Ford Mondeo 4 Owners Manual

4If a hose proves stubborn, try to release it
by rotating it on its unions before attempting
to work it off. Gently prise the end of the hose
with a blunt instrument (such as a flat-bladed
screwdriver), but do not apply too much force,
and take care not to damage the pipe stubs or
hoses. Note in particular that the radiator hose
unions are fragile; do not use excessive force
when attempting to remove the hoses. If all
else fails, cut the hose with a sharp knife, then
slit it so that it can be peeled off...

Caution: Don’t drive the vehicle
without a thermostat. The lack of
a thermostat will slow warm-up
time. The engine management system’s
ECU will then stay in warm-up mode for
longer than necessary, causing emissions
and fuel economy to suffer.
9If the radiator top hose is hot, it means that
the coolant is flowing and the thermostat is
open. Consult the “Fault diagnosis”section at
the front of this manual to assist in tracing
possible cooling system faults.
Thermostat test
10If the thermostat remains in...

sender’s electrical connector, and use a
jumper wire to connect the white/red wire to a
clean earth point (bare metal) on the engine.
Switch on the ignition without starting the
engine. If the gauge now indicates Hot, renew
the sender.
5If the gauge still does not work, the circuit
may be open, or the gauge may be faulty. See
Chapter 12 for additional information.
Removal
6Unbolt the resonator support bracket from
the engine compartment front crossmember.
Slacken the two clamp screws securing the...

Warning: Do not disconnect any
of the refrigerant hoses.
5Unbolt the radiator mounting brackets from
the subframe; note that they are handed, and
are marked to ensure correct refitting (see
illustration). Collect the bottom mounting
rubbers, noting which way up they are fitted,
and store them carefully.
6Carefully lower the radiator from the
vehicle, and withdraw it.
7With the radiator removed, it can be
inspected for leaks and damage. If it needs
repair, have a radiator specialist or dealer
service...

Heater blower motor
Removal
1Disconnect the battery negative (earth) lead
(see Chapter 5, Section 1).
2Release the four clips (by pulling them out)
securing the passenger side footwell upper
trim panel, then withdraw the panel.
3Unplug the motor’s electrical connector.
4Lift the motor’s retaining lug slightly, twist
the motor anti-clockwise (seen from beneath)
through approximately 30°, then withdraw the
assembly.
5The motor’s control resistor can be
removed by sliding a slim screwdriver into the
slot...

duct is lowered from the air distributor and
secured with its screw.
16Refill the cooling system with the proper
mixture of antifreeze and water (see Chapter
1). Start the engine and allow it to reach
normal operating temperature, indicated by
the radiator top hose becoming hot. Recheck
the coolant level and add more if required,
then check for leaks. Check the operation of
the heater.
Pollen filter
17Refer to Chapter 1.
Blower/air conditioning control
Removal
1Disconnect the battery negative (earth)...

the refrigerant. The liquid refrigerant boils off
into low-pressure vapour, taking the heat with
it when it leaves the evaporator.
Precautions
Warning: The air conditioning
system is under high pressure.
Do not loosen any fittings or
remove any components until
after the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an approved type of
container, at a dealer service department
or an automotive air conditioning repair
facility capable of handling R134a...

to unscrew the pressure-cycling switch to
allow the use of the tool. Immediately cap the
open fittings, to prevent the entry of dirt and
moisture.
27Withdraw the accumulator/dehydrator.
28Refit the accumulator/dehydrator in the
reverse order of removal; renew all seals
disturbed.
29If you are installing a new accumulator/
dehydrator, refer to the manufacturer’s
instructions for adding refrigerant oil to the
system.
30Have the system evacuated, charged and
leak-tested by the specialist that discharged...

Chapter 4 Fuel and exhaust systems
Accelerator cable (models with traction control) - 
removal, refitting and adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accelerator cable (models without traction control) - 
removal, refitting and adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accelerator pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 7
Air cleaner assembly/air intake components - removal and refitting  . 4
Air filter element renewal  . . ....

This Chapter is concerned with those
features of the engine management system
that supply clean fuel and air to the engine,
meter it in the required proportions, and
dispose of the results. Since the emission
control sub-systems modify the functions of
both the fuel and exhaust sub-systems, all of
which are integral parts of the whole engine
management system, there are many cross-
references to Chapters 5 and 6. Information
on the electronic control system, its fault
diagnosis, sensors and actuators, is...