wheel alignment FORD MONDEO 1993 Service Owner's Manual

REF•11Fault Finding
9 Suspension and steering systems
Note:Before diagnosing suspension or steering faults, be sure that the trouble is not due to incorrect tyre pressures, mixtures of tyre types, or
binding brakes. Apart from checking the condition of all electrical connections, any faults occurring on the Adaptive Damping System should be
referred to a Ford dealer for diagnosis.
Vehicle pulls to one side
m mDefective tyre (Chapter 1).
m mExcessive wear in suspension or steering components (Chap-
ter 10).
m mIncorrect front wheel alignment (Chapter 10).
m mAccident damage to steering or suspension components (Chap-
ter 10).
Wheel wobble and vibration
m mFront roadwheels out of balance (vibration felt mainly through the
steering wheel) (Chapter 1).
m mRear roadwheels out of balance (vibration felt throughout the
vehicle) (Chapter 1).
m mRoadwheels damaged or distorted (Chapter 1).
m mFaulty or damaged tyre (Chapter 1).
m mWorn steering or suspension joints, bushes or components
(Chapter 10).
m mRoadwheel nuts loose (Chapter 1).
Excessive pitching and/or rolling around corners, or
during braking
m mDefective shock absorbers (Chapter 10).
m mBroken or weak coil spring and/or suspension component (Chap-
ter 10).
m mWorn or damaged anti-roll bar or mountings (Chapter 10).
Wandering or general instability
m
mIncorrect front wheel alignment (Chapter 10).
m mWorn steering or suspension joints, bushes or components
(Chapter 10).
m mRoadwheels out of balance (Chapter 1).
m mFaulty or damaged tyre (Chapter 1).
m mRoadwheel nuts loose (Chapter 1).
m mDefective shock absorbers (Chapter 10).
Excessively-stiff steering
m
mLack of steering gear lubricant (Chapter 10).
m mSeized track-rod end balljoint or suspension balljoint (Chapter 10).
m mBroken or slipping auxiliary drivebelt (Chapter 1).
m mIncorrect front wheel alignment (Chapter 10).
m mSteering rack or column bent or damaged (Chapter 10).
Excessive play in steering
m
mWorn steering column universal joint(s) or flexible coupling
(Chapter 10).
m mWorn steering track-rod end balljoints (Chapter 10).
m mWorn rack-and-pinion steering gear (Chapter 10).
m mWorn steering or suspension joints, bushes or components
(Chapter 10).
Lack of power assistance
m mBroken or slipping auxiliary drivebelt (Chapter 1).
m mIncorrect power steering fluid level (Chapter 1).
m mRestriction in power steering fluid hoses (Chapter 10).
m mFaulty power steering pump (Chapter 10).
m mFaulty rack-and-pinion steering gear (Chapter 10).
Tyre wear excessive
Tyres worn on inside or outside edges
m
mTyres under-inflated (wear on both edges) (Chapter 1).
m mIncorrect camber or castor angles (wear on one edge only)
(Chapter 10).
m mWorn steering or suspension joints, bushes or components
(Chapter 10).
m mExcessively-hard cornering.
m mAccident damage.
Tyre treads exhibit feathered edges
m
mIncorrect toe setting (Chapter 10).
Tyres worn in centre of tread
m
mTyres over-inflated (Chapter 1).
Tyres worn on inside and outside edges
m
mTyres under-inflated (Chapter 1).
Tyres worn unevenly
m
mTyres out of balance (Chapter 1).
m mExcessive wheel or tyre run-out (Chapter 1).
m mWorn shock absorbers (Chapter 10).
m mFaulty tyre (Chapter 1).
Brake pedal feels spongy when depressed
m
mAir in hydraulic system (Chapter 9).
m mDeteriorated flexible rubber brake hoses (Chapter 9).
m mMaster cylinder mounting nuts loose (Chapter 9).
m mFaulty master cylinder (Chapter 9).
Excessive brake pedal effort required to stop
vehicle
m mFaulty vacuum servo unit (Chapter 9).
m mDisconnected, damaged or insecure brake servo vacuum hose
(Chapter 9).
m mPrimary or secondary hydraulic circuit failure (Chapter 9).
m mSeized brake caliper or wheel cylinder piston(s) (Chapter 9).
m mBrake pads or brake shoes incorrectly fitted (Chapter 9).
m mIncorrect grade of brake pads or brake shoes fitted (Chapter 1).
m mBrake pads or brake shoe linings contaminated (Chapter 1).
Judder felt through brake pedal or steering wheel
when braking
m mExcessive run-out or distortion of front discs or rear drums
(Chapter 9).
m mBrake pad or brake shoe linings worn (Chapter 1).
m mBrake caliper or rear brake backplate mounting bolts loose
(Chapter 9).
m mWear in suspension or steering components or mountings (Chapter 10).
Brakes binding
m
mSeized brake caliper or wheel cylinder piston(s) (Chapter 9).
m mFaulty handbrake mechanism (Chapter 9).
m mFaulty master cylinder (Chapter 9).
Rear wheels locking under normal braking
m
mRear brake shoe linings contaminated (Chapter 1).
m mFaulty brake pressure regulator (Chapter 9).
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REF•13Glossary of Technical Terms
A
ABS (Anti-lock brake system)A system,
usually electronically controlled, that senses
incipient wheel lockup during braking and
relieves hydraulic pressure at wheels that are
about to skid.
Air bag An inflatable bag hidden in the
steering wheel (driver’s side) or the dash or
glovebox (passenger side). In a head-on
collision, the bags inflate, preventing the
driver and front passenger from being thrown
forward into the steering wheel or windscreen.
Air cleanerA metal or plastic housing,
containing a filter element, which removes
dust and dirt from the air being drawn into the
engine.
Air filter elementThe actual filter in an air
cleaner system, usually manufactured from
pleated paper and requiring renewal at regular
intervals.
Allen keyA hexagonal wrench which fits into
a recessed hexagonal hole.
Alligator clipA long-nosed spring-loaded
metal clip with meshing teeth. Used to make
temporary electrical connections.
AlternatorA component in the electrical
system which converts mechanical energy
from a drivebelt into electrical energy to
charge the battery and to operate the starting
system, ignition system and electrical
accessories.
Ampere (amp)A unit of measurement for the
flow of electric current. One amp is the
amount of current produced by one volt
acting through a resistance of one ohm.
Anaerobic sealerA substance used to
prevent bolts and screws from loosening.
Anaerobic means that it does not require
oxygen for activation. The Loctite brand is
widely used.
AntifreezeA substance (usually ethylene
glycol) mixed with water, and added to a
vehicle’s cooling system, to prevent freezing
of the coolant in winter. Antifreeze also
contains chemicals to inhibit corrosion and
the formation of rust and other deposits that
would tend to clog the radiator and coolant
passages and reduce cooling efficiency.
Anti-seize compoundA coating that
reduces the risk of seizing on fasteners that
are subjected to high temperatures, such as
exhaust manifold bolts and nuts.
AsbestosA natural fibrous mineral with great
heat resistance, commonly used in the
composition of brake friction materials.Asbestos is a health hazard and the dust
created by brake systems should never be
inhaled or ingested.
AxleA shaft on which a wheel revolves, or
which revolves with a wheel. Also, a solid
beam that connects the two wheels at one
end of the vehicle. An axle which also
transmits power to the wheels is known as a
live axle.
AxleshaftA single rotating shaft, on either
side of the differential, which delivers power
from the final drive assembly to the drive
wheels. Also called a driveshaft or a halfshaft.
BBall bearingAn anti-friction bearing
consisting of a hardened inner and outer race
with hardened steel balls between two races.
BearingThe curved surface on a shaft or in a
bore, or the part assembled into either, that
permits relative motion between them with
minimum wear and friction.
Big-end bearingThe bearing in the end of
the connecting rod that’s attached to the
crankshaft.
Bleed nippleA valve on a brake wheel
cylinder, caliper or other hydraulic component
that is opened to purge the hydraulic system
of air. Also called a bleed screw.
Brake bleedingProcedure for removing air
from lines of a hydraulic brake system.
Brake discThe component of a disc brake
that rotates with the wheels.Brake drumThe component of a drum brake
that rotates with the wheels.
Brake liningsThe friction material which
contacts the brake disc or drum to retard the
vehicle’s speed. The linings are bonded or
riveted to the brake pads or shoes.
Brake padsThe replaceable friction pads
that pinch the brake disc when the brakes are
applied. Brake pads consist of a friction
material bonded or riveted to a rigid backing
plate.
Brake shoeThe crescent-shaped carrier to
which the brake linings are mounted and
which forces the lining against the rotating
drum during braking.
Braking systemsFor more information on
braking systems, consult the Haynes
Automotive Brake Manual.
Breaker barA long socket wrench handle
providing greater leverage.
BulkheadThe insulated partition between
the engine and the passenger compartment.
CCaliperThe non-rotating part of a disc-brake
assembly that straddles the disc and carries
the brake pads. The caliper also contains the
hydraulic components that cause the pads to
pinch the disc when the brakes are applied. A
caliper is also a measuring tool that can be set
to measure inside or outside dimensions of an
object.
CamshaftA rotating shaft on which a series
of cam lobes operate the valve mechanisms.
The camshaft may be driven by gears, by
sprockets and chain or by sprockets and a
belt.
CanisterA container in an evaporative
emission control system; contains activated
charcoal granules to trap vapours from the
fuel system.
CarburettorA device which mixes fuel with
air in the proper proportions to provide a
desired power output from a spark ignition
internal combustion engine.
CastellatedResembling the parapets along
the top of a castle wall. For example, a
castellated balljoint stud nut.
CastorIn wheel alignment, the backward or
forward tilt of the steering axis. Castor is
positive when the steering axis is inclined
rearward at the top.
Canister
Brake bleeding
Bearing
Air filter
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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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