Ford Mondeo 4 Owners Manual

and remove the clevis pin securing the servo
unit pushrod to the pedal cross-link arm.
7On left-hand drive models, unscrew the nut
securing the pedal trunnion to the servo unit
pushrod inside the passenger compartment.
The nut is located near the top of the pedal,
and is accessible through an access hole. For
improved access, remove the lower facia
panel first.
8Withdraw the servo unit from the bulkhead,
and remove it from the engine compartment.
On left-hand drive models, take care not to
damage the...

Note:If any part of the ABS hydraulic unit is
defective, it must be renewed as an assembly.
Apart from the relay box (Section 22),
individual spare parts are not available.
Removal
1Remove both pressure-control relief valves
as described in Section 19.
2Identify the location of the remaining brake
hydraulic pipes on the ABS hydraulic unit,
then unscrew the union nuts and pull out the
pipes. Carefully bend the pipes away from the
hydraulic unit, to allow the unit to be removed.
3Disconnect the multi-plugs...

5Slacken and remove the four Torx retaining
screws, and withdraw the relay box from the
hydraulic unit (see illustration).
Refitting
6Refitting is a reversal of the removal
procedure. Do not overtighten the relay box
retaining screws, as the plastic is easily
cracked
Removal
1Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2Using a small screwdriver and a suitable
pad (to protect the facia), prise out the TCS
inhibitor switch from the facia.3Disconnect the multi-plug from the...

Refitting and adjustment
5With the switch removed, reset it by fully
extending its plunger.
6Depress the brake pedal until the distance
between the pedal and mounting bracket is as
shown (see illustration).
7Hold the pedal in this position, and refit the
stop-light switch to the mounting bracket .
8With the switch securely clipped in position,
release the brake pedal, and gently pull it fully
back to the at-rest position. This will
automatically set the adjustment of the stop-
light switch.
9reconnect...

Chapter 6 Emissions control systems
Catalytic converter - general information, checking 
and component renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnosis system - general information  . . . . . . . . . . . . . . . . . . . . . . 3
Electronic control system - description and precautions  . . . . . . . . . 2
Engine compartment wiring check  . . . . . . . . . . . . . . . See Chapter 1
EVAPorative emissions control (EVAP) system - general 
information, checking and component...

To minimise pollution of the atmosphere
from incompletely-burned and evaporating
gases, and to maintain good driveability and
fuel economy, a number of emission control
systems are used on these vehicles. They
include the following:
(a) The engine management system
(comprising both fuel and ignition sub-
systems) itself.
(b) Positive Crankcase Ventilation (PCV)
system.
(c) Evaporative Emissions Control (EVAP)
system.
(d) Exhaust Gas Recirculation (EGR) system.
(e) Catalytic converter.
The Sections of...

Emissions control systems  6•3
6
2.1B  Location of principal fuel injection, ignition and
emissions control system components 2.1A  Engine management system, showing fuel injection, 
ignition and emissions control sub-systems
1  ECU (Electronic Control Unit)
2  Fuel pump/fuel gauge sender
unit
3  Fuel pump relay
4  Fuel filter
5  Idle speed control valve
6  Air mass meter
7  Air cleaner assembly
8  Fuel pressure regulator
9  Fuel rail
10  Throttle potentiometer
11  Intake air temperature sensor
12  Fuel...

constantly monitors the oxygen content of the
exhaust gas. If the percentage of oxygen in
the exhaust gas is incorrect, an electrical
signal is sent to the ECU. The ECU processes
this information, and then sends a command
to the fuel injection system, telling it to change
the air/fuel mixture; the end result is an air/fuel
mixture ratio which is constantly maintained
at a predetermined ratio, regardless of driving
conditions. This happens in a fraction of a
second, and goes on almost all the time while...

coolant or EGR pipes, etc. In almost all cases,
damage of this sort is caused in the first
instance by incorrect routing on reassembly
after previous work has been carried out (see
the note at the beginning of this sub-Section).
6Obviously wires can break or short together
inside the insulation so that no visible
evidence betrays the fault, but this usually
only occurs where the wiring loom has been
incorrectly routed so that it is stretched taut or
kinked sharply; either of these conditions
should be...

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...