Ford Mondeo 4 Owners Manual

Chapter 5 Engine electrical systems
Alternator - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Alternator brushes and voltage regulator - renewal  . . . . . . . . . . . . . 13
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . See Chapter 1
Battery - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery check, maintenance and charging  . . . . . . . . . See Chapter 1
Battery leads - check and renewal  . . . . . . . . . ....

General information
The engine electrical systems include all
ignition, charging and starting components.
Because of their engine-related functions,
these components are discussed separately
from body electrical devices such as the
lights, the instruments, etc (which are
included in Chapter 12).
Precautions
Always observe the following precautions
when working on the electrical system:
(a) Be extremely careful when servicing
engine electrical components. They are
easily damaged if checked, connected or...

5If you are renewing the battery, make sure
that you get one that’s identical, with the
same dimensions, amperage rating, cold
cranking rating, etc. Dispose of the old battery
in a responsible fashion. Most local authorities
have facilities for the collection and disposal
of such items - batteries contain sulphuric
acid and lead, and should not be simply
thrown out with the household rubbish!
6Refitting is the reverse of the removal
procedure.
Note:See also the relevant Sections of
Chapter 1....

3Using an ohmmeter, measure the
resistance of the coil’s primary windings,
connecting the meter between the coil’s
terminal pins as follows. Measure first from
one outer pin to the centre pin, then from the
other outer pin to the centre. Compare your
readings with the coil primary resistance listed
in the Specifications Section at the beginning
of this Chapter.
4Disconnect the spark plug (HT) leads - note
their connections or label them carefully, as
described in Chapter 1. Use the meter to
check that...

5Undo the sensor’s retaining screw and
withdraw the sensor. The sensor’s bracket
cannot be unbolted from the cylinder
block/crankcase unless the transmission and
flywheel/driveplate have been removed (see
Chapter 2).
6Refitting is the reverse of the removal
procedure.
General information
The charging system includes the
alternator, an internal voltage regulator, a no-
charge (or “ignition”) warning light, the
battery, and the wiring between all the
components. The charging system supplies
electrical...

at the top, two at the bottom). Withdraw the
alternator from the engine, and manoeuvre it
out through the wheel arch (see illustration).
Do not drop it, it is fragile.
7If you are renewing the alternator, take the
old one with you when purchasing a
replacement unit. Make sure that the new or
rebuilt unit is identical to the old alternator.
Look at the terminals - they should be the
same in number, size and location as the
terminals on the old alternator. Finally, look at
the identification markings -...

starter motor must be overhauled or renewed.
(Other possibilities are that the starter motor
mounting bolts are very loose, or that teeth
are missing from the flywheel/driveplate ring
gear.)
4If, when the switch is actuated, the starter
motor does not operate at all but the solenoid
clicks, then the problem lies with either the
battery, the main solenoid contacts, or the
starter motor itself (or the engine is seized).
5If the solenoid plunger cannot be heard to
click when the switch is actuated, the...

Brush renewal
2Remove the brushes as shown (see
illustrations).
3In some cases, the brushes will have wear
limit marks, in the form of a groove etched
along one face of each brush; when the
brushes are worn down to these marks, they
must be renewed. If no marks are provided,
measure the length of each brush, and
compare it with the minimum length given in
the Specifications Section of this Chapter. If
any brush is worn below this limit, renew the
brushes as a set. If the brushes are still
serviceable,...

Chapter 9 Braking system
ABS hydraulic unit - removal and refitting  . . . . . . . . . . . . . . . . . . . . 20
ABS relay box - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 22
ABS wheel sensor - testing, removal and refitting  . . . . . . . . . . . . . . 21
Brake check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Brake pedal - removal and refitting  . . ....

Torque wrench settingsNm lbf ft
Front caliper bracket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Rear caliper bracket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 44
Front caliper guide bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Rear caliper guide bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
Rear drum brake backplate . . . . . . . . . ....