Ford Mondeo 4 Owners Manual

Ford Mondeo
Service and Repair Manual
Jeremy Churchill and A K Legg LAE MIMI 
Models covered
All Ford Mondeo models with four-cylinder petrol engines,
including special/limited editions
1597 cc, 1796 cc and 1988 cc 
Does not cover Diesel or V6 engines, or four-wheel-drive models
© Haynes Publishing 1996
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including...

LIVING WITH YOUR FORD MONDEO
IntroductionPage 0•4
Safety First!Page 0•5
General dimensions and weights Page0•6
MOT Test Checks
Checks carried out from the driver’s seat Page0•7
Checks carried out with the vehicle on the ground Page0•8
Checks carried out with the vehicle raised Page0•9
Checks carried out on your vehicle’s exhaust emission system Page0•10
Roadside Repairs
Jacking, towing and wheel changing Page0•11
Booster battery (jump) starting Page0•12
Identifying leaksPage0•13
Conversion...

REPAIRS & OVERHAUL
Engine and Associated Systems
In-car engine repair procedures Page 2A•1
Engine removal and general engine overhaul procedures Page 2B•1
Cooling, heating and air conditioning systems Page3•1
Fuel and exhaust systems  Page 4•1
Engine electrical systems Page 5•1
Emissions control systems Page 6•1
Transmission
Manual transmission Page 7A•1
Automatic transmission Page7B•1
Clutch and driveshafts  Page 8•1
Brakes 
Braking systemPage 9•1
Suspension 
Suspension and steering systems Page 10•1...

0•4Introduction
Introduced in March 1993, the Ford
Mondeo models are available in four-door
Saloon, five-door Hatchback and five-door
Estate configurations. All feature a high
standard of equipment, with driver/passenger
safety in accidents being a particularly high
design priority; all models are fitted with
features such as side impact bars in all doors,
“anti-submarine” seats combined with “seatbelt grabbers” and pre-tensioners, and an
airbag fitted to the steering wheel. Vehicle
security is enhanced,...

Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be...

0•6General Dimensions & Weights
Dimensions
Overall length:
Saloon, Hatchback  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4481 mm
Estate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4631 mm
Overall width - including mirrors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1925 mm
Overall height - at kerb weight:
Saloon, Hatchback   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403 to...

0•7
This is a guide to getting your vehicle through the MOT test.
Obviously it will not be possible to examine the vehicle to the same
standard as the professional MOT tester. However, working through
the following checks will enable you to identify any problem areas
before submitting the vehicle for the test.
Where a testable component is in borderline condition, the tester
has discretion in deciding whether to pass or fail it. The basis of such
discretion is whether the tester would be happy for a...

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...

Exhaust system
MStart the engine. With your assistant 
holding a rag over the tailpipe, check the
entire system for leaks. Repair or renew
leaking sections.
Jack up the front and rear of the vehicle,
and securely support it on axle stands.
Position the stands clear of the suspension
assemblies. Ensure that the wheels are
clear of the ground and that the steering
can be turned from lock to lock.
Steering mechanism 
MHave your assistant turn the steering from
lock to lock. Check that the steering turns...

0•10
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test
can be carried out later to check that the
vehicle pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All...