brakes FORD MONDEO 1993 Service Repair Manual

REPAIRS & OVERHAUL
Engine and Associated Systems
In-car engine repair procedures Page 2A•1
Engine removal and general engine overhaul procedures Page 2B•1
Cooling, heating and air conditioning systems Page3•1
Fuel and exhaust systems Page 4•1
Engine electrical systems Page 5•1
Emissions control systems Page 6•1
Transmission
Manual transmission Page 7A•1
Automatic transmission Page7B•1
Clutch and driveshafts Page 8•1
Brakes
Braking systemPage 9•1
Suspension
Suspension and steering systems Page 10•1
Body Equipment
Bodywork and fittings Page 11•1
Electrical
Body electrical systems Page 12•1
Wiring DiagramsPage 12•24
REFERENCE
Tools and Working Facilities Page REF• 1
General Repair Procedures Page REF• 4
Buying spare parts and vehicle identification numbers PageREF• 5
Fault FindingPage REF• 6
Glossary of Technical Terms PageREF•13
IndexPage REF•17
Contents
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0•4Introduction
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 “seatbelt 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 litrecapacities. 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
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1•5
1
Maintenance procedures
Rear underbody view - Saloon and
Hatchback models
1 Silencers (Section 21)
2 Rear brakes (Section 23)
3 Exhaust system rubber mounting
(Section 21)
4 Handbrake cables (Section 23)
5 Suspension struts and springs
(Section 19)
6 Fuel tank filler neck (Section 22)
7 Fuel filter (Section 33)
Rear underbody view - Estate models
1 Silencers (Section 21)
2 Rear brakes (Section 23)
3 Exhaust system rubber mounting
(Section 21)
4 Handbrake cables (Section 23)
5 Suspension springs (Section 19)
6 Suspension shock absorbers (Section 19)
7 Fuel tank filler neck (Section 22)
8 Evaporative emissions control system
charcoal canister (Chapter 6)
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This Chapter is designed to help the home
mechanic maintain the Ford Mondeo models
for peak performance, economy, safety and
long life.
On the following pages are Sections
dealing specifically with each item on the
maintenance schedule. Visual checks,
adjustments, component replacement and
other helpful items are included. Refer to the
accompanying illustrations of the engine
compartment and the underside of the vehicle
for the location of various components.
Servicing your Mondeo in accordance with
the mileage/time maintenance schedule and
the following Sections will provide it with a
planned maintenance programme, which
should result in a long and reliable service life.
This is a comprehensive plan, so maintaining
some items but not others at the specified
service intervals will not produce the same
results.
As you service your Mondeo, you will
discover that many of the procedures can -
and should - be grouped together, because of
the nature of the particular procedure you’re
performing, or because of the close proximity
to one another of two otherwise-unrelated
components.
For example, if the vehicle is raised for anyreason, you should inspect the exhaust,
suspension, steering and fuel systems while
you’re under the vehicle. When you’re
checking the tyres, it makes good sense to
check the brakes and wheel bearings,
especially if the roadwheels have already
been removed.
Finally, let’s suppose you have to borrow or
hire a torque wrench. Even if you only need to
tighten the spark plugs, you might as well
check the torque of as many critical fasteners
as time allows.
The first step of this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
Sections which are relevant to the procedures
you’re planning to carry out, then make a list
of, and gather together, all the parts and tools
you will need to do the job. If it looks as if you
might run into problems during a particular
segment of some procedure, seek advice
from your local parts man or dealer service
department.
Ford state that, where antifreeze to
specification ESD-M97B-49-A (the type with
which the vehicle’s cooling system would
have been filled on production at the factory)
is used, it will last the lifetime of the vehicle.This is subject to it being used in the
recommended concentration, unmixed with
any other type of antifreeze or additive, and
topped-up when necessary using only that
antifreeze mixed 50/50 with clean water. If any
other type of antifreeze is added, the lifetime
guarantee no longer applies; to restore the
lifetime protection, the system must be
drained and thoroughly reverse-flushed
before fresh coolant mixture is poured in.
If the vehicle’s history (and therefore the
quality of the antifreeze in it) is unknown,
owners who wish to follow Ford’s
recommendations are advised to drain and
thoroughly reverse-flush the system, as
outlined in Section 28, before refilling with
fresh coolant mixture. If the appropriate
quality of antifreeze is used, the coolant can
then be left for the life of the vehicle.
If any antifreeze other than Ford’s is to be
used, the coolant must be renewed at regular
intervals to provide an equivalent degree of
protection; the conventional recommendation
is to renew the coolant every two years.
The above assumes the use of a mixture (in
exactly the specified concentration) of clean,
soft water and of antifreeze to Ford’s
specification or equivalent. It is also assumed
that the cooling system is maintained in a
scrupulously-clean condition, by ensuring that
only clean coolant is added on topping-up,
and by thorough reverse-flushing whenever
the coolant is drained (Section 28).
2 Coolant renewal
1 Introduction
1•6Weekly checks
Weekly checks
General
1Fluids are an essential part of the
lubrication, cooling, braking and other
systems. Because these fluids gradually
become depleted and/or contaminated during
normal operation of the vehicle, they must be
periodically replenished. See “Lubricants and
fluids and capacities”at the beginning of this
Chapter before adding fluid to any of the
following components. Note:The vehicle
must be on level ground before fluid levels can
be checked.
Engine oil
2The engine oil level is checked with a
dipstick located at the front of the engine; it
can be identified by its yellow/black plastic
grip (see illustration). The dipstick extends
through a metal tube, from which it protrudes
down into the sump at the bottom of the
engine.
3The oil level should be checked before the
vehicle is driven, or about 5 minutes after the
engine has been switched off.4Pull the dipstick from the tube, and wipe all
the oil from the end with a clean rag or paper
towel; note the dipstick’s maximum and
minimum levels, indicated by notches (seeillustration). Insert the clean dipstick all the way
back into its metal tube, and pull it out again.
Observe the oil on the end of the dipstick; its
level should be between these two notches.
5Do not allow the level to drop below the
minimum level notch, or oil starvation may
cause engine damage. Conversely, overfilling
the engine (adding oil above the maximum
level notch) may cause oil-fouled spark plugs,
oil leaks or oil seal failures.
6The yellow/black plastic oil filler cap is
screwed into the left-hand front end of the
3 Fluid level checks
3.2 The engine oil dipstick (arrowed) is
located at the front of the engine - note
yellow/black plastic grip
3.4 The oil level should be at or near the
maximum level notch (A) - if not, add
enough oil to correct the level. It takes
approximately 0.5 to 1.0 litre of oil to raise
the level from the minimum level notch (B)
to the maximum
If the level is checked
immediately after driving the
vehicle, some of the oil will
remain in the engine upper
components, producing an inaccurate
dipstick reading.
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evidence of leaks, severe corrosion, or
damage. Make sure that all brackets and
rubber mountings are in good condition, and
tight; if any of the mountings are to be
renewed, ensure that the replacements are of
the correct type (see illustration). Leakage at
any of the joints or in other parts of the system
will usually show up as a black sooty stain in
the vicinity of the leak. Note:Exhaust sealants
should not be used on any part of the exhaust
system upstream of the catalytic converter -
even if the sealant does not contain additives
harmful to the converter, pieces of it may
break off and foul the element, causing local
overheating.
3At the same time, inspect the underside of
the body for holes, corrosion, open seams,
etc. which may allow exhaust gases to enter
the passenger compartment. Seal all body
openings with silicone or body putty.
4Rattles and other noises can often be
traced to the exhaust system, especially the
rubber mountings. Try to move the system,
silencer(s) and catalytic converter. If any
components can touch the body or
suspension parts, secure the exhaust system
with new mountings.
5Check the running condition of the engine
by inspecting inside the end of the tailpipe;
the exhaust deposits here are an indication of
the engine’s state of tune. The inside of the
tailpipe should be dry, and should vary in
colour from dark grey to light grey/brown; if it
is black and sooty, or coated with white
deposits, the engine is in need of a thorough
fuel system inspection.
1With the vehicle raised and supported on
axle stands or over an inspection pit,
thoroughly inspect the underbody and wheel
arches for signs of damage and corrosion. In
particular, examine the bottom of the side
sills, and any concealed areas where mud can
collect. Where corrosion and rust is evident,press and tap firmly on the panel with a
screwdriver, and check for any serious
corrosion which would necessitate repairs. If
the panel is not seriously corroded, clean
away the rust, and apply a new coating of
underseal. Refer to Chapter 11 for more
details of body repairs.
2At the same time, inspect the PVC-coated
lower body panels for stone damage and
general condition.
3Inspect all of the fuel and brake lines on the
underbody for damage, rust, corrosion and
leakage. Also make sure that they are
correctly supported in their clips. Where
applicable, check the PVC coating on the
lines for damage.
Note:For detailed photographs of the brake
system, refer to Chapter 9.
1The work described in this Section should
be carried out at the specified intervals, or
whenever a defect is suspected in the braking
system. Any of the following symptoms could
indicate a potential brake system defect:
(a) The vehicle pulls to one side when the
brake pedal is depressed.
(b) The brakes make scraping or dragging
noises when applied.
(c) Brake pedal travel is excessive.
(d) The brake fluid requires repeated topping-
up.
2A brake pad wear warning light is fitted, and
it is illuminated when the thickness of the front
(or rear) disc brake pad linings reach the
minimum amount. However, a physical check
should be made to confirm the thickness of
the linings, as follows.
Disc brakes
3Jack up the front or rear of the vehicle, as
applicable, and support it on axle stands.
Where rear brake pads are fitted, also jack up
the rear of the vehicle and support on axle
stands.
4For better access to the brake calipers,
remove the wheels.
5Look through the inspection window in thecaliper, and check that the thickness of the
friction lining material on each of the pads is
not less than the recommended minimum
thickness given in the Specifications. Note:
Bear in mind that the lining material is normally
bonded to a metal backing plate.
6If it is difficult to determine the exact
thickness of the pad linings, or if you are at all
concerned about the condition of the pads,
then remove them from the calipers for further
inspection (refer to Chapter 9).
7Check the remaining brake caliper(s) in the
same way.
8If any one of the brake pads has worn down
to, or below, the specified limit, all fourpads
at that end of the car must be renewed as a
set (ie all the front pads or all the rear pads).
9Measure the thickness of the discs with a
micrometer, if available, to make sure that
they still have service life remaining. If any
disc is thinner than the specified minimum
thickness, renew it (refer to Chapter 9). In any
case, check the general condition of the
discs. Look for excessive scoring and
discolouration caused by overheating. If these
conditions exist, remove the relevant disc and
have it resurfaced or renewed (refer to
Chapter 9).
10Before refitting the wheels, check all
brake lines and hoses (refer to Chapter 9). In
particular, check the flexible hoses in the
vicinity of the calipers, where they are
subjected to most movement. Bend them
between the fingers (but do not actually bend
them double, or the casing may be damaged)
and check that this does not reveal
previously-hidden cracks, cuts or splits (see
illustration).
Rear drum brakes
11Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands.
12For better access, remove the rear
wheels.
13To check the brake shoe lining thickness
without removing the brake drums, prise the
rubber plugs from the backplates, and use an
electric torch to inspect the linings of the
leading brake shoes (see illustration). Check
that the thickness of the lining material on the
23 Brake check
22 Underbody and fuel/brake
line check
1•19
121.2 If any of the exhaust system rubber
mountings are to be renewed, ensure that
the replacements are of the correct type -
their colour is a good guide. Those nearest
to the catalytic converter are more heat-
resistant than the others23.10 Checking the condition of a flexible
brake hose23.13 Prise the rubber plugs from the
backplates to inspect the leading brake
shoe linings
Every 000 miles
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9Remove the nuts and detach the manifold
and gasket (see illustration). Take care not
to damage vulnerable components such as
the EGR pipe as the manifold assembly is
manoeuvred out of the engine compartment.
When removing the manifold with the engine
in the vehicle, additional clearance can be
obtained by unscrewing the studs from the
cylinder head; a female Torx-type socket will
be required (see illustration).
10Always fit a new gasket on reassembly, to
carefully-cleaned components (see below).
Do notattempt to re-use the original gasket.
Inspection
11Use a scraper to remove all traces of old
gasket material and carbon deposits from the
manifold and cylinder head mating surfaces. If
the gasket was leaking, have the manifold
checked for warpage at an automotive
machine shop, and have it resurfaced if
necessary.
Caution: When scraping, be very
careful not to gouge or scratch
the delicate aluminium alloy
cylinder head.
12Provided both mating surfaces are clean
and flat, a new gasket will be sufficient to
ensure the joint is gas-tight. Do notuse any
kind of exhaust sealant upstream of the
catalytic converter.
13Note that the downpipe is secured to the
manifold by two bolts, with a coil spring,
spring seat and self-locking nut on each. On
refitting, tighten the nuts until they stop on thebolt shoulders; the pressure of the springs will
then suffice to make a leakproof joint (see
illustrations).
14Do not overtighten the nuts to cure a leak
- the bolts will shear; renew the gasket and
the springs if a leak is found. The bolts
themselves are secured by spring clips to the
manifold, and can be renewed easily if
damaged (see illustration).
Refitting
15Refitting is the reverse of the removal
procedure, noting the following points:
(a) Position a new gasket over the cylinder
head studs, and fit a new plastic guide
sleeve to the stud nearest to the
thermostat housing, so that the manifold
will be correctly located (see illustration).
Do notrefit the manifold without this
sleeve.
(b) Refit the manifold, and finger-tighten the
mounting nuts.
(c) Working from the centre out, and in three
or four equal steps, tighten the nuts to the
torque wrench setting given in the
Specifications Section of this Chapter.
(d) Refit the remaining parts in the reverse
order of removal. Tighten all fasteners to
the specified torque wrench settings.
(e) Refill the cooling system (see Chapter 1).
(f) Run the engine, and check for exhaust
leaks. Check the coolant level when fully
warmed-up to normal operating
temperature.1Remove the auxiliary drivebelt - either
remove the drivebelt completely, or just
secure it clear of the crankshaft pulley,
depending on the work to be carried out (see
Chapter 1).
2If necessary, rotate the crankshaft until the
timing marks align (see Section 4).
3The crankshaft must now be locked to
prevent its rotation while the pulley bolt is
unscrewed. Proceed as follows:
(a) If the engine/transmission is still installed
in the vehicle:
(1) If the vehicle is fitted with manual
transmission, select top gear, and have an
assistant apply the brakes hard.
(2) If the vehicle is fitted with automatic
transmission, unbolt the small metal cover
plate from the sump, and use a large
screwdriver or similar to lock the
driveplate ring gear teeth while an
assistant slackens the pulley bolt; take
care not to damage the teeth or the
surrounding castings when using this
method.
(b) If the engine/transmission has been
removed but not yet separated:
(1) If the vehicle is fitted with manual
transmission, remove the starter motor
(see Chapter 5) and lock the flywheel
8 Crankshaft pulley -
removal and refitting
In-car engine repair procedures 2A•9
2A
7.13B Renew exhaust system downpipe-
to-manifold gasket to prevent leaks7.14 Release spring clip to extract
securing bolt from manifold, when required7.15 Fit plastic guide sleeve to stud
arrowed when refitting exhaust manifold
7.9A Unscrew nuts (arrowed) to remove
exhaust manifold . . .
7.9B . . . studs can be unscrewed also, if
required, to provide additional working
space7.13A Showing exhaust downpipe-to-
manifold securing bolts - note coil spring,
and shoulder on bolt
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Chapter 9 Braking system
ABS hydraulic unit - removal and refitting . . . . . . . . . . . . . . . . . . . . 20
ABS relay box - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 22
ABS wheel sensor - testing, removal and refitting . . . . . . . . . . . . . . 21
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake pedal-to-servo cross-link (right-hand-drive models
only) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . 3
Front brake disc - inspection, removal and refitting . . . . . . . . . . . . . 4
Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake cables - removal and refitting . . . . . . . . . . . . . . . . . . . . . 27
Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic pipes and hoses - inspection, removal and refitting . . . . . 14
Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Master cylinder - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure-control relief valve (ABS models) - removal and refitting . . 19
Pressure-control relief valve (non-ABS models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 9
Rear brake disc - inspection, removal and refitting . . . . . . . . . . . . . 10
Rear brake drum - removal, inspection and refitting . . . . . . . . . . . . . 5
Rear brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 7
Stop-light switch - removal, refitting and adjustment . . . . . . . . . . . . 25
TCS inhibitor switch - removal and refitting . . . . . . . . . . . . . . . . . . . 23
TCS throttle actuator - removal and refitting . . . . . . . . . . . . . . . . . . 24
Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . 16
Vacuum servo unit vacuum hose and non-return valve -
removal, testing and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilated disc, with single-piston floating caliper
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260.0 mm
Disc thickness:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.15 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.20 mm
Maximum disc run-out (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Maximum disc thickness variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm
Front hub face maximum run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
Rear drum brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leading and trailing shoes, with automatic adjusters
Drum diameter:
New:
1.6 Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.0 mm
1.8 and 2.0 Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228.6 mm
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228.6 mm
Maximum diameter:
1.6 Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.2 mm
1.8 and 2.0 Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229.6 mm
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229.6 mm
Rear disc brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid disc, with single-piston floating caliper
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252.0 mm
Disc thickness:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.0 mm
Maximum disc run-out (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Maximum disc thickness variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm
Rear hub face maximum run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
9•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
9
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Torque wrench settingsNm lbf ft
Front caliper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Rear caliper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 44
Front caliper guide bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Rear caliper guide bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
Rear drum brake backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Vacuum servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
ABS hydraulic unit to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 63
9•2 Braking system
1.2 Handbrake lever and associated components
1 Handbrake lever
2 Clock spring
3 Handbrake cable
4 Toothed segment and pawl to lock the
handbrake lever5 Fine-toothed segment for the clock spring
6 Pawl for the clock spring
7 Underbody bracket
The braking system is of diagonally-split,
dual-circuit design, with ventilated discs at
the front, and drum or disc brakes (according
to model) at the rear. The front calipers are of
floating single-piston design, using asbestos-
free pads. The rear drum brakes are of the
leading and trailing shoe type. They are self-
adjusting during footbrake operation. The rear
brake shoe linings are of different
thicknesses, in order to allow for the different
proportional rates of wear.
Pressure-control relief (PCR) valves are
fitted to the rear brakes, to prevent rear wheel
lock-up under hard braking. The valves are
sometimes referred to as pressure-conscious
reducing valves. On non-ABS models, theyare fitted in the master cylinder rear brake
outlet ports; on ABS models, they are located
on the ABS unit.
When rear disc brakes are fitted, the rear
brake caliper is located on the front of the
knuckle on Saloon and Hatchback models,
and on the rear of the knuckle on Estate
models (see illustration).
The handbrake is cable-operated, and acts
on the rear brakes. On rear drum brake
models, the cables operate on the rear trailing
brake shoe operating levers, and on rear disc
brake models, they operate on levers on the
rear calipers. The handbrake lever
incorporates an automatic adjuster, which
removes any slack from the cables when the
lever is disengaged (see illustration).
Handbrake lever movement remains
consistent at all times, and no adjustment is
necessary or possible.
Where fitted, the anti-lock braking system
(ABS) is of the four-channel low-pressure type
(see illustration). It uses the basic
conventional brake system, together with aBendix ABS hydraulic unit fitted between the
master cylinder and the four wheel brakes.
The hydraulic unit consists of a hydraulic
actuator, an ABS brake pressure pump, an
ABS module with built-in relay box, and two
pressure-control relief valves. Braking at each
of the four wheels is controlled by separate
solenoid valves in the hydraulic actuator. If
wheel lock-up is detected on a wheel when
the vehicle speed is above 3 mph, the valve
opens, releasing pressure to the relevant
brake, until the wheel regains a rotational
speed corresponding to the speed of the
vehicle. The cycle can be repeated many
times a second. In the event of a fault in the
ABS system, the conventional braking system
is not affected. Diagnosis of a fault in the ABS
system requires the use of special equipment,
and this work should therefore be left to a
Ford dealer. Diagnostic connectors are
located on the side of the left-hand front
suspension turret.
The traction control system (TCS) is fitted
as an option to some models, and uses the
1 General information
1.1 Rear disc brake location on
Saloon/Hatchback models (A) and Estate
models (B)
1 Handbrake cable lever facing away from
caliper
2 Handbrake cable lever facing towards
caliper
3 Brake hose banjo bolt
4 Front of vehicle
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basic ABS system, with an additional pump
and valves fitted to the hydraulic actuator (see
illustration). If wheelspin is detected at a
speed below 30 mph, one of the valves
opens, to allow the pump to pressurise the
relevant brake, until the spinning wheel slows
to a rotational speed corresponding to the
speed of the vehicle. This has the effect of
transferring torque to the wheel with mosttraction. At the same time, the throttle plate is
closed slightly, to reduce the torque from the
engine. At speeds above 30 mph, the TCS
operates by throttle plate adjustment only.
Warning: Disc brake pads must
be renewed on both front wheels
at the same time - never renew
the pads on only one wheel, as
uneven braking may result. Although
genuine Ford linings are asbestos-free, the
dust created by wear of non-genuine pads
may contain asbestos, which is a health
hazard. Never blow it out with compressed
air, and don’t inhale any of it. DO NOT use
petroleum-based solvents to clean brake
parts; use brake cleaner or methylated
spirit only. DO NOT allow any brake fluid,
oil or grease to contact the brake pads or
disc. Also refer to the warning at the start
of Section 15 concerning brake fluid.
1Apply the handbrake. Loosen the front
wheel nuts, jack up the front of the vehicle
and support it on axle stands.
2Remove the front wheels. Work on onebrake assembly at a time, using the
assembled brake for reference if necessary.
3Follow the accompanying photos,
beginning with illustration 2.3A, for the pad
removal procedure. Be sure to stay in order,
and read the caption under each illustration.
4Inspect the front brake disc for scoring and
cracks. If a detailed inspection is necessary,
refer to Section 4.
5The piston must be pushed back into the
2 Front brake pads - renewal
Braking system 9•3
9
1.4 Solenoid valves fitted to the ABS/TCS
hydraulic actuator
1 ABS/TCS actuator
2 ABS solenoid valves
3 TCS solenoid valves
1.3 Anti-lock Braking System (ABS) and Traction Control System (TCS) component locations (left-hand-drive shown,
right-hand-drive similar)
1 ABS/TCS unit
2 ABS/TCS warning lights
3 TCS switch4 Rear wheel sensor ring location (drum
brakes left, disc brakes right)
5 Stop-light switch6 Self-test/diagnosis connectors
7 Front wheel sensor and ring
8 Throttle actuator
2.3A Prise the retaining clip from the
caliper. Hold it with a pair of pliers, to
avoid personal injury. On models fitted
with pad wear sensors, it will be necessary
to disconnect the wiring
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caliper bore, to provide room for the new
brake pads. A C-clamp can be used to
accomplish this. As the piston is depressed to
the bottom of the caliper bore, the fluid in the
master cylinder will rise slightly. Make sure
that there is sufficient space in the brake fluid
reservoir to accept the displaced fluid, and if
necessary, syphon some off first.
6Fit the new pads using a reversal of the
removal procedure, but tighten the guide
bolts to the torque wrench setting given in the
Specifications at the beginning of this
Chapter.
7On completion, firmly depress the brakepedal a few times, to bring the pads to their
normal working position. Check the level of
the brake fluid in the reservoir, and top-up if
necessary.
8Give the vehicle a short road test, to make
sure that the brakes are functioning correctly,
and to bed-in the new linings to the contours
of the disc. New linings will not provide
maximum braking efficiency until they have
bedded-in; avoid heavy braking as far as
possible for the first hundred miles or so.
Note:Refer to the warning at the beginning of
the previous Section before proceeding.Removal
1Apply the handbrake. Loosen the front
wheel nuts, jack up the front of the vehicle
and support it on axle stands. Remove the
appropriate front wheel.
2Fit a brake hose clamp to the flexible hose
leading to the front brake caliper. This will
minimise brake fluid loss during subsequent
operations (see illustration).
3Loosen (but do not completely unscrew) the
union on the caliper end of the flexible brake
hose (see illustration).
4Remove the front brake pads as described
in Section 2.
3 Front brake caliper -
removal, overhaul and refitting
9•4 Braking system
2.3B Prise the plastic covers from the
ends of the two guide pins2.3C Using a 7 mm Allen key, unscrew . . .2.3D . . . and remove the guide bolts
securing the caliper to the carrier bracket
2.3E Withdraw the caliper from the disc,
and support it on an axle stand to avoid
straining the hydraulic hose. The outer pad
will normally remain in position against the
disc, but the inner pad will stay attached to
the piston in the caliper2.3F Pull the inner pad from the piston in
the caliper
3.2 Brake hose clamp fitted to the front
flexible brake hose3.3 Loosening the flexible brake hose at
the caliper3.6 Removing the caliper carrier bracket
2.3G Remove the outer pad from the
caliper frame. Brush all dust and dirt from
the caliper, pads and disc, but do not
inhale it, as it may be harmful to health.
Scrape any corrosion from the disc.
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