Ford Mondeo (petrol engines). Manual — part 4

Chapter 1 Routine maintenance and servicing

Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . .

7

Automatic transmission linkage lubrication . . . . . . . . . . . . . . . . . . . 18
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery check, maintenance and charging . . . . . . . . . . . . . . . . . . . .

9

Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 28
Door and bonnet check and lubrication . . . . . . . . . . . . . . . . . . . . . . 24
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 20
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Idle speed and mixture check and adjustment . . . . . .

See Chapter 4

Ignition timing check . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 16
Positive Crankcase Ventilation (PCV) system check

and filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Power steering fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . See end of Chapter
Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 19
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tyre and tyre pressure checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 22
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 12
Ventilation system pollen filter renewal . . . . . . . . . . . . . . . . . . . . . . . 27
Windscreen/tailgate washer system and wiper blade check . . . . . .

6

1•1

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult, suitable
for competent DIY
mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

Contents

1

1•2

Lubricants, Fluids & Capacities

Lubricants and fluids

Component or system

Lubricant type/specification

Engine

Multigrade engine oil to specification API SG/CD or better, viscosity range 5W/50 to 10W/30

Manual transmission

Gear oil to Ford specification ESD-M2C-186-A

Automatic transmission

Transmission fluid to Ford specification ESP-M2C-166-H

Power steering

Transmission fluid to Ford specification ESP-M2C-166-H

Cooling system

Soft water, and antifreeze (ethylene glycol-based, suitable for use in mixed-metal cooling systems) to
Ford specification ESD-M97B-49-A

Braking system

Hydraulic fluid to Ford specification ESD-M6C-57-A, Super DOT 4 or equivalent

Driveshaft joints

Long-life grease to Ford specification SQM-1C 9004-A

Capacities

Engine oil:

At oil and filter change . . . . . . . . . . . . . . . . . . . . . . . 4.25 litres
Dry - at engine overhaul . . . . . . . . . . . . . . . . . . . . . . 4.50 litres
Difference between dipstick minimum and
maximum level notches . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.0 litre

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 litres

Cooling system:

Manual transmission models . . . . . . . . . . . . . . . . . . 6.6 litres
Automatic transmission models . . . . . . . . . . . . . . . 7.1 litres

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 litres
Automatic transmission:

Total, including fluid cooler . . . . . . . . . . . . . . . . . . . 7.2 litres
Drain and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 litres

Ford Mondeo maintenance schedule

1•3

1

Maintenance schedule

The manufacturer’s recommended maintenance schedule for these

vehicles is as described below - note that the schedule starts from the
vehicle’s date of registration. These are the minimum maintenance
intervals recommended by the factory for Mondeos driven daily, but
subjected only to “normal” use. If you wish to keep your vehicle in
peak condition at all times, you may wish to perform some of these
procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your vehicle,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of
these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit with
the engine idling or drive at low speeds for extended periods (ie, in
heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.

When your vehicle is new, it should be serviced by a Ford dealer

service department to protect the factory warranty. In many cases, the
initial maintenance check is done at no cost to the owner. Note that
this first free service (carried out by the selling dealer 1500 miles or 3
months after delivery), although an important check for a new vehicle,
is not part of the regular maintenance schedule, and is therefore not
mentioned here.

Weekly checks

m

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Check the engine oil level, and top-up if necessary
(Section 3)

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Check the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Sections 12 and 22)

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Check the windscreen/tailgate washer fluid level, and top-
up if necessary (Section 3)

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Check the tyre pressures, including the spare (Section 4)

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Visually check the tyres for excessive tread wear, or
damage (Section 4)

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Check the operation of all (exterior and interior) lights and
the horn, wipers and windscreen/tailgate washer system
(Sections 6 and 8). Renew any blown bulbs (Chapter 12),
and clean the lenses of all exterior lights

Monthly checks

m

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Check the coolant level, and top-up if necessary (Sec-
tion 3)

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Check the battery electrolyte level, where applicable
(Section 3)

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Check the power steering fluid level, and top-up if
necessary (Section 5)

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Visually check all reservoirs, hoses and pipes for leakage
(Section 12)

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Check the operation of the air conditioning system
(Section 14)

m

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Check the operation of the handbrake (Section 23)

m

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Check the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6)

m

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Check the condition of the wiper blades, renewing them if
worn or no longer effective - note that the manufacturer
recommends renewing the blades as a safety precaution,
irrespective of their apparent condition, at least once a
year (Section 6)

Every 10 000 miles or 12 months,
whichever occurs first

Note:

If the vehicle is used regularly for very short (less than

10 miles), stop/go journeys, the oil and filter should be renewed
between services (ie, every 5000 miles/6 months).

m

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Check the electrical system (Section 8)

m

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Check the battery (Section 9)

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Check the seat belts (Section 10)

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Check the auxiliary drivebelt (Section 11)

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Check for fluid leaks and hose condition (Section 12)

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Check the condition of all wiring (Section 13)

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Check all air conditioning components (Section 14)

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Change the engine oil and filter (Section 15)

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Check the manual transmission oil level (Section 16)

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Check the adjustment of the clutch pedal (Section 17)

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Lubricate the automatic transmission linkage (Section 18)

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Check the steering, suspension and wheels (Section 19)

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Check the driveshaft gaiters and CV joints (Section 20)

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Check the exhaust system (Section 21)

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Check the underbody, and all fuel/brake lines (Section 22)

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Check the brake system (Section 23)

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Check and lubricate the doors and bonnet (Section 24)

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Check the security of all roadwheel nuts (Section 25)

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Road test (Section 26). Check the level of the automatic
transmission fluid with the engine still hot, after the road
test (Section 7)

Every 20 000 miles or 2 years,
whichever occurs first

Carry out all operations listed above, plus the following:

m

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Renew the ventilation system pollen filter (Section 27)

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Renew the coolant (Sections 2 and 28)

Every 30 000 miles or 3 years,
whichever occurs first

Carry out all operations listed above, plus the following:

m

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Renew the air filter element (Section 29). Note that this
task must be carried out at more frequent intervals if the
vehicle is used in dusty or polluted conditions

m

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Check the Positive Crankcase Ventilation (PCV) system,
and clean the filter (Section 30)

m

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Renew the spark plugs (Section 31)

Every 60 000 miles

Carry out all operations listed above, plus the following:

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Renew the timing belt (Section 32)

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Renew the fuel filter (Section 33)

Every 3 years
(regardless of mileage)

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Renew the brake fluid (Section 34)

1•4

Engine compartment components

1 Spark plugs (Section 31)
2 Engine oil filler cap (Section 3)
3 Brake fluid reservoir (Section 3)
4 Auxiliary fusebox (Chapter 12)
5 Air cleaner assembly (Section 29)
6 Battery (Section 9)
7 Cooling system expansion tank

(Section 28)

8 Ventilation system pollen filter - under

cowl grille panel (Section 27)

9 Air intake resonator (Chapter 4)

10 Radiator top hose (Section 12)
11 Cooling system expansion tank filler cap

(Section 3)

12 Air intake plenum chamber (Chapter 4)
13 Engine oil dipstick (Section 3)
14 Vehicle Identification Number (VIN) plate
15 Windscreen/tailgate washer fluid reservoir

(Section 3)

16 Auxiliary drivebelt (Section 11)
17 Power steering fluid reservoir (Section 5)

Front underbody view

1 Radiator bottom hose (Section 12)
2 Exhaust gas oxygen sensor (Chapter 6)
3 Braking system, fuel and emission control

system lines (Section 22)

4 Front disc brake (Section 23)
5 Manual transmission drain plug

(Chapter 7, Part A)

6 Front suspension subframe (Chapter 2,

Part B)

7 Manual transmission filler/level plug

(Section 16)

8 Radiator undershield (Section 28)
9 Catalytic converter (Section 21)

10 Exhaust system rubber mountings

(Section 21)

11 Engine oil drain plug (Section 15)
12 Engine oil filter (Section 15)

Maintenance procedures