Ford Mondeo (petrol engines). Manual — part 69

REF•16

Glossary of Technical Terms

Rotor

In a distributor, the rotating device

inside the cap that connects the centre
electrode and the outer terminals as it turns,
distributing the high voltage from the coil
secondary winding to the proper spark plug.
Also, that part of an alternator which rotates
inside the stator. Also, the rotating assembly
of a turbocharger, including the compressor
wheel, shaft and turbine wheel.
Runout

The amount of wobble (in-and-out

movement) of a gear or wheel as it’s rotated.
The amount a shaft rotates “out-of-true.” The
out-of-round condition of a rotating part.

S

Sealant

A liquid or paste used to prevent

leakage at a joint. Sometimes used in
conjunction with a gasket.
Sealed beam lamp An older headlight design
which integrates the reflector, lens and
filaments into a hermetically-sealed one-piece
unit. When a filament burns out or the lens
cracks, the entire unit is simply replaced.
Serpentine drivebelt

A single, long, wide

accessory drivebelt that’s used on some
newer vehicles to drive all the accessories,
instead of a series of smaller, shorter belts.
Serpentine drivebelts are usually tensioned by
an automatic tensioner.

Shim Thin spacer, commonly used to adjust
the clearance or relative positions between
two parts. For example, shims inserted into or
under bucket tappets control valve
clearances. Clearance is adjusted by
changing the thickness of the shim.
Slide hammer A special puller that screws
into or hooks onto a component such as a
shaft or bearing; a heavy sliding handle on the
shaft bottoms against the end of the shaft to
knock the component free.

Sprocket

A tooth or projection on the

periphery of a wheel, shaped to engage with a
chain or drivebelt. Commonly used to refer to
the sprocket wheel itself.
Starter inhibitor switch On vehicles with an
automatic transmission, a switch that
prevents starting if the vehicle is not in Neutral
or Park.
Strut See MacPherson strut.

T

Tappet

A cylindrical component which

transmits motion from the cam to the valve
stem, either directly or via a pushrod and
rocker arm. Also called a cam follower.
Thermostat

A heat-controlled valve that

regulates the flow of coolant between the
cylinder block and the radiator, so maintaining
optimum engine operating temperature. A
thermostat is also used in some air cleaners in
which the temperature is regulated.
Thrust bearing

The bearing in the clutch

assembly that is moved in to the release
levers by clutch pedal action to disengage the
clutch. Also referred to as a release bearing.
Timing belt A toothed belt which drives the
camshaft. Serious engine damage may result
if it breaks in service.
Timing chain

A chain which drives the

camshaft.
Toe-in

The amount the front wheels are

closer together at the front than at the rear. On
rear wheel drive vehicles, a slight amount of
toe-in is usually specified to keep the front
wheels running parallel on the road by
offsetting other forces that tend to spread the
wheels apart.
Toe-out

The amount the front wheels are

closer together at the rear than at the front. On
front wheel drive vehicles, a slight amount of
toe-out is usually specified.
Tools

For full information on choosing and

using tools, refer to the Haynes Automotive
Tools Manual.
Tracer A stripe of a second colour applied to
a wire insulator to distinguish that wire from
another one with the same colour insulator.
Tune-up A process of accurate and careful
adjustments and parts replacement to obtain
the best possible engine performance.

Turbocharger A centrifugal device, driven by
exhaust gases, that pressurises the intake air.
Normally used to increase the power output
from a given engine displacement, but can
also be used primarily to reduce exhaust
emissions (as on VW’s “Umwelt” Diesel
engine).

U

Universal joint or U-joint A double-pivoted
connection for transmitting power from a
driving to a driven shaft through an angle. A
U-joint consists of two Y-shaped yokes and a
cross-shaped member called the spider.

V

Valve

A device through which the flow of

liquid, gas, vacuum, or loose material in bulk
may be started, stopped, or regulated by a
movable part that opens, shuts, or partially
obstructs one or more ports or passageways.
A valve is also the movable part of such a
device.
Valve clearance The clearance between the
valve tip (the end of the valve stem) and the
rocker arm or tappet. The valve clearance is
measured when the valve is closed.
Vernier caliper

A precision measuring

instrument that measures inside and outside
dimensions. Not quite as accurate as a
micrometer, but more convenient.
Viscosity

The thickness of a liquid or its

resistance to flow.
Volt

A unit for expressing electrical

“pressure” in a circuit. One volt that will
produce a current of one ampere through a
resistance of one ohm.

W

Welding Various processes used to join metal
items by heating the areas to be joined to a
molten state and fusing them together. For
more information refer to the Haynes
Automotive Welding Manual.
Wiring diagram

A drawing portraying the

components and wires in a vehicle’s electrical
system, using standardised symbols. For
more information refer to the Haynes
Automotive Electrical and Electronic Systems
Manual.

Serpentine drivebelt

REF•17

Index

A

A pillar trim - 11•20
ABS - 9•14
Accelerator cable - 4•4
Accelerator pedal - 4•5
Accumulator - 3•9
Acknowledgements - 0•4
Adaptive damping switch - 12•8
Aerial - 12•22
Air bag - 0•5, 1•22, 12•22
Air cleaner - 4•3, 6•19
Air conditioning - 1•15, 3•2, 3•8, 3•9, 6•11
Air distribution control - 3•8
Air induction system - 4•9
Air intake components - 4•3
Air mass meter - 4•3, 6•10, 6•11, 6•12
Air temperature warning sender unit -

12•18

Alarm - 11•17, 12•18
Alternator - 5•5, 5•6
Amplifier - 12•21
Anti-lock Braking System - 9•14
Anti-roll bar - 10•8, 10•12, 10•15
Anti-theft alarm system - 12•18
Antifreeze - 1•2, 1•22, 3•2
Asbestos - 0•5
ATF - 1•2
Automatic transmission - 1•11, 1•17,

2A•24, 2B•3, 2B•4, 6•11, 7B•1 et seq,
12•11

Automatic transmission fault finding -

REF•10

Automatic transmission fluid - 1•2
Auxiliary drivebelt - 1•13
Auxiliary warning system - 12•17

B

B pillar trim - 11•20
Backfire - REF•8
Backrest - 11•18
Battery - 0•5, 1•8, 1•11, 5•2, 5•3
Battery fault - REF•12
Big-end bearings - 2B•18, 2B•21
Bleeding brakes - 9•12
Bleeding power steering - 10•21
Blower/air conditioning control - 3•8

Body corrosion - 0•10
Body electrical system - 12•1 et seq
Bodywork and fittings - 11•1 et seq
Bonnet - 1•20, 11•5, 11•6
Booster battery (jump) starting - 0•12
Boot - 11•14, 11•15
Brake check - 1•19
Brake fluid - 1•2, 1•8, 1•26
Brake line check - 1•19
Braking system - 0•7, 0•8, 0•9, 1•20, 9•1 et

seq

Braking system fault finding - REF•10
Brush renewal - 5•8
Bulb failure module - 12•18
Bulbs - 12•8, 12•11, 12•18
Bumpers - 11•4, 11•5
Burning - 0•5

C

C pillar trim - 11•20, 11•21
Cables - 4•4, 7B•2, 8•2, 9•16, 11•6, 12•15
Calipers - 9•4, 9•9
Camshaft - 2A•13, 2A•14, 6•11, 6•12
Cassette player - 12•21
Catalytic converter - 6•19
CD player - 12•22
Central locking system - 11•17
Central locking system fault - REF•12
Centre console - 11•21
Charcoal canister - 6•14
Charging - 1•12, 5•5
Check strap - 11•13
Clock - 12•11, 12•15
Clutch and driveshafts - 1•17, 1•20, 8•1 et

seq

Clutch fault finding - REF•9
CO emissions (mixture) - 0•10
Coil spring - 10•15
Compact disc player - 12•22
Compression test - 2A•5
Compressor - 3•9
Condenser - 3•9
Connecting rods - 2B•12, 2B•17, 2B•21,

2B•22

Console - 11•21, 11•22
Contents - 0•2
Conversion factors - 0•14

Coolant - 1•2, 1•6, 1•7, 1•21
Coolant leakage - REF•9
Coolant low level switch - 3•5
Coolant temperature gauge sender - 3•4
Coolant temperature sensor - 3•5, 6•11,

6•13

Coolant warning switch - 12•18
Cooling, heating, and air conditioning

systems - 1•22, 3•1 et seq

Cooling, heating, and air conditioning

systems fault finding - REF•8

Corrosion - REF•9
Courtesy light - 12•8
Crankcase - 2B•13
Crankshaft - 2A•9, 2A•13, 2A•22, 2B•13,

2B•18, 2B•20, 5•4, 6•10, 6•11, 6•12

Crossmember - 10•13, 10•17
Cruise control system - 12•19
Crushing - 0•5
Cushion - 11•18
CV joints - 1•18, 8•7, 8•9
Cylinder block - 2B•13
Cylinder head - 2A•6, 2A•17, 2B•9, 2B•10,

2B•11, 6•19

D

D pillar trim - 11•21
Damping switch - 12•8
Dehydrator - 3•9
Dents in bodywork - 11•3
Depressurisation - 4•2
Diagnosis system - 6•4
Differential - 7A•2, 7B•3
Dimensions - 0•6
Dipped beam switch - 12•7
Direction indicators - 12•7, 12•9, 12•12
Discs - 1•19, 9•5, 9•10
Display warning bulb - 12•18
Doors - 0•8, 1•20, 11•6, 11•7, 11•8, 11•9,

11•10, 11•11, 11•13, 12•7, 12•8, 12•11,
12•18

Drivebelts - 1•13
Driveplate - 2A•24
Driveshafts - 0•9, 1•18, 8•5, 8•6, 8•7, 8•9,

8•10

Driveshafts fault finding - REF•10
Drivetrain - 1•20
Drums - 1•19, 9•6

Note: References throughout this index relate to Chapter•page number

REF•18

Index

E

Earth fault - 12•4
Economy/Sport mode switch - 12•7
ECU (Electronic Control Unit) - 6•10, 6•11,

6•12

EGR exhaust gas pressure differential

sensor - 6•16

EGR system - 6•15, 6•16
Electric shock - 0•5
Electric windows fault - REF•12
Electrical system - 0•8, 1•11, 1•20
Electrical system fault - REF•12
Electrically-operated windows - 12•7
Electrolyte - 1•8
Electronic control system - 4•9, 6•2
Emblems - 11•17
Emission checks - 0•10
Emissions control systems - 6•1
Engine compartment light - 12•11
Engine electrical systems - 5•1 et seq
Engine fault finding - REF•7, REF•8, REF•10
Engine management system - 4•8, 4•9
Engine oil - 1•2, 1•6, 1•16
Engine oil level sensor - 12•18
Engine removal and general engine

overhaul procedures - 2B•1 et seq

Environmental considerations - REF•4
Evaporative emissions control (EVAP)

system - 6•14

Evaporator - 3•9
Exhaust gas pressure differential sensor -

6•11, 6•12, 6•13

Exhaust Gas Recirculation (EGR) system -

6•15, 6•16

Exhaust manifold - 2A•8
Exhaust system - 0•9, 0•10, 1•18, 4•12,

REF•9

Expansion tank - 3•5, 3•6

F

Facia - 11•21, 11•23
Fan(s) - 3•4, 12•11
Fault code read-out - 6•6
Fault finding - REF•6 et seq
Fault finding - automatic transmission -

7B•1

Fault finding - electrical system - 12•4
Filling - 11•3
Fire - 0•5
Fluid level checks - 1•6
Flywheel - 2A•24
Foglight - 12•7, 12•9, 12•13
Foglight warning indicator - 12•11
Fuel and exhaust systems - 0•10, 4•1 et

seq

Fuel and exhaust system fault finding -

REF•9

Fuel consumption high - REF•9
Fuel cut-off switch - 4•8
Fuel filter - 1•26
Fuel gauge - 4•6
Fuel gauge fault - REF•12
Fuel hoses - 1•15
Fuel injection system - 4•8, 4•9
Fuel injectors - 4•10
Fuel lines - 1•19, 4•2
Fuel odour - REF•9

Fuel pressure check - 4•5
Fuel pressure regulator - 4•11
Fuel pump - 4•5, 4•6
Fuel rail - 4•10
Fuel system - 4•2
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fumes from exhaust system - REF•9
Fuses - 12•5

G

Gaiters - 1•18, 8•7, 8•9, 10•21
Gashes in bodywork - 11•3
Gaskets - REF•4
Gear lever - 7A•2
Gear selection problems - REF•9, REF•10
Gearbox oil - 1•2
Gearchange linkage - 7A•2
Gearchange selector shaft - 7A•3
Glossary of technical terms - REF•13
Glovebox - 11•22
Glovebox light - 12•11
Grab handle - 11•20

H

Handbrake - 0•7, 9•16, 12•7
Handles - 11•10, 11•11, 11•12, 11•13,

12•11

Hazard flashers - 12•7, 12•11
HC emissions - 0•10
Headlight - 1•8, 12•7, 12•8, 12•12, 12•13
Heated rear window - 12•8
Heated seat - 12•8
Heated windscreen - 12•8
Heater - 3•2, 3•7, 3•8, 12•11, 12•12
Horn - 12•7, 12•15
Horn fault - REF•12
Hoses - 1•14, 3•2, 9•11
HT leads - 1•24
Hub and bearings - 10•5, 10•9, 10•14
Hydraulic fluid - 1•2
Hydraulic pipes and hoses - 9•11
Hydraulic system - 9•12
Hydraulic tappets - 2A•14
Hydrofluoric acid - 0•5

I

Idle speed - 4•9, 4•11, 6•10
Idle-increase solenoid valve - 4•12
Ignition coil - 5•3
Ignition module - 5•4
Ignition switch - 12•6
Ignition system - 5•3
Ignition timing - 5•4, 6•10
In-car engine repair procedures - 2A•1 et

seq

Indicators - 12•7, 12•9, 12•12
Information sensors - 6•10
Inlet manifold - 2A•7
Instrument panel - 12•7, 12•11, 12•14
Instruments - 1•20
Instruments fault - REF•12
Intake air temperature sensor - 6•11, 6•13
Introduction to the Ford Mondeo - 0•4

J

Jacking - 0•11
Joint mating faces - REF•4
Jump starting - 0•12

K

Knuckle - 10•5, 10•10, 10•14

L

Leaks - 0•13, 1•14, REF•9
Light units - 12•12
Lights - 12•7, 12•11
Lights inoperative - REF•12
Locknuts, locktabs and washers - REF•4
Locks - 11•6, 11•10, 11•12, 11•13, 11•15,

11•16, 11•17, 12•6, REF•12

Low air temperature warning sender unit -

12•18

Low coolant warning switch - 12•18
Low washer fluid switch - 12•18
Lower suspension arm - 10•8, 10•9, 10•13,

10•16

Lubrication system - 2A•4
Luggage compartment switch - 12•7

M

Main bearings - 2B•18, 2B•20
Maintenance - Also see Routine

maintenance

Maintenance - bodywork and underframe -

11•2

Maintenance - upholstery and carpets -

11•3

Manifolds - 2A•7, 2A•8
Manual transmission - 1•17, 2A•24, 2B•3,

2B•4, 7A•1 et seq

Manual transmission fault finding - REF•9
Manual transmission oil - 1•2
Master cylinder - 9•10
Mirrors - 0•7, 11•14, 12•7
Misfire - REF•7, REF•8
Mixture - 0•10, 4•9
MOT test checks - 0•7 et seq
Mountings - 2A•24, 7A•7, 7B•5

N

Number plate light - 12•10, 12•13

O

Oil (transmission) - 1•2
Oil (engine) - 1•2, 1•6, 1•16
Oil cooler - 2A•22
Oil level sensor - 2A•22, 12•18
Oil pressure warning light illuminated -

REF•8

REF•19

Index

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•1 et

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•20

Seats - 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•1 et 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•22

Traction 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•23 et seq
Working facilities - REF•3