check engine FORD MONDEO 1993 Service Repair Manual

6 Automatic transmission
REF•10Fault Finding
Note:Due to the complexity of the automatic transmission and its
electronic control system, it is difficult for the home mechanic to
properly diagnose and service this unit. For problems other than the
following, the vehicle should be taken to a dealer service department
or automatic transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.
m mTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
(a) Housing joints (Chapters 1 and 7, Part B).
(b) Dipstick tube (Chapters 1 and 7, Part B).
(c) Transmission-to-fluid cooler pipes/unions (Chapters 3 and 7,
Part B).
(d) Speedometer drive pinion O-ring (Chapter 7, Part B).
(e) Differential side gear oil seals (Chapter 7, Part B).
Transmission fluid brown, or has burned smell
m mTransmission fluid level low, or fluid in need of renewal (Chapter 1).
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
m mLow transmission fluid level (Chapter 1).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
General gear selection problems
m
mChapter 7, Part B, deals with checking and adjusting the selector
cable on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:
(a) Engine starting in gears other than Park or Neutral.
(b) Indicator on gear selector lever pointing to a gear other than the
one actually being used.
(c) Vehicle moves when in Park or Neutral.
(d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7, Part B for the selector cable adjustment
procedure.
Engine will not start in any gear, or starts in gears
other than Park or Neutral
m mIncorrect selector lever position sensor adjustment (Chapter 7,
Part B).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.
7 Driveshafts
Clicking or knocking noise on turns (at slow speed
on full-lock)
m mLack of constant velocity joint lubricant (Chapter 8).
m mWorn outer constant velocity joint (Chapter 8).
Vibration when accelerating or decelerating
m
mWorn inner constant velocity joint (Chapter 8).
m mBent or distorted driveshaft (Chapter 8).
8 Braking system
Note:Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose
connections, any faults occurring on the Anti-lock Braking System (ABS) should be referred to a Ford dealer for diagnosis - the same applies to the
components of the Traction Control System (TCS).
Vehicle pulls to one side under braking
m mWorn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).
m mSeized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).
m mA mixture of brake pad/shoe lining materials fitted between sides
(Chapter 1).
m mBrake caliper mounting bolts loose (Chapter 9).
m mRear brake backplate mounting bolts loose (Chapter 9).
m mWorn or damaged steering or suspension components (Chap-
ter 10).
Noise (grinding or high-pitched squeal) when brakes
applied
m mBrake pad or shoe friction lining material worn down to metal
backing (Chapter 1).
m mExcessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).
m mForeign object (stone chipping, etc) trapped between brake disc
and splash shield (Chapter 1).
Excessive brake pedal travel
m mInoperative rear brake self-adjust mechanism (Chapter 9).
m mFaulty master cylinder (Chapter 9).
m mAir in hydraulic system (Chapter 9).
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REF•14Glossary of Technical Terms
Catalytic converterA silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
CirclipA ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
groove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
ClearanceThe amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil springA spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
CompressionReduction in volume, and
increase in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compression ratioThe relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) jointA type of
universal joint that cancels out vibrations
caused by driving power being transmitted
through an angle.
Core plugA disc or cup-shaped metal device
inserted in a hole in a casting through which
core was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
CrankcaseThe lower part of the engine
block in which the crankshaft rotates.
CrankshaftThe main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
rods are attached.
Crocodile clipSee Alligator clipDDiagnostic codeCode numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
where a malfunction may be located.
Disc brakeA brake design incorporating a
rotating disc onto which brake pads are
squeezed. The resulting friction converts the
energy of a moving vehicle into heat.
Double-overhead cam (DOHC)An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s)The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor, etc. off the crankshaft pulley.
DriveshaftAny shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brakeA type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pressed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electronic control unit (ECU)A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electronic Fuel Injection (EFI)A computer
controlled fuel system that distributes fuel
through an injector located in each intake port
of the engine.
Emergency brakeA braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depressed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.EndfloatThe amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS)A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifoldA part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
F
Fan clutchA viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds.
Feeler bladeA thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing orderThe order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
energy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Free playThe amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
FuseAn electrical device which protects a
circuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible linkA circuit protection device
consisting of a conductor surrounded by
heat-resistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.Catalytic converter
Crankshaft assembly
Accessory drivebelts
Feeler blade
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REF•18Index
E
Earth fault - 12•4
Economy/Sport mode switch - 12•7
ECU (Electronic Control Unit) - 6•10, 6•11,
6•12
EGR exhaust gas pressure differential
sensor - 6•16
EGR system - 6•15, 6•16
Electric shock - 0•5
Electric windows fault - REF•12
Electrical system - 0•8, 1•11, 1•20
Electrical system fault - REF•12
Electrically-operated windows - 12•7
Electrolyte - 1•8
Electronic control system - 4•9, 6•2
Emblems - 11•17
Emission checks - 0•10
Emissions control systems - 6•1
Engine compartment light - 12•11
Engine electrical systems- 5•1et seq
Engine fault finding - REF•7, REF•8, REF•10
Engine management system - 4•8, 4•9
Engine oil - 1•2, 1•6, 1•16
Engine oil level sensor - 12•18
Engine removal and general engine
overhaul procedures- 2B•1et seq
Environmental considerations - REF•4
Evaporative emissions control (EVAP)
system - 6•14
Evaporator - 3•9
Exhaust gas pressure differential sensor -
6•11, 6•12, 6•13
Exhaust Gas Recirculation (EGR) system -
6•15, 6•16
Exhaust manifold - 2A•8
Exhaust system - 0•9, 0•10, 1•18, 4•12,
REF•9
Expansion tank - 3•5, 3•6
FFacia - 11•21, 11•23
Fan(s) - 3•4, 12•11
Fault code read-out - 6•6
Fault finding- REF•6et seq
Fault finding - automatic transmission -
7B•1
Fault finding - electrical system - 12•4
Filling - 11•3
Fire - 0•5
Fluid level checks - 1•6
Flywheel - 2A•24
Foglight - 12•7, 12•9, 12•13
Foglight warning indicator - 12•11
Fuel and exhaust systems- 0•10, 4•1et
seq
Fuel and exhaust system fault finding -
REF•9
Fuel consumption high - REF•9
Fuel cut-off switch - 4•8
Fuel filter - 1•26
Fuel gauge - 4•6
Fuel gauge fault - REF•12
Fuel hoses - 1•15
Fuel injection system - 4•8, 4•9
Fuel injectors - 4•10
Fuel lines - 1•19, 4•2
Fuel odour - REF•9Fuel pressure check - 4•5
Fuel pressure regulator - 4•11
Fuel pump - 4•5, 4•6
Fuel rail - 4•10
Fuel system - 4•2
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fumes from exhaust system - REF•9
Fuses - 12•5
G
Gaiters - 1•18, 8•7, 8•9, 10•21
Gashes in bodywork - 11•3
Gaskets - REF•4
Gear lever - 7A•2
Gear selection problems - REF•9, REF•10
Gearbox oil - 1•2
Gearchange linkage - 7A•2
Gearchange selector shaft - 7A•3
Glossary of technical terms - REF•13
Glovebox - 11•22
Glovebox light - 12•11
Grab handle - 11•20
H
Handbrake - 0•7, 9•16, 12•7
Handles - 11•10, 11•11, 11•12, 11•13,
12•11
Hazard flashers - 12•7, 12•11
HC emissions - 0•10
Headlight - 1•8, 12•7, 12•8, 12•12, 12•13
Heated rear window - 12•8
Heated seat - 12•8
Heated windscreen - 12•8
Heater - 3•2, 3•7, 3•8, 12•11, 12•12
Horn - 12•7, 12•15
Horn fault - REF•12
Hoses - 1•14, 3•2, 9•11
HT leads - 1•24
Hub and bearings - 10•5, 10•9, 10•14
Hydraulic fluid - 1•2
Hydraulic pipes and hoses - 9•11
Hydraulic system - 9•12
Hydraulic tappets - 2A•14
Hydrofluoric acid - 0•5
I
Idle speed - 4•9, 4•11, 6•10
Idle-increase solenoid valve - 4•12
Ignition coil - 5•3
Ignition module - 5•4
Ignition switch - 12•6
Ignition system - 5•3
Ignition timing - 5•4, 6•10
In-car engine repair procedures- 2A•1et
seq
Indicators - 12•7, 12•9, 12•12
Information sensors - 6•10
Inlet manifold - 2A•7
Instrument panel - 12•7, 12•11, 12•14
Instruments - 1•20
Instruments fault - REF•12
Intake air temperature sensor - 6•11, 6•13
Introduction to the Ford Mondeo - 0•4
J
Jacking - 0•11
Joint mating faces - REF•4
Jump starting - 0•12
K
Knuckle - 10•5, 10•10, 10•14
L
Leaks - 0•13, 1•14, REF•9
Light units - 12•12
Lights - 12•7, 12•11
Lights inoperative - REF•12
Locknuts, locktabs and washers - REF•4
Locks - 11•6, 11•10, 11•12, 11•13, 11•15,
11•16, 11•17, 12•6, REF•12
Low air temperature warning sender unit -
12•18
Low coolant warning switch - 12•18
Low washer fluid switch - 12•18
Lower suspension arm - 10•8, 10•9, 10•13,
10•16
Lubrication system - 2A•4
Luggage compartment switch - 12•7
M
Main bearings - 2B•18, 2B•20
Maintenance- Also see Routine
maintenance
Maintenance - bodywork and underframe -
11•2
Maintenance - upholstery and carpets -
11•3
Manifolds - 2A•7, 2A•8
Manual transmission- 1•17, 2A•24, 2B•3,
2B•4, 7A•1et seq
Manual transmission fault finding - REF•9
Manual transmission oil - 1•2
Master cylinder - 9•10
Mirrors - 0•7, 11•14, 12•7
Misfire - REF•7, REF•8
Mixture - 0•10, 4•9
MOT test checks- 0•7et seq
Mountings - 2A•24, 7A•7, 7B•5
N
Number plate light - 12•10, 12•13
O
Oil (transmission) - 1•2
Oil (engine) - 1•2, 1•6, 1•16
Oil cooler - 2A•22
Oil level sensor - 2A•22, 12•18
Oil pressure warning light illuminated -
REF•8
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REF•19Index
Oil pressure warning light switch - 2A•22
Oil pump - 2A•21
Oil seals - 2A•13, 2A•22, 7A•2, 7B•3, REF•4
Oil separator - 6•19
Open-circuit - 12•4
Overcooling - REF•8
Overhead console - 11•22
Overheating - REF•8
Oxygen sensor - 6•11, 6•12, 6•13
P
Pads - 9•3, 9•8
Pedals - 1•17, 4•5, 8•3, 9•10, 9•11
Piston rings - 2B•19
Pistons - 2B•12, 2B•17, 2B•21, 2B•22
Pitching and/or rolling around corners -
REF•11
Plastic components - 11•4
Plenum chamber - 4•3
Poisonous or irritant substances - 0•5
Pollen filter - 1•20, 3•8
Position sensor - 5•4, 6•10, 6•11, 6•12
Positive Crankcase Ventilation (PCV)
system - 1•23, 6•18, 6•19
Power steering - 1•8, 1•10, 6•11, 6•12,
6•13, 10•20, 10•21, 10•22
Power steering fluid - 1•2
Pressure-control relief valve - 9•13
Pressure-cycling and pressure-regulating
switches - 3•10
Project vehicles - 0•4
Pulse-air - 6•17, 6•18
Purge solenoid valve - 6•14
R
Radiator - 3•4, 3•5
Radiator grille - 11•5
Radio - 12•21, 12•22
Radio aerial - 12•22
Reading light - 12•11
Rear light cluster - 12•9, 12•13
Rear window - 12•8, 12•21
Relays - 12•5
Repair procedures - REF•4
Resonator (engine compartment) - 4•3
Respraying - 11•3
Reversing light switch - 7A•3
Road test - 1•20
Roadwheels - 1•17, 1•18, 1•20
Roll-over valves - 4•8
Routine maintenance and servicing- 1•1et
seq
Rubber gaiters- 1•18, 8•7, 8•9, 10•21
Rust holes in bodywork - 11•3
S
Safety first! - 0•5
Scalding - 0•5
Scratches in bodywork - 11•3
Screw threads and fastenings - REF•4
Seat belts - 0•8, 1•13, 11•19, 11•20Seats - 0•8, 11•18, 12•8
Selector assembly - 7B•2
Selector cable - 7B•2
Selector lever position sensor - 7B•2
Selector panel illumination - 12•11
Service indicator - 12•17, 12•18
Servo unit - 9•12, 9•13
Shock absorbers - 0•8, 0•9, 10•14
Shoes - 9•6
Short-circuit - 12•4
Sidelight - 12•9
Solenoid renewal - 5•8
Spare parts - REF•5
Spark plugs - 1•23
Speakers - 12•22
Speed control - 12•20
Speed sensor - 6•11, 6•12, 6•13
Speedometer - 7A•2, 7A•3, 7B•2, 7B•3,
12•15
Springs - 0•9
Starter motor - 5•7
Starter motor fault - REF•7
Starting system - 5•6
Steering - 0•7, 0•8, 0•9, 1•17, 1•20
Steering angles - 10•22
Steering column - 10•18, 10•20
Steering fault - REF•11
Steering knuckle - 10•5
Steering wheel - 10•17
Stop-light switch - 9•15
Striker - 11•13
Struts - 10•6, 10•7, 10•10, 10•12
Sump - 2A•19
Sun visor - 11•20
Sunroof - 11•18, 12•7
Suspension and steering systems- 0•8,
0•9, 1•17, 1•18, 1•20, 10•1et seq
Suspension and steering systems fault
finding - REF•11
Switches - 2A•22, 3•4, 3•5, 3•10, 4•8-
6•11, 6•12, 6•13, 7A•3, 9•15, 11•17,
12•6, 12•7, 12•8, 12•11, 12•18, 12•20
T
Tailgate - 1•8, 1•10, 11•15, 11•16, 12•17,
12•20, REF•12
Tappets - 2A•14
TCS inhibitor switch - 9•15
TCS throttle actuator - 9•15
Temperature gauge fault - REF•12
Thermostat - 3•3, 3•4
Throttle actuator - 9•15
Throttle housing - 4•9
Throttle potentiometer - 6•11, 6•13
Tie-bar - 10•13, 10•16
Timer module - 12•5
Timing - 5•4, 6•10
Timing belt - 1•26, 2A•10, 2A•13
Tools - REF•1, REF•3, REF•4
Top Dead Centre (TDC) for No 1 piston -
2A•6
Towing - 0•11
Track rod end - 10•22Traction Control System - 9•15, 12•7
Transmission- 1•11, 1•17, 2A•24, 2B•3,
2B•4, 7A•1 et seq, 7B•1 et seq, 12•11
Trim mouldings - 11•17
Trim panels - 11•6, 11•20
Trip computer - 12•17
Tyre wear - REF•11
Tyres - 0•10, 1•8
U
Underbody check - 1•19
Upper suspension arm - 10•16
V
Vacuum hoses - 1•15
Vacuum servo unit - 9•12, 9•13
Valve clearances - 2A•5
Valves - 2B•10, 2B•11
Vehicle identification - 0•8, REF•5
Vehicle pulls to one side - REF•10, REF•11
Vehicle speed sensor - 6•11, 6•12, 6•13
Ventilation system - 1•20, 3•7
Voltage regulator - 5•6
W
Warning lights - 12•11
Warning system - 12•17
Washer jets fault - REF•12
Washer nozzle - 12•21
Washer pump fault - REF•12
Washer reservoir and pump - 12•20
Washer system - 1•8, 1•10, 12•18, 12•20
Water pump - 3•6
Weights - 0•6
Wheel alignment - 10•22
Wheel arch liner - 11•24
Wheel bearings - 0•9
Wheel changing - 0•11
Wheel cylinders - 9•8
Wheel sensors - 9•14
Wheel wobble - REF•11
Wheels - 0•10, 1•17, 1•18, 1•20
Wheels locking - REF•11
Window glass - 11•8
Window regulator - 11•9
Windows - 11•17, 12•7, 12•8, 12•21,
REF•12
Windscreen - 0•7, 1•8, 1•10, 11•17, 12•6,
12•8, 12•16, 12•20, 12•21, REF•12
Wiper arms - 12•16
Wiper blade - 1•10
Wiper blade fault - REF•12
Wiper motor - 12•16, 12•17
Wipers - 12•6
Wiper fault - REF•12
Wiring - 1•15
Wiring diagrams- 12•23et seq
Working facilities - REF•3
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