Ford Mondeo (petrol engines). Manual - part 67

Engine misfires throughout the driving speed range

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Fuel filter choked (Chapter 1).

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Fuel pump faulty or delivery pressure low (Chapter 4).

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Fuel tank vent blocked or fuel pipes restricted (Chapter 4).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Faulty spark plug HT leads (Chapter 1).

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Faulty ignition coil (Chapter 5).

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Engine management system fault (Chapters 1, 4, 5 and 6)

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Uneven or low cylinder compressions (Chapter 2, Part A).

Engine hesitates on acceleration

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

Engine stalls

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Idle speed control valve faulty (Chapter 4).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

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Fuel filter choked (Chapter 1).

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Fuel pump faulty or delivery pressure low (Chapter 4).

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Fuel tank vent blocked or fuel pipes restricted (Chapter 4).

Engine lacks power

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Incorrect ignition timing (Chapters 5 and 6).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Timing belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).

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Fuel filter choked (Chapter 1).

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Fuel pump faulty or delivery pressure low (Chapter 4).

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Uneven or low cylinder compressions (Chapter 2, Part A).

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

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Brakes binding (Chapters 1 and 9).

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Clutch slipping (Chapter 8).

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Automatic transmission fluid level incorrect (Chapter 1).

Engine runs-on after switching off

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Idle speed excessively high (Chapters 4 and 6).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Excessive carbon build-up in engine (Chapter 2, Part A).

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High engine operating temperature (Chapter 3).

Engine backfires

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Ignition timing incorrect (Chapters 5 and 6).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Timing belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

Oil pressure warning light illuminated with engine
running

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Low oil level or incorrect oil grade (Chapter 1).

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Faulty oil pressure warning light switch (Chapter 2, Part A).

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Worn engine bearings and/or oil pump (Chapter 2).

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High engine operating temperature (Chapter 3).

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Oil pressure relief valve defective (Chapter 2, Part A).

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Oil pick-up strainer clogged (Chapter 2, Part A).

Engine noises

Pre-ignition (pinking) or knocking during acceleration or under
load

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Ignition timing incorrect (Chapters 5 and 6).

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Incorrect grade of fuel (Chapter 4).

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Vacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).

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Excessive carbon build-up in engine (Chapter 2, Part A).

Whistling or wheezing noises

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Leaking inlet manifold gasket (Chapter 2, Part A).

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Leaking exhaust manifold gasket or downpipe-to-manifold joint
(Chapters 1, 2 Part A, and 4).

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Leaking vacuum hose (Chapters 1, 4, 6 and 9).

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Blowing cylinder head gasket (Chapter 2, Part A).

Tapping or rattling noises

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Faulty hydraulic tappet(s) (Chapter 2, Part A).

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Worn valve gear or camshaft (Chapter 2, Part A).

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Worn timing belt or tensioner (Chapter 2, Part A).

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Ancillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).

Knocking or thumping noises

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Worn big-end bearings (regular heavy knocking, perhaps less
under load) (Chapter 2, Part B).

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Worn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2, Part B).

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Piston slap (most noticeable when cold) (Chapter 2, Part B).

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Ancillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).

REF•8

Fault Finding

2 Cooling system

Overheating

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Insufficient coolant in system (Chapter 1).

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Thermostat faulty (Chapter 3).

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Radiator core blocked or grille restricted (Chapter 3).

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Radiator electric cooling fan(s) or coolant temperature sensor faulty
(Chapter 3).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Pressure cap faulty (Chapter 3).

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Auxiliary drivebelt worn or slipping (Chapter 1).

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Ignition timing incorrect (Chapters 5 and 6).

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Inaccurate coolant temperature gauge sender (Chapter 3).

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Air-lock in cooling system (Chapter 1).

Overcooling

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Thermostat faulty (Chapter 3).

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Inaccurate coolant temperature gauge sender (Chapter 3).

External coolant leakage

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Deteriorated or damaged hoses or hose clips (Chapter 1).

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Radiator core or heater matrix leaking (Chapter 3).

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Pressure cap faulty (Chapter 3).

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Water pump seal leaking (Chapter 3).

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Boiling due to overheating (Chapter 3).

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Core plug leaking (Chapter 2, Part B).

REF•9

Excessive fuel consumption

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Unsympathetic driving style, or adverse conditions.

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Air filter element dirty or clogged (Chapter 1).

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Engine management system fault (Chapters 1, 4, 5 and 6).

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Ignition timing incorrect (Chapters 5 and 6).

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Tyres under-inflated (Chapter 1).

Fuel leakage and/or fuel odour

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Damaged or corroded fuel tank, pipes or connections (Chapter 1).

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Charcoal canister and/or connecting pipes leaking (Chapter 6).

Excessive noise or fumes from exhaust system

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Leaking exhaust system or manifold joints (Chapters 1, 2 Part A,
and 4).

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Leaking, corroded or damaged silencers or pipe (Chapter 1).

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Broken mountings, causing body or suspension contact (Chap-
ters 1 and 4).

Fault Finding

3 Fuel and exhaust system

Noisy in neutral with engine running

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Input shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7, Part A).*

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Clutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 8).

Noisy in one particular gear

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Worn, damaged or chipped gear teeth (Chapter 7, Part A).*

Difficulty engaging gears

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Clutch fault (Chapter 8).

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Worn or damaged gear linkage (Chapter 7, Part A).

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Incorrectly-adjusted gear linkage (Chapter 7, Part A).

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Worn synchroniser assemblies (Chapter 7, Part A).*

Vibration

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Lack of oil (Chapter 1).

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Worn bearings (Chapter 7, Part A).*

Jumps out of gear

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Worn or damaged gear linkage (Chapter 7, Part A).

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Incorrectly-adjusted gear linkage (Chapter 7, Part A).

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Worn synchroniser assemblies (Chapter 7, Part A).*

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Worn selector forks (Chapter 7, Part A).*

Lubricant leaks

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Leaking differential side gear oil seal (Chapter 7, Part A).

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Leaking housing joint (Chapter 7, Part A).*

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Leaking input shaft oil seal (Chapter 7, Part A).*

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Leaking selector shaft oil seal (Chapter 7, Part A).

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Leaking speedometer drive pinion O-ring (Chapter 7, Part A).

* Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.

4 Clutch

5 Manual transmission

Pedal travels to floor - no pressure or very little
resistance

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Broken clutch cable (Chapter 8).

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Incorrect clutch adjustment (Chapter 8).

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Broken clutch release bearing or fork (Chapter 8).

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Broken diaphragm spring in clutch pressure plate (Chapter 8).

Clutch fails to disengage (unable to select gears)

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Incorrect clutch adjustment (Chapter 8).

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Clutch disc sticking on transmission input shaft splines (Chapter 8).

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Clutch disc sticking to flywheel or pressure plate (Chapter 8).

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Faulty pressure plate assembly (Chapter 8).

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Clutch release mechanism worn or incorrectly assembled (Chapter 8).

Clutch slips (engine speed increases with no
increase in vehicle speed)

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Incorrect clutch adjustment (Chapter 8).

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Clutch disc linings excessively worn (Chapter 8).

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Clutch disc linings contaminated with oil or grease (Chapter 8).

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Faulty pressure plate or weak diaphragm spring (Chapter 8).

Judder as clutch is engaged

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Clutch disc linings contaminated with oil or grease (Chapter 8).

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Clutch disc linings excessively worn (Chapter 8).

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Clutch cable sticking or frayed (Chapter 8).

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Faulty or distorted pressure plate or diaphragm spring (Chapter 8).

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Worn or loose engine/transmission mountings (Chapter 2, Part A).

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Clutch disc hub or transmission input shaft splines worn (Chap-
ter 8).

Noise when depressing or releasing clutch pedal

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Worn clutch release bearing (Chapter 8).

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Worn or dry clutch pedal bushes (Chapter 8).

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Faulty pressure plate assembly (Chapter 8).

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Pressure plate diaphragm spring broken (Chapter 8).

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Broken clutch disc cushioning springs (Chapter 8).

Internal coolant leakage

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Leaking cylinder head gasket (Chapter 2, Part A).

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Cracked cylinder head or cylinder bore (Chapter 2, Part B).

Corrosion

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Infrequent draining and flushing (Chapter 1).

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Incorrect antifreeze mixture, or inappropriate antifreeze type
(Chapter 1).

6 Automatic transmission

REF•10

Fault Finding

Note: Due to the complexity of the automatic transmission and its
electronic control system, it is difficult for the home mechanic to
properly diagnose and service this unit. For problems other than the
following, the vehicle should be taken to a dealer service department
or automatic transmission specialist.

Fluid leakage

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Automatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.

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To determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
(a) Housing joints (Chapters 1 and 7, Part B).
(b) Dipstick tube (Chapters 1 and 7, Part B).
(c) Transmission-to-fluid cooler pipes/unions (Chapters 3 and 7,

Part B).

(d) Speedometer drive pinion O-ring (Chapter 7, Part B).
(e) Differential side gear oil seals (Chapter 7, Part B).

Transmission fluid brown, or has burned smell

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Transmission fluid level low, or fluid in need of renewal (Chapter 1).

Transmission will not downshift (kickdown) with
accelerator pedal fully depressed

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Low transmission fluid level (Chapter 1).

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Incorrect selector cable adjustment (Chapter 7, Part B).

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Engine management system fault (Chapters 1, 4, 5 and 6).

General gear selection problems

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Chapter 7, Part B, deals with checking and adjusting the selector
cable on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:
(a) Engine starting in gears other than Park or Neutral.
(b) Indicator on gear selector lever pointing to a gear other than the

one actually being used.

(c) Vehicle moves when in Park or Neutral.
(d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7, Part B for the selector cable adjustment
procedure.

Engine will not start in any gear, or starts in gears
other than Park or Neutral

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Incorrect selector lever position sensor adjustment (Chapter 7, 
Part B).

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Incorrect selector cable adjustment (Chapter 7, Part B).

Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears

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There are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.

7 Driveshafts

Clicking or knocking noise on turns (at slow speed
on full-lock)

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Lack of constant velocity joint lubricant (Chapter 8).

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Worn outer constant velocity joint (Chapter 8).

Vibration when accelerating or decelerating

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Worn inner constant velocity joint (Chapter 8).

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Bent or distorted driveshaft (Chapter 8).

8 Braking system

Note: Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose
connections, any faults occurring on the Anti-lock Braking System (ABS) should be referred to a Ford dealer for diagnosis - the same applies to the
components of the Traction Control System (TCS).

Vehicle pulls to one side under braking

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Worn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).

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Seized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).

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A mixture of brake pad/shoe lining materials fitted between sides
(Chapter 1).

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Brake caliper mounting bolts loose (Chapter 9).

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Rear brake backplate mounting bolts loose (Chapter 9).

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Worn or damaged steering or suspension components (Chap-
ter 10).

Noise (grinding or high-pitched squeal) when brakes
applied

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Brake pad or shoe friction lining material worn down to metal
backing (Chapter 1).

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Excessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).

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Foreign object (stone chipping, etc) trapped between brake disc
and splash shield (Chapter 1).

Excessive brake pedal travel

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Inoperative rear brake self-adjust mechanism (Chapter 9).

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Faulty master cylinder (Chapter 9).

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Air in hydraulic system (Chapter 9).

REF•11

Fault 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

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Defective tyre (Chapter 1).

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Excessive wear in suspension or steering components (Chap-
ter 10).

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Incorrect front wheel alignment (Chapter 10).

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Accident damage to steering or suspension components (Chap-
ter 10).

Wheel wobble and vibration

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Front roadwheels out of balance (vibration felt mainly through the
steering wheel) (Chapter 1).

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Rear roadwheels out of balance (vibration felt throughout the
vehicle) (Chapter 1).

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Roadwheels damaged or distorted (Chapter 1).

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Faulty or damaged tyre (Chapter 1).

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Worn steering or suspension joints, bushes or components
(Chapter 10).

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Roadwheel nuts loose (Chapter 1).

Excessive pitching and/or rolling around corners, or

during braking

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Defective shock absorbers (Chapter 10).

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Broken or weak coil spring and/or suspension component (Chap-
ter 10).

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Worn or damaged anti-roll bar or mountings (Chapter 10).

Wandering or general instability

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Incorrect front wheel alignment (Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapter 10).

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Roadwheels out of balance (Chapter 1).

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Faulty or damaged tyre (Chapter 1).

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Roadwheel nuts loose (Chapter 1).

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Defective shock absorbers (Chapter 10).

Excessively-stiff steering

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Lack of steering gear lubricant (Chapter 10).

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Seized track-rod end balljoint or suspension balljoint (Chapter 10).

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Broken or slipping auxiliary drivebelt (Chapter 1).

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Incorrect front wheel alignment (Chapter 10).

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Steering rack or column bent or damaged (Chapter 10).

Excessive play in steering

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Worn steering column universal joint(s) or flexible coupling
(Chapter 10).

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Worn steering track-rod end balljoints (Chapter 10).

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Worn rack-and-pinion steering gear (Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapter 10).

Lack of power assistance

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Broken or slipping auxiliary drivebelt (Chapter 1).

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Incorrect power steering fluid level (Chapter 1).

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Restriction in power steering fluid hoses (Chapter 10).

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Faulty power steering pump (Chapter 10).

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Faulty rack-and-pinion steering gear (Chapter 10).

Tyre wear excessive

Tyres worn on inside or outside edges

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Tyres under-inflated (wear on both edges) (Chapter 1).

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Incorrect camber or castor angles (wear on one edge only)
(Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapter 10).

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Excessively-hard cornering.

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Accident damage.

Tyre treads exhibit feathered edges

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Incorrect toe setting (Chapter 10).

Tyres worn in centre of tread

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Tyres over-inflated (Chapter 1).

Tyres worn on inside and outside edges

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Tyres under-inflated (Chapter 1).

Tyres worn unevenly

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Tyres out of balance (Chapter 1).

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Excessive wheel or tyre run-out (Chapter 1).

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Worn shock absorbers (Chapter 10).

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Faulty tyre (Chapter 1).

Brake pedal feels spongy when depressed

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Air in hydraulic system (Chapter 9).

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Deteriorated flexible rubber brake hoses (Chapter 9).

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Master cylinder mounting nuts loose (Chapter 9).

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Faulty master cylinder (Chapter 9).

Excessive brake pedal effort required to stop
vehicle

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Faulty vacuum servo unit (Chapter 9).

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Disconnected, damaged or insecure brake servo vacuum hose
(Chapter 9).

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Primary or secondary hydraulic circuit failure (Chapter 9).

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Seized brake caliper or wheel cylinder piston(s) (Chapter 9).

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Brake pads or brake shoes incorrectly fitted (Chapter 9).

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Incorrect grade of brake pads or brake shoes fitted (Chapter 1).

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Brake pads or brake shoe linings contaminated (Chapter 1).

Judder felt through brake pedal or steering wheel
when braking

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Excessive run-out or distortion of front discs or rear drums
(Chapter 9).

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Brake pad or brake shoe linings worn (Chapter 1).

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Brake caliper or rear brake backplate mounting bolts loose
(Chapter 9).

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Wear in suspension or steering components or mountings (Chapter 10).

Brakes binding

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Seized brake caliper or wheel cylinder piston(s) (Chapter 9).

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Faulty handbrake mechanism (Chapter 9).

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Faulty master cylinder (Chapter 9).

Rear wheels locking under normal braking

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Rear brake shoe linings contaminated (Chapter 1).

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Faulty brake pressure regulator (Chapter 9).