Ford Mondeo (petrol engines). Manual - part 1

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

photocopying, recording or by any information storage or retrieval system,

without permission in writing from the copyright holder.

ISBN 1 85960 167 7

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library.

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,
Somerset BA22 7JJ  

Haynes Publishing

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

Editions Haynes S.A.

147/149, rue Saint Honoré, 75001 PARIS, France

(1923-304-10X3)

0•4

Introduction

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 “seat

belt grabbers” and pre-tensioners, and an
airbag fitted to the steering wheel. Vehicle
security is enhanced, with an in-built alarm
system and engine immobiliser being fitted as
standard, as well as double-locking doors
with shielded locks, and security-coded audio
equipment.

The four-cylinder petrol engine is a new

design, available in 1.6, 1.8 and 2.0 litre

capacities. It is controlled by a sophisticated
engine management system, which combines
multi-point sequential fuel injection and
distributorless ignition systems with
evaporative emissions control, exhaust gas
recirculation and a three-way regulated
catalytic converter (with a pulse-air system for
rapid warm-up) to ensure that the vehicle
complies with the most stringent of the
emissions control standards currently in force,
and yet provides the levels of performance
and fuel economy expected.

The transversely-mounted engine drives

the front roadwheels through either a five-
speed manual transmission with a cable-
operated clutch, or through an electronically-
controlled four-speed automatic transmission.

The fully-independent suspension is by

MacPherson strut on all four roadwheels,
located by transverse lower arms at the front,
and by transverse and trailing arms at the rear;
anti-roll bars are fitted at front and rear. The
Estate rear suspension is of a different design,
to give maximum loadspace inside the
vehicle, with self-levelling suspension units
available as an option. On some models, the
suspension is electronically-controlled
through the Adaptive Damping System.

The steering is power-assisted, the pump

being belt-driven from the engine, and the
rack-and-pinion steering gear mounted
behind the engine.

The vacuum servo-assisted brakes are disc

at the front, with drums at the rear on most
models; disc rear brakes and an
electronically-controlled Anti-lock Braking
System (ABS) are available on some models,
with a Traction Control System (TCS) available
as a further option where ABS is fitted.

Acknowledgements

Thanks are due to Champion Spark Plug,

who supplied the illustrations showing spark
plug conditions. Certain other illustrations are
the copyright of the Ford Motor Company,
and are used with their permission. Thanks
are also due to Sykes-Pickavant Limited, who
provided some of the workshop tools, and to
all those people at Sparkford who helped in
the production of this manual.

Project vehicles

The main project vehicle used in the

preparation of this manual, and appearing in
many of the photographic sequences, was a
1993-model Ford Mondeo 2.0 Si Hatchback.
Additional work was carried out and
photographed on a 1993-model 2.0 Si Saloon
and a 1993-model 2.0 Ghia Estate (with
automatic transmission).

Introduction to the Ford Mondeo

Ford Mondeo 2.0 Ghia Saloon

Ford Mondeo 1.8 GLX Estate

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 extremely hot
immediately after use.

Crushing

• When working under or near
a raised vehicle, always
supplement the
jack with axle
stands, or use
drive-on ramps.

Never venture
under a car
which is only
supported by
a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.

Fire

• Fuel is highly flammable; fuel vapour is
explosive. 
• Don’t let fuel spill onto a hot engine. 
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks 
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.

Electric shock 

• Ignition HT
voltage can be
dangerous,
especially to
people with
heart problems
or a pacemaker.
Don’t work on or
near the ignition
system with the
engine running or the
ignition switched on.

• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.

Fume or gas intoxication 

• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.

Poisonous or irritant substances

• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.

Asbestos

• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.

Special hazards

Hydrofluoric acid

• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400

0

C. The

rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.

The battery

• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.

Air bags

• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
manuals may apply.

Diesel injection equipment

• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.

Warning: Never expose the
hands, face or any other part of
the body to injector spray; the

fuel can penetrate the skin with
potentially fatal results.

Remember...

DO

• Do use eye protection when using power
tools, and when working under the vehicle.

• Do wear gloves or use barrier cream to
protect your hands when necessary.

• Do get someone to check periodically
that all is well when working alone on the
vehicle.

• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.

• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.

• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.

A few tips

DON’T

• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.

• Don’t rush to finish a job, or take
unverified short cuts.

• Don’t use ill-fitting tools which may slip
and cause injury.

• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.

• Don’t allow children or pets to play in or
near a vehicle being worked on.

0•5

Safety First!

0•6

General 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 1435 mm

Estate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1416 to 1501 mm

Wheelbase  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2704 mm

Front track - all models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1503 mm

Rear track:

Saloon, Hatchback  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1486 to 1487 mm

Estate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1504 mm

Turning circle  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.9 m

Weights

Kerb weight:

1.6 Saloon, Hatchback models  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1215 to 1250 kg

1.6 Estate models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1265 to 1275 kg

1.8 Saloon, Hatchback models:

Manual transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1225 to 1260 kg

Automatic transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1260 to 1280 kg

1.8 Estate models:

Manual transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1275 to 1285 kg

Automatic transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1305 kg

2.0 Saloon, Hatchback models:

Manual transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1250 to 1310 kg

Automatic transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1285 to 1340 kg

2.0 Estate models:

Manual transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1295 to 1335 kg

Automatic transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1330 to 1415 kg

Maximum gross vehicle weight:

Saloon, Hatchback:

1.6 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1725 kg

1.8 Saloon models, automatic transmission  . . . . . . . . . . . . . . . . .

1750 kg

2.0 models, automatic transmission  . . . . . . . . . . . . . . . . . . . . . . .

1800 kg

All others  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1775 kg

Estate:

1.6 models, 2.0 models with manual transmission  . . . . . . . . . . . .

1900 kg

All others  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1925 kg

Maximum roof rack load:

Estate models with integral roof rack  . . . . . . . . . . . . . . . . . . . . . . . .

100 kg

All others  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 kg

Maximum towing weight  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500 kg

Trailer nose weight limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 kg