FORD MONDEO 1993 Service Owner's Manual

cylinder head cover; unscrew it to add oil (see
illustration). When topping-up, use only the
correct grade and type of oil, as given in the
Specifications Section of this Chapter; use a
funnel if necessary to prevent spills. It takes
approximately 0.5 to 1.0 litre of oil to raise the
level from the dipstick’s minimum level notch
to its maximum level notch. After adding the
oil, refit the filler cap hand-tight. Start the
engine, and allow it to idle while the oil is
redistributed around the engine - while you
are waiting, look carefully for any oil leaks,
particularly around the oil filter or drain plug.
Stop the engine; check the oil level again,
after the oil has had enough time to drain from
the upper block and cylinder head galleries.
7Checking the oil level is an important
preventive maintenance step. A continually-
dropping oil level indicates oil leakage through
damaged seals and from loose connections,
or oil consumption past worn piston rings or
valve guides. If the oil looks milky in colour, or
has water droplets in it, the cylinder head
gasket may be blown - the engine’s
compression pressure should be checked
immediately (see Chapter 2A). The condition
of the oil should also be checked. Each time
you check the oil level, slide your thumb and
index finger up the dipstick before wiping off
the oil. If you see small dirt or metal particles
clinging to the dipstick, the oil should be
changed (Section 15).
Coolant
Warning: Do not allow antifreeze
to come in contact with your skin
or painted surfaces of the
vehicle. Flush contaminated areas
immediately with plenty of water. Don’t
store new coolant, or leave old coolant
lying around, where it’s accessible to
children or pets - they’re attracted by its
sweet smell. Ingestion of even a small
amount of coolant can be fatal! Wipe up
garage-floor and drip-pan spills
immediately. Keep antifreeze containers
covered, and repair cooling system leaks
as soon as they’re noticed.8All vehicles covered by this manual are
equipped with a sealed, pressurised cooling
system. A translucent plastic expansion tank,
located on the right-hand side of the engine
compartment, is connected by a hose to the
thermostat housing. As the coolant heats up
during engine operation, surplus coolant
passes through the connecting hose into the
expansion tank; a connection to the radiator
bottom hose union allows coolant to circulate
through the tank and back to the water pump,
thus purging any air from the system. As the
engine cools, the coolant is automatically
drawn back into the cooling system’s main
components, to maintain the correct level.
9While the coolant level must be checked
regularly, remember therefore that it will vary
with the temperature of the engine. When the
engine is cold, the coolant level should be
between the “MAX” and “MIN” level lines on
the tank, but once the engine has warmed up,
the level may rise to above the “MAX” level
line.
10For an accurate check of the coolant
level, the engine must be cold. The level must
be between the “MAX” and “MIN” level lines
on the tank (see illustration). If it is below the
“MIN” level line, the coolant must be topped-
up as follows.
11First prepare a sufficient quantity of
coolant mixture, using clean, soft water and
antifreeze of the recommended type, in the
specified mixture ratio. If you are using
antifreeze to Ford’s specification or equivalent
(see the note at the beginning of Section 2 of
this Chapter), mix equal quantities of water
and antifreeze to produce the 50/50 mixture
ratio specified when topping-up; if using any
other type of antifreeze, follow its
manufacturer’s instructions to achieve the
correct ratio. If only a small amount of coolant
is required to bring the system up to the
proper level, plain water can be used, but
repeatedly doing this will dilute the
antifreeze/water solution in the system,
reducing the protection it should provide
against freezing and corrosion. To maintainthe specified antifreeze/water ratio, it is
essential to top-up the coolant level with the
correct mixture, as described here. Use only
ethylene/glycol type antifreeze, and do not
use supplementary inhibitors or additives.
Warning: Never remove the
expansion tank filler cap when
the engine is running, or has just
been switched off, as the cooling system
will be hot, and the consequent escaping
steam and scalding coolant could cause
serious injury.
12If topping-up is necessary, wait until the
system has cooled completely (or at least 10
minutes after switching off the engine, if lack
of time means it is absolutely necessary to
top-up while the engine may still be warm).
Wrap a thick cloth around the expansion tank
filler cap, and unscrew it one full turn. If any
hissing is heard as steam escapes, wait until
the hissing ceases, indicating that pressure is
released, then slowly unscrew the filler cap
until it can be removed. If more hissing
sounds are heard, wait until they have
stopped before unscrewing the filler cap
completely. At all times, keep your face,
hands and other exposed skin well away from
the filler opening.
13When the filler cap has been removed,
add coolant to bring the level up to the “MAX”
level line (see illustration). Refit the cap,
tightening it securely.
14With this type of cooling system, the
addition of coolant should only be necessary at
very infrequent intervals. If topping-up is
regularly required, or if the coolant level drops
within a short time after replenishment, there
may be a leak in the system. Inspect the
radiator, hoses, expansion tank filler cap,
radiator drain plug and water pump. If no leak is
evident, have the filler cap and the entire
system pressure-tested by your dealer or
suitably-equipped garage; this will usually show
up a small leak not otherwise visible. If
significant leakage is found at any time, use an
antifreeze hydrometer to check the con-
centration of antifreeze remaining in the coolant.
1•7
13.13 Remove the cap to add coolant only
when the engine is cold - top-up to the
“MAX” level line using the specified
coolant mixture3.6 The yellow/black oil filler cap is
screwed into the cylinder head cover.
Always make sure the area around the
opening is clean before unscrewing the
cap, to prevent dirt from contaminating the
engine3.10 The cooling system expansion tank is
located on the right-hand side of the
engine compartment. The coolant level
must be between the tank “MAX” and
“MIN” level lines (arrowed) when the
engine is cold
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15Coolant hydrometers are available at
most automotive accessory shops. If the
specific gravity of a sample taken from the
expansion tank (when the engine is switched
off and fully cooled down) is less than that
specified, the coolant mixture strength has
fallen below the minimum. If this is found,
either the coolant strength must be restored
by adding neat antifreeze to Ford’s
specification (if that is what is in the system)
or by draining and flushing the system, then
refilling it with fresh coolant mixture of the
correct ratio (if any other type of antifreeze is
being used).
16When checking the coolant level, always
note its condition; it should be relatively clear.
If it is brown or rust-coloured, the system
should be drained, flushed and refilled. If
antifreeze has been used which does not
meet Ford’s specification, its corrosion
inhibitors will lose their effectiveness with
time; such coolant must be renewed regularly,
even if it appears to be in good condition,
usually at the intervals suggested at the
beginning of Section 2 of this Chapter.
Windscreen/tailgate and
headlight washer fluid
17Fluid for the windscreen/tailgate washer
system (and where applicable the headlight
washer system) is stored in a plastic reservoir,
which is located at the right front corner of the
engine compartment. In milder climates, plain
water can be used to top-up the reservoir, but
the reservoir should be kept no more than
two-thirds full, to allow for expansion should
the water freeze. In colder climates, the use of
a specially-formulated windscreen washer
fluid, available at your dealer or any car
accessory shop, will help lower the freezing
point of the fluid (see illustration). Do notuse
regular (engine) antifreeze - it will damage the
vehicle’s paintwork.
Battery electrolyte
18On models not equipped with a sealed
battery (see Section 9), check the electrolyte
level of all six battery cells. The level must be
approximately 10 mm above the plates; this
may be shown by maximum and minimum
level lines marked on the battery’s casing (seeillustration). If the level is low, use a coin to
release the filler/vent cap, and add distilled
water. Install and securely retighten the cap.
Caution: Overfilling the cells may
cause electrolyte to spill over
during periods of heavy charging,
causing corrosion or damage.
Refer also to the warning at the beginning
of Section 9.
Brake fluid
19The brake fluid reservoir is located on the
top of the brake master cylinder, which is
attached to the front of the vacuum servo unit.
The “MAX” and “MIN” marks are indicated on
the side of the translucent reservoir, and the
fluid level should be maintained between
these marks at all times (see illustration).
20The brake fluid inside the reservoir is
readily visible. With the vehicle on level
ground, the level should normally be on or just
below the “MAX” mark.
21Progressive wear of the brake pads and
brake shoe linings causes the level of the
brake fluid to gradually fall; however, when
the brake pads are renewed, the original level
of the fluid is restored. It is not therefore
necessary to top-up the level to compensate
for this minimal drop, but the level must never
be allowed to fall below the minimum mark.
22If topping-up is necessary, first wipe the
area around the filler cap with a clean rag
before removing the cap. When adding fluid,
pour it carefully into the reservoir, to avoid
spilling it on surrounding painted surfaces
(see illustration). Be sure to use only the
specified hydraulic fluid (see “Lubricants,
fluids and capacities”at the start of this
Chapter) since mixing different types of fluid
can cause damage to the system.
Warning: Brake hydraulic fluid
can harm your eyes and damage
painted surfaces, so use extreme
caution when handling and
pouring it. Wash off spills immediately with
plenty of water. Do not use fluid that has
been standing open for some time, as it
absorbs moisture from the air. Excessmoisture can cause corrosion and a
dangerous loss of braking effectiveness.
23When adding fluid, it is a good idea to
inspect the reservoir for contamination. The
system should be drained and refilled if
deposits, dirt particles or contamination are
seen in the fluid.
24After filling the reservoir to the correct
level, make sure that the cap is refitted
securely, to avoid leaks and the entry of
foreign matter.
25If the reservoir requires repeated
replenishing to maintain the correct level, this
is an indication of an hydraulic leak
somewhere in the system, which should be
investigated immediately.
Power steering fluid
26See Section 5 of this Chapter.
1Periodic inspection of the tyres may spare
you from the inconvenience of being stranded
with a flat tyre. It can also provide you with
vital information regarding possible problems
in the steering and suspension systems
before major damage occurs.
2The original tyres on this vehicle are
equipped with tread wear indicator (TWI)
bands, which will appear when the tread
depth reaches approximately 1.6 mm. Most
tyres have a mark around the tyre at regular
intervals to indicate the location of the tread
4 Tyre and tyre pressure checks
1•8
3.17 Topping-up the windscreen washer
reservoir3.18 On non-sealed batteries, keep the
electrolyte level of all the cells in the
battery between the maximum and
minimum levels (arrowed) - ie, 10 mm
above the plates. Use only distilled water,
and never overfill3.19 Brake fluid reservoir, showing “MAX”
and “MIN” marks
3.22 Topping-up the brake fluid reservoir
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wear indicators, the mark being TWI, an
arrow, or the tyre manufacturer’s symbol (see
illustration). Tread wear can also be
monitored with a simple inexpensive device
known as a tread depth indicator gauge (see
illustration).
3Ensure that tyre pressures are checked
regularly and maintained correctly (see the
Specifications at the beginning of this Chapterfor pressures). Checking should be carried out
with the tyres cold, and notimmediately after
the vehicle has been in use. If the pressures
are checked with the tyres hot, an apparently-
high reading will be obtained, owing to heat
expansion. Under no circumstancesshould an
attempt be made to reduce the pressures to
the quoted cold reading in this instance, or
effective under-inflation will result.
1•9
1
Tyre Tread Wear Patterns
Shoulder Wear
Underinflation
(wear on both sides)
Check and adjust pressures
Incorrect wheel camber
(wear on one side)
Repair or renew suspension
parts
Hard cornering
Reduce speed!
Centre Wear
Overinflation
Check and adjust pressures
If you sometimes have to inflate
your car’s tyres to the higher
pressures specified for maximum
load or sustained high speed,
don’t forget to reduce the pres-
sures to normal afterwards.
Toe Wear
Incorrect toe setting
Adjust front wheel alignment
Note: The feathered edge of
the tread which characterises
toe wear is best checked by
feel.
Uneven Wear
Incorrect camber or castor
Repair or renew suspension
parts
Malfunctioning suspension
Repair or renew suspension
parts
Unbalanced wheel
Balance tyres
Out-of-round brake disc/drum
Machine or renew
4.2A The TWI mark on the side of the tyre
shows the position of the tread wear
indicator bands
4.2B A tyre tread depth indicator should
be used to monitor tyre wear - they are
available at accessory shops and service
stations, and cost very little
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Most garage forecourts have a
pressure line which combines a gauge
to check and adjust the tyre pressures,
but they may vary in accuracy, due to
general misuse and abuse. It therefore
pays to carry a good-quality tyre
pressure gauge in the vehicle, to make
the regular checks required and ensure
pressure accuracy.
4Note any abnormal tread wear (see
illustration). Tread pattern irregularities such
as feathering, flat spots, and more wear on
one side than the other, are indications of
front wheel alignment and/or balance
problems. If any of these conditions are
noted, they should be rectified as soon as
possible.5Under-inflation will cause overheating of the
tyre, owing to excessive flexing of the casing,
and the tread will not sit correctly on the road
surface. This will cause a consequent loss of
adhesion and excessive wear, not to mention
the danger of sudden tyre failure due to heat
build-up.
6Over-inflation will cause rapid wear of thecentre part of the tyre tread, coupled with
reduced adhesion, harder ride, and the
danger of damage occurring in the tyre
casing.
7Regularly check the tyres for damage in the
form of cuts or bulges, especially in the
sidewalls. Remove any nails or stones
embedded in the tread, before they penetrate
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the tyre to cause deflation. If removal of a nail
reveals that the tyre has been punctured, refit
the nail, so that its point of penetration is
marked. Then immediately change the wheel,
and have the tyre repaired by a tyre dealer. Do
not drive on a tyre in such a condition. If in any
doubt as to the possible consequences of any
damage found, consult your local tyre dealer
for advice.
8General tyre wear is influenced to a large
degree by driving style - harsh braking and
acceleration, or fast cornering, will all produce
more rapid tyre wear. Interchanging of tyres
may result in more even wear; however, it is
worth bearing in mind that if this is completely
effective, the added expense is incurred of
replacing simultaneously a complete set of
tyres, which may prove financially restrictive
for many owners.
9Front tyres may wear unevenly as a result of
wheel misalignment. The front wheels should
always be correctly aligned according to the
settings specified by the vehicle
manufacturer.10Don’t forget to check the spare tyre for
condition and pressure.
11Legal restrictions apply to many aspects
of tyre fitting and usage, and in the UK this
information is contained in the Motor Vehicle
Construction and Use Regulations. It is
suggested that a copy of these regulations is
obtained from your local police, if in doubt as
to current legal requirements with regard to
tyre type and condition, minimum tread depth,
etc.
1The power steering fluid reservoir is located
on the right-hand rear corner of the engine
compartment.
2For the fluid level check, the power steering
system should be at its normal operating
temperature, so it is best to carry out the
check after a run.
3Position the vehicle on level ground, withthe front wheels pointing straight ahead, and
switch off the engine.
4Check that the fluid level is up to the “MAX”
mark on the reservoir (see illustration).
5If topping-up is required, first use a clean
rag to wipe the filler cap and the surrounding
area, to prevent foreign matter from entering
the system. Unscrew and remove the filler
cap.
6Top-up the level to the “MAX” mark, using
the grade of fluid specified at the beginning of
this Chapter (see illustration). Be careful not
to introduce dirt into the system, and do not
overfill. The need for frequent topping-up
indicates a leak, which should be
investigated.
7Refit the filler cap.
1The windscreen wiper and blade assembly
should be inspected at the specified intervals
for damage, loose components, and cracked
or worn blade elements.
2Road film can build up on the wiper blades
and affect their efficiency, so they should be
washed regularly with a mild detergent
solution.
3The action of the wiping mechanism can
loosen bolts, nuts and fasteners, so they
should be checked and tightened, as
necessary, at the same time as the wiper
blades are checked.
4If the wiper blade elements are cracked,
worn or warped, or no longer clean
adequately, they should be replaced with new
ones.
5Lift the wiper arm and blade away from the
glass.
6To remove the windscreen wiper blade,
release the catch on the arm, then turn the
blade through 90° and withdraw the blade
from the end of the arm (see illustration).
7To remove the tailgate wiper blade, push
the wiper blade forward, and at the same time
depress it against the spring pressure, then
withdraw it from the end of the arm (see
illustration).
8If the metal part of the wiper blade is in
good condition, it may be possible to renew
the rubber insert separately. The insert can be
obtained from a car accessory shop and,
according to type, it may need to be cut to the
correct length before sliding into the clips.
9Refit the wiper blade assembly using a
reversal of the removal procedure, making
sure that it fully engages with the spring clip.
10Check that the washer jets direct the fluid
onto the upper part of the
windscreen/tailgate/rear window/headlight,
and if necessary adjust the small sphere on
the jet with a pin.
6 Windscreen/tailgate washer
system and wiper blade check
5 Power steering fluid level
check
1•10
5.4 Power steering fluid reservoir,
showing “MAX” and “MIN” marks5.6 Topping-up the power steering fluid
reservoir
6.7 Tailgate wiper blade removal6.6 Releasing the catch to remove a
windscreen wiper blade
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Every 10 000 miles or 12 months
1•11
17.4 Removing the automatic transmission
dipstick from its tube7.6A “MIN” and “MAX” marks on the
dipstick7.6B Adding automatic transmission fluid
through the dipstick tube
Every 10 000 miles
1The level of the automatic transmission fluid
should be carefully maintained. Low fluid level
can lead to slipping or loss of drive, while
overfilling can cause foaming, loss of fluid and
transmission damage.
2The transmission fluid level should only be
checked when the transmission is hot (at its
normal operating temperature). If the vehicle
has just been driven over 10 miles (15 miles in
a cold climate), and the fluid temperature is
160 to 175°F, the transmission is hot.
Caution: If the vehicle has just
been driven for a long time at
high speed or in city traffic in hot
weather, or if it has been pulling
a trailer, an accurate fluid level reading
cannot be obtained. In these
circumstances, allow the fluid to cool
down for about 30 minutes.
3Park the vehicle on level ground, apply the
handbrake, and start the engine. While the
engine is idling, depress the brake pedal and
move the selector lever through all the gear
ranges three times, beginning and ending in
“P”.
4Allow the engine to idle for one minute, then
(with the engine still idling) remove the dipstick
from its tube (see illustration). Note the
condition and colour of the fluid on the dipstick.
5Wipe the fluid from the dipstick with a clean
rag, and re-insert it into the filler tube until the
cap seats.
6Pull the dipstick out again, and note the
fluid level. The level should be between the
“MIN” and “MAX” marks. If the level is on the
“MIN” mark, stop the engine, and add the
specified automatic transmission fluid through
the dipstick tube, using a clean funnel if
necessary (see illustrations). It is important
not to introduce dirt into the transmission
when topping-up.
7Add the fluid a little at a time, and keep
checking the level as previously described
until it is correct.8The need for regular topping-up of the
transmission fluid indicates a leak, which
should be found and rectified without delay.
9The condition of the fluid should also be
checked along with the level. If the fluid at the
end of the dipstick is black or a dark reddish-
brown colour, or if it has a burned smell, the
fluid should be changed. If you are in doubt
about the condition of the fluid, purchase
some new fluid, and compare the two for
colour and smell.
1Check the operation of all external lights
and indicators (front and rear).
2Check for satisfactory operation of the
instrument panel, its illumination and warning
lights, the switches and their function lights.
3Check the horn(s) for satisfactory operation.
4Check all other electrical equipment for
satisfactory operation.
5Check all electrical wiring in the engine
compartment for correct routing, and for any
signs of physical or heat-damage or chafing.
Warning: Certain precautions
must be followed when checking
and servicing the battery.
Hydrogen gas, which is highly
flammable, is always present in the battery
cells, so keep lighted tobacco and all other
open flames and sparks away from the
battery. The electrolyte inside the battery
is actually dilute sulphuric acid, which will
cause injury if splashed on your skin or in
your eyes. It will also ruin clothes and
painted surfaces. When disconnecting the
battery, always detach the negative (earth)
lead first and connect it last!
Note: Before disconnecting the battery, refer
to Section 1 of Chapter 5.
9 Battery check, maintenance
and charging
8 Electrical system check
7 Automatic transmission fluid
level check
9.1 Tools and materials required for
battery maintenance
1Face shield/safety goggles- When
removing corrosion with a brush, the acidic
particles can easily fly up into your eyes
2Baking soda- A solution of baking soda
and water can be used to neutralise corrosion
3Petroleum jelly- A layer of this on the
battery terminals will help prevent corrosion
4Battery terminal/lead cleaner- This wire
brush cleaning tool will remove all traces of
corrosion from the battery terminals and lead
clamps
5Treated felt washers- Placing one of
these on each terminal, directly under the
lead clamps, will help prevent corrosion
6Puller- Sometimes the lead clamps are
very difficult to pull off the terminals, even
after the nut has been completely slackened.
This tool pulls the clamp straight up and off
the terminal without damage
7Battery terminal/lead cleaner- Here is
another cleaning tool which is a slightly
different version of number 4 above, but does
the same thing
8Rubber gloves- Another safety item to
consider when servicing the battery;
remember, that’s acid inside the battery!
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General
1A routine preventive maintenance
programme for the battery in your vehicle is
the only way to ensure quick and reliable
starts. Before performing any battery
maintenance, make sure that you have the
proper equipment necessary to work safely
around the battery (see illustration).
2There are also several precautions that
should be taken whenever battery
maintenance is performed. Before servicing
the battery, always turn the engine and all
accessories off, and disconnect the lead from
the negative terminal of the battery - see
Chapter 5, Section 1.
3The battery produces hydrogen gas, which
is both flammable and explosive. Never create
a spark, smoke, or light a match around the
battery. Always charge the battery in a well-
ventilated area.
4Electrolyte contains poisonous and
corrosive sulphuric acid. Do not allow it to get
in your eyes, on your skin, or on your clothes.
Never ingest it. Wear protective safety glasses
when working near the battery. Keep children
away from the battery.
5Note the external condition of the battery. If
the positive terminal and lead clamp on your
vehicle’s battery is equipped with a plastic
cover or rubber protector, make sure that it’s
not torn or damaged. It should completelycover the terminal. Look for any corroded or
loose connections, cracks in the case or
cover, or loose hold-down clamps. Also check
the entire length of each lead for cracks and
frayed conductors.
6If corrosion, which looks like white, fluffy
deposits (see illustration)is evident,
particularly around the terminals, the battery
should be removed for cleaning. Slacken the
lead clamp nuts with a spanner, being careful
to remove the negative (earth) lead first, and
slide them off the terminals (see illustration).
Then unscrew the hold-down clamp nuts,
remove the clamp, and lift the battery from the
engine compartment.
7Clean the lead clamps thoroughly, using a
soft wire brush or a terminal cleaner, with a
solution of warm water and baking soda.
Wash the terminals and the top of the battery
case with the same solution, but make sure
that the solution doesn’t get into the battery.
When cleaning the leads, terminals and
battery top, wear safety goggles and rubber
gloves, to prevent any solution from coming in
contact with your eyes or hands. Wear old
clothes too - even when diluted, sulphuric
acid splashed onto clothes will burn holes in
them. If the terminals have been extensively
corroded, clean them up with a terminal
cleaner (see illustrations). Thoroughly wash
all cleaned areas with plain water.
8Make sure that the battery tray is in good
condition and the hold-down clamp nuts are
tight (see illustration). If the battery isremoved from the tray, make sure no parts
remain in the bottom of the tray when the
battery is refitted. When refitting the
hold-down clamp nuts, do not overtighten
them.
9Information on removing and installing the
battery can be found in Chapter 5. Information
on jump starting can be found at the front of
this manual. For more detailed battery
checking procedures, refer to the Haynes
Automobile Electrical and Electronic Systems
Manual.
Cleaning
10Corrosion on the hold-down components,
battery case and surrounding areas can be
removed with a solution of water and baking
soda. Thoroughly rinse all cleaned areas with
plain water.
11Any metal parts of the vehicle damaged
by corrosion should be covered with a
zinc-based primer, then painted.
Charging
Warning: When batteries are
being charged, hydrogen gas,
which is very explosive and
flammable, is produced. Do not
smoke, or allow open flames, near a
charging or a recently-charged battery.
Wear eye protection when near the battery
during charging. Also, make sure the
charger is unplugged before connecting or
disconnecting the battery from the
charger.
12Slow-rate charging is the best way to
restore a battery that’s discharged to the
point where it will not start the engine. It’s also
a good way to maintain the battery charge in a
vehicle that’s only driven a few miles between
starts. Maintaining the battery charge is
particularly important in winter, when the
battery must work harder to start the engine,
and electrical accessories that drain the
battery are in greater use.
13It’s best to use a one- or two-amp battery
charger (sometimes called a “trickle” charger).
They are the safest, and put the least strain on
the battery. They are also the least expensive.
For a faster charge, you can use a higher-
1•12
9.6A Battery terminal corrosion usually
appears as light, fluffy powder9.6B Removing a lead from the battery
terminal - always remove the earth lead
first, and connect it last!9.7A When cleaning the lead clamps, all
corrosion must be removed - the inside of
the clamp is tapered to match the terminal,
so don’t remove too much material
9.7B Regardless of the method used to
clean the terminals, a clean, shiny surface
should result9.8 Make sure the battery hold-down nuts
(arrowed) are tight
Every 10 000 miles
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amperage charger, but don’t use one rated
more than 1/10th the amp/hour rating of the
battery (ie no more than 5 amps, typically).
Rapid boost charges that claim to restore the
power of the battery in one to two hours are
hardest on the battery, and can damage
batteries not in good condition. This type of
charging should only be used in emergency
situations.
14The average time necessary to charge a
battery should be listed in the instructions that
come with the charger. As a general rule, a
trickle charger will charge a battery in 12 to
16 hours.
1Check the seat belts for satisfactory
operation and condition. Inspect the webbing
for fraying and cuts. Check that they retract
smoothly and without binding into their reels.
2Check that the seat belt mounting bolts are
tight, and if necessary tighten them to the
specified torque wrench setting.
General
1The auxiliary drivebelt is of the flat, multi-
ribbed (or “polyvee”) type, and is located on
the right-hand end of the engine. It drives the
alternator, water pump, power steering pump
and (when fitted) the air conditioning
compressor from the engine’s crankshaft
pulley.
2The good condition and proper tension of
the auxiliary drivebelt is critical to the
operation of the engine. Because of their
composition and the high stresses to which
they are subjected, drivebelts stretch anddeteriorate as they get older. They must,
therefore, be regularly inspected.
Check
3With the engine switched off, open and
support the bonnet, then locate the auxiliary
drivebelt on the right-hand end of the engine,
under the engine right-hand mounting
bracket. (Be very careful, and wear protective
gloves to minimise the risk of burning your
hands on hot components, if the engine has
recently been running.) For improved access,
jack up the front right-hand side of the
vehicle, support it securely on an axle stand,
remove the roadwheel, then remove the
auxiliary drivebelt cover (two fasteners) from
inside the wheel arch (see illustration).
4Using an inspection light or a small electric
torch, and rotating the engine when necessary
with a spanner applied to the crankshaft
pulley bolt, check the whole length of the
drivebelt for cracks, separation of the rubber,
and torn or worn ribs (see illustration). Also
check for fraying and glazing, which gives the
drivebelt a shiny appearance. Both sides of
the drivebelt should be inspected, which
means you will have to twist the drivebelt to
check the underside. Use your fingers to feel
the drivebelt where you can’t see it. If you are
in any doubt as to the condition of the
drivebelt, renew it (go to paragraph 7).
Drivebelt tension
5The auxiliary drivebelt is tensioned by an
automatic tensioner; regular checks are not
required, and manual “adjustment” is not
possible.
6If you suspect that the drivebelt is slipping
and/or running slack, or that the tensioner is
otherwise faulty, it must be renewed. To do
this, remove the drivebelt as described below,
then unbolt the tensioner (two Torx-type
screws accessible from underneath, via the
wheel arch) from the alternator mounting
bracket (see illustration). On fitting the new
tensioner, ensure it is aligned correctly on its
mountings, and tighten the screws to the
specified torque wrench setting.
Renewal
7Open the bonnet. Jack up the front right-
hand side of the vehicle and support it
securely on an axle stand, remove the
roadwheel, then remove the auxiliary drivebelt
cover (two fasteners) from inside the wheel
arch.
8If the existing drivebelt is to be refitted,
mark it, or note the maker’s markings on its
flat surface, so that it can be installed the
same way round.
9Reaching up between the body and the
engine (above and to the rear of the
crankshaft pulley), apply a spanner to the
hexagon in the centre of the automatic
tensioner’s pulley. Rotate the tensioner pulley
clockwise to release its pressure on the
drivebelt, then slip the drivebelt off the
crankshaft pulley, and release the tensioner
again (see illustration). Working from the
wheel arch or engine compartment as
necessary, and noting its routing, slip the
drivebelt off the remaining pulleys and
withdraw it.
10Check all the pulleys, ensuring that their
grooves are clean, and removing all traces of
oil and grease. Check that the tensioner
works properly, with strong spring pressure
11 Auxiliary drivebelt check and
renewal
10 Seat belt check
1•13
1
11.9 Rotate the tensioner pulley clockwise
to release its pressure on the drivebelt,
then slip the drivebelt off the crankshaft
pulley
11.3 Removing the auxiliary drivebelt
cover - it is secured by a fastener at each
end (arrowed) - from inside the right-hand
front wheel arch
11.4 Check the auxiliary drivebelt for signs
of wear like these. Very small cracks across
the drivebelt ribs are acceptable. If the
cracks are deep, or if the drivebelt looks
worn or damaged in any other way, renew it
11.6 The auxiliary drivebelt is tensioned by
an automatic tensioner; Torx screws
(arrowed) secure it to alternator mounting
bracket
Every 10 000 miles
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being felt when its pulley is rotated clockwise,
and a smooth return to the limit of its travel
when released.
11If the original drivebelt is being refitted,
use the marks or notes made on removal, to
ensure that it is installed to run in the same
direction as it was previously. To fit the
drivebelt, arrange it on the grooved pulleys so
that it is centred in their grooves, and not
overlapping their raised sides (note that the
flat surface of the drivebelt is engaged on the
idler, tensioner and water pump pulleys) and
routed correctly (see illustrations). Start at
the top, and work down to finish at the
crankshaft pulley; rotate the tensioner pulley
clockwise, slip the drivebelt onto the
crankshaft pulley, then release the tensioner
again.
12Using a spanner applied to the crankshaft
pulley bolt, rotate the crankshaft through at
least two full turns clockwise to settle the
drivebelt on the pulleys, then check that the
drivebelt is properly installed.
13Refit the auxiliary drivebelt cover and
roadwheel, then lower the vehicle to the
ground.
Caution: Renewal of air
conditioning hoses must be left
to a dealer service department or
air conditioning specialist who has the
equipment to depressurise the systemsafely. Never remove air conditioning
components or hoses until the system has
been depressurised.
General
1High temperatures in the engine
compartment can cause the deterioration of
the rubber and plastic hoses used for engine,
accessory and emission systems operation.
Periodic inspection should be made for
cracks, loose clamps, material hardening and
leaks.
2Carefully check the large top and bottom
radiator hoses, along with the other smaller-
diameter cooling system hoses and metal
pipes; do not forget the heater hoses/pipes
which run from the engine to the bulkhead,
and those to the engine oil cooler (where
fitted). Inspect each hose along its entire
length, replacing any that is cracked, swollen
or shows signs of deterioration. Cracks may
become more apparent if the hose is
squeezed (see illustration). If you are using
non-Ford specification antifreeze, and so
have to renew the coolant every two years or
so, it’s a good idea to renew the hoses at that
time, regardless of their apparent condition.
3Make sure that all hose connections are
tight. A leak in the cooling system will usually
show up as white- or rust-coloured deposits
on the areas adjoining the leak; if the spring
clamps that are used to secure the hoses in
this system appear to be slackening, they
should be renewed to prevent the possibility
of leaks.
4Some other hoses are secured to theirfittings with clamps. Where clamps are used,
check to be sure they haven’t lost their
tension, allowing the hose to leak. If clamps
aren’t used, make sure the hose has not
expanded and/or hardened where it slips over
the fitting, allowing it to leak.
12 Underbonnet check for fluid
leaks and hose condition
1•14
11.11A When installing the auxiliary
drivebelt, make sure that it is centred - it
must not overlap either edge of the
grooved pulleys11.11B Auxiliary drivebelt routing
1 Power steering pump
2 Idler pulley
3 Alternator4 Automatic tensioner
5 Air conditioning
compressor (when fitted)6 Crankshaft pulley
7 Water pump pulley
12.2 Hoses, like drivebelts, have a habit of
failing at the worst possible time - to
prevent the inconvenience of a blown
radiator or heater hose, inspect them
carefully as shown here
Every 10 000 miles
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5Check all fluid reservoirs, filler caps, drain
plugs and fittings etc, looking for any signs of
leakage of oil, transmission and/or brake
hydraulic fluid, coolant and power steering
fluid. If the vehicle is regularly parked in the
same place, close inspection of the ground
underneath it will soon show any leaks; ignore
the puddle of water which will be left if the air
conditioning system is in use. As soon as a
leak is detected, its source must be traced
and rectified. Where oil has been leaking for
some time, it is usually necessary to use a
steam cleaner, pressure washer or similar, to
clean away the accumulated dirt, so that the
exact source of the leak can be identified.
Vacuum hoses
6It’s quite common for vacuum hoses,
especially those in the emissions system, to
be colour-coded, or to be identified by
coloured stripes moulded into them. Various
systems require hoses with different wall
thicknesses, collapse resistance and
temperature resistance. When renewing
hoses, be sure the new ones are made of the
same material.
7Often the only effective way to check a
hose is to remove it completely from the
vehicle. If more than one hose is removed, be
sure to label the hoses and fittings to ensure
correct installation.
8When checking vacuum hoses, be sure to
include any plastic T-fittings in the check.
Inspect the fittings for cracks, and check the
hose where it fits over the fitting for distortion,
which could cause leakage.
9A small piece of vacuum hose (quarter-inch
inside diameter) can be used as a
stethoscope to detect vacuum leaks. Hold
one end of the hose to your ear, and probe
around vacuum hoses and fittings, listening
for the “hissing” sound characteristic of a
vacuum leak.
Warning: When probing with the
vacuum hose stethoscope, be
very careful not to come into
contact with moving engine
components such as the auxiliary
drivebelt, radiator electric cooling fan, etc.
Fuel hoses
Warning: There are certain
precautions which must be taken
when inspecting or servicing fuel
system components. Work in a well-
ventilated area, and do not allow open
flames (cigarettes, appliance pilot lights,
etc.) or bare light bulbs near the work
area. Mop up any spills immediately, and
do not store fuel-soaked rags where they
could ignite.
10Check all fuel hoses for deterioration and
chafing. Check especially for cracks in areas
where the hose bends, and also just before
fittings, such as where a hose attaches to the
fuel filter.
11High-quality fuel line, usually identified by
the word “Fluoroelastomer” printed on thehose, should be used for fuel line renewal.
Never, under any circumstances, use
unreinforced vacuum line, clear plastic tubing
or water hose for fuel lines.
12Spring-type clamps are commonly used
on fuel lines. These clamps often lose their
tension over a period of time, and can be
“sprung” during removal. Replace all
spring-type clamps with screw clamps
whenever a hose is replaced.
Metal lines
13Sections of metal piping are often used
for fuel line between the fuel filter and the
engine. Check carefully to be sure the piping
has not been bent or crimped, and that cracks
have not started in the line.
14If a section of metal fuel line must be
renewed, only seamless steel piping should
be used, since copper and aluminium piping
don’t have the strength necessary to
withstand normal engine vibration.
15Check the metal brake lines where they
enter the master cylinder and ABS hydraulic
unit (if used) for cracks in the lines or loose
fittings. Any sign of brake fluid leakage calls
for an immediate and thorough inspection of
the brake system.
1With the vehicle parked on level ground,
apply the handbrake firmly and open the
bonnet. Using an inspection light or a small
electric torch, check all visible wiring within
and beneath the engine compartment.
2What you are looking for is wiring that is
obviously damaged by chafing against sharp
edges, or against moving suspension/
transmission components and/or the auxiliary
drivebelt, by being trapped or crushed
between carelessly-refitted components, or
melted by being forced into contact with the
hot engine castings, coolant 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.
3Depending on the extent of the problem,
damaged wiring may be repaired by rejoining
the break or splicing-in a new length of wire,
using solder to ensure a good connection,
and remaking the insulation with adhesive
insulating tape or heat-shrink tubing, as
appropriate. If the damage is extensive, given
the implications for the vehicle’s future
reliability, the best long-term answer may well
be to renew that entire section of the loom,
however expensive this may appear.
4When the actual damage has been
repaired, ensure that the wiring loom is re-
routed correctly, so that it is clear of other
components, and not stretched or kinked, and
is secured out of harm’s way using the plastic
clips, guides and ties provided.
5Check all electrical connectors, ensuringthat they are clean, securely fastened, and
that each is locked by its plastic tabs or wire
clip, as appropriate. If any connector shows
external signs of corrosion (accumulations of
white or green deposits, or streaks of “rust”),
or if any is thought to be dirty, it must be
unplugged and cleaned using electrical
contact cleaner. If the connector pins are
severely corroded, the connector must be
renewed; note that this may mean the renewal
of that entire section of the loom - see your
local Ford dealer for details.
6If the cleaner completely removes the
corrosion to leave the connector in a
satisfactory condition, it would be wise to
pack the connector with a suitable material
which will exclude dirt and moisture,
preventing the corrosion from occurring
again; a Ford dealer may be able to
recommend a suitable product.
7Check the condition of the battery
connections - remake the connections or
renew the leads if a fault is found (see Chap-
ter 5). Use the same techniques to ensure that
all earth points in the engine compartment
provide good electrical contact through clean,
metal-to-metal joints, and that all are securely
fastened. (In addition to the earth connection
at the engine lifting eye, and that from the
transmission to the body/battery, there are
one or two earth points behind each headlight
assembly, and one below the power steering
fluid reservoir.)
8Refer to Section 31 for details of spark plug
(HT) lead checks.
Warning: The air conditioning
system is under high pressure.
Do not loosen any fittings or
remove any components until
after the system has been discharged. Air
conditioning refrigerant must be properly
discharged into an approved type of
container, at a dealer service department
or an automotive air conditioning repair
facility capable of handling R134a
refrigerant. Always wear eye protection
when disconnecting air conditioning
system fittings.
1The following maintenance checks should
be performed on a regular basis, to ensure
that the air conditioner continues to operate at
peak efficiency:
(a) Check the auxiliary drivebelt. If it’s worn
or deteriorated, renew it (see Section 11).
(b) Check the system hoses. Look for cracks,
bubbles, hard spots and deterioration.
Inspect the hoses and all fittings for oil
bubbles and seepage. If there’s any
evidence of wear, damage or leaks, renew
the hose(s).
(c) Inspect the condenser fins for leaves,
insects and other debris. Use a “fin
14 Air conditioning system
check
13 Engine compartment wiring
check
1•15
1
Every 10 000 miles
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comb” or compressed air to clean the
condenser.
Warning: Wear eye protection
when using compressed air!
(d) Check that the drain tube from the front
of the evaporator is clear - note that it is
normal to have clear fluid (water) dripping
from this while the system is in operation,
to the extent that quite a large puddle can
be left under the vehicle when it is parked.
2It’s a good idea to operate the system forabout 30 minutes at least once a month,
particularly during the winter. Long term
non-use can cause hardening, and
subsequent failure, of the seals.
3Because of the complexity of the air
conditioning system and the special
equipment necessary to service it, in-depth
fault diagnosis and repairs are not included in
this manual. For more complete information
on the air conditioning system, refer to the
Haynes Automotive Heating and Air
Conditioning Manual.
4The most common cause of poor cooling is
simply a low system refrigerant charge. If a
noticeable drop in cool air output occurs, the
following quick check will help you determine
if the refrigerant level is low.
5Warm the engine up to normal operating
temperature.
6Place the air conditioning temperature
selector at the coldest setting, and put the
blower at the highest setting. Open the doors
- to make sure the air conditioning system
doesn’t cycle off as soon as it cools the
passenger compartment.
7With the compressor engaged - the clutch
will make an audible click, and the centre of
the clutch will rotate - feel the inlet and outlet
pipes at the compressor. One side should be
cold, and one hot. If there’s no perceptible
difference between the two pipes, there’s
something wrong with the compressor or the
system. It might be a low charge - it might be
something else. Take the vehicle to a dealer
service department or an automotive air
conditioning specialist.1Make sure that you have all the necessary
tools before you begin this procedure (see
illustration). You should also have plenty of
rags or newspapers handy, for mopping up
any spills.
2To avoid any possibility of scalding, and to
protect yourself from possible skin irritants
and other harmful contaminants in used
engine oils, it is advisable to wear gloves
when carrying out this work.
3Access to the underside of the vehicle is
greatly improved if the vehicle can be lifted on
a hoist, driven onto ramps, or supported by
axle stands.
Warning: Do not work under a
vehicle which is supported only
by an hydraulic or scissors-type
jack, or by bricks, blocks of
wood, etc.
4If this is your first oil change, get under the
vehicle and familiarise yourself with the
position of the engine oil drain plug, which is
located at the rear of the sump. The engine
and exhaust components will be warm during
the actual work, so try to anticipate any
potential problems while the engine and
accessories are cool.
5The oil should preferably be changed when
the engine is still fully warmed-up to normal
operating temperature, just after a run (the
needle on the temperature gauge should be in
the “Normal” sector of the gauge); warm oil
and sludge will flow out more easily. Park the
vehicle on firm, level ground, apply the
handbrake firmly, then select 1st or reverse
gear (manual transmission) or the “P” position
(automatic transmission). Open the bonnet
and remove the engine oil filler cap from the
cylinder head cover, then remove the oil level
dipstick from its tube (see Section 3).
6Raise the front of the vehicle, and support it
securely on axle stands. Remove the front
right-hand roadwheel to provide access to the
oil filter; if the additional working clearance is
required, remove also the auxiliary drivebelt
cover (two fasteners).
15 Engine oil and filter change
1•16
15.1 These tools are required when
changing the engine oil and filter
1Drain pan- It should be fairly shallow in
depth, but wide to prevent spills
2Rubber gloves- When removing the drain
plug and filter, it is inevitable that you will get
oil on your hands (the gloves will prevent
burns from hot oil)
3Breaker bar- Sometimes the oil drain plug
is pretty tight, and a long breaker bar is
needed to loosen it
4Socket- To be used with the breaker bar
or a ratchet (must be the correct size to fit the
drain plug)
5Filter wrench- This is a metal band-type
wrench, which requires clearance around the
filter to be effective
6Filter wrench- This type fits on the
bottom of the filter, and can be turned with a
ratchet or breaker bar (different size wrenches
are available for different types of filters)
15.7 Use the correct-size spanner or
socket to remove the oil drain plug and
avoid rounding it off15.9 Since the oil filter is usually on very
tight, you’ll need a special wrench for
removal. DO NOT use the wrench to
tighten the new filter. Pack rag under the
filter before removal to minimise the mess
Every 10 000 miles
Frequent oil changes are the
best preventive maintenance
the home mechanic can give
the engine, because ageing
oil becomes diluted and contaminated,
which leads to premature engine wear.
Note: It is
antisocial and
illegal to dump
oil down the
drain. To find
the location of
your local oil
recycling bank,
call this
number free.
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