Ford Mondeo Service and Repair Manual

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Ford Mondeo
Service and Repair Manual
Jeremy Churchill and A K Legg                                                                       LAE MIMI

                                                                                                                                (1923-304-10X3)
Models covered
All Ford Mondeo models with four-cylinder petrol engines,
including special/limited editions
1597 cc, 1796 cc and 1988 cc
Does not cover Diesel or V6 engines, or four-wheel-drive models

© Haynes Publishing 1996                                                     Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,
                                                                             Somerset BA22 7JJ
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted   Haynes Publishing
in any form or by any means, electronic or mechanical, including             Sparkford, Nr Yeovil, Somerset BA22 7JJ, England
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the copyright holder.                     Haynes North America, Inc
                                                                             861 Lawrence Drive, Newbury Park, California 91320, USA
ISBN 1 85960 167 7
British Library Cataloguing in Publication Data                              Editions Haynes S.A.
A catalogue record for this book is available from the British Library.      147/149, rue Saint Honoré, 75001 PARIS, France
Contents
LIVING WITH YOUR FORD MONDEO
Introduction                                                   Page    0•4
Safety First!                                                  Page    0•5
General dimensions and weights                                 Page    0•6

MOT Test Checks
Checks carried out from the driver’s seat                      Page    0•7
Checks carried out with the vehicle on the ground              Page    0•8
Checks carried out with the vehicle raised                     Page    0•9
Checks carried out on your vehicle’s exhaust emission system   Page   0•10

Roadside Repairs
Jacking, towing and wheel changing                             Page   0•11
Booster battery (jump) starting                                Page   0•12
Identifying leaks                                              Page   0•13
Conversion factors                                             Page   0•14

Routine Maintenance
Routine maintenance and servicing                              Page    1•1
Lubricants, fluids and capacities                              Page    1•2
Maintenance schedule                                           Page    1•3
    Weekly checks                                              Page    1•6
    Every 10 000 miles or 12 months                            Page   1•11
    Every 20 000 miles or 2 years                              Page   1•20
    Every 30 000 miles or 3 years                              Page   1•22
    Every 60 000 miles                                         Page   1•26
    Every 3 years                                              Page   1•26
Contents
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                 Page    3•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                                        Page 7B•1
Clutch and driveshafts                                        Page    8•1

Brakes
Braking system                                                Page    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 Diagrams                                               Page 12•24

REFERENCE
Tools and Working Facilities                                Page REF• 1
General Repair Procedures                                   Page REF• 4
Buying spare parts and vehicle identification numbers       Page REF• 5
Fault Finding                                               Page REF• 6
Glossary of Technical Terms                                 Page REF•13

Index                                                       Page REF•17
0•4          Introduction
Introduction to the Ford Mondeo
  Introduced in March 1993, the Ford              belt grabbers” and pre-tensioners, and an       capacities. It is controlled by a sophisticated
Mondeo models are available in four-door          airbag fitted to the steering wheel. Vehicle    engine management system, which combines
Saloon, five-door Hatchback and five-door         security is enhanced, with an in-built alarm    multi-point sequential fuel injection and
Estate configurations. All feature a high         system and engine immobiliser being fitted as   distributorless     ignition    systems     with
standard of equipment, with driver/passenger      standard, as well as double-locking doors       evaporative emissions control, exhaust gas
safety in accidents being a particularly high     with shielded locks, and security-coded audio   recirculation and a three-way regulated
design priority; all models are fitted with       equipment.                                      catalytic converter (with a pulse-air system for
features such as side impact bars in all doors,      The four-cylinder petrol engine is a new     rapid warm-up) to ensure that the vehicle
“anti-submarine” seats combined with “seat        design, available in 1.6, 1.8 and 2.0 litre     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
                                Ford Mondeo 2.0 Ghia Saloon                                       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).
                                Ford Mondeo 1.8 GLX Estate
Safety First!                                               0•5

   Working on your car can be dangerous.         • Mains voltage is also dangerous. Make
This page shows just some of the potential       sure that any mains-operated equipment is
                                                                                                   Special hazards
risks and hazards, with the aim of creating a    correctly earthed. Mains power points should      Hydrofluoric acid
safety-conscious attitude.                       be protected by a residual current device
                                                                                                   • This extremely corrosive acid is formed
                                                 (RCD) circuit breaker.
General hazards                                                                                    when certain types of synthetic rubber, found
                                                                                                   in some O-rings, oil seals, fuel hoses etc, are
                                                 Fume or gas intoxication
Scalding                                                                                           exposed to temperatures above 4000C. The
                                                 • Exhaust fumes are
• Don’t remove the radiator or expansion                                                           rubber changes into a charred or sticky
                                                 poisonous; they often
tank cap while the engine is hot.                                                                  substance containing the acid. Once formed,
                                                 contain carbon
• Engine oil, automatic transmission fluid or                                                      the acid remains dangerous for years. If it
                                                 monoxide, which is
power steering fluid may also be dangerously                                                       gets onto the skin, it may be necessary to
                                                 rapidly fatal if inhaled.
hot if the engine has recently been running.                                                       amputate the limb concerned.
                                                 Never run the
                                                                                                   • When dealing with a vehicle which has
Burning                                          engine in a
                                                                                                   suffered a fire, or with components salvaged
                                                 confined space
• Beware of burns from the exhaust system                                                          from such a vehicle, wear protective gloves
                                                 such as a garage
and from any part of the engine. Brake discs                                                       and discard them after use.
                                                 with the doors shut.
and drums can also be extremely hot              • Fuel vapour is also                             The battery
immediately after use.                           poisonous, as are the vapours from some
                                                                                                   • Batteries contain sulphuric acid, which
Crushing                                         cleaning solvents and paint thinners.
                                                                                                   attacks clothing, eyes and skin. Take care
• When working under or near                     Poisonous or irritant substances                  when topping-up or carrying the battery.
a raised vehicle, always                                                                           • The hydrogen gas given off by the battery
                                                 • Avoid skin contact with battery acid and
supplement the                                                                                     is highly explosive. Never cause a spark or
                                                 with any fuel, fluid or lubricant, especially
jack with axle                                                                                     allow a naked light nearby. Be careful when
                                                 antifreeze, brake hydraulic fluid and Diesel
stands, or use                                                                                     connecting and disconnecting battery
                                                 fuel. Don’t syphon them by mouth. If such a
drive-on ramps.                                                                                    chargers or jump leads.
                                                 substance is swallowed or gets into the eyes,
Never venture                                    seek medical advice.                              Air bags
under a car                                      • Prolonged contact with used engine oil can
which is only                                                                                      • Air bags can cause injury if they go off
                                                 cause skin cancer. Wear gloves or use a
supported by                                                                                       accidentally. Take care when removing the
                                                 barrier cream if necessary. Change out of oil-
a jack.                                                                                            steering wheel and/or facia. Special storage
                                                 soaked clothes and do not keep oily rags in
• Take care if loosening or tightening high-                                                       instructions may apply.
                                                 your pocket.
torque nuts when the vehicle is on stands.       • Air conditioning refrigerant forms a            Diesel injection equipment
Initial loosening and final tightening should    poisonous gas if exposed to a naked flame
be done with the wheels on the ground.                                                             • Diesel injection pumps supply fuel at very
                                                 (including a cigarette). It can also cause skin
                                                                                                   high pressure. Take care when working on
Fire                                             burns on contact.
                                                                                                   the fuel injectors and fuel pipes.
• Fuel is highly flammable; fuel vapour is       Asbestos
explosive.                                       • Asbestos dust can cause cancer if inhaled                Warning: Never expose the
• Don’t let fuel spill onto a hot engine.        or swallowed. Asbestos may be found in                     hands, face or any other part of
• Do not smoke or allow naked lights             gaskets and in brake and clutch linings.                   the body to injector spray; the
(including pilot lights) anywhere near a         When dealing with such components it is           fuel can penetrate the skin with
vehicle being worked on. Also beware of          safest to assume that they contain asbestos.      potentially fatal results.
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
                                                  Remember...                                      A few tips
• Another cause of fire is an electrical          DO                                               DON’T
overload or short-circuit. Take care when         • Do use eye protection when using power         • Don’t attempt to lift a heavy component
repairing or modifying the vehicle wiring.        tools, and when working under the vehicle.       which may be beyond your capability – get
• Keep a fire extinguisher handy, of a type                                                        assistance.
suitable for use on fuel and electrical fires.    • Do wear gloves or use barrier cream to
                                                  protect your hands when necessary.               • Don’t rush to finish a job, or take
Electric shock                                                                                     unverified short cuts.
                                                  • Do get someone to check periodically
• Ignition HT                                     that all is well when working alone on the       • Don’t use ill-fitting tools which may slip
voltage can be                                    vehicle.                                         and cause injury.
dangerous,
                                                  • Do keep loose clothing and long hair well      • Don’t leave tools or parts lying around
especially to
                                                  out of the way of moving mechanical parts.       where someone can trip over them. Mop
people with
                                                                                                   up oil and fuel spills at once.
heart problems                                    • Do remove rings, wristwatch etc, before
or a pacemaker.                                   working on the vehicle – especially the          • Don’t allow children or pets to play in or
Don’t work on or                                  electrical system.                               near a vehicle being worked on.
near the ignition
                                                  • Do ensure that any lifting or jacking
system with the
                                                  equipment has a safe working load rating
engine running or the
                                                  adequate for the job.
ignition switched on.
0•6               General Dimensions & Weights

Dimensions
Overall length:
  Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            4481 mm
  Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4631 mm
Overall width - including mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              1925 mm
Overall height - at kerb weight:
  Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1403   to 1435 mm
  Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   1416   to 1501 mm
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      2704   mm
Front track - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .         1503   mm
Rear track:
  Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1486 to 1487 mm
  Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   1504 mm
Turning circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .     10.9 m

Weights
Kerb weight:
  1.6 Saloon, Hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . .                   1215 to 1250 kg
  1.6 Estate models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .          1265 to 1275 kg
  1.8 Saloon, Hatchback models:
      Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1225 to 1260 kg
      Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .             1260 to 1280 kg
  1.8 Estate models:
      Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1275 to 1285 kg
      Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .             1305 kg
  2.0 Saloon, Hatchback models:
      Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1250 to 1310 kg
      Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .             1285 to 1340 kg
  2.0 Estate models:
      Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .            1295 to 1335 kg
      Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .             1330 to 1415 kg
Maximum gross vehicle weight:
  Saloon, Hatchback:
      1.6 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .     1725 kg
      1.8 Saloon models, automatic transmission . . . . . . . . . . . . . . . . .                        1750 kg
      2.0 models, automatic transmission . . . . . . . . . . . . . . . . . . . . . . .                   1800 kg
      All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   1775 kg
  Estate:
      1.6 models, 2.0 models with manual transmission . . . . . . . . . . . .                            1900 kg
      All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   1925 kg
Maximum roof rack load:
  Estate models with integral roof rack . . . . . . . . . . . . . . . . . . . . . . . .                  100 kg
  All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   75 kg
Maximum towing weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              1500 kg
Trailer nose weight limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .        75 kg
MOT Test Checks                                                                   0•7

   This is a guide to getting your vehicle through the MOT test.
Obviously it will not be possible to examine the vehicle to the same
standard as the professional MOT tester. However, working through
the following checks will enable you to identify any problem areas
before submitting the vehicle for the test.
   Where a testable component is in borderline condition, the tester
has discretion in deciding whether to pass or fail it. The basis of such
discretion is whether the tester would be happy for a close relative or
friend to use the vehicle with the component in that condition. If the
vehicle presented is clean and evidently well cared for, the tester may
be more inclined to pass a borderline component than if the vehicle is
scruffy and apparently neglected.
   It has only been possible to summarise the test requirements here,
based on the regulations in force at the time of printing. Test standards
are becoming increasingly stringent, although there are some
exemptions for older vehicles. For full details obtain a copy of the Haynes
publication Pass the MOT! (available from stockists of Haynes manuals).
   An assistant will be needed to help carry out some of these checks.

The checks have been sub-divided into four categories, as follows:

1    Checks carried out
     FROM THE DRIVER’S
                                        2    Checks carried out
                                             WITH THE VEHICLE
                                                                              3   Checks carried out
                                                                                  WITH THE VEHICLE
                                                                                                                  4    Checks carried out on
                                                                                                                       YOUR VEHICLE’S
     SEAT                                    ON THE GROUND                        RAISED AND THE                       EXHAUST EMISSION
                                                                                  WHEELS FREE TO                       SYSTEM
                                                                                  TURN

 1    Checks carried out
      FROM THE DRIVER’S SEAT

Handbrake
M Test the operation of the handbrake.
Excessive travel (too many clicks) indicates
incorrect brake or cable adjustment.
M Check that the handbrake cannot be
released by tapping the lever sideways. Check
the security of the lever mountings.

                                                    M Check that the brake pedal is secure and in     movement of the steering wheel, indicating
                                                    good condition. Check also for signs of fluid     wear in the column support bearings or
                                                    leaks on the pedal, floor or carpets, which       couplings.
                                                    would indicate failed seals in the brake master
                                                    cylinder.                                         Windscreen and mirrors
                                                    M Check the servo unit (when applicable) by
                                                                                                      M The windscreen must be free of cracks or
                                                    operating the brake pedal several times, then
                                                                                                      other significant damage within the driver’s
                                                    keeping the pedal depressed and starting the
                                                                                                      field of view. (Small stone chips are
                                                    engine. As the engine starts, the pedal will
                                                                                                      acceptable.) Rear view mirrors must be
                                                    move down slightly. If not, the vacuum hose or
                                                                                                      secure, intact, and capable of being adjusted.
                                                    the servo itself may be faulty.

                                                    Steering wheel and column
Footbrake
                                                    M Examine the steering wheel for fractures or
M Depress the brake pedal and check that it         looseness of the hub, spokes or rim.
does not creep down to the floor, indicating a      M Move the steering wheel from side to side
master cylinder fault. Release the pedal, wait      and then up and down. Check that the
a few seconds, then depress it again. If the        steering wheel is not loose on the column,
pedal travels nearly to the floor before firm       indicating wear or a loose retaining nut.
resistance is felt, brake adjustment or repair is   Continue moving the steering wheel as before,
necessary. If the pedal feels spongy, there is      but also turn it slightly from left to right.
air in the hydraulic system which must be           M Check that the steering wheel is not loose
removed by bleeding.                                on the column, and that there is no abnormal
0•8           MOT Test Checks
                                                     Electrical equipment                                 M Inspect both front brake flexible hoses for
                                                                                                          cracks or deterioration of the rubber. Turn the
                                                     M Switch on the ignition and check the
                                                                                                          steering from lock to lock, and ensure that the
                                                     operation of the horn.
                                                                                                          hoses do not contact the wheel, tyre, or any
                                                     M Check the windscreen washers and wipers,
                                                                                                          part of the steering or suspension mechanism.
                                                     examining the wiper blades; renew damaged
                                                                                                          With the brake pedal firmly depressed, check
                                                     or perished blades. Also check the operation
                                                                                                          the hoses for bulges or leaks under pressure.
                                                     of the stop-lights.

Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
M Examine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible       M Check the operation of the sidelights and
from inside the vehicle.                             number plate lights. The lenses and reflectors       Steering and suspension
M The front seats themselves must be                 must be secure, clean and undamaged.
                                                                                                          M Have your assistant turn the steering wheel
securely attached and the backrests must             M Check the operation and alignment of the
lock in the upright position.                                                                             from side to side slightly, up to the point where
                                                     headlights. The headlight reflectors must not
                                                                                                          the steering gear just begins to transmit this
                                                     be tarnished and the lenses must be
Doors                                                                                                     movement to the roadwheels. Check for
                                                     undamaged.
M Both front doors must be able to be opened                                                              excessive free play between the steering
                                                     M Switch on the ignition and check the
and closed from outside and inside, and must                                                              wheel and the steering gear, indicating wear or
                                                     operation of the direction indicators (including
latch securely when closed.                                                                               insecurity of the steering column joints, the
                                                     the instrument panel tell-tale) and the hazard
                                                                                                          column-to-steering gear coupling, or the
                                                     warning lights. Operation of the sidelights and
                                                                                                          steering gear itself.
                                                     stop-lights must not affect the indicators - if it
 2    Checks carried out
      WITH THE VEHICLE ON THE
                                                     does, the cause is usually a bad earth at the
                                                     rear light cluster.
                                                                                                          M Have your assistant turn the steering wheel
                                                                                                          more vigorously in each direction, so that the
                                                                                                          roadwheels just begin to turn. As this is done,
                                                     M Check the operation of the rear foglight(s),
      GROUND                                                                                              examine all the steering joints, linkages,
                                                     including the warning light on the instrument
                                                                                                          fittings and attachments. Renew any
                                                     panel or in the switch.
Vehicle identification                                                                                    component that shows signs of wear or
                                                     Footbrake                                            damage. On vehicles with power steering,
M Number plates must be in good condition,                                                                check the security and condition of the
secure and legible, with letters and numbers         M Examine the master cylinder, brake pipes
                                                                                                          steering pump, drivebelt and hoses.
correctly spaced – spacing at (A) should be          and servo unit for leaks, loose mountings,
                                                                                                          M Check that the vehicle is standing level,
twice that at (B).                                   corrosion or other damage.
                                                                                                          and at approximately the correct ride height.
                                                                                                          Shock absorbers
                                                                                                          M Depress each corner of the vehicle in turn,
                                                                                                          then release it. The vehicle should rise and
                                                                                                          then settle in its normal position. If the vehicle
                                                                                                          continues to rise and fall, the shock absorber
                                                                                                          is defective. A shock absorber which has
                                                                                                          seized will also cause the vehicle to fail.

                                                     M The fluid reservoir must be secure and the
M The VIN plate (A) and homologation plate           fluid level must be between the upper (A) and
(B) must be legible.                                 lower (B) markings.
MOT Test Checks                                                                        0•9

Exhaust system                                     Front and rear suspension and                         M The same general checks apply to vehicles
M Start the engine. With your assistant            wheel bearings                                        fitted with other suspension types, such as
                                                                                                         torsion bars, hydraulic displacer units, etc.
holding a rag over the tailpipe, check the         M Starting at the front right-hand side, grasp
                                                                                                         Ensure that all mountings and attachments are
entire system for leaks. Repair or renew           the roadwheel at the 3 o’clock and 9 o’clock
                                                                                                         secure, that there are no signs of excessive
leaking sections.                                  positions and shake it vigorously. Check for
                                                                                                         wear, corrosion or damage, and (on hydraulic
                                                   free play or insecurity at the wheel bearings,
                                                                                                         types) that there are no fluid leaks or damaged
                                                   suspension balljoints, or suspension mount-
                                                                                                         pipes.
                                                   ings, pivots and attachments.
                                                                                                         M Inspect the shock absorbers for signs of
                                                   M Now grasp the wheel at the 12 o’clock and
                                                                                                         serious fluid leakage. Check for wear of the
                                                   6 o’clock positions and repeat the previous
                                                                                                         mounting bushes or attachments, or damage
                                                   inspection. Spin the wheel, and check for
                                                                                                         to the body of the unit.
                                                   roughness or tightness of the front wheel
                                                   bearing.                                              Driveshafts
                                                                                                         (fwd vehicles only)
                                                                                                         M Rotate each front wheel in turn and inspect
                                                                                                         the constant velocity joint gaiters for splits or
                                                                                                         damage. Also check that each driveshaft is
                                                                                                         straight and undamaged.

 3    Checks carried out
      WITH THE VEHICLE RAISED
      AND THE WHEELS FREE TO
      TURN
Jack up the front and rear of the vehicle,
                                                   M If excess free play is suspected at a
and securely support it on axle stands.
                                                   component pivot point, this can be confirmed
Position the stands clear of the suspension
                                                   by using a large screwdriver or similar tool and
assemblies. Ensure that the wheels are
                                                   levering between the mounting and the
clear of the ground and that the steering
                                                   component attachment. This will confirm
can be turned from lock to lock.
                                                   whether the wear is in the pivot bush, its            Braking system
                                                   retaining bolt, or in the mounting itself (the bolt
Steering mechanism                                                                                       M If possible without dismantling, check
                                                   holes can often become elongated).
                                                                                                         brake pad wear and disc condition. Ensure
M Have your assistant turn the steering from
                                                                                                         that the friction lining material has not worn
lock to lock. Check that the steering turns
                                                                                                         excessively, (A) and that the discs are not
smoothly, and that no part of the steering
                                                                                                         fractured, pitted, scored or badly worn (B).
mechanism, including a wheel or tyre, fouls
any brake hose or pipe or any part of the body
structure.
M Examine the steering rack rubber gaiters
for damage or insecurity of the retaining clips.
If power steering is fitted, check for signs of
damage or leakage of the fluid hoses, pipes or
connections. Also check for excessive
stiffness or binding of the steering, a missing
split pin or locking device, or severe corrosion
of the body structure within 30 cm of any
steering component attachment point.
                                                   M Carry out all the above checks at the other
                                                   front wheel, and then at both rear wheels.

                                                   Springs and shock absorbers                           M Examine all the rigid brake pipes
                                                   M Examine the suspension struts (when                 underneath the vehicle, and the flexible
                                                   applicable) for serious fluid leakage, corrosion,     hose(s) at the rear. Look for corrosion, chafing
                                                   or damage to the casing. Also check the               or insecurity of the pipes, and for signs of
                                                   security of the mounting points.                      bulging under pressure, chafing, splits or
                                                   M If coil springs are fitted, check that the          deterioration of the flexible hoses.
                                                   spring ends locate in their seats, and that the       M Look for signs of fluid leaks at the brake
                                                   spring is not corroded, cracked or broken.            calipers or on the brake backplates. Repair or
                                                   M If leaf springs are fitted, check that all          renew leaking components.
                                                   leaves are intact, that the axle is securely          M Slowly spin each wheel, while your
                                                   attached to each spring, and that there is no         assistant depresses and releases the
                                                   deterioration of the spring eye mountings,            footbrake. Ensure that each brake is operating
                                                   bushes, and shackles.                                 and does not bind when the pedal is released.
0•10         MOT Test Checks
                                                                                                       for smoke emissions from the exhaust
                                                                                                       tailpipe. If the idle speed is obviously much
                                                                                                       too high, or if dense blue or clearly-visible
                                                                                                       black smoke comes from the tailpipe for more
                                                                                                       than 5 seconds, the vehicle will fail. As a rule
                                                                                                       of thumb, blue smoke signifies oil being burnt
                                                                                                       (engine wear) while black smoke signifies
                                                                                                       unburnt fuel (dirty air cleaner element, or other
                                                                                                       carburettor or fuel system fault).
                                                                                                       M An exhaust gas analyser capable of
                                                                                                       measuring carbon monoxide (CO) and
                                                                                                       hydrocarbons (HC) is now needed. If such an
                                                                                                       instrument cannot be hired or borrowed, a
M Examine the handbrake mechanism,                 properly seated, and that the wheel is not          local garage may agree to perform the check
checking for frayed or broken cables,              distorted or damaged.                               for a small fee.
excessive corrosion, or wear or insecurity of      M Check that the tyres are of the correct size
the linkage. Check that the mechanism works        for the vehicle, that they are of the same size     CO emissions (mixture)
on each relevant wheel, and releases fully,        and type on each axle, and that the pressures       M At the time or writing, the maximum CO
without binding.                                   are correct.
                                                                                                       level at idle is 3.5% for vehicles first used after
M It is not possible to test brake efficiency      M Check the tyre tread depth. The legal
                                                                                                       August 1986 and 4.5% for older vehicles.
without special equipment, but a road test         minimum at the time of writing is 1.6 mm over
                                                                                                       From January 1996 a much tighter limit
can be carried out later to check that the         at least three-quarters of the tread width.
vehicle pulls up in a straight line.                                                                   (around 0.5%) applies to catalyst-equipped
                                                   Abnormal tread wear may indicate incorrect
                                                                                                       vehicles first used from August 1992. If the
                                                   front wheel alignment.
Fuel and exhaust systems                                                                               CO level cannot be reduced far enough to
M Inspect the fuel tank (including the filler      Body corrosion                                      pass the test (and the fuel and ignition
                                                                                                       systems are otherwise in good condition) then
cap), fuel pipes, hoses and unions. All            M Check the condition of the entire vehicle
components must be secure and free from            structure for signs of corrosion in load-           the carburettor is badly worn, or there is some
leaks.                                             bearing areas. (These include chassis box           problem in the fuel injection system or
M Examine the exhaust system over its entire       sections, side sills, cross-members, pillars,       catalytic converter (as applicable).
length, checking for any damaged, broken or        and all suspension, steering, braking system
missing mountings, security of the retaining       and seat belt mountings and anchorages.)            HC emissions
clamps and rust or corrosion.                      Any corrosion which has seriously reduced           M With the CO emissions within limits, HC
                                                   the thickness of a load-bearing area is likely to   emissions must be no more than 1200 ppm
                                                   cause the vehicle to fail. In this case             (parts per million). If the vehicle fails this test
                                                   professional repairs are likely to be needed.       at idle, it can be re-tested at around 2000
                                                   M Damage or corrosion which causes sharp            rpm; if the HC level is then 1200 ppm or less,
                                                   or otherwise dangerous edges to be exposed          this counts as a pass.
                                                   will also cause the vehicle to fail.                M Excessive HC emissions can be caused by
                                                                                                       oil being burnt, but they are more likely to be
                                                                                                       due to unburnt fuel.
                                                    4    Checks carried out on
                                                         YOUR VEHICLE’S EXHAUST
                                                                                                       Diesel models
                                                                                                       M The only emission test applicable to Diesel
                                                         EMISSION SYSTEM
                                                                                                       engines is the measuring of exhaust smoke
                                                                                                       density. The test involves accelerating the
                                                   Petrol models                                       engine several times to its maximum
Wheels and tyres                                   M Have the engine at normal operating               unloaded speed.
                                                   temperature, and make sure that it is in good
M Examine the sidewalls and tread area of                                                              Note: It is of the utmost importance that the
                                                   tune (ignition system in good order, air filter     engine timing belt is in good condition before
each tyre in turn. Check for cuts, tears, lumps,
                                                   element clean, etc).                                the test is carried out.
bulges, separation of the tread, and exposure
                                                   M Before any measurements are carried out,
of the ply or cord due to wear or damage.
                                                   raise the engine speed to around 2500 rpm,          M Excessive smoke can be caused by a dirty
Check that the tyre bead is correctly seated
                                                   and hold it at this speed for 20 seconds. Allow     air cleaner element. Otherwise, professional
on the wheel rim, that the valve is sound and
                                                   the engine speed to return to idle, and watch       advice may be needed to find the cause.
Roadside Repairs                                                                   0•11

Jacking, towing and wheel changing
    To change a wheel, remove the spare            no risk of the jack slipping or buckling the         If the vehicle is equipped with automatic
wheel and jack, apply the handbrake, and           flange. Never work under, around or near a        transmission, the following precautions must
chock the wheel diagonally opposite the            raised vehicle unless it is adequately            be observed if the vehicle is to be towed,
one to be changed. On manual transmission          supported in at least two places with axle        particularly if any kind of transmission fault is
models, select first or reverse gear; on           stands or suitable sturdy blocks.                 suspected. Preferably, a front-end-suspended
automatic transmission models, place the              The vehicle may be towed, for breakdown        tow should be used (ie with the front wheels
selector lever in “P”. Make sure that the          recovery purposes only, using the towing eyes     off the ground). If this is not possible, place
vehicle is located on firm level ground. Use       positioned at the front and rear of the vehicle   the selector lever in “N” and tow the vehicle -
the flat end of the wheelbrace carefully to        (see illustrations). These eyes are intended      forwards only, never backwards - for a
remove the trim covering the wheel nuts,           for towing loads only, and must not be used       distance of no more than 30 miles (50 km),
then slightly loosen the wheel nuts with the       for lifting the vehicle, either directly or       and at speeds no greater than 30 mph
brace (see illustrations). Locate the jack         indirectly.                                       (50 km/h).
head in the jacking point nearest to the
wheel to be changed, ensuring that the
channel in the jack head fits over the body
flange (see illustrations) and turn its
handle to raise the jack. When the wheel is
clear of the ground, remove the nuts and lift
off the wheel. Fit the spare wheel, and
moderately tighten the nuts. Lower the
vehicle, then tighten the nuts fully and refit
the trim. With the spare wheel in position,
remove the chock, and stow the jack and
tools.
    When jacking up the vehicle to carry out
repair or maintenance tasks, position the jack
as follows.
    If the front of the vehicle is to be raised,
either place the jack head under the sump,         Use flat end of wheelbrace to remove trim             Slacken roadwheel nuts in diagonal
with a block of wood to prevent damage, or                  covering roadwheel nuts                                  sequence
place a jacking beam across the two front
points “B” shown in the accompanying
illustration, and lift the vehicle evenly.                                                                            Jacking and supporting
    To raise the rear of the vehicle, place a                                                                                 points
jacking beam across the two rear points “B”                                                                          A Jacking points (for
shown in the accompanying illustration, and                                                                            vehicle jack in roadside
lift the vehicle evenly.                                                                                               use) - support points (for
    To raise the side of the vehicle, place the                                                                        axle stands in
jack head under the appropriate point                                                                                  servicing/overhaul work)
indicated in the accompanying illustration - if                                                                      B Jacking points (for
a trolley jack or similar is used on the points                                                                        trolley jack or workshop
“A” provided for the vehicle’s jack, make up a                                                                         hoist in
wooden spacer with a groove cut in it to                                                                               servicing/overhaul work)
accept the underbody flange, so that there is                                                                          - additional support
                                                                                                                       points

With jack base on firm ground, locate jack
   head in jacking point - indentations
 (arrowed) in sill identify jacking points                      Front towing eye                                    Rear towing eye
0•12       Roadside Repairs
Booster battery (jump) starting                                                                         Jump starting will get you out
                                                                                                        of trouble, but you must correct
                                                                                                        whatever made the battery go
When jump-starting a car using a              C) Make sure that the booster battery is                  flat in the first place. There are
booster battery, observe the following           the same voltage as the discharged                     three possibilities:
precautions:                                     one in the vehicle.                             The battery has been drained by

A) Before connecting the booster              D) If the battery is being jump-started
                                                                                             1   repeated attempts to start, or by
                                                                                             leaving the lights on.
   battery, make sure that the ignition is       from the battery in another vehicle,
                                                 the two vehcles MUST NOT TOUCH                  The charging system is not working
   switched off.
B) Ensure that all electrical equipment
                                                 each other.                                 2   properly (alternator drivebelt slack
                                                                                             or broken, alternator wiring fault or
   (lights, heater, wipers, etc) is           E) Make sure that the transmission is in       alternator itself faulty).
   switched off.                                 neutral (or PARK, in the case of
                                                                                                 The battery itself is at fault
                                                 automatic transmission).
                                                                                             3   (electrolyte low, or battery worn out).

1   Connect one end of the red jump lead to   2   Connect the other end of the red lead to   3   Connect one end of the black jump lead
    the positive (+) terminal of the flat         the positive (+) terminal of the booster       to the negative (-) terminal of the
    battery                                       battery.                                       booster battery

                                                                                             4   Connect the other end of the black
                                                                                                 jump lead to a bolt or bracket on the
                                                                                                 engine block, well away from the
                                                                                                 battery, on the vehicle to be started.

                                                                                                 Make sure that the jump leads will not
                                                                                             5   come into contact with the fan, drive-
                                                                                                 belts or other moving parts of the
                                                                                                 engine.

                                                                                                 Start the engine using the booster
                                                                                             6   battery, then with the engine running at
                                                                                                 idle speed, disconnect the jump leads in
                                                                                                 the reverse order of connection.
Roadside Repairs                                                          0•13

Identifying leaks
   Puddles on the garage floor or drive, or                 Warning: Most automotive oils
                                                                                                         The smell of a fluid leaking
obvious wetness under the bonnet or                         and fluids are poisonous. Wash               from the car may provide a
underneath the car, suggest a leak that needs               them off skin, and change out of             clue to what’s leaking. Some
investigating. It can sometimes be difficult to             contaminated clothing, without               fluids are distictively coloured.
decide where the leak is coming from,                       delay.                              It may help to clean the car carefully
especially if the engine bay is very dirty                                                      and to park it over some clean paper
already. Leaking oil or fluid can also be blown                                                 overnight as an aid to locating the
rearwards by the passage of air under the car,                                                  source of the leak.
giving a false impression of where the                                                          Remember that some leaks may only
problem lies.                                                                                   occur while the engine is running.

Sump oil                                          Oil from filter                              Gearbox oil

Engine oil may leak from the drain plug...        ...or from the base of the oil filter.       Gearbox oil can leak from the seals at the
                                                                                               inboard ends of the driveshafts.

Antifreeze                                        Brake fluid                                  Power steering fluid

Leaking antifreeze often leaves a crystalline     A leak occurring at a wheel is almost        Power steering fluid may leak from the pipe
deposit like this.                                certainly brake fluid.                       connectors on the steering rack.
0•14          Conversion Factors
Length (distance)
Inches (in)                         x 25.4    = Millimetres (mm)                  x 0.0394 = Inches (in)
Feet (ft)                           x 0.305   = Metres (m)                        x 3.281 = Feet (ft)
Miles                               x 1.609   = Kilometres (km)                   x 0.621 = Miles
Volume (capacity)
Cubic inches (cu in; in3)           x   16.387 =   Cubic centimetres (cc; cm3)    x   0.061   =   Cubic inches (cu in; in3)
Imperial pints (Imp pt)             x   0.568 =    Litres (l)                     x   1.76    =   Imperial pints (Imp pt)
Imperial quarts (Imp qt)            x   1.137 =    Litres (l)                     x   0.88    =   Imperial quarts (Imp qt)
Imperial quarts (Imp qt)            x   1.201 =    US quarts (US qt)              x   0.833   =   Imperial quarts (Imp qt)
US quarts (US qt)                   x   0.946 =    Litres (l)                     x   1.057   =   US quarts (US qt)
Imperial gallons (Imp gal)          x   4.546 =    Litres (l)                     x   0.22    =   Imperial gallons (Imp gal)
Imperial gallons (Imp gal)          x   1.201 =    US gallons (US gal)            x   0.833   =   Imperial gallons (Imp gal)
US gallons (US gal)                 x   3.785 =    Litres (l)                     x   0.264   =   US gallons (US gal)
Mass (weight)
Ounces (oz)                         x 28.35 = Grams (g)                           x 0.035 = Ounces (oz)
Pounds (lb)                         x 0.454 = Kilograms (kg)                      x 2.205 = Pounds (lb)
Force
Ounces-force (ozf; oz)              x 0.278 = Newtons (N)                         x 3.6   = Ounces-force (ozf; oz)
Pounds-force (lbf; lb)              x 4.448 = Newtons (N)                         x 0.225 = Pounds-force (lbf; lb)
Newtons (N)                         x 0.1   = Kilograms-force (kgf; kg)           x 9.81 = Newtons (N)
Pressure
Pounds-force per square inch        x 0.070 = Kilograms-force per square          x 14.223 = Pounds-force per square inch
(psi; lbf/in2; lb/in2)                        centimetre (kgf/cm2; kg/cm2)                   (psi; lbf/in2; lb/in2)
Pounds-force per square inch        x 0.068 = Atmospheres (atm)                   x 14.696 = Pounds-force per square inch
(psi; lbf/in2; lb/in2)                                                                       (psi; lbf/in2; lb/in2)
Pounds-force per square inch        x 0.069 = Bars                                x 14.5 = Pounds-force per square inch
(psi; lbf/in2; lb/in2)                                                                       (psi; lbf/in2; lb/in2)
Pounds-force per square inch        x 6.895 = Kilopascals (kPa)                   x 0.145 = Pounds-force per square inch
(psi; lbf/in2; lb/in2)                                                                       (psi; lbf/in2; lb/in2)
Kilopascals (kPa)                   x 0.01     = Kilograms-force per square       x 98.1 = Kilopascals (kPa)
                                                 centimetre (kgf/cm2; kg/cm2)
Millibar (mbar)                     x   100    = Pascals (Pa)                     x 0.01 = Millibar (mbar)
Millibar (mbar)                     x   0.0145 = Pounds-force per square inch     x 68.947 = Millibar (mbar)
                                                 (psi; lbf/in2; lb/in2)
Millibar (mbar)                     x   0.75 = Millimetres of mercury (mmHg)      x   1.333   =   Millibar (mbar)
Millibar (mbar)                     x   0.401 = Inches of water (inH2O)           x   2.491   =   Millibar (mbar)
Millimetres of mercury (mmHg)       x   0.535 = Inches of water (inH2O)           x   1.868   =   Millimetres of mercury (mmHg)
Inches of water (inH2O)             x   0.036 = Pounds-force per square inch      x   27.68   =   Inches of water (inH2O)
                                                 (psi; lbf/in2; lb/in2)
Torque (moment of force)
Pounds-force inches                 x 1.152 = Kilograms-force centimetre          x 0.868 = Pounds-force inches
(lbf in; lb in)                               (kgf cm; kg cm)                               (lbf in; lb in)
Pounds-force inches                 x 0.113 = Newton metres (Nm)                  x 8.85 = Pounds-force inches
(lbf in; lb in)                                                                             (lbf in; lb in)
Pounds-force inches                 x 0.083 = Pounds-force feet (lbf ft; lb ft)   x 12    = Pounds-force inches
(lbf in; lb in)                                                                             (lbf in; lb in)
Pounds-force feet (lbf ft; lb ft)   x 0.138 = Kilograms-force metres              x 7.233 = Pounds-force feet (lbf ft; lb ft)
                                              (kgf m; kg m)
Pounds-force feet (lbf ft; lb ft)   x 1.356 = Newton metres (Nm)                  x 0.738 = Pounds-force feet (lbf ft; lb ft)
Newton metres (Nm)                  x 0.102 = Kilograms-force metres              x 9.804 = Newton metres (Nm)
                                              (kgf m; kg m)
Power
Horsepower (hp)                     x 745.7 = Watts (W)                           x 0.0013 = Horsepower (hp)
Velocity (speed)
Miles per hour (miles/hr; mph)      x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph)
Fuel consumption*
Miles per gallon (mpg)              x 0.354 = Kilometres per litre (km/l)         x 2.825 = Miles per gallon (mpg)
Temperature
Degrees Fahrenheit = (°C x 1.8) + 32              Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56
* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 282
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