Ford Mondeo 4 Owners Manual

each of the holes, to remove rust, corrosion,
thread sealant or sludge, and to restore
damaged threads (see illustration). If
possible, use compressed air to clear the
holes of debris produced by this operation; a
good alternative is to inject aerosol-applied
water-dispersant lubricant into each hole,
using the long spout usually supplied. 
Warning: Wear eye protection
when cleaning out these holes in
this way, and be sure to dry out
any excess liquid left in the holes.
9When all inspection and repair...

15Measure the piston diameter at right-
angles to the gudgeon pin axis, just above the
bottom of the skirt; again, note the results
(see illustration).
16If it is wished to obtain the piston-to-bore
clearance, measure the bore and piston skirt
as described above, and subtract the skirt
diameter from the bore measurement. If the
precision measuring tools shown are not
available, the condition of the pistons and
bores can be assessed, though not quite as
accurately, by using feeler gauges as follows....

Note:Always check first what replacement
parts are available before planning any
overhaul operation; refer to Section 1 of this
Part. A Ford dealer, or a good engine
reconditioning specialist/automotive parts
supplier may be able to suggest alternatives
which will enable you to overcome the lack of
replacement parts.
1Before the inspection process can be
carried out, the piston/connecting rod
assemblies must be cleaned, and the original
piston rings removed from the pistons. The
rings should have smooth,...

Note:Always check first what replacement
parts are available before planning any
overhaul operation; refer to Section 1 of this
Part. A Ford dealer, or a good engine
reconditioning specialist/automotive parts
supplier, may be able to suggest alternatives
which will enable you to overcome the lack of
replacement parts.
1Clean the crankshaft, and dry it with
compressed air if available. 
Warning: Wear eye protection
when using compressed air! Be
sure to clean the oil holes with a
pipe cleaner or similar...

to the engine bearings, the acid attacks and
corrodes the bearing material.
7Incorrect shell refitting during engine
assembly will lead to bearing failure as well.
Tight-fitting shells leave insufficient bearing
running clearance, and will result in oil
starvation. Dirt or foreign particles trapped
behind a bearing shell result in high spots on
the bearing, which lead to failure. Do not
touch any shell’s bearing surface with your
fingers during reassembly; there is a risk of
scratching the delicate...

(see illustration). Next, install the upper side
rail in the same manner.
8After the three oil ring components have
been installed, check that both the upper and
lower side rails can be turned smoothly in the
ring groove.
9The second compression (middle) ring is
installed next, followed by the top
compression ring - ensure their marks are
uppermost, and be careful not to confuse
them. Don’t expand either ring any more than
necessary to slide it over the top of the piston.
10With all the rings in...

make sure that no dirt or oil was between the
bearing shells and the caps or block when the
clearance was measured. If the Plastigage is
noticeably wider at one end than the other,
the journal may be tapered (see Section 13).
12Carefully scrape all traces of the
Plastigage material off the main bearing
journals and the bearing surfaces. Be very
careful not to scratch the bearing - use your
fingernail or the edge of a credit card.
Final refitting
13Carefully lift the crankshaft out of the
engine. Clean...

rod’s big-end onto the crankpin. The piston
rings may try to pop out of the ring
compressor just before entering the cylinder
bore, so keep some pressure on the ring
compressor. Work slowly, and if any
resistance is felt as the piston enters the
cylinder, stop immediately. Find out what’s
binding, and fix it before proceeding. Do not,
for any reason, force the piston into the
cylinder - you might break a ring and/or the
piston.
10To check the big-end bearing running
clearance, cut a piece of the...

Chapter 3
Cooling, heating, and air conditioning systems
Air conditioning system - general information 
and precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air conditioning system components - removal and refitting  . . . . . . 12
Antifreeze - general information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . See Chapter 1
Coolant level check  . . . . . . . . . . . . . . . . . . ....

Torque wrench settingsNm lbf ft
Radiator mounting bracket-to-subframe bolts  . . . . . . . . . . . . . . . . . . . . 23 17
Fluid cooler pipe unions - automatic transmission  . . . . . . . . . . . . . . . . . 23 17
Thermostat housing-to-cylinder head bolts  . . . . . . . . . . . . . . . . . . . . . . 20 15
Water outlet-to-thermostat  housing bolts  . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
Coolant temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23...