercooling
m mOverheating
Fuel and exhaust systems 3
m
mExcessive fuel consumption
m mExcessive noise or fumes from exhaust system
m mFuel leakage and/or fuel odour
Clutch 4
m
mClutch fails to disengage (unable to select gears)
m mClutch slips (engine speed increases with no increase
in vehicle speed)
m mJudder as clutch is engaged
m mNoise when depressing or releasing clutch pedal
m mPedal travels to floor - no pressure or very little resistance
Manual transmission 5
m
mJumps out of gear
m mLubricant leaks
m mNoisy in neutral with engine running
m mNoisy in one particular gear
m mVibration
Automatic transmission 6
m
mEngine will not start in any gear, or starts in gears
other than Park or Neutral
m mFluid leakage
m mGeneral gear selection problems
m mTransmission fluid brown, or has burned smell
m mTransmission slips, shifts roughly, is noisy, or
has no drive in forward or reverse gears
m mTransmission will not downshift (kickdown) with
accelerator fully depressed
Driveshafts 7
m mClicking or knocking noise on turns (at slow speed on full-lock)
m mVibration when accelerating or decelerating
Braking system 8
m
mBrake pedal feels spongy when depressed
m mBrakes binding
m mExcessive brake pedal effort required to stop vehicle
m mExcessive brake pedal travel
m mJudder felt through brake pedal or steering wheel when braking
m mNoise (grinding or high-pitched squeal) when brakes applied
m mRear wheels locking under normal braking
m mVehicle pulls to one side under braking
Suspension and steering systems 9
m
mExcessive pitching and/or rolling around corners, or during
braking
m mExcessive play in steering
m mExcessively-stiff steering
m mLack of power assistance
m mTyre wear excessive
m mVehicle pulls to one side
m mWandering or general instability
m mWheel wobble and vibration
Electrical system 10
m
mBattery will not hold a charge for more than a few days
m mCentral locking system inoperative, or unsatisfactory in operation
m mElectric windows inoperative, or unsatisfactory in operation
m mHorn inoperative, or unsatisfactory in operation
m mIgnition warning light fails to come on
m mIgnition warning light remains illuminated with engine running
m mInstrument readings inaccurate or erratic
m mLights inoperative
m mWindscreen/tailgate washers inoperative, or unsatisfactory in
operation
m mWindscreen/tailgate wipers inoperative, or unsatisfactory in
operation
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REF•12
Battery will not hold a charge more than a few days
m mBattery defective internally (Chapter 5).
m mBattery electrolyte level low (Chapter 1).
m mBattery terminal connections loose or corroded (Chapter 5).
m mAuxiliary drivebelt worn or incorrectly-adjusted (Chapter 1).
m mAlternator not charging at correct output (Chapter 5).
m mAlternator or voltage regulator faulty (Chapter 5).
m mShort-circuit causing continual battery drain (Chapters 5 and 12).
Ignition (no-charge) warning light remains
illuminated with engine running
m mAuxiliary drivebelt broken, worn, or incorrectly-adjusted (Chapter 1).
m mAlternator brushes worn, sticking, or dirty (Chapter 5).
m mAlternator brush springs weak or broken (Chapter 5).
m mInternal fault in alternator or voltage regulator (Chapter 5).
m mBroken, disconnected, or loose wiring in charging circuit (Chapter 5).
Ignition (no-charge) warning light fails to come on
m
mWarning light bulb blown (Chapter 12).
m mBroken, disconnected, or loose wiring in warning light circuit
(Chapters 5 and 12).
m mAlternator faulty (Chapter 5).
Lights inoperative
m
mBulb blown (Chapter 12).
m mCorrosion of bulb or bulbholder contacts (Chapter 12).
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken, loose, or disconnected wiring (Chapter 12).
m mFaulty switch (Chapter 12).
Instrument readings inaccurate or erratic
Instrument readings increase with engine speed
m
mFaulty voltage regulator (Chapter 12).
Fuel or temperature gauges give no reading
m
mFaulty gauge sender unit (Chapters 3 or 4).
m mWiring open-circuit (Chapter 12).
m mFaulty gauge (Chapter 12).
Fuel or temperature gauges give continuous maximum reading
m mFaulty gauge sender unit (Chapters 3 or 4).
m mWiring short-circuit (Chapter 12).
m mFaulty gauge (Chapter 12).
Horn inoperative, or unsatisfactory in operation
Horn fails to operate
m
mBlown fuse (Chapter 12).
m mCable or cable connections loose, broken or disconnected (Chapter 12).
m mFaulty horn (Chapter 12).
Horn emits intermittent or unsatisfactory sound
m
mCable connections loose (Chapter 12).
m mHorn mountings loose (Chapter 12).
m mFaulty horn (Chapter 12).
Horn operates all the time
m
mHorn push either earthed or stuck down (Chapter 12).
m mHorn cable to horn push earthed (Chapter 12).
Windscreen/tailgate wipers inoperative or
unsatisfactory in operation
Wipers fail to operate, or operate very slowly
m mWiper blades stuck to screen, or linkage seized or binding (Chapter 12).
m mBlown fuse (Chapter 12).
m mCable or cable connections loose, broken or disconnected (Chapter 12).
m mFaulty relay (Chapter 12).
m mFaulty wiper motor (Chapter 12).
Wiper blades sweep over too large or too small an area of
the glass
m mWiper arms incorrectly-positioned on spindles (Chapter 1).
m mExcessive wear of wiper linkage (Chapter 1).
m mWiper motor or linkage mountings loose or insecure (Chapter 12).
Wiper blades fail to clean the glass effectively
m
mWiper blade rubbers worn or perished (Chapter 1).
m mWiper arm tension springs broken, or arm pivots seized (Chapter 1).
m mInsufficient windscreen washer additive to adequately remove road
film (Chapter 1).
Windscreen/tailgate washers inoperative, or
unsatisfactory in operation
One or more washer jets inoperative
m mBlocked washer jet (Chapter 1).
m mDisconnected, kinked or restricted fluid hose (Chapter 1).
m mInsufficient fluid in washer reservoir (Chapter 1).
Washer pump fails to operate
m
mBroken or disconnected wiring or connections (Chapter 12).
m mBlown fuse (Chapter 12).
m mFaulty washer switch (Chapter 12).
m mFaulty washer pump (Chapter 12).
Washer pump runs for some time before fluid is emitted
from jets
m mFaulty one-way valve in fluid supply hose (Chapter 12).
Electric windows inoperative, or unsatisfactory in
operation
Window glass will only move in one direction
m mFaulty switch (Chapter 12).
Window glass slow to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m mRegulator seized or damaged, or in need of lubrication (Chapter 11).
m mDoor internal components or trim fouling regulator (Chapter 11).
m mFaulty motor (Chapter 12).
Window glass fails to move
m
mIncorrectly-adjusted door glass guide channels (Chapter 11).
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken or disconnected wiring or connections (Chapter 12).
m mFaulty motor (Chapter 12).
Central locking system inoperative, or
unsatisfactory in operation
Complete system failure
m mBlown fuse (Chapter 12).
m mFaulty relay (Chapter 12).
m mBroken or disconnected wiring or connections (Chapter 12).
Latch locks but will not unlock, or unlocks but will not lock
m
mFaulty master switch (Chapter 11).
m mBroken or disconnected latch operating rods or levers (Chapter 11).
m mFaulty relay (Chapter 12).
One lock motor fails to operate
m
mBroken or disconnected wiring or connections (Chapter 12).
m mFaulty lock motor (Chapter 11).
m mBroken, binding or disconnected latch operating rods or levers
(Chapter 11).
m mFault in door latch (Chapter 11).
Fault Finding
10 Electrical system
Note:For problems associated with the starting system, refer to the faults listed under “Engine”earlier in this Section.
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REF•19Index
Oil pressure warning light switch - 2A•22
Oil pump - 2A•21
Oil seals - 2A•13, 2A•22, 7A•2, 7B•3, REF•4
Oil separator - 6•19
Open-circuit - 12•4
Overcooling - REF•8
Overhead console - 11•22
Overheating - REF•8
Oxygen sensor - 6•11, 6•12, 6•13
P
Pads - 9•3, 9•8
Pedals - 1•17, 4•5, 8•3, 9•10, 9•11
Piston rings - 2B•19
Pistons - 2B•12, 2B•17, 2B•21, 2B•22
Pitching and/or rolling around corners -
REF•11
Plastic components - 11•4
Plenum chamber - 4•3
Poisonous or irritant substances - 0•5
Pollen filter - 1•20, 3•8
Position sensor - 5•4, 6•10, 6•11, 6•12
Positive Crankcase Ventilation (PCV)
system - 1•23, 6•18, 6•19
Power steering - 1•8, 1•10, 6•11, 6•12,
6•13, 10•20, 10•21, 10•22
Power steering fluid - 1•2
Pressure-control relief valve - 9•13
Pressure-cycling and pressure-regulating
switches - 3•10
Project vehicles - 0•4
Pulse-air - 6•17, 6•18
Purge solenoid valve - 6•14
R
Radiator - 3•4, 3•5
Radiator grille - 11•5
Radio - 12•21, 12•22
Radio aerial - 12•22
Reading light - 12•11
Rear light cluster - 12•9, 12•13
Rear window - 12•8, 12•21
Relays - 12•5
Repair procedures - REF•4
Resonator (engine compartment) - 4•3
Respraying - 11•3
Reversing light switch - 7A•3
Road test - 1•20
Roadwheels - 1•17, 1•18, 1•20
Roll-over valves - 4•8
Routine maintenance and servicing- 1•1et
seq
Rubber gaiters- 1•18, 8•7, 8•9, 10•21
Rust holes in bodywork - 11•3
S
Safety first! - 0•5
Scalding - 0•5
Scratches in bodywork - 11•3
Screw threads and fastenings - REF•4
Seat belts - 0•8, 1•13, 11•19, 11•20Seats - 0•8, 11•18, 12•8
Selector assembly - 7B•2
Selector cable - 7B•2
Selector lever position sensor - 7B•2
Selector panel illumination - 12•11
Service indicator - 12•17, 12•18
Servo unit - 9•12, 9•13
Shock absorbers - 0•8, 0•9, 10•14
Shoes - 9•6
Short-circuit - 12•4
Sidelight - 12•9
Solenoid renewal - 5•8
Spare parts - REF•5
Spark plugs - 1•23
Speakers - 12•22
Speed control - 12•20
Speed sensor - 6•11, 6•12, 6•13
Speedometer - 7A•2, 7A•3, 7B•2, 7B•3,
12•15
Springs - 0•9
Starter motor - 5•7
Starter motor fault - REF•7
Starting system - 5•6
Steering - 0•7, 0•8, 0•9, 1•17, 1•20
Steering angles - 10•22
Steering column - 10•18, 10•20
Steering fault - REF•11
Steering knuckle - 10•5
Steering wheel - 10•17
Stop-light switch - 9•15
Striker - 11•13
Struts - 10•6, 10•7, 10•10, 10•12
Sump - 2A•19
Sun visor - 11•20
Sunroof - 11•18, 12•7
Suspension and steering systems- 0•8,
0•9, 1•17, 1•18, 1•20, 10•1et seq
Suspension and steering systems fault
finding - REF•11
Switches - 2A•22, 3•4, 3•5, 3•10, 4•8-
6•11, 6•12, 6•13, 7A•3, 9•15, 11•17,
12•6, 12•7, 12•8, 12•11, 12•18, 12•20
T
Tailgate - 1•8, 1•10, 11•15, 11•16, 12•17,
12•20, REF•12
Tappets - 2A•14
TCS inhibitor switch - 9•15
TCS throttle actuator - 9•15
Temperature gauge fault - REF•12
Thermostat - 3•3, 3•4
Throttle actuator - 9•15
Throttle housing - 4•9
Throttle potentiometer - 6•11, 6•13
Tie-bar - 10•13, 10•16
Timer module - 12•5
Timing - 5•4, 6•10
Timing belt - 1•26, 2A•10, 2A•13
Tools - REF•1, REF•3, REF•4
Top Dead Centre (TDC) for No 1 piston -
2A•6
Towing - 0•11
Track rod end - 10•22Traction Control System - 9•15, 12•7
Transmission- 1•11, 1•17, 2A•24, 2B•3,
2B•4, 7A•1 et seq, 7B•1 et seq, 12•11
Trim mouldings - 11•17
Trim panels - 11•6, 11•20
Trip computer - 12•17
Tyre wear - REF•11
Tyres - 0•10, 1•8
U
Underbody check - 1•19
Upper suspension arm - 10•16
V
Vacuum hoses - 1•15
Vacuum servo unit - 9•12, 9•13
Valve clearances - 2A•5
Valves - 2B•10, 2B•11
Vehicle identification - 0•8, REF•5
Vehicle pulls to one side - REF•10, REF•11
Vehicle speed sensor - 6•11, 6•12, 6•13
Ventilation system - 1•20, 3•7
Voltage regulator - 5•6
W
Warning lights - 12•11
Warning system - 12•17
Washer jets fault - REF•12
Washer nozzle - 12•21
Washer pump fault - REF•12
Washer reservoir and pump - 12•20
Washer system - 1•8, 1•10, 12•18, 12•20
Water pump - 3•6
Weights - 0•6
Wheel alignment - 10•22
Wheel arch liner - 11•24
Wheel bearings - 0•9
Wheel changing - 0•11
Wheel cylinders - 9•8
Wheel sensors - 9•14
Wheel wobble - REF•11
Wheels - 0•10, 1•17, 1•18, 1•20
Wheels locking - REF•11
Window glass - 11•8
Window regulator - 11•9
Windows - 11•17, 12•7, 12•8, 12•21,
REF•12
Windscreen - 0•7, 1•8, 1•10, 11•17, 12•6,
12•8, 12•16, 12•20, 12•21, REF•12
Wiper arms - 12•16
Wiper blade - 1•10
Wiper blade fault - REF•12
Wiper motor - 12•16, 12•17
Wipers - 12•6
Wiper fault - REF•12
Wiring - 1•15
Wiring diagrams- 12•23et seq
Working facilities - REF•3
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